Maestro Installation and Service Manual
Contents
1. Start up Procedure 4 Procedures 5 Troubleshooting Moisture 6 Error Codes 7 Spare Part Numbers 8 Version History 9 End User Installation Manual fy HIRSCHMANN SkyAzul Equipment Solutions www skyazul com 301 371 61262 fy HIRSCHMANN CONTENTS GENERAL INFORMATION esee 5 SAFETY INSTRUCTIONS wassccscccccsecccsassccscesctanctcnssscessssccsnczexccnceveese 5 Hsec EE 6 What is new or changed ooooccccnoccccccccoooccccononnnnnnnnonnnoncnnnnnnnnnnonnnnnos 6 What remains same c cecceeeeceeeeeeececeeeeeeeeeceeeeeeseeeesaeeeeseneess 6 Installation Instructions eeeeeeeeeeneeneennnnn 7 Central processing unit 7 rg sem 8 Pressure transducers ccecceceeeeeceeeeseeeeeeeeeenaeeeeeseeeeeeeeeeaeeeeeaes 9 Maestro system wiring 0006 Central Unit 11 Maestro system wiring 0011 Central Unit 12 Sensor installation noone 13 Relay installation maestro central unit 0006 14 Data acceptance or using data EPROM from previous system 15 Data EPROM extraction from previous system 15 Cable Reel LWG208 0001 Manual Adjustment Procedure 16 Automatic sensor adjustment via the console 17 Start up procedure 5 earn cete ker tec kae a ha2. EQUIPMENT SOLUTIONS BEBEHHEERRI 23 4 16 3 6 41 AA b OMS N 20 1 B 01 64 71 68 maestro ee SERVICE MANUAL NOTICE SkyAzul 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 SkyAzul 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 SkyAz l SkyAzul 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 SkyAzul The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice r SkyAz l Inc gai 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Fax 301 371 0029 info skyazul com SkyAz l Equipment Solutions www skyazul com 301 371 6126 fy HIRSCHMANN Contents maestro c eneral Information 1 LMI System Safety Instructions 2 Installation Instructions 3
3. amp b y ea A14 5t 1112 15 dns N iz nfedi o5 16 20N E t SS SSS Adjustment of the main boom length greatest length The boom must be completely extended Display for length of main boom and the prewarning light flash Do not try to adjust the length this is pre set in the software and is the actual boom length If you have the original cali bration sheet this should match the length displayed If in doubt contact the authorized dealer The maximum boom length value is pre set in the original crane software ONLY a con firmation of this length is required To confirm this value simultaneously press the and keys to reconfirm the maximum boom length stored in the DATA EPROM CAUTION Do not attempt to arrow up down to change this indication es to highlight the next adjustment value Adjustment of the main boom angle Display for angle of main boom flashes Measure the boom angle to the horizontal with an angle spirit level and input this value by pressing key or 4 mes LE to highlight the next adjustment value SkyAzul Equipment Solutions www skyazul com 301 371 6126 19 HIRSCHMANN maestro Installation Information fy HIRSCHMANN Comments J t Input Display examples d Adjustment of force measurement in the case of systems with load recording via a force measurement this additional adjustment stage is also displa
4. 2 Remove the old DATA EPROM from the main board Be careful to pull the EPROM out without bending the legs Refer to drawing at right P NOTE The notch on the EPROM and in the socket determines the correct orientation of the EPROM Refer to the drawing below for correct B EPROM locations 3 Carefully align the new EPROM legs with the socket and push the EPROM into the EPROM module Be careful not to bend any of the legs Data EPROM location SkyAz l Equipment Solutions www skyazul com 301 371 6126 1 5 HIRSCHMANN HIRSCHMANN maestro Installation Information 3 8 Cable Reel LWG208 0001 Manual Adjustment Procedure me NY N U ANGLE PARALLEL WITH BOOM Z ADJUST RETRACTEI TURN THE CE A SOFT STOF SkyAz l Eguipment Solutions www skyazul com 301 371 6126 16 HIRSCHMANN HIRSCHMANN maestro Installation Information 3 9 Automatic sensor adjustment via the console Input Display examples Comments Conditions
5. Reset length potentiometer in length angle transducer screw is located in center of white gear with boom fully retracted turn potentiometer carefully counter clockwise until it stops Recheck length and angle display Refer to Cable Reel LWG308 0001 Adjustment Procedure SkyAzul Equipment Solutions www skyazul com 301 371 6126 24 fy HIRSCHMANN HIRSCHMANN maestro Procedures 6 Troubleshooting moisture The maestro contains electronic components in various locations such as central unit sensors junction boxes etc These internal components cannot be designed to withstand exposure to moisture over a longer period of time For this reason the housings of the components are water protected according to IP 65 If you find water or moisture inside any of the housings the source for the water ingress has to be detected and corrected to ensure proper operation There are two major possibilities for the occurrence of excessive moisture inside an enclosure 1 Water ingress 2 Condensation This outline gives instructions for detecting the cause for excessive moisture by using simple troubleshooting methods and how to prevent the moisture ingress from happening again 6 1 Water Ingress There are 6 possibilities for water to enter an enclosure 1 Spray Cleaning 2 Missing Loose Screws 3 Bent Lid 4 Defective Gasket 5 Loose Strain Relieves 6 Water Entry Through External Cabling It is possible to find out the source
6. o sane sa bw 805403 DAVS14 5A tL 606647 55 1 sia 606713 DAVSENJSXBSAMI PRESSURE TRANSDUCER CUTTING RING 2X o TI BULKHEAD ADAPTER MOUNTING PLATE EXTRA NUT ETRIC TO JIC SkyAz l Equipment Solutions www skyazul com 301 371 6126 10 fy HIRSCHMANN HIRSCHMANN maestro Installation Information 3 4 Maestro system wiring 0006 Central Unit prior to May 2006 x1 1 2 X x5 3 E E 2 3 4 E al 1 1 ES ren T lt A A S m x lt s Ze lt p pc 4 a 3 xi 4 Zec gt 7 HOLE PLL e 7 TO PISTON SIDE PRE e E E 6 ROD SIDE PRESSURE TRANSDUCER 15 _ lt F F lt e cc POSITION NTRAL UNIT CENTRAL UNIT S I LOAD d A e 2 gt 8 at lu 5 E RED mi 9 6 o m 0 gt JOTES E o TAPE AND STO ES NOT CONNECTED 2 4 gt 5 OUTER SHIELD CONNECTED T
7. 282 CUT OFF RELAY 12V 024 000 100 286 CUT OFF REALY 24V ALT STOWED INSIDE CU 000 313 301 002 FUSE 10A 50844 KEY CENTRAL UNIT item without illustration comprised in lead item SkyAzul Equipment Solutions www skyazul com 301 371 6126 33 SkyAz l Inc 200 W Main Street Suite 2A dr Middletown MD 21769 Phone 301 371 6126 EQUIPMENT SOLUTIONS Fax 301 371 0029 www skyazul com info skyazul com
8. OUTER SHIELD RAIN RELIEF INSERT FOR C gt IM 16 3 CABLE LE MEASURED NNER SHIELD CUT AND INSULATED IDENTIFICATION ARE AS FOLL APE OM TERMINALS 1 TO SkyAzul Equipment Solutions www skyazul com 301 371 6126 12 A HIRSCHMANN HIRSCHMANN maestro Installation Information 3 5 1 Sensor installation Reconnect all sensors through the provided locations Length Angle Sensor A 2 B Signal from Cable Reel Console Pressure Transducers and Digital inputs and outputs of the crane electrics Power source and Lock out to Crane Ref 3 4 maestro wiring diagram MAIN BOARD A 4A 7T 024 050 300 046 OOOO ODO 0 BOBO DO gt 32 2 KEYSWITCH 024 350 100 661 I 34 000009 pongan poon paco SPARE KEY 050844 7 7 ad E Z I 1D LODI Naa 4 ju hh TOOL E m SkyAz l Eguipment Solutions www skyazul com 301 371 6126 1 3 f HIRSCHMANN HIRSCHMANN maestro Installation Information 3 5 2 Relay installation maestro central unit 0006 Ref 3 4 maestro system wiring 1 Connect the wires to the relay as described and
9. Ref 4 2 1 LMI Test Procedure SkyAz l Equipment Solutions www skyazul com 301 371 6126 21 fy HIRSCHMANN HIRSCHMANN maestro Installation Information 4 2 1 LMI system test procedure WARNING Do not operate the crane out side the permissible operating range for the type of crane capacity chart being tested 1 Most crane manufacturer calibrate the cranes with the jib removed it is recommended that this is done to carry out the following test How ever on some cranes this might not be the case if in doubt contact the manufacturer 2 For calibration verification a test load is to be employed for each of the following configuration NOTE For safety reasons first measure the allowable radius for the load being used have a spotter to ensure the system stops the functions at or before this point 3 Maximum Boom Length and Middle Radius select a load that will lock out the functions about the middle of the load chart in the long boom length step 4 The following test should be recorded signed and dated A copy of this test sheet should be available at all times 5 Test load to be applied by suspending known weights accurate to 1 Weights of all additional equipment such as blocks slings sensors etc are included in the test load The total load is to be known to an accuracy of 1 With extended boom and the load suspended move the load smoothly from the short radius to overload lock out measure and reco
10. The system program PROM e Replace system program course is defective PROM PROM No 0 e Computer module 80C537 e Replace computer module defective 80C537 e LMI board defective e Replace LMI board System program and data e The system program in the e Replace the system pro EPROM do not match LMI does not match to the gram PROM or the data programming in the data EPROM PROM No 1 EPROM Error in the internal e Computer component e Replace computer compo write read memory RAM 80C537 defective nent 800537 of the computer component 80C537 e CPU module defective e Replace CPU module e LMI board defective e Replace LMI board with CPU module Error in the external e Write read memory CMOS e Replace LMI board write read memory 1st part RAM or LMI board defec RAM tive SkyAzul Equipment Solutions www skyazul com 301 371 6126 29 Error Codes f HIRSCHMANN Error in the external e refer to E42 e refer to E42 write read memory 2nd part RAM Cyclic RAM test error in e Computer component e Replace computer compo the internal write read 80C537 defective nent 800537 memory RAM of the com puter component 80C537 e LMI board defective e Replace LMI board Error in the crane data e No valid data in the crane e Load crane data EEPROM EPROM or EEPROM data EEPROM containing valid data e Memory module wrongly e Bridge memory module acc bridged to memory type e Crane data EPROM defec e Replace crane
11. e To start ensure the boom is completely down retracted depressurised and en gine power turned off e Remove Jumper from J1 and place on Br 1 of data EPROM module e Turn on crane power e A valid operational mode must be se lected No error message present e While power is on relocate the bridge from position Br 1 to Br 3 of the data EPROM module to start the sensor ad justment function A After closing the bridge B3 two additional values for pressure at the cylinder and rod u will appear in the middle of the display MINI PRESS t To highlight the first adjustment value re CT 3 g rpe 1 bob HE Hill Hii Sm BE 7 De oT Epa A Pr Hp Z peste Bete fa lll e A e Adjustment of pressure at the cylinder ric ri BEI 11 Display for pressure at the cylinder flashes EH peip r Jn pia A rc Epis face 7 De De petes feie Bee a t By means of brief simultaneous pressing the and keys the value for pres sure at the cylinder is set at zero Press e to highlight the next adjustment value SkyAz l Equipment Solutions www skyazul com 301 371 6126 17 HIRSCHMANN maestro Installation Information f HIRSCHMANN Input Display examples Comments N I Adjustment of pressure at the rod kr t PRI 23 1 A pL Aby fem z Display for pressure at the rod f
12. pressure transducer the following parts are use to make a hydraulic connection to a 9 16 18 JIC fitting 000 209 140 016 Pressure Transducer Cutting Ring Seal 031 300 050 689 Pressure Transducer Adapter 9 16 18 UNF 2B M16 X 1 5 You will need hydraulic adaptors to suit the new pressure transducers The details are shown on the next page SkyAzul Equipment Solutions www skyazul com 301 371 6126 9 fy HIRSCHMANN HIRSCHMANN maestro Installation Information gt Conversion from OLD to NEW Data for current pressure transducers Kits for 100 replacement of current types obw 604240 DAVS314 SA 606652 532726 532674 606720 DAVS300 3403SAMI6 o ber 605237 DAISSILSAMGO Loses sur mer eat oes onan amo asobar 605238 DAYS 354 350 bar SA Ria _c0sees 532726 coma DAVS350 34025A sobr 605304 DAVS la 5A EOL MiS Las sms ser uen soar same soobar esu OAVS314 5A E0L mie 60ses2 532726 532674 606720 DAYS 300 3403 SAMI6 Ls ese a p su mu sns Hen se soobar 405972 DAYS 314 09 5A TT 606652 532726 532674 606720 DAYS 300 3403 SAMI6 ao ber 80606 DAYSa1a SA EOL MIS 606669 532726 532675 006724 DAVS 400 3404SAMIC 3o bw 805173 DAYS 14 07 sa Raya 6oses2 saare 606725 DAVS300 34025A 355b 805151 DAYS 350 350ba1 SA 60eees 532726 smera 606726 DAVSSSU MONSAMIE Lue un osea mes mx y
13. wiring can be retained as far as possible This can be done to install the Maestro C U at same place as of Old C U However since Maestro C U is smaller in Size than most of the previous PAT C U s it would be advisable to install it inside the crane cabin behind the operator s seat If installing the C U inside the Crane Cabin ensure that the existing cables are long enough to reach inside the Cabin after re routing Instead of welding the mounting squares of the C U you may also use Flat Bars with holes at each end enabling the use of the existing holes Note that you may be required to modify the Strain reliefs in the C U depending on the amount and size of wires being used If an extra hole is needed you can remove the breather from the side of the C U and utilize this hole always leave a drip loop in the cables for external mounted C U s f HIRSCHMANN HIRSCHMANN maestro Installation Information 3 2 Console Install the maestro console with proper positioning within the field of vision and operating area of the crane operator There is a standard length of cable with multi pin connector supplied with the Maestro console Ensure there is an adequate length of cable between the console and the central unit The console has a mount that allows the console to be swiveled into any direction and to be mounted in a variety of locations and on nearly any surface Choose a location that is in line of site of the sensor and
14. with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Hirschmann shall not be liable for errors contained herein 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 All rights reserved No part of this document may be photocopied reproduced or translated into another language without the prior written consent of Hirschmann fy HIRSCHMANN HIRSCHMANN maestro Installation Information 2 1 Tools required e Installation tools for mechanical and micro electric work as o Multimeter Tools for Wiring Crimping tool knife cutter etc o Screw Drivers Wrenches Welder Digital level 2 2 What is new or changed e Central Unit has changed to the Maestro Central Unit e The maestro console in now used in place of the DS 100 DS 200 DS 350 KD LC DS 350 G E GW consoles e Pressure Transducers KMD Loadcells SKM Lineriders will need to be modified or replaced by CURRENT Output type sensors 4 20 mA e You can either use the same Cannon Plug Cables with adaptor available or use new 5 pin cable for Pressure Load Sensors e Any additional Length Angle Sensor will be changed to Current Type 4 20 mA e Data Eproms will need to changed if not already a 27C256 e Elimination of the Lightbar option 2 3 What
15. O STRAIN RELIEF INSERT 14 CABLE IDENTIFICATION ARE AS FOLL i S gt CABLE LENGTH S MLIES ARE MEASURED F RAIN RELIEF gt INNER SHIELD IN THE NORMAL OPERATING C POSITION JMPER IN TO 6 STALLED FROM TERMINALS SkyAzul Equipment Solutions www skyazul com 301 371 6126 11 fy HIRSCHMANN HIRSCHMANN maestro Installation Information 3 5 Maestro system wiring 0011 Central Unit May 2006 current INTERFACE KEY BOARD OU 11 1 2 3 4 E 5 a sil e L 1 1 2 3 4 e ge PLUG NO LABEL REQUIRED e lt A AC b 2 e BB 2 JRE DRAIN NO LABEL REQUIRED Hs B xij 1 4 lt t am REQUIRED 4 lt p De E o JRE TRANS e LE E er Fe DE PRESSURE TRANSDUCER Gs F POSITION NUMBER REFERENCE UNIT CEN UNIT E o S S d 1 g 5 E Aa E 1 a X1 2 3c N N vx vx2 vxa 9m 9 x 8 ON 4v2 1774 NOTES SHIELD SZ e TAPE AND ST 12 gt 13 1 gt
16. d and analog input module from the main board due to the fact that these boards have pins on the bottom side which insert into the main board 3 Disconnect the wiring by unplugging terminal blocks ensure all blocks and wires are marked to simplify installation If disconnecting wires from terminal blocks refer to the system wiring diagram in this manual or in the central unit lid for wiring connections 4 Remove the EPROM module board by taking out the 2 small Philips screws holding it in place 5 Remove the system EPROM 6 Remove the main board by taking out the 4 Philips screws holding it in place 7 Take notice of the orientation of the main board in the central unit Remove main board and place in the packing material that the replacement main board came in 8 Carefully insert the new main board in place 9 Insert the 4 Philips mounting screws 10 Insert system EPROM 11 Insert EPROM module board by lining up the pins into the sockets X14 and the 2 screw holes 12 Insert the 2 small Philips screws and washers 13 Connect the X1 terminal blocks wires to the main board Refer to the system wiring diagram in this manual or in the central unit lid for wiring connections 14 Turn power on and test system 15 Inspect the gasket for nicks cuts or damages before installing and tightening the cover SkyAzul Equipment Solutions www skyazul com 301 371 6126 23 fy HIRSCHMANN HIRSCHMANN maestro Procedures 5 2 Cabl
17. data EPROM tive Error in crane data e Memory module wrongly e Bridge memory module acc EEPROM bridged to memory type e Crane data EEPROM defec e Replace crane data tive EEPROM Error in serial crane data e Serial crane data EEPROM e Write data on the serial EEPROM does not contain valid data crane data EEPROM by means of test program or on line function then restart the LMI e Memory module defective Replace memory module Error in the serial analog e No valid data in the serial e Write data on the serial ana data EEPROM analog data EEPROM log data EEPROM by means of the test program then restart the LMI e LMI main board defective e Replace LMI main board Short circuit in the A2B e Short circuit in the A2B e Replace A2B switch switch circuit switch e Short circuit in the cable to e Replace cable to the A2B the A2B switch Switch No data transmission form e 24V supply of the console is e Check 24 V at terminal X1 of the console to the central interrupted the console electronics Interruption or accidental e Check the connection con ground in the line between sole electronics central console electronics and cen unit In case of an accidental tral unit ground the transmitter module of the console elec tronics might be damaged Therefore replaces the con sole electronics e Transmitter receiver module e Exchange console electron is defective ics or LMI main board resp SkyAzul Equipment Soluti
18. drops build up on the inner components when humid air is trapped inside the box With condensation water tightness is not a problem the box is sealed just fine which is what prevents the trapped air from exiting the box There are two ways to deal with condensation 1 Ifthe volume is very small a desiccant bag might be able to soak up the air s humidity 2 If the effect is more severe the only way to get rid of this effect is then to give the box the ability to breath without sacrificing its water tightness Contact your Hirschmann repre sentative for breathing elements to than can be added to the box and will help to reduce the effects of humid climates SkyAzul Equipment Solutions www skyazul com 301 371 6126 26 fy HIRSCHMANN Error Codes 7 Error Codes Error Code Error Cause Remedy U cutoff due to overload e reduce load moment e prewaming O A2B switch e the A2B switch is activated e lower the hook block Fallen below radius range e fallen below the minimum or angle range exceeded radius or gone past the maximum angle specified in the respective load chart due to luffing up the boom too far Radius range exceeded or e gone past the maximum fallen below angle range radius or fallen below the minimum angle specified in the respective load chart due to luffing up the boom too far Operating mode not ac e Anon existing operating knowledged or non permit mode has been selected ted slewing zone luff u
19. e Reel Length Cable Replacement Procedure Replace length cable using the following procedure Refer to system electrical wiring diagram and cable reel parts list 1 Cut old cable at cable drum 2 Disconnect damaged length cable from junction box at the boom nose 3 Open cable reel cover and disconnect wiring from terminal block Pull 7 conductor cable out of strain relief Note Mark wires to make connection simpler after cable installation 4 Remove cable reel from mounting brackets 5 Remove damaged length cable which is mounted to the slip rings in the cable reel from slip ring terminal 6 On the backside of the cable reel open the strain relief attached to the axle in the center of the drum Pull existing length cable out of the cable reel 7 Pull new length cable through the hole pipe and strain relief and push it through the axle of the reeling drum Tighten new strain relief to ensure sealing 8 Reconnect the length cable to the slip ring 9 Remount cable reel to the boom 10 Turn reeling drum clockwise to spool the new cable neatly onto the drum 11 Set pre load on cable reel by turning the drum counter clockwise 5 to 8 turns 12 Run the new length cable through the cable guides and wrap the length cable around the boom tip anchor pin 4 or 5 wraps and secure with tie wraps Leave enough length cable to connect into the boom tip junction box 13 Connect the length cable into the boom tip junction box 14
20. e sa Rad en Rara 20 Checking the data display ner nnnnrnnnnnnnnn 20 gut cec 20 LMI system test procedure oosoooorovnnn nn nn nn 22 dol me 23 Main Board Replacement Procedure ssssssss 23 Cable Reel Length Cable Replacement Procedure 24 Troubleshooting moisture eene 25 Water Ingress ER 25 Condensation 2 cccecccceeccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeecaeeeeeeeeteeeeeseneees 26 Error COMES qme 27 Spare part numbers eeesesessesesesseeeeree nennen 32 maestro Console ssssssssssssssseseee eene 32 Pressure Transducer DAVS300 3401 nen 32 Maestro Central Unit ira 33 Version History co concordia siii 34 f HIRSCHMANN fy HIRSCHMANN HIRSCHMANN maestro Installation Information 1 GENERAL INFORMATION This manual describes the procedure for installation of the HIRSCHMANN maestro system as a replacement for older PAT systems Well grounded knowledge regarding the method of functioning of load moment indicators as well as knowledge of the start up procedure and adjustment of such systems are required In some cases knowledge of the operation and use of burning devices for EPROM s is also required Please always comply with the safety instructions If yo
21. fer to system wiring diagram for console wiring connections to central unit maestro PART NO QTY DESCRIPTION T 031 300 050 635 2 BASE 2 5 DIA 050 000 100 27 4 1 BUZZER 024 350 100 312 1 MOISTURE DRAINAGE PLUG 031 300 100 391 1 CONNECTOR 7 PIN RECEPTACLE 031 300 100 024 1 DUST CAP 031 300 050 624 1 MOUNTING ARM 4 63 FOR 1 5 BALL 050 160 100 008 1 HOUSING PREASSEMBLED WITH FRONT FOIL 050 050 300 030 1 CONSOLE CPU UNIT 050 000 100 267 1 DISPLAY UNIT 1 050 050 300 036 KEYBOARD WITHOUT ILLUSTRATION c MO r I gt o 8 2 Pressure Transducer DAVS300 3401 Part Number 031 300 060 452 4 20mA 300 bar M12 9 16 18 There are no spare parts associated with the pressure transducer the following parts are use to make a hydraulic connection to a 9 16 18 JIC fitting 000 209 140 016 Pressure Transducer Cutting Ring Seal 031 300 050 689 Pressure Transducer Adapter 9 16 18 UNF 2B M16 X 1 5 Ref 3 3 Pressure Transducer Installation SkyAzul Equipment Solutions www skyazul com 301 371 6126 32 f HIRSCHMANN Version History 8 3 Maestro Central Unit Part Number 024 160 060 011 Refer to system wiring diagram for wiring 024 000 050 339 HOUSING 024 050 300 046 MAIN BOARD LMI 024 050 300 021 DATA EPROM MODULE JUMPER W O PROMs 024 000 100 281 KEYSWITCH KIT 024 000 100 095 PRESSURE COMPENSATION ELEMENT PG11 024 000 100 285 CUT OFF RELAY KIT 12V 024 000 100
22. lace LMI board the overload relay of the LMI board e LMI board defective Relay should be energized but 2nd contact is indicated off or the 2nd contact is indicated on while the relay should be deenergized No acknowledgement of e cf error E07 e cf error E07 the anti two block switch relay Fallen below limit for the e Length sensor pot defec e Replace length sensor po measuring channel Length tive tentiometer main boom e Replace LMI board e Electronic board in the measuring channel defec tive Fallen below the lower limit e Cable between the central e Check cable as well as value in the measuring unit and pressure transduc plugs replace if need be channel pressure piston ers defective or water inside side the plugs e Pressure transducer is de e Replace pressure trans A A ee e Electronic component in the measuring channel is defec processor board a tive Fallen below lower limit e refer to E12 e refer to E12 value in the measuring channel pressure rod side Fallen below lower limit e refer to E12 e refer to E12 value in the measuring channel pressure piston side Cyl 2 Fallen below lower limit e Angle sensor defective e Replace angle sensor value for the measuring channel angle main e Electronic part in the meas Replace LMI board boom uring channel defective Fallen below lower limit refer to E12 refer to E12 value in the measuring channel pressure rod side Cyl 2 Reference a
23. lashes A E Am TERIA Hes Dos Nie eet Ho 16 nA 8 By means of brief simultaneous pressing the and keys the value for pres sure at the rod is set at zero MO to highlight the next adjustment value r 7 ce CEEE ka m s LA De De PL ECTS Hill HH pis JUN ciori Bill HIT A ais at k L s r La co cn Adjustment of the main boom length shortest length The boom must be completely retracted with length potentiometer adjusted counter clockwise to a soft stop 5V on term 14 Do not try to adjust the length this is pre set in the software and is the actual boom length If you have the original cali bration sheet this value should match the length displayed If in doubt contact the authorized dealer The minimum boom length value is pre set in the original crane software ONLY a con firmation of this length is required To confirm this value simultaneously press the and keys to reconfirm the mini mum boom length stored in the DATA EPROM CAUTION Do not attempt to arrow up down to change this indication MO to highlight the next adjustment value SkyAzul Equipment Solutions www skyazul com 18 301 371 6126 HIRSCHMANN maestro Installation Information f HIRSCHMANN Comments Input Display examples 5 b gdi JA A i4 a FER SS SEE B5 16 215 J fsz PERA Io t b 3
24. nd or supply e The supply voltage is falsi Check the voltages on the voltage defective fied by one of the sensors LMI main board AGND DAV LWG MPO Check sensors plugs and cable replace if need be e Electronic component is e Replace LMI board defective SkyAzul Equipment Solutions www skyazul com 301 371 6126 28 HIRSCHMANN Error Codes e A D converter of CPU e Replace LMI board 80C537 defective Upper limit value for meas e Length sensor pot defective e Replace length sensor po uring channel length main tentiometer boom exceeded e Electronic part in the meas e Replace LMI board uring channel defective Upper limit value in meas e refer to E12 e refer to E12 uring channel pressure piston side has been ex ceeded Upper limit value in meas e refer to E12 e refer to E12 uring channel pressure rod side has been exceeded Upper limit value in meas e refer to E12 e refer to E12 uring channel pressure piston side Cyl 2 has been exceeded Upper limit value in meas e refer to E15 e refer to E15 uring channel angle main boom exceeded Upper limit value in meas e refer to E12 e refer to E12 uring channel pressure rod side Cyl 2 has been ex ceeded Reference and or supply e refer to E19 e refer to E19 voltage defective Error in the system pro e The system program PROM e Replace system program gram is defective PROM PROM No 0 E37 Error in the logic program e
25. of water ingress by going through the following steps and ruling out one possibility after the other until the cause is identified 1 Spray Cleaning The enclosures used for the maestro system are water protected to IP 65 This means protection against the environment such as rain However through the use of spray cleaner at short distances it is possible to force water through the gasket or strain relieves For this reason avoid spraying any components from short distances with spray cleaners Convey this fact to any member of a maintenance crew 2 Missing Loose Screws All screws have to be present and to be equally tight to ensure water protection of the enclosure If there are screws missing replace them If no screw is missing check the tightness If any were loose then open all screws and then re tighten them equally 3 Bent Lid An enclosure will only seal correctly if the lid is not bent To check this loosen all screws of the lid take the lid off the box and visually inspect it for deflection If the lid is bent or damaged it needs to be replaced Try to determine what has caused the lid to be bent and eliminate the reason for that Order a new lid through your Hirschmann representative SkyAzul Equipment Solutions www skyazul com 301 371 6126 25 fy HIRSCHMANN HIRSCHMANN maestro Procedures 4 Defective Gasket The gasket underneath the lid seals the unit The gasket needs to be in good condition in order to seal cor
26. ons www skyazul com 301 371 6126 30 Error Codes Error in the data transmis sion from console to central unit Error in the data transmis sion from the central unit to the console No data transmission from the central unit to the con sole Error in the console EPROM Error in the internal RAM of the console SkyAzul Equipment Solutions HIRSCHMANN Check the connection be tween console electronics and central unit Exchange console electron ics or LMI main board resp refer to E92 Loose connection in the line between console electronics and central unit Transmitter receiver module is defective e referto E92 Interruption or accidental ground in the line central unit console Check line to the console in case of accidental ground replace console electronics too in the central unit is missing power unit board is defective or LMI main board e Replace processor board tive Electro magnetic interfer Eliminate the source of inter ences e g when switching ferences by inverse diodes contactors or valves or varistors The console EPROM is e Replace the console EPROM defective The CPU of the console is Replace the CPU of the console defective The console main board is defective Replace the console main board www skyazul com 301 371 6126 31 HIRSCHMANN Version History 8 Spare part numbers 8 1 maestro Console Part Number 050 160 060 008 Re
27. p the boom to a radius or angle specified in the load chart luff down the boom to a ra dius or angle specified in the load chart Set the correct operating mode for the operating state in question e The boom is in a non e Slew the boom to a permit permitted slewing zone ted area the boom having to be ex tended to a certain length The length sensor adjust ment was modified e g rope slid off the length sen Sor reel Clutch between length sen sor pot and drive is defective Failure of the 5V supply for the analog part of the LMI analog board Length potentiometer de fective Es HE Forbidden length range of e Boom has been extended the main boom too far or not enough e g if operation is only admitted up to a certain boom length or for load charts of jibs with SkyAzul Equipment Solutions www skyazul com Retract or extend boom to the correct length Retract the boom Check the prestress of the cable reel the rope has to be under traction Open the length sensor and carefully turn the length pot counterclockwise to the detent by use of a screwdriver Completely replace the clutch with the drive wheel and adjust length sensor pot Check 5V voltage If there is no voltage or break down at a charge of 50 ohm ap proximately exchange LMI board Replace length potentiome ter 301 371 6126 27 HIRSCHMANN Error Codes Faulty acknowledgment by e Overload relay defective e Rep
28. rd radius calculate cut off see section 6 Ensure the appropriate functions are disabled 6 Computations For each radius measured in the above tests refer to the applicable load rating chart and determine the rated load At radii intermediate to those on the load chart rated load shall be determined by linear interpolation unless otherwise specified by the crane manufacturer The system accuracy is to be determined from the following formula TEST LOAD x 100 OF RATED LOAD RATED LOAD at cut off radius angle 7 The actual load which activates the overload lock out is not less than 90 of the rated load nor more than 100 of the rated load for the corresponding actual load radius or boom angle Note This is a general standard and variations may exist if in doubt contact the crane manufacturer CALIBRATION TEST CRANE SIN Op Parts of Main B Main B Jib Ext Jib Actual Indicated Actual Indicated Cutoff Mode Line Length Angle Length Offset Load Load Radius Radius SkyAzul Equipment Solutions www skyazul com 301 371 6126 22 fy HIRSCHMANN HIRSCHMANN maestro Procedures 5 Procedures 5 1 Main Board Replacement Procedure Refer to section 8 2 central unit parts list for board location 1 Turn system power off 2 Remove the central unit lid NOTE Take care not to damage the boards with the screwdriver when removing and inserting screws NOTE Use care when lifting the CPU module boar
29. rectly If the gasket is torn brittle or severely bent it needs to be replaced Order a new gasket through your Hirschmann representative 5 Loose Strain Relieves The strain relieves allow cabling to enter the box without allowing water to enter it The strain relieves have to be correctly tightened in order to do this Check the tightness by taking the external cable into one hand and carefully trying to turn it If the internal wires turn with the outer cable the strain relief is loose Get a new grommet insert through your Hirschmann representative and replace the existing one with the new one Tighten the strain relief correctly Note Whenever a strain relief is opened i e to replace a cable a new grommet needs to be used Never re use any grommet or the strain relief will not seal properly 6 Water Entry through External Cabling Even with a tight strain relief water may still enter the box through the inside of the cable In this case you have to find out why and where water enters the cable Look for damages to the cable itself and inspect the opposite side of the cable In example if the cable comes from a connector that is full of water the water will run through the inside of the cable and fill up the central unit too 6 2 Condensation In a climate with high humidity and rapidly changing temperatures condensation can happen inside any enclosure usually the larger the volume of the box the more likely In this case water
30. remains same e Main Cable Reel will remain with Voltage Outputs e A 2 B Switch remains same e Most Cables will remain same except for Load Sensors 7 cond cables from cable reel to C U and Console cable e All Digital Inputs amp outputs cables remain same e Data Eprom from DS 350 G E amp GW and some DS 150 amp DS 350 KD LC s will remain the same If the Data Eprom is 27C256 you can use it as it is fy HIRSCHMANN HIRSCHMANN maestro Installation Information 3 Installation Instructions The following instructions are to simplify the conversion of the old LMI system to the HIRSCH MANN maestro LMI 3 1 Central processing unit A N NOTICE Before uninstalling the current central unit be sure to note the locations of each wire be fore disconnecting them from the terminal strips A wiring diagram of the previously in stalled system will be useful It is necessary to note all Digital Inputs and their respective loca tions before disconnecting them from the original central unit to ensure proper reinstallation Ex DI 1 Outriggers area definition DI 2 Rubber area definition DI 3 No load Power pin fly Carefully remove the Data EPROM from the original central unit This EPROM will be reinstalled into the new data EPROM module at a later point Please contact your authorized regional dealer with any installation questions Install the maestro central processing unit in such a way that the old electrical
31. shown below e Yellow wire to relay terminal 85 e Black wire to relay terminal 86 e White wire to relay terminal 30 e Orange wire to relay terminal 87 3 The load A2B lock wire wire 3 in power cable will be crimped into uis empty 74 female crimp terminal that is in terminal 1 Crimp lockout wire in 74 female crimp terminal 1 SkyAzul Equipment Solutions www skyazul com 301 371 6126 1 4 A HIRSCHMANN HIRSCHMANN maestro Installation Information 3 6 Data acceptance or using data EPROM from previous system A distinctive feature of the Hirschmann maestro system is the possibility of data acceptance from a multitude of older PAT systems see list in chapter 2 1 to convert the data instructions are provided below for the acceptance with various PAT systems This means you can insert Old Data Eprom from Old System without any changes in the software However the accep tance of these Data Eproms is limited to the Types System Codes given in Chapter 2 1 If any uncertainty or doubt exists as to whether the data can be accepted in your particular case please contact Hirschmann or an authorised and trained regional dealer to have the conversion capability checked 3 7 Data EPROM extraction from previous system 1 Remove cover from central unit CAUTION Before handling the EPROM discharge any static electricity from your body by touching a grounded point The EPROM could be damaged by static electricity
32. u have any questions please contact your authorized regional dealer 2 SAFETY INSTRUCTIONS The following safety instructions must always be observed and complied with To prevent material damage and serious or even fatal injuries to staff the correct ad justment of the LMI has to be ensured before starting operation of the equipment The LMI can only function correctly after the conversion if the following points have been complied with the correct installation and wiring of all hardware components the transfer of the data contents of the old system the checking and if necessary adjusting of the zero points of the sensor technology the checking of the data display a functionality test of the entire system and in conclusion a load test It is imperative that the operational and safety instructions as well as the load charts provided by the crane manufacturer particularly for specific operating conditions and load limits are always referred to This system can be equipped with a bypass function which bypasses the switching off of the control lever function by the LMI or the A2B switch es system The bypass control switches must only be activated in emergencies and by authorised staff Fail ure to comply with this instruction can result in material damage and serious or even fatal injuries to staff The information in this document is subject to change without notice Hirschmann makes no warranty of any kind
33. within reach of the operator Securely attach the two RAM mount bases onto a solid surface for the left and right side operation The console cable may not fit through goose neck conduit as existing wiring therefore run the console cable to the outside of the conduit and insure there no interference fy HIRSCHMANN HIRSCHMANN maestro Installation Information 3 3 Pressure transducers Prior to replacing hydraulic connections of Pressure Transducers these must be de pressurised The boom should first of all be completely put down and the derrick lift cylinder de pressurised after that The pressure transducers of the old system can only continue to be used in case of GC sys tems if these have a signal output of 4 20 mA A three pole cable matcher from three pole Canon to M12x1 is available for the electrical connection In the case of the older systems pressure transducers with voltage output are however nor mally in use which should be replaced with the new pressure transducers of the DAVS 300 3401 SA type with the same pressure range In this case it is advisable to also replace the feeder cables at the same time with new cables with pre assembled connection plugs which are included in the scope of supplies of the maestro conversion kit Pressure Transducer DAVS300 3401 Part Number 031 300 060 452 4 20mA 300 bar M12 9 16 18 There are no spare parts associated with the
34. yed Display for force measurement flashes By means of brief simultaneous pressing of the and keys the value for the force measurement is set at zero Press to highlight the next adjustment value End the process with a final pressing of the key After that the adjustment process is con cluded The calibration values are stored Remove the bridge Br 3 and reinstall in Br 1 Bridge must be moved to Br 1 before crane power is turned off to avoid an error 4 Start up procedure The start up procedure of the new system is normally shortened a great deal in terms of time due to the transfer of the contents from the central processor memory and the automatic sensor adjustment It is nevertheless necessary to check the contents of the data displays 4 1 Checking the data display Check the geometric data which are shown on the display by measuring for accuracy If devia tions arise these can only be taken in hand by the inputting of correction values in the EEPROM Ref 5 5 LMI test procedure If necessary you can use Hand Terminal to correct any data as usual for old PAT systems 4 2 Final tests SkyAzul Equipment Solutions www skyazul com 301 371 6126 20 fy HIRSCHMANN HIRSCHMANN maestro Installation Information When all of the settings have been made it is still necessary for the system to be checked and load testing completed in accordance with the manufacturer s specifications
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