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IFLEX2 + iSCOUT expert compact Service Manual

1. d i m vA Cr Qu 5 f co bi u Ql in x ol i ol gi AN i o 21 300 060 23 m gt lt 31 300 060 BASE SECT JUNCTION BOX ASS d 12 lt j 5 m lt Z r e o vl 2 z ot m j I m m D D D n EE o E I d ml e z x amp x d m LG152 56 CABLE REEL 067 2 060 056 INNER MID LENGTH 2 a x o z v EL 2 j al a BG el z x 3 m m m Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice 2007 HIRSCHMANN Automation and Control GmbH 39 Service Manual PPAT iFLEX2 with iSCOUT expert compact 14 4 2 Cable Reel LWG520 0002 Wiring Diagram TO PRESSURE TRANSDUCER BLOCK REFER TO CONSOLE AND SENSOR WIRING DIAGRAM CAN BUS CABLING
2. ADJUST LENGTH WITH BOOM FULLY RETRACTED TURN THE CENTER SCREW COUNTER CLOCKWISE TO SOFT STOP e With boom fully retracted turn the center screw of the length pot unit counter clockwise to a soft stop e During adjustment an additional button OK appears Check value and set actual length as fully retracted length by pressing OK Afterward next calibration screen appears V Calibration screen minimum length skip calibration step set minimum length cancel and return to LMI screen 2007 HIRSCHMANN Automation and Control GmbH 47 Service Manual PPAT iFLEX2 with iSCOUT expert compact e Now extend main boom all the way out Make sure you are within the allowed operating range especially maximum radius e During telescoping out the boom an additional button OK appears V Start calibration maximum length stipcattratonsiep calibration step cancel and return to LMI screen e Check whether boom is fully extended then press OK Afterward next calibration step angle appears skip calibration step set maximum length cancel and return to LMI screen V Calibration screen maximum length 48 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk Sensor Calibration f HIRSCHMANN A Belden Company 15 4 1 Cable Reel Length Ca
3. 17 9 031 300 0 50 1 e E B A A 9 H x e lt 2 e L lt e a o n 2 u ur o H T 7 CONNECTION BOARD lt I a gt 068 000 300 102 T gt pi J amp m 6 8 9 22 ES K 5 a 5 gt Oo 7 6 E v o o 9 ES o o i D o 8 o i5 o o S e 9 lt u u 2 NI u a QJ o u M V v x 7 E a mM QJ I 9 e 2 e e e e R e 4 0 x 2 5 J o z 2 Z D 9 BOOM JBA 00 060 467 BRN RN 5 BLK 5 lt LU Orc ee UU lt vo YZ 22 z r ua Z m oc S a gt NK WER Z gt 11 1e 14 15 16 17 18 1 1 0b is lt e 2 O 503 GR e lt OF a WHT M 2 x 9 lt 2 X iRN N 2 eoe lt 1 1 1 19 17 1 amp H p 2 e 9 9 lt o D of r o e SO z S o o 9 o o lt z a z 2 Es Y Y Qe a I o 5 m 2 m TA e lt gt H gt D gt 4 4 Ly by 4l 2 GMK SWITCH b e gt gt z ol al z gt of sa x 2 cx el n 21 red B gt m Im 4 2 2 c f N ul e 1 S 6 8 9 10 11 18 x 1874
4. 8 4 6 The console display Re DTE 8 Have PODION m 8 4 8 I Have 8 4 9 need to identify a spare part ius cou coded irre ete er a otn prse peres ux deu ven ded ers 8 4 10 I have noticed water in some part of the 8 5 SINS ING 9 5 1 Angle sensing error flow 10 6 Sensing MEE m ERR 12 6 1 Length sensing error flow 13 7 Pressure Sensit EE Dc ts dm D TEE E NOUS 15 7 1 Pressure sensing error flow 15 8 Slewirg Sensiid onsec taie a iv devis uada EC us m PINE 16 8 1 Slew sensing error flow 17 9 Lodd SENS 18 9 1 Load Sensing error flow 18 10 CONSO CUS Ly me 19 11 PZB i o T 20 12 CAN B s CONTEC AU OIA ecc 21 c r 21 dU REEL 22 122 rc m 2
5. 39 14 4 2 Cable Reel LWG520 0002 Wiring 40 14 4 3 Luffer Extension Wiring 41 15 mU 43 15 1 Activating the Service Screen for Sensor 43 152 Zero Seting te Pressure dnpDUls suivis tid iaa Senne da ova i Don vcr Ea a 44 9 9 ero ssetung thie slewing ida pota ae o baa iat soda boi ea Don d utra DU i EA 45 15 4 Length Sensor Calibration PrOCGeGUre u eee taa ume xod uus n reus aea Dre si uv 46 15 4 1 Cable Reel Length Cable Replacement 49 15 5 Angle Sensor Calibration 50 16 Error COUS cnt 53 17 Troubleshooting Moisture E a 58 WAEN ESS esre a 58 0 25 Condens atO 59 The manufacturer reserves the right to modify the contents of this manual without notice Hirschmann 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 wr
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7. H 3AE CAM k Dema OUTPUT B 14 DUM P CUO UA DREUT 10 MLE EATON OUTPUT 11 1 SIME HA AE CAMI TEMM sig d JH moo rn cn m Ho av SWCD POwOR nm 4 aw CONETANT POSER CHAME 4v CONN CTID CONNECTIE CONNECTED h CONNECTED CANI L CAMOPEM afa em UNES OT to console l 3 5 gt ANALOG PUT O amp 20mA SLEW OF 1 AMALOG PUT 4 SLEW POT CH 2 nm to crane interface gt 4 a ANALOG PUT 2 4 20mA ANALOG PUT 3 4 20mA Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice is fe fe fs fe Js fe Je Je fe Je fe Jo Jo fo Js Io fo Jo fe fe 3L Je Je ju fe Js fe fe ev ANALOG 4 ANALOG PUT 4 20mA ANALOG PUT amp 4 J0mA ANALOG PUT 7 ETERS CONNECTION gt aw POE m izv fee fe fe fe fe fe fe fe fe fe fe fee fe fe e Jo fe Tome 6 fe fe fe fo
8. ol vf ni 2 dd 2 Li E pees N i i ix d 1 m mi n n ley la Eg key 5 Qd 2 3 E 2 2 0i 2 a lt 1 ji gt Sag E 7i l gt d I zn gt 4 4 2 C cx t1 1 1 1 1 E a EM l o 1 E gt gt 1 S44 c 0 lt di 26 090 0C 1 0 Var 1353350 83440 4 2 v 810 006 000 89 I dqavod 10 HION31 lt r IND ot lum um mom a Y Y 2 100015 e 2 WNBIS gl o A 2 T E A Z ad L d x m v v v ID n OOo ag 4 Eque 31692 dev 41 Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there drawing and data confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice 2007 HIRSCHMANN Automation and Control GmbH Service Manual PPA
9. Y a lt 9 ou j T o m m x 5 S o 9 9 o H u oO D 2 gt vov o VV Y 5 16152 0056 Z REFER TO CABLE REEL LG152 0056 WIRING DIAGRAM 2 2 2 a m E A i a e AcB SWITCH A2B SWITCH Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice 40 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk Belden Company f HIRSCHMANN Luffer Extension Wiring Diagram Drawings 14 4 3 Ls a S e em qp pe qe ce eR pese qBemEeERERS ae o Nal cd v z a 3 J 2 YD ET bi aon m lt 1 I s trem 2 2 ut ES EM x Le E E r ap
10. Service Manual PPAT iFLEX2 with iSCOUT expert compact 15 4 LENGTH SENSOR CALIBRATION PROCEDURE NOTE The length sensor can be calibrated for its zero point and its full range With retracted boom the potentiometer of the length sensor has to be at its O position which is all the way counter clockwise For extended boom the adjustment is done by software as described below The length should be calibrated to be about 0 1 feet or 0 05m for metric accurate for retracted and extended lengths Perform the following steps V Calibration screen boom length skip calibration step start length calibration cancel and return to LMI screen Start procedure by pressing OK Start calibration minimum length next calibration step cancel and return to LMI screen e Fully retract the main boom and check if indicated length is within 0 1 feet or 0 05m for metric o actual retracted boom length e fitis not adjust length potentiometer mechanically as described below 46 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk Sensor Calibration h HIRSCHMANN A Belden Company pe
11. 0U Pin 3 Ground Pin 4 CAN High Pin 5 CAN Low Measure between pins 3 and 2 for crane voltage If you see voltage check all pins for continuity The iFLEX2 must be replaced if this cable is functioning correctly If the E61 error code has become an E64 connect the cable reel can bus cable to the transducer block and remove the can bus connector at the cable reel If this causes an E61 to appear the can bus cable between the cable reel and transducer block must be replaced If an E64 remains use the Ohm meter to check the connector in the cable reel Either the connector has failed or the can bus converter boards must be replaced 2007 HIRSCHMANN Automation and Control GmbH 21 Service Manual PPAT iFLEX2 with iSCOUT expert compact 12 1 1 E61 Flow Chart Connect the two cables on the Transducer block together Replace Transducer Block Disconnect cables and connect cable from c u to transducer block Connect the cable reel can bus cable to Ohm cable from c u to the the transducer block Remove can bus transducer block If cable checks connector at cable reel good replace c u Replace can bus cable between Cable reel and transducer block Ohm out connector in cable reel If connector checks good replace can bus converter board 22 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk fy HIRSCHMANN CAN bus communication A Belden Company 12 2 E62 In case of an E62 the CU is reporting no signal from t
12. 2 is GND measure in line between the cable from the slew unit and the central unit The two outputs will vary as shown in chart below You can also leave the wires connected as use your meter in Voltage mode to measure the output signals In this case you will see the 4 20mA range as a 1 1 to 5 5 Volt range If the voltage or currents do not fall in line with the charts and tables shown below and no system errors are present the problem may be Open the slip ring unit and determine if the slew potentiometer is set 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN No console display A Belden Company 10 NO CONSOLE DISPLAY If the console is not showing any lights such as warning lights backlighting etc it is most likely missing power Start with the following Ensure that no lights warning lights or backlighting is visible Check wiring harness NO Check if power is being supplied Measure Is power voltage at outer connector being Pin 1 is Ub 12V and Pin 2 is OV supplied Check fuses on the interface board mounted to YES the inside of the housing F5 protects the override key switch function and the bar graph The main fuse F1 is located on the same Check for power on connector X2 y eid Are fuses of the interface eing in line board Pin 1 is supplied Ub 12V and Pin 2 is OV NO YES Replace fuse Follow power from this connector
13. 4 20 ANALOG INPUT 5 4 20mA ANALOG INPUT B 4 20 ANALOG INPUT 7 4 20mA EXTENSION CONNECTION OPTIONAL EXTENSION CONNECTION OPTIONAL EXTENSION CONNECTION OPTIONAL EXTENSION CONNECTION OPTIONAL HE v POWER IN 12V CRANE GROUND Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice 2007 HIRSCHMANN Automation and Control GmbH 31 Service Manual PPAT iFLEX2 with iSCOUT expert compact 14 3 3 Central Unit Detail B GROUND DIGITAL INPUT 0 DIGITAL INPUT 1 DIGITAL 2 DIGITAL INPUT 3 DIGITAL INPUT 4 CFS OVERLOAD DIGITAL INPUT 5 DIGITAL INPUT DIGITAL INPUT 7 DIGITAL INPUT DIGITAL INPUT 9 to crane DIGITAL INPUT 10 interface DIGITAL INPUT 11 gt page 4 DIGITAL INPUT 12 DIGITAL INPUT 13 DIGITAL INPUT 14 DIGITAL INPUT 15 EXTENSION CONNECTION OPTIONAL EXTENSION CONNECTION OPTIONAL EXTENSION CONNECTION OPTIONAL EXTENSION CONNECTION OPTIONAL LOCKOUT RELAY N O GROUND fe fe fe fe le fe fe Je fe fe le fe fe fe fe m 4 gt 2 d d 9 2 DB9 SERIAL INTERFACE LAM TWHINSS XM gag Hirschmann Automation and
14. Control GmbH reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice 32 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN Drawi ngs A Belden Company 14 3 4 Sensors Wiring page 2 UNNA TWWALN3O OL 1 O3dVl 102 Q 3IHS YINNI lt NMOHS SY Q3103NNOO G3LVINSNI Q 3lHS lt IN3SNI 331138 NIVMIS OL Q3103NNOO 13 5 3100 lt IV13O Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice 2007 HIRSCHMANN Automation and Control GmbH 33 Service Manual PPAT iFLEX2 with iSCOUT expert compact 14 3 5 Console Wiring page to central unit to central unit 5 X 0 5 SS i 5 5 EXPERT COMPACT CONSOLE co gt a v 2 IN 5 S CO 5 2 Uu 4 V POWER CAN SHLD CAN V CAN OV CAN CAN L f lt 77 CAN SHLD ANALOG OUTPUT D ANALOG OUTPUT V SYSTEM 2 o dq m m CAN2 T
15. Diagram Angle CAN Bus 2 Sensor Converter CU Pressure Transducer Cable Reel L The signal runs from the angle sensor to the Can Bus converter board both located in the cable reel From there it travels as digital information on the CAN Bus to the pressure transducer which acts as a T connector to the main CAN Bus running to the central unit So what do you do when you are having a problem with your angle read out Start by verifying the angle display Refer to the section Troubleshooting A Sensor Problem Using The Display to call up the sensor signal on your console display The CAN Bus is digital and as such will either transmit the signal correctly or not at all If your readings are off you have to determine what is causing the problem reference the following flow charts X1 X14 A2B JE M d co X20 L 2 P Pe TT ry fe 3 5 y4 gib NI 7 I 1 D wre 4 4 1 5 1 Lan 3 2 sm um E 4 4 9 52 LJ L A N gt E 5 tC et S 2 4 SENE S 24 P 2 5 524 PN mmm 0 424 5 gt r 4 d Pie etal ates Lt m gt gt gt e t p CAN Bus electronics in c
16. ap Ww 25 ea om m ui 22 ui E A m Y pomme Sapo qeu ee ubere eese n 6 6 0 09 9 6 0 09 9 09 9 0 0 09 gt de Gi o XE DO 0d d dod odi he petes ae poc ene ep No N 21 Y 27 5 Y Y V M Y M M M N MY SIS eem n 1 1 o ot Si ei di ip dw LE C B t J J 6 9 o o 9 o 6 6 6 rd m bou T Mi EN IN o a i ae 0 1 1 1 2 2 i Al N y I AUN oe a 11 4 3 SU s E ou A X l a 1 1 1 1 m le zx ae aa g Eh mb ae ups e A cm CO x Y
17. cable the strain relief is loose Get a new grommet insert through your PAT 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 58 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN Troubleshooting Moisture 17 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 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 e fthe volume is very small a desiccant bag might be a
18. f HIRSCHMANN A Belden Company IFLEX2 iSCOUT expert compact LMI system for Grove RT IM Contents General Information Warnings GROVE System Description What s wrong Angle sensing Length sensing Pressure sensing Service Manual Issue 8 2007 Rev A This document is listed under Order No 50 650 69 0101e Grove RT TM f HIRSCHMANN General Information A Belden Company TABLE OF CONTENTS 1 General dai osuicuvc qusc 5 2 cid 5 3 Description OF TING SYSTEM ins taxi dus nud t cz ducts eund EA EE Aaa aa a AAE EA iA 6 3 1 Description of syster 6 3 2 Description Or A Can BUS dade tose aa deed dave vene auos baie tan ARDET 6 3 3 Description of the System Components 4 8 41 have an error code indicated on the console 8 4 2 The displayed angle does not match the actual boom angle 8 4 3 The displayed length does not match the actual boom length 8 4 4 The displayed slewing does not match the actual slewing 8 4 5 The displayed load does not match the
19. sensor Replace sensor unit Replace length sensor Replace sensor unit e Cable between the central Check cable as well as plugs unit and the slewing angle replace if need be sensor defective or loose Water inside the plug of the angle sensor e Electronic component in the measuring channel defective Angle potentiometer defective e Electronic component in the measuring channel defective Length potentiometer defective e Electronic component in the measuring channel defective e Front outrigger overloaded e 1 cannel slew sensor min e value 11 5 7 lt gt 0 Slewing angle potentiometer Replace slewing angle sensor Replace sensor unit is defective refer to E1A Electronic component in the e Replace angle sensor move to allowed slew range Angle potentiometer defective Electronic component in the measuring channel defective measuring channel defective e referto E1A e Replace sensor unit refer to E11 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk e referto E11 refer to E12 refer to E12 refer to E14 refer to E15 refer to E16 Error Codes f HIRSCHMANN A Belden Company Error code Error Cause Elimination Upper limit value in measuring E27 channel length telescope 11 has been exceeded Upper limit value in measuring channel slewing angle 1 has 2 been exceeded slew above allowed ran
20. to LMI screen e Now boom up to steep boom range is 70 80 boom up to next angle skip calibration step cancel and return to LMI screen 2007 HIRSCHMANN Automation and Control GmbH 51 Service Manual PPAT iFLEX2 with iSCOUT expert compact When the boom angle is within the calibration range the screen will add the CHANGE SET and OK text as shown below cancel and return to LMI screen calibrate angle set current angle to defined angle calibrate angle e Measure the boom angle with the inclinometer and when the boom is positioned in the calibration range compare the measured angle to the displayed angle e If the indicated angle is within 0 1 degrees of the measured angle confirm with Ok Otherwise select SET to adjust the angle adjust angle Confirm angle e Once you push SET the screen is going to change to the angle adjustment screen Use the and buttons to adjust the indicated angle to match the measured angle e When the display shows the correct angle press OK Press ESC to leave sensor adjustments and return to normal LMI screen 52 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk Error Codes 16 ERROR CODES f HIRSCHMANN A Belden Company The following Error Code Table gives a brief description of Error Codes elimination Refer to the noted sections for detailed Troubleshooting inform
21. to the console computer board connector X1 Pin 1 is 12V and Pin 2 is OV If no power was supplied on the connection board but was supplied on the external connector the interface board must be replaced Connecting ble i is power Cable IS NO being YES Check power rail signal LEDs H1 H4 on the loose or supplied console main board These LEDs must defective continuously light c 4 10 V all power LEDs continuously on 10 V Console main Software board need Error replaced 2007 HIRSCHMANN Automation and Control GmbH 1 9 Service Manual PPAT iFLEX2 with iSCOUT expert compact 11 A2B PROBLEM Are the control levers locked out and is the crane in an anti two block condition Is the anti two block warning light on B YES Lower the hook block and or headache ball to correct the Ensure the two block problem If two Turn power off remove bypass plug and bypass hoists are in use both measure the resistance at the boom nose box plug is hooks must be lowered between terminals 1 and 3 with an ohmmeter installed Switch closed 0 ohms weight installed Switch open z 1 Megaohm weight removed Ensure bypass plug is plugg
22. 0 500 m m m rmn 45 45 e Potentiometer 1 Potentiometer 2 90 135 180 225 270 315 360 90 135 180 135 90 45 0 SLEW ANGLE 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN Slewing sensing A Belden Company 8 1 SLEW SENSING ERROR FLOW CHART First verify the slew angle displayed through the console by using the sensor output screen Slew potentiometer is functioning correctly Select info twice piston 114 59 5 b il rod 3 1 6 8 7 1 ange 18 5 55 15 length 8 8 2994 5 85 D 41 804 48 7 HF slang 8 5 240 Does the displayed value differ from the actual value Ensure that the slew pot unit is supplied with crane voltage Pin 7 must carry crane The slew unit output can be found on pins 8 and 9 In order to voltage and Pin 2 is GND measure current however you must disconnect a pin and measure in line between the cable from the slew unit and the central unit The two outputs will vary as shown in chart below You can also leave the wires connected as use your meter in Voltage mode to measure the output signals In this case you will see the 4 20mA range as a 1 1 to 5 5 Volt range If the voltage or currents do not fall in line with the charts and tables shown below and no system errors are present the problem may be mechanical Open t
23. 3 220 E ete beens E 23 o EEEE cate bare ue EEE EE eee de NEE EAA EE 23 MEZ 50 46 REEL 24 4 EE ZU 24 13 Troubleshooting a sensor problem using the 25 2007 HIRSCHMANN Automation and Control GmbH Service Manual PPAT iFLEX2 with iSCOUT expert compact 14 Draw S Rte EN PR 28 14 1 Components of the LMI system PAT iFLEX2 with iSCOUT expert compact 28 QU MEME ie QC D D LIU LT 29 14 3 Electrical System Diagram Standard 30 14 5 1 Central nib OVelVIGW curat E Pul eet tour me est baad eumd utu 30 14 5 2 entra UNG succes dutttus tumet metas dandi 31 E BETRIEB s TE E 32 3 tss oe 33 uestis capiunt to ovem ep Sada 34 14 3 6 Crane Interface RT530 2 540 4 35 14 3 7 Crane Interface 600 RT7OOE RT875E page 4 36 14 3 8 Crane Interface TM500E 2 page 4 37 14 4 Main Central Unit 38 14 4 1 Cable Reel LG152 0056 Wiring
24. C Rev A 2007 08 17 rk f HIRSCHMANN Drawings A Belden Company 14 3 8 Crane Interface TM500E 2 page 4 Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice 2007 HIRSCHMANN Automation and Control GmbH 37 38 Service Manual PPAT iFLEX2 with iSCOUT expert compact 14 4 MAIN CENTRAL UNIT CONNECTOR This is a 70 pass connector Gum Gum oum Ls i a wi 1 1 s a E ME inc T m Emo rz T d 2 813 il E LES CE ND ee A 50 650 69 0101E_REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN Drawings A Belden Company 14 4 1 Cable Reel LG152 0056 Wiring Diagram TO LWG520 0002 TO BOOM BASE CONNECTOR REFER TO CABLE REEL LWG520 0002 REFER TO CONSOLE AND SENSOR WIRING DIAGRAM WIRING DIAGRAM A S _ o inl i 7 22 _ O ea Dp Gi Ld o n EJ b e 4 l
25. N 208 La Y 7 2 Mis MULA TAM l N E he POPE 2 12 t E dass a 1 H Da me 214 94 2 7 E EI 7 4 p ng 4 F a 77 aas gt B tC 4 5 1 Pe 2222 9 277 MES 25 I imminent TOS I E 4 5 r lt TEER ERT TX 59 4 CAN Bus electronics in cable reel CAN SHLD CAN UB CAN H CAN L 2007 HIRSCHMANN Automation and Control GmbH 23 Service Manual PPAT iFLEX2 with iSCOUT expert compact 12 4 1 E64 Flow Chart E64 Connect the two cables on the Transducer block together Replace transducer block 12 5 E65 In case of an E65 the cable reel is reporting an internal problem In most cases this will be an angle sensor length potentiometer or A2B wiring Go to those chapters Angle Sensing Length Sensing A2B PROBLEM to continue trouble shooting 24 K Ohm cable from the transducer block to cable reel Cable checks good Check connector at cable reel Connector checks good Replace can bus board in cable reel Replace cable Replace connector 50 650 69 0101E_REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN Troubleshooting a sensor problem using the display 13 TROUBLE
26. O LMI LIGHTBAR KIT OPTIONAL Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice 34 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk Drawings f HIRSCHMANN A Belden Company 14 3 6 Crane Interface RT530 2 RT540E page 4 Rear Keyswitch 1 4 1 5 1 3 z 2 ga Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice 2007 HIRSCHMANN Automation and Control GmbH 35 Service Manual PPAT iFLEX2 with iSCOUT expert compact 14 37 Crane Interface RT600E RT7OOE RT875E page 4 Rear Keyswitch 5 E gt 38525 2 s if E 1 Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice 36 50 650 69 0101E REV A GROVE RT TM DO
27. SHOOTING A SENSOR PROBLEM USING THE DISPLAY To determine whether there is a problem with a sensor the system has sensor value screen built in to make trouble shooting easier This is the right place to start if you are suspecting a problem with a sensor and you don t have an error code displayed e to access the sensor output screen select phys piston 22 9 1417 63 5 the INFO button twice rod 83 82 COLI Y eq I 22 22 slang 48 7 2127 _ sae 65 75 to review software 0 D4 DISPLAY Susten Software 4 W2 61 c 1990 2007 HAC GnbH Ettlin version information a select the INFO and i A U configuration U1 00 HAC G then the INFO y C 2 y ims CAN mapping 10803 Grove with iF Haeder button once lex2 Systen Grafik Grove RT 530 expert compact The screen will show all sensor inputs as in the example below For each sensor an equivalent voltage is shown in millivolts along with the physical sensor value that that voltage refers to Pressure sensors are shown with physical values of bar angle sensors and slew sensors in degrees and length sensors in feet or meter for metric charts Info nu phys piston 22 9 141 69 5 rad 3 1 623 4 2 angle 57 6 388 56 15 length 8 808 2004 9 83 sl ang 46 7 2121 sl ang 0 2 846 The values shown in the screen here are just examples of actual values Refer to the table listed belo
28. T iFLEX2 with iSCOUT expert compact 42 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN A Belden Company Sensor Calibration 15 SENSOR CALIBRATION 15 1 ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION e access the service screen and sensor E calibration function il 2 22 from main menu input service code for access to calibration menus For access to the calibration menus itis necessary to input a matching 5 digit code Please enter Use the rotary selection wheel to servicecode input a numeral and then push the 55 5 5 5 wheel button to select the next digit If input is complete the confirmation screen appears OK confirm selected code Cancel and return to LMI screen V input service code confirmation screen Please enter Servicecode Now you can follow the calibration procedure step by step or can select the type of calibration by scrolling with function key Press ESC to finish calibration procedure pressure signal pressure signal slewing angle boom length signal boom angle signal piston side rod side signal 2007 HIRSCHMANN Automation and Control GmbH 43 Service Manual PPAT iFLEX2 with iSCOUT expert compact 15 2 ZERO SETTING THE PRESSURE INPUTS NOTE The only thing adjustable for the pressure transducers is the zero point which is the signal the transducer outputs when there is no zero pressure sensed Ensure there i
29. able reel The angle sensor has a potentiometer built in that is driven by a pendulum As the angle changes so Will the pendulum and with it the potentiometer s axle The converter board supplies a constant voltage of 5V to the angle sensor and in return monitors the voltage of the potentiometer The terminal used is X21 The angle sensor is connected as follows Terminal X21 2007 HIRSCHMANN Automation and Control GmbH 9 Service Manual PPAT iFLEX2 with iSCOUT expert compact 5 1 ANGLE SENSING ERROR FLOW CHART First verify the angle displayed through the console by using the sensor output screen Select info twice Angle sensor 3 as range values i i s E compare 4500mV at 0 p 2500mvV at 45 900m at 90 Recalibrate angle sensor Reference Angle sensor calibration procedure Open the cable reel and locate the angle sensor right and CAN Bus converter YES board left 2ND Does the displayed value differ from the actual value Angle sensor is Continue with angle sensing flow chart next page Unplug angle sensor and measure again functioning Is the voltage between the range of 4 75 to 5 25V Verify that the sensor is 1ST being supplied with 5V by measuring between pin 5 GND and Pin 1 of terminal X21 46 MEASURE AGAIN Replace converter by Is the voltage between the range o
30. ation LMI System Error Code Table LSQG V 1 xx Error code Error Cause Elimination Fallen below the minimum radius or gone past the maximum angle specified in the respective load chart due to luffing up the boom too far Fallen below radius range or angle range exceeded Radius range exceeded or fallen below angle range Non permitted slewing zone no load area Operating mode not acknowledged or non permitted slewing zone Radius range exceeded or fallen below angle range with luffing jib operation Fallen below lower limit value e for measuring channel length main boom Fallen below the lower limit value in the measuring channel pressure piston side Prohibited length range 2007 HIRSCHMANN Automation and Control GmbH Gone past the maximum radius or fallen below the minimum angle specified in the respective load chart due to luffing down the boom too far A non existing operating mode has been selected Boom has been extended either too far or not far enough e g if it is prohibited to go beyond a certain maximum boom length or with load curves for jibs where the main boom has to be extended to a certain length Length sensor adjustment has changed e g the cable slid off the length sensor reel Clutch between length sensor pot and drive is defective Maximum radius as specified in the load chart exceeded or fallen below minimum angle due to luffing down the luffing jib too far Leng
31. ble Replacement Procedure Replace length cable using the following procedure Refer to system electrical wiring diagram and cable reel parts list pU go I cm o 10 11 12 13 14 15 16 2007 HIRSCHMANN Automation and Control GmbH Cut old cable at cable drum Disconnect damaged length cable from junction box at the boom nose Open cable reel cover and disconnect bus connector Remove cable reel from mounting brackets Remove damaged length cable which is mounted to the slip rings in the cable reel from slip ring terminal 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 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 Reconnect the length cable to the slip ring Remount cable reel to the boom Turn reeling drum clockwise to spool the new cable neatly onto the drum Set pre load on cable reel by turning the drum counter clockwise 5 to 8 turns 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 Connect the length cable into the boom tip junction box Reset length potentiometer in length angle transducer screw is located in center
32. ble to soak up the air s humidity e fthe 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 PAT representative for breathing elements to than can be added to the box and will help to reduce the effects of humid climates 2007 HIRSCHMANN Automation and Control GmbH 59 Service Manual PPAT iFLEX2 with iSCOUT expert compact NOTES 60 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN Revision History Bolden Company Version Date Modifications Name Rev A 2007 08 17 First Issue for Grove RT and TM cranes Konopka IFLEX2 with iSCOUT expert compact Application base Grove RT 530 expert compact V 1 04 20070511 HAC GmbH 34230104 2007 HIRSCHMANN Automation and Control GmbH 61
33. e Replace A2B switch Short circuit in the A2B switch circuit Short circuit in the cable to not with radio A2B the A2B switch Replace cable to the A2B switch 56 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN A Belden Company e Disconnected cable in the e Connect or replace cable in the A2B switch A2B switch Error Codes A2B switch circuit disconnected not with radio A2B e Disconnected cable to the Connect or replace cable to the A2B switch A2B switch Sensor wrong function Replace A2B switch CAN bus delay Replace cable to the A2B switch No valid 2 switch status e Radio telegram delay module e Replace battery of radio module radio A2B radio A2B Radio telegram ID is invalid Setup ID in DGA12 9 Datalogger setup error battery buffered RAM Datalogger watchdog activated limit exceeded Connect PC terminal and watch error messages Battery empty voltage of the battery of RTC Not possible to save data Message disappears after a few Record lost because other task saves seconds data at the same time Flash block Not possible to save more e Message disappears after a few data seconds a funktion needs more than e Message disappears after a few LMI Watchdog e Setup of the datalogger is e transfer data and setup cleared ser crane data file or datalogger again Note a fault message is displayed that is not included in th
34. e data stored in the central processor memory and evaluated in the microprocessor When limits are reached an overload warning signal is generated at the operators console At the same time the aggravating crane movements such as hoist up telescope out and boom down will be stopped The fixed data regarding the crane such as capacity charts boom weights centers of gravity and dimensions are stored in memory chips in the central processor unit This data is the reference information used to calculate the operating conditions Boom length and boom angle are registered by the length angle sensor mounted inside the cable reel which is mounted on the boom The boom length is measured by the cable reel cable which also serves as an electrical conductor for the anti two block switches The crane load is measured by pressure transducer block attached to the piston and rod side of the hoist cylinders The interactive user guidance considerably simplifies the input of operating modes as well as the setting of geometry limit values 3 2 DESCRIPTION OF A CAN BUS SYSTEM CAN stands for Controller Area Network Its intended use is as a serial bus system for a network of controllers Each controller connected through a CAN chip is called a node and is mostly used to acquire data from a sensor All nodes are connected to a common bus and all nodes are able to simultaneously read the data on that bus Also all nodes are able to transmit data on
35. e present list then please contact your local Hirschmann Customer Service gt www hirschmann ac de lt 2007 HIRSCHMANN Automation and Control GmbH 57 Service Manual PPAT iFLEX2 with iSCOUT expert compact 17 TROUBLESHOOTING MOISTURE The PAT iFLEX LMI 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 Water ingress 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 17 4 WATER INGRESS There are different possibilities for water ingress It is possible to find out the source 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 PAT LMI system are water protected to IP 65 This means protection against the environment such as rain However through the use of spray cleaner at s
36. ed into the boom nose box Remove wires and measure the A2B signal in the cable reel between the X1 brown an X2 red wires on the slip ring with an ohmmeter Plug the bypass Switch closed 4700 500 Ohms plug Into the boom Switch open gt 1 Meaaohm nose box and refer Are tecohinnieter to system wiring to readings correct check wire connections boom nose box Check for damaged length Are the ohmmeter readings correct Remove wires measure the A2B cable and wiring signal in the cable reel between terminal If broken length 7 and 8 with an ohmmeter cable refer to Switch closed 4700 500 Ohms If wiring is correct system wiring Switch open 1 Megaohm replace A2B switch Are the ohmmeter readings correct Replace the slip ring A problem lies with either the wiring YES harness cable reel length angle boards and or the iFLEX2 central unit 20 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN A Belden Company CAN bus communication 12 CAN BUS COMMUNICATION The System measures the length of the main boom the angle of the main boom the pressures of the lift cylinder and the A2B state of the machine via a CAN Bus connection Since this is a digital bus connection it is not possible to measure the signals on the bus with a multimeter Instead the LMI provides you with error codes that give you an indication of the bus s
37. ensors are the same as described above with the exception of cable reel internals location of hardware wiring and gear wheels Refer to the LWG520 5152 spare part list for these differences 1 4 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN Pressure Sensing A Belden Company 7 PRESSURE SENSING The System measures the pressure of the boom lift cylinder for both rod and piston side Both sensors are contained within one box that also contains the electronics needed for amplification and creation of the CAN Bus signal Block Diagram 3 2 Pressure CAN Bus IFLEX2 Measuring Converter CU Cells The signal runs from the pressure transducer as digital information on the CAN Bus to the central unit Pressure Transducer 71 PRESSURE SENSING ERROR FLOW CHART First verify the pressure displayed through the console by using the sensor output screen Select info twice piston 1144 1417 83 3 il rod 8 7 1 ange 15 5 55 15 length 8 8 7884 9 85 22 slang 2 _ slang 2 5 Pressure transducers are functioning correctly Does the displayed value differ from the actual value YES Ensure that the pressure lines are drained and disconnected The readout should read 500mV 25mV and 0 PSI Replace pressure transducers If the reading is slightly off
38. entiometer which is the length transducer Part of the length transducer circuit is the length cable on the drum which is a multi conductor cable It is connected to the anti two block switch at the boom head and to a slip ring body in the LWG The angle transducer is a potentiometer driven by a weighted pendulum that is oil damped Both length and angle transducer are connected to a CAN bus controller board which is connected to the bus system Anti Two Block Switch The anti two block switch monitors the load block and its relationship with the head of the boom In working condition the switch is closed When the load block strikes the weight the circuit opens disengaging a relay output to the lock out solenoid valves where applicable To check the cable for damage short circuit to ground there is a 4 7k resistor between ground and the contact of the switch to give a signal back to the central unit The weight at the anti two block switch keeps the switch closed until the load block strikes it Console The graphic console displays all geometrical information such as length and angle of main boom working radius and head height of the boom It also displays the actual load and the maximum load permitted by load chart Furthermore it has an alarm horn a warning light for overload and a pre warning light The graphic display allows for a simple interactive configuration setup as well as sensor calibration zero adjustment and troublesh
39. erence Angle 0 03 0 03 o 400 1200 90 7 1200 2000 90 1200 400 If the displayed angle is incorrect please go to section Slewing Sensing 2007 HIRSCHMANN Automation and Control GmbH 27 Service Manual PPAT iFLEX2 with iSCOUT expert compact 14 DRAWINGS 14 4 Components of the LMI system PAT iFLEX2 with iSCOUT expert compact Bedienkonsole iSCOUT expert compact operator s console ISCOUT expert compact 2 fach Druckaufnehmer DAVS Langen Winkelgeber UNG 2 fold pressure transducer length angle sensor Sensorik Signale sensors signals 28 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN Drawings A Belden Company 14 2 BLOCK DIAGRAM 70 pin Connector Crane Power Graphic Console Lockout CAN BUS Current CAN connector 4 20mA CAN connector CAN connector 2007 HIRSCHMANN Automation and Control GmbH 29 Service Manual PPAT iFLEX2 with iSCOUT expert compact 14 3 ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM 14 3 1 Central Unit Overview POWER CRANE W OUTPUT D 24 CAM BUS W Dental OUTPUT 1 2A OUTPUT 2 24 SLEW NOT USED DAL OUTPUT 3 2A OUTPUT 4 to sensors ED ONT 8 On Dru OUTPUT 6 24 gt page 2 OUTPUT 8 2 CANOPEN
40. f 4 75 to 5 25V 2ND YES If unplugging the angle sensor made the voltage return to the acceptable range replace the angle sensor Follow procedure for angle sensor installation and calibration 1 0 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk Angle Sensing h HIRSCHMANN A Belden Company Angle Sensor signal varies Ensure the angle sensor returns a voltage between 1 875V at 90 and 3 125V at 0 Verify the voltage by measuring Between Pin 5 GND and Pin3 signal of terminal X21 Angle Sensor Signal On Pin 3 f de E X 9 p a t a r Ed go LoT i 1 5 E eI E da ae e E TE GI gt Note Actual voltages will vary slightly Does the indicated angle vary by more than 0 25 from the actual angle If this angle varies significantly from your actual angle YES replace the angle sensor NO Ensure correct software has been installed and crane operator is not in Replace converter board Note If you need to determine the angle for voltages other than shown above do so by using the following formula Angle degrees 90 degrees Voltage 1 875 72 2007 HIRSCHMANN Automation and Control GmbH 1 1 Service Manual PPAT iFLEX2 with iSCOUT expert compact 6 LENGTH SENSING The system measures the length of the main boom of the machine with a length sensor The length sensor is contained within the cable ree
41. fe fs 8 33883688 DEG SERIAL INTERFACE 30 50 650 69 0101E_REV A GROVE RT TM DOC Rev A 2007 08 17 rk Drawings 14 3 2 Central Unit Detail A to sensors gt page 2 LET LT to console gt page 3 SX0555 2 ew Js Je lels Js e le Js fs le ls le ees qu uu mmm je mss sumi fo I 1 f HIRSCHMANN A Belden Company E v SWITCHED POWER CRANE V DIGITAL OUTPUT O 2A PWM CAN BUS 4V DIGITAL OUTPUT 1 2A PWM DIGITAL OUTPUT 2 2A PWM SLEW POT NOT USED DiGITAL OUTPUT 3 2A PWM DIGITAL OUTPUT 4 2A PWM DIGITAL OUTPUT 5 2A DIGITAL OUTPUT 6 2A PWM DIGITAL OUTPUT B 2A PWM H CANOPEN CAN 1 CANOPEN CAN H SAE J1939 CAN L SAE 1939 DIGITAL OUTPUT 8 1A DIGITAL OUTPUT 9 1A LMI D MM DIGITAL OUTPUT 10 14 DIGITAL OUTPUT 11 1 LIMIT CUTOFF CAN2 L SAE J9139 H J1939 CAN2 TERM 10V REFout OUT EN2 424V LE v SWITCHED POWER CRANE V HE v SWITCHED POWER CRANE 4V E 4v CONSTANT POWER CRANE V NOT CONNECTED HOT CONNECTED NOT CONNECTED CAN L CANOPEN CAN H CANOPEN CAM TERM OUT EN2 424V ANALOG INPUT O 4 20mA SLEW POT CH 1 ANALOG INPUT 1 4 20m SLEW POT CH 2 ANALOG INPUT 2 4 20mA ANALOG INPUT 3 4 20 ANALOG INPUT 4
42. ge Upper limit value in measuring channel slewing angle 2 has been exceeded Upper limit value in measuring channel luffing jib angle has been exceeded E2C Error in the system program Error in the power supply E37 Error in the logical program flow System program and crane data file do not match System program and load chart file do not match Error in the write read memory RAM Error in the monitored write read memory E47 The CRC verification of the monitored write read memory provides an incoherent result m Error in the crane data file Error in load chart file 2007 HIRSCHMANN Automation and Control GmbH refer to E1A 1 cannel slew sensor max value DGA 11 5 8 lt gt 0 The system program file is defective Flash EPROM defective UB System not present at the system start UB System not present at the system finish Contact problems at UB switch off on System program file is defective Flash EPROM defective The system program in the LMI does not match to the programming in the crane data file The system program in the LMI and the programming in the load chart file do not match Write read memory RAM or central unit defective The CRC sign of the monitored write read memory is wrong The buffer battery is decharged lt 2V at 1kOhm Central unit defective No valid data in the crane data file Flash EPROM defective No val
43. h potentiometer and in return monitors the output voltage of the potentiometer The terminal used is X20 The length sensor is connected as follows Terminal X20 4 8V 1 2 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN A Belden Company Length Sensing 6 1 LENGTH SENSING ERROR FLOW CHART First verify the length displayed through the console is off bv the sensor output screen Select info twice Qua piston 22 9 1417 69 5 rod 3 1 623 9 2 angle 37 6 508 96 15 length 8 08 2004 9 85 sl ang 48 7 2127 sl ang 8 5 848 Length sensor is functioning correctly Ensure the cable reel has 5 8 turns of preloading on YES the reel Does the displayed value differ from the actual value Measure voltage between Pin 5 and Pin 3 signal Open the cable reel of terminal X20 and compare and locate the length sensor right and CAN Bus converter board left Fully retract the boom and turn the screw of the length potentiometer with a small screwdriver counter clockwise to a soft stop bringing the sensor voltage to OV 0 1 Volt Select info twice Return to the indication screen and again Info compare the indicated and actual length 4 phus 221 3 5 30H 56 15 Replace length ength 2004 3 83 sl ag 87 2177 Sensor sl ang 8 5 B4B 13 43 Does the indicated length vary significantly from the ac
44. he indicated length 4 4 THE DISPLAYED SLEWING DOES NOT MATCH THE ACTUAL SLEWING ANGLE Refer to section Slewing Sensing to check the slew sensor 4 5 THE DISPLAYED LOAD DOES NOT MATCH THE ACTUAL LOAD Please note that the indicated load is calculated by the system from the geometry information in the computer the operator s selections and all the sensor inputs If the load display is off it can therefore be due to an error in any or several of these inputs Refer to section Load sensing to narrow down the source of your problem 4 6 THE CONSOLE DISPLAY IS BLANK If the console does not show any sign at all no lights no buzzer no display the problem is either in the wiring between console and central unit or the console itself Refer to section No console display for further troubleshooting 47 AN A2B PROBLEM Please go to section A2B PROBLEM 4 8 CAN BUS PROBLEM Please go to section CAN Bus Communication 4 9 NEED TO IDENTIFY A SPARE PART Please go to the Spare Part Listings 4 10 I HAVE NOTICED WATER IN SOME PART OF THE SYSTEM Please go to section Troubleshooting Moisture 8 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk fy HIRSCHMANN A Belden Company Angle Sensing 5 ANGLE SENSING The System measures the angle of the main boom of the machine with an angle sensor The angle sensor is contained within the cable reel located on the left side of the main boom Block
45. he pressure transducer Start by checking your cabling between CU and pressure transducer even though it is not very likely that there is a problem with it since the same cable carries also the signals from the cable reel and those appear to be fine You can verify that power is being supplied to the sensor by testing the CAN connectors per the above pin layout If you are sure that the sensor is being supplied you have to replace the pressure transducer 12 3 E63 In case of an E63 the pressure transducer is reporting an internal problem You cannot troubleshoot any further but need to replace the pressure transducer 12 4 E64 In case of an E64 the CU is reporting no signal from the cable reel unit Start by connecting the two cables on the transducer block together If an E62 occurs the transducer block must be replaced If an E61 occurs measure the cable from the transducer block to the cable reel with an Ohm meter Check all pins of the CAN bus cable for continuity and cross check for short circuits If the continuity check fails the cable must be replaced If the cable appears to be fine next check the connector at the cable reel You can verify that power is being supplied to the sensor by testing the CAN connectors per the pin layout see E61 Replace the connector if this check fails If the connector checks properly the board in the cable reel might be defective X1 X14 A2B d ve occ X20 i AH S
46. he slip ring unit and determine if the slew potentiometer is set Modular Slew Pot Output Currents mA 2 B mA 3 n When the crane is over front you should 16 see about 4 channel wire 2 512 and 12 the other channel wire 3 Degrees 2007 HIRSCHMANN Automation and Control GmbH 1 7 Service Manual PPAT iFLEX2 with iSCOUT expert compact 9 LOAD SENSING Please note that the load displayed by the LMI is not a direct measurement but a calculated value that is based on a lot of factors Outside of the measured values sensors those include 9 1 18 e Operator settings such as o Operating mode configuration o Parts of Line Reeving Rigging parts such as Hookblock weight Sling weights etc Tip height length of load line used Boom weights Boom attachments such as Stowed jibs Auxiliary boom nose etc LOAD SENSING ERROR FLOW CHART First verify the slew angle displayed through the console using the sensor output screen Select info twice piston 12 38 69 5 ilp rod 94 1 UN angle 3 6 508 55 15 291 9 85 Slew potentiometer is functioning Does the displayed value NO differ from the Actual value The slew unit output can be found on pins 8 and 9 In order to Pin 7 must carry crane measrure current however you must disconnect a pin and voltage and Pin
47. hort 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 PAT representative 4 Defective Gasket The gasket underneath the lid seals the unit The gasket needs to be in good condition in order to seal correctly If the gasket is torn brittle or severely bent it needs to be replaced Order a new gasket through your PAT 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
48. id data in the load chart file Flash EPROM defective e referto E17 e refer to E17 refer to E1A move to allowed slew range e referto E1A e referto E1A Angle potentiometer defective Replace angle sensor Electronic component in the Replace sensor unit measuring channel defective Upload valid system software Replace central unit UB System and UB Power must be wired separately System connected direct with the crane battery Power for switch on off UB switch off on again Upload valid system software Replace central unit Upload valid system program file or the valid crane data file Upload valid system program file or the valid load chart file Replace central unit Restart the LMI Replace buffer battery on the central unit Replace central unit Upload valid crane data file Replace central unit Upload valid load chart file Replace central unit Service Manual PPAT iFLEX2 with iSCOUT expert compact Wrong setup of min analog Analog input not supported Setup correct Flag in in DGA inputs length1 angle 6 1 2 pressure1 No valid data in the crane Restore or upload valid crane Error in crane data file data file during calibration data file Flash EPROM defective Replace central unit Buffered data file does not Reset system contain valid data Error in buffered data file Flash EPROM defective Replace central unit CAN Bus cable betwee
49. ied are fully understood and observed Prior to operating the crane the operator must carefully and thoroughly read and understand the information in this manual to ensure that he knows the operation and limitations of indicator and crane Proper functioning depends upon proper daily inspection and observance of the operating instructions set forth in this manual Refer to Section 6 Pre Operation Inspection and Calibration Verification of the operator s manual The LMI can only work correctly if all adjustments have been properly set For correct adjustment the operator has to answer thoroughly and correctly all questions asked during the setup procedure in accordance with the real rigging state of the crane To prevent material damage and serious or even fatal accidents the correct adjustment of the LMI has to be ensured before starting the crane operation 2007 HIRSCHMANN Automation and Control GmbH 5 Service Manual PPAT iFLEX2 with iSCOUT expert compact 3 DESCRIPTION OF THE SYSTEM 31 Description of system function The iFLEX2 system is a CAN bus system made up of a central microprocessor unit operating console length angle sensor pressure transducers and anti two block switches All components and sensors are equipped with CAN bus controllers The PAT Load Moment Indicator system operates on the principle of reference real comparison The real value resulting from the pressure measurement is compared with the referenc
50. itten consent of Hirschmann Hirschmann 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 Hirschmann The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice 4 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN A Belden Company General Information 1 GENERAL INFORMATION This service manual is designed to assist a service or maintenance person in identifying system problem areas or malfunctions A digital voltmeter with the capability to measure current will be required along with standard maintenance and service tools NOTE Knowledge of how to use a voltmeter to measure both voltage and current is assumed REFERENCE For system operation refer to the consoles operator s manual 50 650 19 0101e 2 WARNINGS The LMI is an operational aid that warns a crane operator of approaching overload conditions and over hoist conditions that could cause damage to equipment and personnel The device is not and shall not be a substitute for good operator judgment experience and use of accepted safe crane operating procedures The responsibility for the safe crane operation shall remain with the crane operator who shall ensure that all warnings and instructions suppl
51. l located on the left side of the main boom Block Diagram Length CAN Bus Sensor Converter IFLEX2 CU Pressure Transducer The signal runs from the length sensor to the CAN Bus converter board both located in the cable reel From there it travels as digital information on the CAN Bus to the pressure transducer which acts as a T connector to the main CAN Bus running to the central unit Cable Reel So what do you do when you are having a problem with your length read out Start by verifying the length display Refer to the section Troubleshooting A Sensor Problem Using The Display to call up the sensor signal on your console display The CAN Bus is digital and as such will either transmit the signal correctly or not at all If your readings are off you have to determine what is causing the problem reference the following flow charts X1 CAN ez 3 UK A M i 0 14 2 Arm NM SOM Ca fev v X 5 bes 6 5 ME 1 t AUT 2 qu X20 5k ER DADR gt H c vL tem EXE I 4 v LED CAN Bus electronics in cable reel The length sensor has a potentiometer built in that is driven by a gear drive from the cable drum As the length changes the cable drum will turn and with it the potentiometer s axle The converter board supplies a voltage of about 4 7V to the lengt
52. n the Check the connection between central unit and the sensor the central unit and the sensor unit defective or not units Error in the CAN bus data connected unit defective cable e Cable between the central Check the cable to the sensor unit and the sensor unit unit defective ent unit defective unit is defective Sensor unit is defective e Replace the sensor unit Error in the can bus pressure analog values of the e Replace the sensor unit transducer sensor unit sensor unit are invalid E63 Error in the can bus data e See E62 e See E62 transfer of the length angle sensor unit length angle sensor unit I O MENTOR e Change MENTOR Error in the can bus data e PDB variable invalid Connect digtal I O external CAN transfer of the digtal I O module external module e The selected rigging condition e Select another rigging condition is not contained in the crane NEFORO nggingconaen data file e Check the programming in the crane data file e The computed radius is too e Check the programming in the Ipod teats small negative deflection crane data file determination Operatii mode switchover wih The operating mode on the Select operating mode without s g console has been switched load on the boom oaa over with the boom loaded LMI processing time limit Reset system LMI watchdog activated exceeded Connect PC terminal and watch error messages Short circuit in the A2B switch
53. nel force Fallen below lower limit value in measuring channel angle main boom Fallen below lower limit value in measuring channel angle 2 Fallen below lower limit value E17 length telescope 11 Fallen below lower limit value in measuring channel slewing angle 1 slew below allowed range Fallen below lower limit value in measuring channel slewing angle 2 Fallen below lower limit value in measuring channel luffing jib angle Upper limit value in measuring channel main boom length has been exceeded Upper limit value in measuring channel pressure piston side has been exceeded Upper limit value in measuring E1C been exceeded Upper limit value in measuring channel force has been exceeded Upper limit value in measuring been exceeded Upper limit value in measuring channel angle 2 has been exceeded I Front outrigger overloaded channel pressure rod side has channel main boom angle has Cause Replace sensor unit e referto E12 e Replace force transducer Replace sensor unit Electronic component in the measuring channel is defective e referto E12 Force transducer defective Electronic component in the measuring channel is defective Angle potentiometer defective PDB variable for analog value not supported Replace angle sensor Setup of correct PDB variable for analog value DGAG i 3 Replace sensor unit Replace angle
54. of white gear with boom fully retracted turn potentiometer carefully counter clockwise until it stops Recheck length and angle display Connect bus connector Follow Length Sensor Adjustment Procedure 49 Service Manual PPAT iFLEX2 with iSCOUT expert compact 15 5 ANGLE SENSOR CALIBRATION PROCEDURE The angle sensor can be calibrated for its zero point and with steep boom Material required calibrated inclinometer e Select Angle sensor calibration menu and start procedure by pressing OK skip calibration step start angle calibration procedure cancel and return to LMI screen V Calibration screen boom angle skip calibration step calibrate next angle cancel and return to LMI screen V Start calibration for zero degree angle 50 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN Sensor Calibration A Belden Company Boom down Release adjustment screws of the angle sensor Mechanically adjust top of angle sensor housing exact parallel with ADJUSTME boom by help of inclinometer SCREWS Fix adjustment screws of the angle sensor ADJUST OF ANGLE SENSO PARALLEL BOOM Having adjusted the angle sensor mechanically check value and press OK for the next step V Start calibration for zero degree angle skip calibration step calibrate next angle cancel and return
55. ooting sensor output screen The console has a warning light for anti two block conditions and an override switch for overload or anti block condition Refer to Operator s Handbook for detailed operation of the console Central Unit Inside the central unit there is a CPU The central unit has a hard mounted connector for all signals A status indicator 7 segment display shows operation and error codes Slew Potentiometer This component is not supplied by PAT Hirschmann It is part of the electrical swivel slip ring assembly The potentiometer has two wipers which are used to determine the slewing angle rotational positioning of the super structure in relation to the carrier The slew input to the central unit is not a CAN signal but rather two 4 20mA analog signals 2007 HIRSCHMANN Automation and Control GmbH 7 Service Manual PPAT iFLEX2 with iSCOUT expert compact 4 WHAT S WRONG 5 what s wrong Assuming you are reading these pages because of some kind of problem with the PAT system let us try to guide you quickly to solving the problem In most cases your problem will fall under the following categories 4 1 I HAVE AN ERROR CODE INDICATED ON THE CONSOLE Please go to section Error Codes 4 2 THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE Start in section Angle Sensing to check the indicated angle 4 3 THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH otart in section Length Sensing to check t
56. s no pressure in the hydraulic line when disconnecting the hoses from pressure transducers The display shows which transducer piston side rod side or force is being zeroed and a horizontal dial marks the present pressure or force difference in 9o NOTE there are two calibration screens for piston and for rod transducer NOTE The range for auto calibrating this value is from 4 to 4 By pressing the AUTO key the zero setting occurs automatically and the indicator line will move to zero on the dial skip calibration step auto calibrate set to zero cancel and return to LMI screen V Calibration screen pressure transducer piston side skip calibration step auto calibrate set to zero cancel and return to LMI screen 44 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN A Belden Company Sensor Calibration 15 3 ZERO SETTING THE SLEWING INPUTS NOTE The only thing adjustable for the slew potentiometer is the zero point which is complete when the boom is at the 0 position over the front of the crane NOTE The range for auto calibrating this value is from 10 to 10 By pressing the AUTO key the zero setting occurs automatically and the indicator line will move to zero on the dial skip calibration step auto calibrate set to zero cancel and return to LMI screen V Calibration screen slewing angle 2007 HIRSCHMANN Automation and Control GmbH 45
57. small variations can be adjusted see section Service Screen For Sensor Calibration Note After exchanging the pressure transducer block both transducer channels need to be zeroed see procedure Zero Setting The Transducer Inputs 2007 HIRSCHMANN Automation and Control GmbH 1 5 Service Manual PPAT iFLEX2 with iSCOUT expert compact 8 SLEWING SENSING The system measures the slewing rotational position of the crane s upper with a slewing sensor The slewing sensor is contained within the slip ring assembly Block Diagram Slew Potentiomet Current i er with 2 outputs Slip Ring Assembly s Converter IFLEX2 CU The slew potentiometer has two potentiometers built in that are driven by the slip ring axle As the slewing angle changes so will the axle and with it the potentiometer s outputs Use the display screen by pressing I info twice to show all sensor inputs The table to the right show measured millivolt reading for the slew potentiotmeter Modular Slew Pot Voltage on Service Screen The converter board is supplied with 12V from the central unit The potentiometer and the board output two signals between 4 and 20mA that go to the central unit You can measure them at the 12 pin crane interface connector 16 ANGLE SL ANG 1 SL ANG 2 mv mv 2161 1e 359 180 0 3595 2161 150 1 3144 1681 MILLIVOLTS 4000 3500 3000 2500 2000 1500 100
58. tate The error codes are one of the following E61 Error in the CAN bus data transfer for all CAN units E62 Error in the can bus data transfer of the pressure transducer sensor unit E63 Error in the can bus pressure transducer sensor unit E64 Error in the can bus data transfer of the length angle sensor unit E65 Error in the can bus length angle sensor unit Block Diagram CU CAN Bus Converter Pressure Transducer Cable Reel The block diagram tries to clarify that If the CU does not see any CAN Bus component it will report an E61 If it sees only the cable reel it will report an E62 pressure transducer missing If it sees only the pressure transducer it will report an E64 cable reel missing E63 means that the pressure transducer is available but is reporting an internal error E65 means that the cable reel unit is available but is reporting an internal error So what do you do when you are having a problem with one of those codes 12 1 E61 In case of an E61 start by connecting the two cables on the transducer block together an E62 appears the transducer block must be replaced If an E61 appears reconnect the cable from the from the central unit to the transducer block At this point if an E61 still appears check your cabling You can verify that power is being supplied to the sensor by testing the CAN connectors per this layout Connector M12 5 contacts Pin 1 Shield Pin Layout DR 303 1 7 2 Pin2
59. th potentiometer is defective PDB variable for analog value not supported Electronic component in the measuring channel is defective Pressure transducer is defective PDB variable for analog value not supported Luff down the boom to a radiu or angle specified in the load chart S Luff up the boom to a radius or angle specified in the load chart Set the correct operating mod for the operating state in question Extend retract boom to the correct length Retract boom Check the prestress of the cable reel The slewing zone with load is e Slew to permitted area not permitted e e he boom is in a non Slew the boom to a permitted permitted slewing zone area cable must be taut Open the length sensor and carefully turn the length sensor pot counterclockwise until the detent by means of a screw driver Replace the complete clutch including drive wheel and adjust length sensor pot as described above Luff the jib to a radius or angle specified in the load chart Replace length potentiometer Setup of correct PDB variable for analog value in DGAG i 3 Replace sensor unit Replace pressure transducer Setup of correct PDB variable for analog value in DGAG i 3 5 Service Manual PPAT iFLEX2 with iSCOUT expert compact Error LC Fallen below lower limit value in the measuring channel Error code pressure rod side Fallen below lower limit value in measuring chan
60. that bus however only one node at a given time has write access to the bus If the message is relevant it will be processed otherwise it is ignored The unique identifier also determines the priority of the message The lower the numerical value of the identifier the higher the priority The cable bus is a twisted pair of shielded wire Data can be transmitted in blocks from 0 8 bytes at a maximum transfer rate of 1 Mbit s for networks up to 40 meters For longer network distances the maximum transfer rate must be reduced to 50 Kbit s for a 1 km network distance CAN will operate in extremely harsh environments and the extensive error checking mechanisms ensure that any transmission errors are detected 6 50 650 69 0101E REV A GROVE RT TM DOC Rev A 2007 08 17 rk f HIRSCHMANN A Belden Company Description Of The System 3 3 X DESCRIPTION OF THE SYSTEM COMPONENTS Pressure Transducer The pressure transducer converts hydraulic pressure into an electric signal A pressure transducer block houses two transducers CAN bus converter board and two bus connectors One pressure transducer is connected to the piston side of the lift cylinder and the other to the rod side The Length Angle Transducer The length angle sensor LWG often referred to as the cable reel is a combination of two transducers in one box installed on the base section of the boom It measures the length and the angle of the boom A reeling drum drives a pot
61. tual length more than 0 3 feet YES Proceed to next length sensing flow chart 4 2007 HIRSCHMANN Automation and Control GmbH 1 3 Service Manual PPAT iFLEX2 with iSCOUT expert compact Length Sensor varies See length sensor signal chart below Ensure the length sensor is being YES supplied with 4 7V by Is the voltage measuring between Is the voltage between the Pin 5 and Pin 1 between the range of 4 7V range of 4 7V to 5 0V to 5 0V Replace converter Unplug the length board sensor and If unplugging the length sensor measure again unplugging g made the voltage return to the acceptable range replace the length sensor Follow procedure for length sensor The length sensor returns a voltage between 0 16V at turns of the length pot fully retracted and 4 84V at 10 turns How many turns you get at full extension depends on the gear ratio the boom length the length cable used and the spooling pattern so we cannot provide a standard table for it What we can give you for trouble shooting however is the following table that shows the expected output voltage measured between X20 5 and X20 3 Signal for each complete turn of the length potentiometer Note that this does not sync to the number of turns of the cable reel though Length Sensor Signal on Pin 3 Turns Note Actual voltages will vary slightly For the boom control system the length s
62. w for actual value ranges If you suspect a sensor error or problem with a sensor compare the indicated physical value of the sensor on the display screen with the real value i e length angle etc The voltages given are internal calculation values only you will not be able to actually measure them anywhere on the electronics Typical values to be expected are e Pressure transducers piston and rod 500mV 0 PSI 4500mV maximum PSI e Length sensor 500mV retracted boom length voltage extended depends on the various boom lengths e Angle sensor 4500mV at 0 2500mvV at 45 or 500mV at 90 Please refer to table below for more values 2007 HIRSCHMANN Automation and Control GmbH 25 Service Manual PPAT iFLEX2 with iSCOUT expert compact Angle Sensor degrees 500 90 boom vertical 1500 675 250 45 3800 22 4500 0 boom horizontal fully retracted If the displayed value does differ from the actual value please refer to the following sections to find the cause of the problem If the displayed angle is incorrect please go to section Angle Sensing If the displayed length is incorrect please go to section Length Sensing If the displayed pressures are incorrect please go to section Pressure Sensing 26 50 650 69 0101E REV A GROVE RT TM DOC Rev 2007 08 17 rk f HIRSCHMANN Troubleshooting a sensor problem using the display Race cana SLEW POT SIGNALS Sig 1 mA Sig 2 mA Ref

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