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Q-iQ Service Manual 7-11 1-3.qxp

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1. Diagram 8 Actuator IO 474 CPU 7 11 8 8 Gorbel Inc G Force Q iQ Service Manual sJequ nN Hed GieqJos ale seseuueJeg Ul SJequinN ON UVTINIS HO 18982 ASSY 318VO MVTIIWIS YO 18982 Assy 318VO YVIINIS YO 12982 ASSY Z18VO E YVJINIS YO 99982 ASSY 318V2 il Slide Model Diagram 9 Handle IO Detai 7 11 8 9 Gorbel Inc G Force Q iQ Service Manual sJequ nN Wed j9qQJ09 aie seseujueJeg Ul SJBQUNN ON NMOHS LON GYVND dOL 4 TQNVH LNVON3d YVIINIS YO 18982 ASSY 318v9 YVTINIS HO 18982 ASSY 318V0 YVIINIS YO 12982 ASSY Z18VO __________ YVTINIS YO 99982 ASSY 318v9 il Pendant Model Diagram 10 Handle IO Detai 8 10 7 11 G Force Q iQ Service Manual Gorbel Inc Chapter 9 Adjustments Upper and Lower Limit Switch Adjustment Under normal conditions the Upper and Lower Limit Switches should not require adjustment in the field unless one were to fail and require replacement These switches are set in the factory during assembly and final testing There could be situations however that would require a slight adjustment For example when replacing a wire rope assembly the end of the wire rope and the retaining plate must be positioned precisely in order to perform the wire rope replacement properly If this is not the case then the Lower Limit
2. Coil Cord Footer Note Numbers in 74205 Parentheses are Clevis Bolt Gorbel amp Part Numbers 74222 Diagram 2 165 Ib 75 kg and 330 Ib 150 kg Standard Length Coil Cord Assembly G FORCE COILCORD ASSEMBLY For replacement of entire Coil Cord Assembly use part name G FORCE COILCORD ASSEMBLY 7 11 10 68 G Force Q iQ Service Manual Gorbel Inc Procedure 2 Double Length Coil Cord Assembly G FORCE COILCORD EXT ASSEMBLY Note Numbers in Coil Cord Bracket Parentheses are 76708 Gorbel Part Numbers 2x BHCS M6 x 12mm Lg 65112 2x Lockwasher M6 ZNPL 03370 2x Strain Relief Clamp 79150 2x SHCS M6 x 25mm Lg 65028 2x Lockwasher M6 ZNPL 03370 Double Cable Assembly Molded 78622 Hex Jam Nut M12x1 75 ZNPL 65064 2x BHCS M4 x 0 7 x 16 Lg 65068 2x Strain Relief Clamp 74232 Plug Air DN8 1 4 NPT 74241 Coil Cord Footer 74205 Clevis Bolt 74222 Diagram 3 660 Ib 300 kg Double Length Coil Cord Assembly G FORCE COILCORD EXT ASSEMBLY For replacement of entire Coil Cord Assembly use part name G FORCE COILCORD EXT ASSEMBLY 10 69 7111 G Force Q iQ Service Manual Gorbel Inc Note Numbers in Coil Cord Bracket Parentheses are 76757 Gorbel Part Numbers 2x BHCS M6 x 12mm Lg 65112 2x Lockwasher M6 ZNPL 03370 2x Strain Relief Clamp 79150 2x SHCS M6 x 25mm Lg 65028 2x Lockwasher M6 ZNPL 03370 Double Cable Assembly Mo
3. 10 75 7 11 G Force Q iQ Service Manual HHCS M16 x 35mm Lg ZNPL 65066 Belleville Washer M16 DIN 2093 Grp 2 65098 Sliding Handle Swivel Sub Assembly 74249 2x PHMS M2x0 4 6 SEMS Split Lock 65073 PCB Slip Ring Aux Out 74282 Collector Shaft 74280 Spring Pin M4 x 24 65102 Standalone Swivel Cover 74283 Push In Plug 5 8 ID Black 70071 3x Lockwasher M3 65051 3x SHCS M3 x 0 5 12 65012 Gorbel Inc Note Numbers in Parentheses are Gorbel Part Numbers Output Connector Nut G360 Collector Label 74284 Strain Relief Clamp Coil Cord 79150 Nylock Nut M6 ZNPL 65090 Diagram 1B Standard G360 Assembly and Disassembly 7 11 10 76 G Force Q iQ Service Manual Gorbel Inc Procedure 2A Swivel Sub Assembly Disassembly Procedure a b C Remove the swivel sub assembly from the G360 assembly Refer to Procedure 1A Remove the C ring from the swivel sub assembly Remove the Delrin spacer washer from the swivel sub assembly Remove the secondary slip ring PCB from the swivel casting Be very careful to not deform the contacts on the PCB Remove the primary slip ring PCB from the swivel by removing the input connector nut 3 M2 Phillips head machine screws PHMS 4 nylon Phillips head machine screws PHMS and 12 flatwashers from the swivel casting Remove the bearing from the swivel casting if necessary Note This bear
4. aad ZZZZZZZ In NN M4 screw Diagram 9C Base plate and screw length selection Installation examples Diagram 9D nstallation on an aluminum frame DIN rail or mounting plate 3 13 7 11 G Force Q iQ Service Manual Gorbel Inc Chapter 4 Removal Procedure If it has been determined that the G Force Q or iQ system must be returned to Gorbel or another authorized service location or if the system is being relocated for some other reason please follow the guidelines listed below 1 Locate the original shipping box and materials or use a suitable alternative if necessary Gorbel can provide a new shipping box upon receipt of a purchase order Do not ship the unit anywhere strapped to a pallet or inside an empty box without any protection or packing material 2 Disconnect any tooling or non Gorbel accessories including air hose fittings external electrical switches harnesses etc Do not send any of these items back unless specifically requested by Gorbel Inside Sales 3 If possible before powering off the system and disconnecting the control handle raise the wire rope assembly to the upper limit 4 Disconnect the coil cord assembly from both the actuator and the handle or swivel assembly Pack these components carefully to avoid shipping damage diagram 1 ACTUATOR ASSEMBLY BLACK CENTER NOT SHOWN 2X SCREW amp WASHER FROM ACTUACTOR ASSEMBLY COIL CORD ASSEMBLY
5. 6 4 After verifying the disconnect switch is turned OFF connect the newly installed receptacle to the male plug at the G Force Step 7 Initial Power Up 7 1 Turn on the disconnect switch by others to apply power to the G Force amp When power is detected POWER ON is displayed on the LCD 7 2 Disengage the emergency stop E stop button located on the front face of the handle 7 3 During the system power up the LCD at the handle will display UNIT POWER UP 7 4 Once the system is on line and ready LIFT READY will be displayed on the LCD 7 5 Standard Operation Slide Handle Configuration Grasp the handle grip to run the unit up and down Do this several times to get a feel for the unit The LCD displays RUN MODE HANDLE e Standard Operation Pendant Handle Configuration Depress the up and down levers to run the unit up and down Do this several times to get a feel for the unit The LCD displays RUN MODE PENDANT Note The LCD backlight will shut off after 10 minutes of inactivity m TIP The operator should always keep their hand under the operator present sensor on the slide handle while operating the unit in standard mode If the hand is frequently moved away from the operator present sensor it will result in jerky movement from the unit 7 6 Finally test the operation of any special tooling that may have been integrated to the G Force m TIP Gorbel Inc does not provide integrated tooling for t
6. Lever Shaft 105 74315 Left Angled Lever 88604 2x BHCS M6 x 16mm Lg 65075 Electric Switch Option Left Side Top Guard 74335 10x Lockwasher M6 ZNPL 03370 2x Flatwasher M6 ZNPL N 65060 Lever Shaft 105 74315 2x Electric Switch Block Assembly 74332 Left Angled Lever 88604 Gorbel Inc Top Guard 74335 Side Guard 74313 Pneumatic Mounting Plate Left Right 74317 4x BHCS M6 x 10mm Lg 65076 6x BHCS M6 x 16mm Lg 65075 Side Guard Valve Option 74329 Right Angled Lever 88605 Electric Switch Option Both Sides 7 11 G Force Q iQ Service Manual Top Guard 74335 10x Lockwasher M6 ZNPL 03370 6x BHCS M6 x 16mm Lg 65075 Lever Shaft 105 74316 One Signal Pilot Valve Block 88881M Left Angled Lever 88604 10x Lockwasher M6 ZNPL 03370 6x BHCS M6 x 16mm Lg 65075 Lever Shaft 105 74316 Single Electric Switch Block Assembly 74332 Left Angled Lever 88604 7 11 Gorbel Inc 4x BHCS M6 x 10mm Lg 65076 2x Flatwasher M6 ZNPL 65060 2x Side Guard Valve Option 74329 Right Angled Lever 88605 a Single Electric Switch Block Assembly 74332 Pneumatic Mounting Plate Both 74318 Electric Switch Right Side Valve Left Side Top Guard 74335 4x BHCS M6 x 10mm Lg 65076 2x Flatwasher M6 ZNPL 65060 2x Side Guard Valve Option 74329
7. One Signal Pilot Valve Block 88881M Right Angled Lever 88605 Pneumatic Mounting Plate Both 74318 Electric Switch Left Side Valve Right Side 10 66 G Force Q iQ Service Manual Gorbel Inc Removal amp Replacement Procedures COIL CORDS Procedure 1 Standard Coil Cord Assembly G FORCE COILCORD ASSEMBLY Coil Cord Bracket 76708 2x BHCS M6 x 12mm Lg 65112 2x Lockwasher M6 ZNPL 03370 2x Strain Relief Clamp 79150 2x SACS M6 x 25mm 1g 65028 2x Lockwasher M6 ZNPL 03370 Standard Cable Assembly Molded 78614 Hex Jam Nut M12x1 75 ZNPL 65064 2x BHCS M4 x 0 7 x 16 Lg 65068 2x Strain Relief Clamp 74232 Plug Air DN8 1 4 NPT 74241 Coil Cord Footer Note Numbers in 74205 Parentheses are Clevis Bolt Gorbel Part Numbers 74222 Diagram 1 660 Ib 300 kg Standard Length Coil Cord Assembly G FORCE COILCORD ASSEMBLY For replacement of entire Coil Cord Assembly use part name G FORCE COILCORD ASSEMBLY 10 67 7 11 G Force Q iQ Service Manual Gorbel Inc Coil Cord Bracket 76757 2x BHCS M6 x 12mm Lg 65112 2x Lockwasher M6 ZNPL 03370 2x Strain Relief Clamp 79150 2x SHCS M6 x 25mm Lg 65028 2x Lockwasher M6 ZNPL 03370 Standard Cable Assembiy Molded 78614 Hex Jam Nut M12x1 75 ZNPL 65064 2x BHCS M4 x 0 7 x 16 Lg 65068 2x Strain Relief Clamp 74232 Plug Air DN8 1 4 NPT 74241
8. 4 on Adapter module 1 798736 798739 Screw in module 1 4 on Adapter module 2 4352 4368 4352 4368 4864 4880 16384 16400 16640 16656 798976 798995 798976 798979 Screw in module 1 4 on Adapter module 1 798992 798995 Screw in module 1 4 on Adapter module 2 799232 799251 799232 799235 Screw in module 1 4 on Adapter module 1 799248 799251 Screw in module 1 4 on Adapter module 2 Open connector or sensor open 799488 799507 799488 799491 Screw in module 1 4 on Adapter module 1 799504 799507 Screw in module 1 4 on Adapter module 2 Converter error 799744 799763 799744 799747 Screw in module 1 4 on Adapter module 1 799760 799763 Screw in module 1 4 on Adapter module 2 Screw in module removed 800000 800019 800000 800003 Screw in module 1 4 on Adapter module 1 800016 800019 Screw in module 1 4 on Adapter module 2 screw in module inactive 800256 800275 800256 800259 Screw in module 1 4 on Adapter module 1 800272 800275 Screw in module 1 4 on Adapter module 2 crew in module communication error 800512 800531 800512 800515 Screw in module 1 4 on Adapter module 1 800528 800531 Screw in module 1 4 on Adapter module 2 crew in module type changed 800768 800787 800768 800771 Screw in module 1 4 on Adapter module 1 800784 800787 Screw in module 1 4 on Adapter module 2 7 28 G Force Q iQ Service Manual Gorbel Inc Cha
9. Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Retain Existing Configurations option to clear the faulty memory and retain the latest configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions For custom iQ units all custom feature settings such as position or weight settings are not retained and are reset to default settings as specified for the unit Error 115 ERROR_SAVE_UNIT_OBJ_STORE Description When saving the current unit specific configuration setting into memory an error is returned Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Retain Existing Configurations option to clear the faulty memory and retain the latest configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions For custom iQ units all custom feature settings such as position or weight settings are not retained and are reset to default settings as specified for the unit 7 11 7 11 G Force Q iQ Service Manual Gorbel Inc
10. Reaction Lift program terminates processing to prevent running with an unconfigured or potentially faulty PLC unit Cause Remedy Please contact Gorbel Inside Sales at 800 821 0086 or 585 924 6262 Error 4 ERROR_UNIT_OBJ_SIZE_MISMATCH Description At startup the stored unit specific configuration variable in memory does not match the version lift program used Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 5 ERROR_UNIT_OBJ_LOCATE Description At startup the query command to locate the stored unit specific configuration variable is returned with an error Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g
11. be turned off by Input 3 see I O Point 3 Output Anti drop feature Unclamp Control nism of an end effector tooling It turns on when Input 3 see I O Point 3 is on and the Anti Drop algorithm determines the sus pended load is at or below the set weight ANTIDROP TOOL WT If it is not turned on the input can be held momentarily do not hold on indefinitely until the tooling is unloaded then the output is urned on Once the output turns on it remains latched on when he input is released It is always turned off with Input 2 see I O Point 2 Chart 2 Expansion 8 Point Input Output Block G Forcee must have Float Mode feature enabled for this feature to work WARNING Please be aware that software versions prior to R1 07 0 use I O block model X67BC7321 while those with R1 07 0 and newer require the X67BC7321 1 model The model number can be ound at the left side of the block when placed in the orientation as shown in the diagram The running software version can be checked through DISPLAY SYS INFO selection under SERVICE MENU in PROGRAM MODE Diagram 6 Handle Input Output Block 7 11 8 6 G Force Q iQ Service Manual Gorbel Inc Gorbel Part Numbers Note Numbers in Parentheses are yyy oyryy Diagram 7 Q iQ Handle Configurations 8 7 7 11 G Force Q iQ Service Manual Gorbel Inc
12. Block Mount ne Signal Pilot Valve Metric eft Angled Lever not shown Right Angled Lever Lever Shaft 38mm Long 7 Lever Guard 40mm Wide BHCS M6 x 16mm Lg BHCS M6 x 10mm Lg HHCS M6x1 0 20 ZNPL Flatwasher M6 ZNPL Lockwasher M6 ZNPL Hexnut M6 ZNPL eo N Ez EM RM ET 13 Single Auxiliary Control Pilot Valve Kit for Slide Handle 6 88507 Lever Guard 40mm Wide 8 65076 BHCS M6 x Tomm ig 9 65060 Flatwasher M6 ZNPL Auxiliary Control Pilot Valve Kit 10 51 7 11 G Force Q iQ Service Manual Gorbel Inc 6 65052 Lockwasher M4 ZNPL 8 88605 Right Angled Lever 9 88901 Lever Shaft 38mm Long Auxiliary Electric Switch with Bracket 6 88604 Left Angled Lever not shown 8 88901 Lever Shaft 38mm Long _ 9 88501 Lever Guard 40mm Wide _ 01764 Hexnut M6 ZNPL Single Electric Switch Assembly for Slide Handle 7 11 10 52 G Force Q iQ Service Manual Gorbel Inc Removal amp Replacement Procedures PENDANT HANDLE Note The following procedures assume any electrical or support cables have been disconnected prior to performing any repairs on the Pendant Handle itself Procedure 1A Top Guard Removal a Remove the 4 M6 button head cap screws BHCS and 4 M6 lockwashers b Slide the top guard off the top portion of the pendant handle Procedure 1B Top Guard Replacement a Position the top guard on the
13. CHECK Download skipped Module already on target Download dataobj br SYSROM CHECK SUCCESSFUL 29 Download brsystem br ROM CHECK Download brsystem br ROM CHECK SUCCESSFUL 30 Download runtime br ROM CHECK Download runtime br ROM CHECK SUCCESSFUL 31 Download asstring br ROM CHECK When the software update is complete a pop up box will appear as a reminder to cycle the power of the G Force unit before proceeding 7 11 Power Cycle Unit 1 Before proceeding to the next step in the process please cycle the unit power using the E stop button 6 6 G Force Q iQ Service Manual Gorbel Inc Step 6 For the final step of the update process the previous settings need to be restored to the unit Click the Restore Settings button and the progress of the restore process will be shown in a gauge beneath the button as well as in the Status and Messages box at the bottom of the program window You will be prompted to depress the E stop button before beginning the retrieval process Step 6 0r i Status of Step 7 Status and Messages 10 10 2007 8 49 09 AM Connected to Global Variables 10 10 2007 8 49 00 4M Connecting to Global Variables please wait 10 10 2007 8 48 57 4M Connected to Virtual Limits Structure 10 10 2007 8 48 57 4M Connecting to Virtual Limits Structure 10 10 2007 8 48 57 4M Connected to Configuration Structure z 1010 20607 8 A857 OM
14. Error 120 ERROR_FACTORY_OBJ_CREATE Description An error has occurred when creating a dummy factory configuration variable Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 121 ERROR_FACTORY_OBJ_COPY Description An error has occurred while copying the dummy factory configuration to be the default factory configuration Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 122 ERROR_FACTORY_OBJ_DELETE Description An error has occurred while deleting the factory configuration from PLC Reaction N A Cause Remedy Run the Gorbel supplied insta
15. Part Numbers Diagram 11B 330 and 660 Ib 150 and 300 kg Motor Set Removal and Replacement 7 11 10 18 G Force Q iQ Service Manual Gorbel Inc Procedure 12A End Support Frame Removal a Turn power off by disconnecting AC power to the system b Remove front cover Refer to Procedure 1A c Remove ACOPOS support bracket with electrical shield main PCB and ACOPOS servo drive still attached Disconnect all cable assemblies from the main PCB and ACOPOS drive as required Refer to Procedure 7A d Remove 7 M5 socket head cap screws SHCS and 7 M5 lockwashers from end support frame Procedure 12B End Support Frame Replacement a Align the end support frame with the holes in the actuator casting and install 7 M5 socket head cap screws SHCS and 7 M5 lockwashers b Install the ACOPOS support bracket with electrical shield main PCB and ACOPOS servo drive Connect all cable assemblies to the main PCB and ACOPOS drive Refer to Procedure 7B c Install the front cover Refer to Procedure 1B d Restore AC power to the system End Support Frame 76758 7x Lockwasher M5 High Collar 65062 7x SHCS M5 x 20mm Lg 65001 4x Front Cover Mounting Bracket 76759 4x SHCS M5 x 12mm Lg 65002 Note Apply 7 Blue Loctite to Threads 2x FHCS M5 x 10mm Lg 65004 Note Numbers in Parentheses are l Bearing Retainer Ring Gorbel Part Numbers i 76512 Diagram 12A 165 and 330 Ib 75 and 15
16. This is caught when the current running feature is a PROCESS specific feature Reaction Handle LCD displays the warning while unit is allowed to continue to run Cause Remedy Please contact Gorbel Customer Service at 800 821 0086 or 585 924 6262 Error 10401 WARN_MULTP_DISP_REQUEST OBSOLETE Description More than two features are attempting to display messages in the LCD at the same time This is caught when the current running feature is a DISPLAY specific feature Reaction Handle LCD displays the warning while unit is allowed to continue to run Cause Remedy Please contact Gorbel Customer Service at 800 821 0086 or 585 924 6262 Error 10402 WARN_SET_MESSAGES_MISMATCH_LENGTHS Description The first and second line of the LCD text display are not the same length when unit attempts to process the message information Reaction Handle LCD displays the warning while unit is allowed to continue to run Cause Remedy Please contact Gorbel Customer Service at 800 821 0086 or 585 924 6262 Error 10403 WARN_ADD_MESSAGES_EXCEED_LENGTH Description The maximum allowable number of consecutive text messages is exceeded when unit attempts to process the message information Reaction Handle LCD displays the warning while unit is allowed to continue to run Cause Remedy Please contact Gorbel Customer Service at 800 821 0086 or 585 924 6262 Error 10404 WARN_PROG_ERROR_LOADCELL_COEF Description This warning is gen
17. 0 60 Replace the E stop switc lid Nu O 0 40 ean the sensor and remove sensor is any blockage blocked for more Look for interference with the levers 4 Air Leaking at O rings are worn O rings 0 38 10 Replace the o rings and Swivel or undersized lubricate with general purpose Assembly Inon synthetic grease 5 Weight readout oad plate oll cord bracket and or nylon wear ring 10 65 thru 10 68 e is not accurate movement is is out of position or nylon wear ring is not within 196 restricted positioned correctly and or Float Mode is jumpy power off the system and power he system back on Use the down jog button to move the load down away from the upper limit switch ean and lubricants slip rings Deoxit or replace if worn excessively 7 11 7 4 G Force Q iQ Service Manual Gorbel Inc Troubleshooting Section Il System Fault Diagnostics Chart Under certain conditions a system fault or warning message may appear on the LCD screen or the G Force handle along with either the red or blue LED flashing The system fault or warning message can be one of the following 1 Command faults describes faults detected by the PLC while executing a command that results in a system shutdown with a message displayed on the LCD screen 2 Command warnings describes a condition that will allow the system to continue to operate with a message being displayed on the LCD screen until that message is cleared using Pro
18. 10 Do not divert attention from load while operating hoist 11 Never leave a suspended load unattended 12 Do not use limit switch es for normal operating stop s These are safety devices only and should be checked on a regular basis for proper operation Never operate a hoist that has an inherent or suspected mechanical or electrical defect Do not use load cable as a ground for welding Never touch a live welding electrode to the load cable Do not jog controls unnecessarily Hoist motors are generally high torque high slip types Each start causes an inrush of current greater than the running current and leads to overheating and current failure or burnout if continued to excess Do not operate hoist if load is not centered under hoist Do not operate hoist if cable is twisted kinked or damaged Do not remove or obscure label Do not permanently activate operator present sensor 13 14 15 16 17 18 19 DO S HOISTS 1 Read and follow manufacturer s instruction installation and maintenance manuals When repairing or maintaining a hoist use only manufacturer s recommended parts and materials 2 Read and follow all instruction and warning information on or attached to a hoist 3 Remove the hoist from service and thoroughly inspect and repair as necessary if unusual performance or visual defects such as peculiar noise jerky operations travel in improper direction or obviously dam
19. 74313 Lever Shaft 105 74315 Side Guard Valve Option 74329 i Pneumatic Mounting Plate Left Right One Signal Pilot Valve Block T 74317 88881M Left Angled Lever 88604 2x BHCS M6 x 16mm Lg 65075 Single Valve Option Left Side 10 63 7 11 G Force Q iQ Service Manual Gorbel Inc 7 11 Top Guard 74335 4x BHCS M6 x 10mm Lg 10x Lockwasher M6 ZNPL 65076 03370 2x Flatwasher M6 ZNPL Ps scr 65060 6x BHCS M6 x 16mm Lg i l 2x Side Guard Valve Option 65075 74329 Lever Shaft 105 74316 ae Right Angled Lever f 88605 2x One Signal Pilot Valve Block Pneumatic Mounting Plate Left Right 88881M 74318 Left Angled Lever 88604 Single Valve Option Right and Left Sides Top Guard 74335 9x Lockwasher M6 ZNPL 03370 7x BHCS M6 x 10mm Lg 65076 Side Guard 0 73 Flatwasher M6 ZNPL 74313 65060 Lever Shaft 10 74315 j Side Guard Valve Option 74329 Pneumatic Mounting Plate Left Right lt OL 74317 J Single Electric Switch Block Assembly 74332 1 muuzi 2x BHCS M6 x 16mm Lg 65075 Right Angled Lever 88605 Electric Switch Options Right Side 10 64 G Force Q iQ Service Manual 9x Lockwasher M6 ZNPL 03370 7x BHCS M6 x 10mm Lg 65076 Flatwasher M6 ZNPL 65060 Side Guard Valve Option 74329 Single Electric Switch Block Assembly 74332
20. An error has occurred when checking if a temporary PLC serial number variable exists This fault can only be triggered during the factory setup process or by authorized personnel attempting to record the PLC serial number Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Please contact Gorbel Inside Sales at 800 821 0086 or 585 924 6262 Error 101 ERROR_DUMMY_SERIAL_NUM_OBJ_DELETE Description An error has occurred while deleting the stored temporary PLC serial number during the factory setup process Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Please contact Gorbel Inside Sales at 800 821 0086 or 585 924 6262 Error 102 ERROR_SERIAL_NUM_OBJ_CHECK Description An error has occurred while checking if a stored PLC serial number exists Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Please contact Gorbel Inside Sales at 800 821 0086 or 585 924 6262 Error 103 ERROR_SERIAL_NUM_OBJ_DELETE Description Prior to saving the PLC serial number the last stored version is deleted and an error is returned while the command is executed Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Please contact Gorbel Inside Sales at 800 821 0086 or 585 924 6262 E
21. Carefully slide the housing sub assembly off the handle shaft Note Be careful to not damage the LVDT sub assembly when removing the housing assembly Procedure 3B Housing Sub Assembly Replacement a Carefully slide the housing sub assembly onto the handle shaft Note Be careful to not damage the LVDT sub assembly when replacing the housing sub assembly b Replace either the swivel sub assembly or remote mount cap sub assembly accordingly Refer to Procedure 1B or 2B c Replace snap ring washers and air extensions if applicable Handle Top Sub Assembly 74248 10 74247 10 Operator Present Sensor 78615 NOTE LOCATION OF Bumper LCD Window o i NUT AND WASHER 74207 74223 E 2x External Snap Ring 6mm 65065 ST i I od 1 Sliding Handle Bottom 2x Handle Pushbutton 74209 74215 i 4x Lockwasher M5 High Collar 65062 4x SHCS M5x0 8 55 65067 Note Numbers in Parentheses are Gorbel Part Numbers Diagram 3 Housing Sub Assembly Removal and Replacement 7 11 10 42 G Force Q iQ Service Manual Gorbel Inc Procedure 4A Housing Sub Assembly Disassembly Note This procedure is applicable to both Q and iQ handle assemblies a Remove the swivel sub assembly or remote mount cap sub assembly Refer to Procedure 1A or 2A accordingly b Remove the housing sub assembly Refer to Procedure 3A Remove 4 M5 socket head cap screws SHCS and 4 M5 flatwashers d Separate the handle t
22. Cord Mounting Plate Dey Note Numbers in 83253 i 7 Wire Rope Assembly Parentheses are 4 Gorbel amp Part Numbers 1320 Ib 600 kg Reeved G Force Coil Cord Assembly 711 10 38 G Force Q iQ Service Manual 4x M4 SHCS 65018 4x M4 Lockwasher 65052 Pulley 83255 Bearing 83261 Snap Ring 65086 H 2x Pulley Spacer 83259 Note Numbers in Parentheses are Gorbel Part Numbers 2x Shaft Collar 83267 6x M4 Lockwasher __ 65052 6x M4 SHCS 83264 2x M8 Shoulder Bolt _ 83263 2x M6 Hexnut Note Numbers in 01764 Parentheses are 2x M6 Lockwasher Gorbel Part Numbers 03370 Gorbel Inc 7 M6 SHCS 2x 17mm Snap Ring 2001 12 Pulley Pin 83258 2x Pulley Side Plate 83254 2x Pulley Side Plate Spacer 83257 97 4x PHMS 3 40 x 1 4 83266 2x Pulley Side Guard 83256 _ Coil Cord Footer 83250 Swivel Sub Assembly 1320 Ib 600 kg Reeved G Force amp Swivel Assembly 7 11 G Force Q iQ Service Manual Gorbel Inc Removal and Replacement Procedures SLIDING HANDLE Procedure 1A Swivel Sub Assembly Removal Note This procedure assumes the Coil Cord and Wire Rope assemblies have been removed prior to performing any repairs on the Sliding Handle itself Refer to the system installation procedures in Chapter 3 for specific instructions regarding Coil Cord and Wire Rope removal a Remove the M16 custom hex head cap
23. Drop algorithm determines suspended load is at or below including handle controller and other accessories he set weight ANTIDROP TOOL WT If Output 8 turns on ithout a pickup part must be suspended solely by the Output 7 is turned off ire rope when tarring The minimum difference between unloaded and loaded tool weight is 20 Ibs for G Force 25 Ibs for Easy Arm and 25 lbs for G Jib products nput Auto Home When this input is toggled momentarily turned on then off again e Auto Home position programming Is located at he G Force automatically travels to the set home position in the SETTINGS MENU 2 MENU 2 SET HOME Move the ertical travel Tracking stops when obstruction is detected i e G Force to the desired position in the vertical travel Q iQ G Force stops at 10 25 lbs depending on unit capacity before selecting the position setting in this menu IS Input controls input 5 on the actuator input output module E used in hen this input is on output 5 on the iQ actuator input output conjunction with module is on and vise versa actuator output 5 IS Input controls input 6 on the actuator input output module control used in hen this input is on output 6 on the iQ actuator input output conjunction with module is on and vise versa actuator output 6 Clamp Control of an end effector tooling It turns on when Input 2 see I O Point is on and remains latched on when the input is released It can
24. Force trolley wheels are correct for the style and capacity track that the unit is being installed on by rolling the actuator assembly ex along the full length of the bridge to ensure that the travel is smooth throughout Diagram 3B Standard Actuator Assembly with Universal Adapter Trolley 3 1 7 11 G Force Q iQ Service Manual Gorbel Inc Step 4 Coil Cord Installation Standard In Line Slide Handle Remote Mounted Slide Handle and Remote Mounted Pendant Handle TIP This step is best completed once the actuator has been installed into the bridge system CAUTION Do not rest the actuator on a hard flat surface with the wear ring and or coil cord attached You will damage the coil cord and bend the wear ring bracket which b Jj ill cause poor performance Note G Force units standard in line or remote mounted that are ordered from the factory will be shipped with the coil cord assembled to the actuator wear ring A and the coil cord footer creating the coil cord assembly diagrams 4A and 4B In B d addition units ordered with air power will have a 1 4 ID nycoil air hose coil cord assembled onto the coil cord assembly not shown e 4 1 Verify the coil cord assembly is correct There are two coil cord Diagram 4A Standard Coil assemblies standard and double length The standard coil cord Gord Assembly assembly is used on systems with a trolley saddle up to 14 4 27m and will measure approximately 8 3 2
25. Gorbel Inc Chapter 11 Preventative Maintenance G Force Model Q and iQ Recommended Preventative Maintenance Note iQ model show with in line slide handle See illustrations below for alternate configurations Remote lk Sliding Handle tooling by others Remote Pendant Handle tooling by others Suspended Pendant Handle 7 16 amp 17 p Diagram 1 G Force with Suspended Pendant Handle Refer to Diagram 1 for the approximate location of the components listed by numbers 1 through 19 on the following pages The procedures are divided into four B specific intervals daily monthly quarterly and yearly I You may find it necessary to increase the frequency b based on equipment use and environmental conditions in your facility Federal state and local codes may require inspection and maintenance checks more often Please check federal state and local code manuals in your area 11 1 7 11 G Force Q iQ Service Manual Gorbel Inc Daily Checks These are quick visual checks that do not require any tools 1 Wire Rope Look for any obvious external defects damage or excessive wear Check the lower end where it attaches to the Handle Swivel Assembly or tooling by others for signs of damage or excessive wear 2 Coil Cord Look for any obvious external defects or damaged caused by the Wire Rope or other external causes Make sure all the Coil Cord Clamps are in place 3 Air Hose if eq
26. Gorbel Inc Chapter 2 Technical Specifications es esre raSoies suus asme ases Sores Series rasere Maximum Capacity Load 1320 Ib 1320 Ib 660 Ib 660 Ib 330 Ib 330 Ib 165 Ib 165 Ib amp Tool 600 Kg 600 kg 300 kg 300 kg 150 kg 150 kg 75 kg 75 kg Maximum Lifting Speed 25 ft min 50 ft min 50 ft min 100 ft min 100 ft min 200 ft min 200 ft min Unloaded 7 47 m min 7 47 m min 14 94 m min 14 94 m min Maximum Lifting Speed 21 ft min 42 ft min 42 ft min 125 ft min 125 ft min Fully Loaded Maximum Float Mode Timin 38 Tumin 38 umin 103 min 103 fmin Option Lifting Speed Maximum Lift Range man Duty Cyce Cycle Lro Available for 24VDC NM 24VDC NM 24VDC NM 24VDC NM Not Available Not Available Not Available Not Available 0 5A 1 4 dia 19x7 1 4 dia 19x7 1 4 dia 19x7 1 4 dia 19x7 3 16 dia 19x7 3 16 dia 19x7 3 16 dia 19x7 3 16 dia 19x7 Preformed Preformed Preformed Preformed Preformed Preformed Preformed Preformed Wire Rope Wire Rope Wire Rope Wire Rope Wire Rope Wire Rope Wire Rope Wire Rope Lifting Media 6 35mm dia 6 35mm dia 6 35mm dia 6 35mm dia 4 76mm dia 4 76mm dia 4 76mm dia 4 76mm dia Wire Rope Wire Rope Wire Rope Wire Rope Wire Rope Wire Rope Wire Rope Wire Rope Operating Temperature 41 122 F 44 122 F 41 122 F 41 122 F 41 122 F 41 122 F 41 122 F 41 122 F Range 5 506 50 C 5 506 50 C 5 50 C 50 C 5 50 C 50 C 5
27. Mode SUB MENU Optional feature utilizing Anti Recoil detection When user sets a weight onto a surface in Float Mode it is terminated if Anti Recoil detects an unloading This can UNLOAD be useful for applications needing a quick Float Mode exit to an idle state to allow STOP ON user to work on the part Note As a result of the extra detection Float Mode is STOP OFF likely to terminate when the upper limit switch is hit while unit is running at a fast speed This false detection can be avoided or reduced by running the unit at a low speed Toggle between enabling and displaying the load weight Once enabled weight is displayed two seconds into standard operation unit idling Configuration Setup Chart 4 continued on pages 5 8 thru 5 11 Program Mode Menu and Selection Settings 5 7 7 11 G Force Q iQ Service Manual Gorbel Inc Program Mode Menu LCD Text Feature Description OVER Startup screen when this sub menu is accessed The correct configured FORCE Anti Recoil detection method is displayed see next item for details on the SPEED detection methods Toggle Anti Recoil detection method between standard over speed and over force detections Anti Recoil protects against a dropped weight while running Float Mode causing the unit to speed upward until hitting an object or a push force equivalent to the dropped weight Over Speed Detection Unit terminates Float Mode if speed exceeds maximum Float Mode speed a
28. On program start up you will see a prompt reminding you that at times during the update you may see a pop up box like the one shown below This is expected and merely needs to be closed to continue with the update PVI Manager Can t find PVI security key e Trial mode is active 7 11 6 2 G Force Q iQ Service Manual Gorbel Inc Step 1 To begin the software update process choose the location to save temp files that are created by the program The program may be left at its default C temp or click the Select Folder button and choose an alternate folder anywhere on the computer Step 1 Select a location to store temp files Select Folder Location c temp Step 2 In this step select the port on the computer that is connected to the G Force unit The program will return an error when attempting to connect to the G Force in step 2 if the correct COM port is not chosen CPU cannot connect to PLC Verify the Com selected is correct then verify cable is connected Step 3 This step begins the software update process by saving the current unit s settings so that they may be restored following the software update Click the Retrieve and Store Current Settings button shown below to start the process A prompt will appear at this point to ensure that the E stop button is pressed before proceeding with the retrieval Engage E Stop 1 Please depress the unit s E Stop button before proceeding 6 3 7 11 G
29. PConnectina ta anflin rahnn Siehe lt gt After the retrieval process is complete a green label next to the Restore Settings button will indicate success Step 6 Restore Settings BRRRRRRRRRRREEI Step 7 completed At this point the G Force unit should be ready to function using the updated software Other Functions There are three additional buttons at the bottom of the program window that perform additional functions During the normal update process there should be no reason to use these buttons and are only present for debugging when working in conjunction with Gorbel to address problems that may occur during the update process Connection Status This button informs the user of the connection status of the Task CPU and Service between the G Force unit and the computer Connection Status fx Task is connected J CPU is connected Service is connected 6 7 7 11 G Force Q iQ Service Manual Gorbel Inc Disconnect PLC This button manually disconnects the PLC from the computer that is performing the update Disconnect Status 1 PLC should be disconnected now PVI Manager Status This button informs the user of the PVI manager status The PVI manager allows the G Force amp to share information with the computer PVI Manager Status E3 e 1 PVI Manager running 7 11 6 8 G Force Q iQ Service Manual Gorbel Inc Chapter 7 Troubleshooting Troubleshooting Procedure If
30. RING Thread the free end of the wire rope through the Heze wear ring and attach the wear ring to the wear ring bracket using the supplied hardware Grab the free end of the wire rope and loop it up towards the underside of the actuator ensuring OS py there are no twists or kinks in the rope Feed the U bolt through the wire rope thimble and insert the U bolt into the appropriate holes in the reinforcement plate Using supplied hexnuts securely tighten the U bolt to the plate diagram 5K page 3 7 Diagram 5L Attaching Wire Rope to Pulley Attach the plate to the underside of the actuator using the supplied cap screws lockwashers and spacers as shown and ensure hardware is completely tightened If an air hose is being installed leave hardware loose for now Insert eyebolt at the end of the pendant cable into the threaded hole on the reinforcement plate and tighten Insert Turck connector into mating connector or the underside of the actuator While holding the G360 loop the pulley through the wire rope and slip the pulley and side spacers down between the plates diagram 5L Align the holes in the plates with the spacers and the bearing insert the pulley pin and install the snap ring on the pulley pin Using the supplied cap screws and lockwashers attach the coil cord mounting plate to the top of the G360 Continue to Step 6 on page 3 9 Step 5G 1320 Ib Air Hose Assembly Installation Optional 5
31. Socket Plug 1 2 NPT 65089 150 300 KG Q CERT Diagram 13B 330 Ib 150 kg and 660 Ib 300 kg Q and iQ Load Cell Removal and Replacement 10 23 7 11 G Force Q iQ Service Manual Note Numbers in Parentheses are Gorbel Part Numbers _ 2x Bumper G Force Trolley 77320 4x Nylock M6 65090 2x End Axle A1001 24 6x Snap Ring 2001 12 Note C H 1 is either of 2 holes off center C H 2 is center hole with slot to edge Gorbel Inc 4x HHCS M12 x 30mm Lg 65020 4x Lockwasher M12 ZNPL 00206 4x End Wheel S2001 14 4x End Spacer 75336 4x Flatwasher M6 65060 4x SHCS M6 x 16mm Lg 00190 Trolley Body 76573 Trolley Components for 2000 Series Steel or Aluminum Track Note Numbers in Parentheses are Gorbel Part Numbers _ 2x Bumper G Force Trolley 77320 4x Nylock M6 65090 2x End Axle 76588 3x Snap Ring 2001 12 Center Axle A1001 24 C H 2 Note C H 1 is either of 2 holes off center C H 2 is center hole with slot to edge 4x HHCS M12 x 30mm Lg 65020 4x Lockwasher M12 ZNPL 00206 2x Center Wheel A2001 16 4x Center Spacer 75336 4x End Wheel A0501 16 4x End Spacer 75765 4x Flatwasher M6 65060 4x SHCS M6 x 16mm Lg 00190 Trolley Body 76573 Trolley Components for 1000 Series Steel or Aluminum Track 7 11 10 24 G Force Q iQ Service Manual Note Numbers in Pa
32. TO SHOW LOCATION OF SENSOR RED BEAM WILL NOT BE VISIBLE DURING NORMAL OPERATION 8 Handle I O Connections both handles Check connections at handle if equipped Wipe off any oil or other contamination from either Handle at this time Clean the LCD screen as well l O CONNECTION PORTS LCD SCREENS 11 3 7 11 G Force Q iQ Service Manual Gorbel Inc Quarterly Tasks Limit SwitcH Tools compressed air and specific lubricants are required ASSEMBLY ACTUATO 9 Limit Switch Assembly Actuator Check for excessive wear and for proper position with the Drum Gate Refer to Chapter 10 for removal and replacement procedures 10 Drum Gate Remove and look for excessive wear Refer to Chapter 10 for removal and replacement procedures Drum GATE 11 Air Swivel Assembly if equipped O Rings These should be replaced if worn or damaged Apply a thin coating of non synthetic general purpose grease Refer to Chapter 10 for removal and replacement procedures i X oa 12 Swivel Assembly Slip Rings Check for wear Wipe clean with soft gt dry cloth and apply a thin layer of DeoxIT This also applies to the e independent G360 Refer to Chapter 10 for removal and replacement procedures aL SLIP eC RINGS Yearly Tasks Tools compressed air and specific lubricants are required 13 Internal and External Electrical Connectors This includes Coil Cord Swivel Assembly and Main pwb connectors Check each co
33. Thread the cable assembly connector into the CADIS ROSE URI tO BOLOM o act nato Asa actuator connector diagram 5E Wie Rope Seer Em Clevis Sleeve Remove the cotter pin and clevis from the wire rope swivel assembly Clevis Reinsert the clevis and cotter pin capturing the wire rope thimble in the swivel assembly diagram 5F Wire Rope Swivel Continue to Step 6 on page 3 9 Assembly Step 5D Remote Mounted Pendant Handle Installation 5D 1 5D 2 5D 3 5D 4 Ensure the wire rope is still fed through the center of the coil cord Hold the G360 swivel just below Diagram 5F Cotter Pin Clevis Wire Rope the coil cord Swivel Assembly and Wire Rope Thimble Center the coil cord footer between the ears of the G360 swivel Note Make sure the fin of the coil cord footer is on the opposite side of the G360 connector Remove the 16mm shoulder bolt from the coil cord footer and wire rope and allow the coil cord footer and wire rope to slide down into the G360 swivel Once the wire rope coil cord footer and G360 swivel are aligned replace the 16mm shoulder bolt thereby capturing the wire rope coil cord footer and G360 swivel diagram 5G page 3 6 3 5 7 11 G Force Q iQ Service Manual Step 5D Remote Mounted Pendant Handle Installation Continued 5D 5 Thread the coil cord connector into the G360 connector diagram 5G 5D 6 Thread the M12 jam nut onto the 16mm shoulder bolt 16 mm
34. Timers A checkup or process causes system to hang up 4 Motion Control N Upper and Lower Virtual limit at the same 7 5 7 11 G Force Q iQ Service Manual Gorbel Inc ACOPOS Drive Fault When the ACOPOS drive detects a fault unit is shutdown with drive fault message displayed on the LCD List of Drive Fault Types ub Category Description and Examples PI Drive Command P command to the drive e g E 1 Invalid parameter and the drive e g E 1004 communication network timeout he CAN network is corrupted sensor data Known Drive Fault Error Numbers Gorresponding to Each Category PLC Drive Communication E Stop Enable Input 60 60 6048 B InptPowr 211 7215 7217 7219 System Setup 32131 10 Motor Regen and Junction Temperature 9002 9010 9030 9031 9040 9070 9071 41011 41031 41041 41070 050 90 9 90 00 410 410 Motor Drive Over Current 9 6 2 Not Handled All others Multiple drive faults can occur at one time and are displayed serially on the LCD screen The first displayed drive fault number is often the initial cause that lead to subsequent triggered faults and is thus a good indicator to the true cause However this is not always the case as E 4005 Drive Error State category always precedes other error numbers that are the cause s of the shutdown User should identify the fault category corresponding to the drive fault number s as a quick reference to the potenti
35. WARN_OVLD_PROGM_NOT_SUCCESSFUL OBSOLETE Description The automatic overload programming routine is interrupted and is not completed Reaction If programming routine is interrupted in an odd state the recorded overload setting may be inaccurate and may falsely trigger overload while lifting Cause Remedy Please re run the overload programming routine Error 11003 WARN SLIDE PENDANT TYPE IO BOTH OFF Description Slide or pendant handle sends a unique signal to the PLC to differentiate the handle type This error is caught if none of them is received Reaction Unit is stopped with a warning display Cause Remedy Replace the slide or pendant handle motherboard Error 11004 WARN UP DOWN V LIMITS AT SAME POSITION Description This warning is triggered when both the Upper and Lower Virtual Limits are falsely attempted to be programmed to the same position which would essentially stop all motion This is done by checking if the distance gap between these two limits is less than 1 In other words the Upper and Lower Virtual Limits must be at least 1 apart Reaction Handle LCD displays the warning message and the virtual limit is not programmed Cause Remedy While this warning attempts to catch and prevent false setup if it is intentional move the two virtual limit positions slightly apart and re program the virtual limit s Error 11005 WARN LOADCELL DROP BELOW MINIMUM Description This warning is triggered when Float M
36. baseline weight that is higher or lower than the actual weight being lifted When the external force is removed the load will begin to drift in the opposite direction of the load that was 8 2 The speed acceleration and other features of the G Force amp can be adjusted using the Program Menu available at the handle See the Program Mode section on page 5 2 for complete details on modifying and programming features 3 11 7 11 G Force Q iQ Service Manual Gorbel Inc Step 9 dd VO Block Mounting instmictions MALUM Dimensions Diagram 9A Expansion I O block dimensions millimeters bic dd CE MM c KAKA i i ni j j Outer edge i Fastened with X67 module i M4 screws I j j i i i j i l 1 N E US FIBI S VENERE JUST Bi aR EDENE RA MN Lg i R i i i i M I 2 j 53 Diagram 9B Screw fastener drilling template 7 11 3 12 G Force Q iQ Service Manual Gorbel Inc Step 9 Expansion I O Block Mounting Instructions Option Continued Installation 9 1 The I O block can be installed into different locations e g to an aluminum frame to DIN rail to a mounting plate or directly on the machine The minimum base plate thickness is 1 5 mm and the screw length should thus be selected accordingly The recommended torque on the M4 screw is of 0 6 Nm
37. blue LED on the control handle to act as an indicator for the anti drop Menuf LED ANTI function When this function is enabled and the anti drop output is off off is Programs the MENU DROP typically the grip clamp state of the tooling the blue LED will flash until the Set Detection Sensitivity to between 5 HIGH and 1 LOW one level decrements at a time iQ Features blue LED as an anti drop output turns on on is typically the release state of the tooling indicator Set Slack Anti Drop to use the blue LED for indication identical to ANTI DROP SLACK 1 dell ES MS ANTIDROP D This selection is not available by default because this is a disabled built in MOTION Item is only selectable if the dual actuator system is set to manual configuration INDEPEND SYNC SETUP MANUAL A dual actuator system defaults to AUTO configuration i e the system automatically configures the various run mode controls to INDEPEND or SYNC Dual Actuator linking If MANUAL option is selected user can choose to overwrite some of the Configuration controls to a specific mode as programmed through MOTION INDEPEND SYNC Menu DUAL ACT The breakdowns are as such MENU MANUAL RUN MODE AUTO MANUAL Dual Actuator Jog Switch INDEPEND SELECTABLE option required Slide Handle SYNC SELECTABLE Pendant Handle SYNC SELECTABLE Float Mode INDEPEND INDEPEND Custom Motion SYNC SELECTABLE SETUP Default dual actuator feature settings to SYNC linking mode and AUT
38. disconnected cable 8608 Repair or replace cable connection assembly imit switches Im t switch is actuated move up or imit switch Is broken down with witch wiring to mother board is handle disconnected or broken ault present nknown Handle failure Blown fuse F andle mother board failure Replace slide or pendant hand Q Q Ea C o m o 2 5 e D D o Q o 2 2 D Q 9 5 5 v Q 3 o a 2 o o o ru Repair or replace cable 0 69 Repair or replace coil cord or E 5 D 5 a D 5 2 O Q amp es D U C Replace P Repair or replace AC power able Replace drive cable CO CO KN Replace slide or pendant hand o 2 2 o Ek 2 D o o z a og the unit off the switc eplace the limit switc Repair the wiring or connection N CO N CO oo oio s ji Tl 4 Refer to Section Replace F fuse Replace slide or pendant hand Nog the unit off the switch 0 4 0 e mother board pm E present sensor andle operator present sensor failure Repair or replace operator i o E D e 23 o c Qo D 9 o X 0 Repair or replace linear ransducer core Any loose connector Repair or tighten connections AN bus Repair or replace CAN bus ables Repair or replace E stop switc Repair or replace handle oil cord or Broken cable Replace cable pendant cable Loose connector Retighten connecti
39. face diagram 3K Diagram 3l c Make sure retainer plug on end of wire rope is fully seated in o m loop in wire rope and insert loop portion into groove of drum recess before replacing rope retainer plate diagram 3L d Install the rope retainer plate over the rope end and install the 2 M8 socket head cap screws and lockwashers Torque hardware to fully compress lockwashers e Ensure that rope is seated in radius channel and install rope gate back in the unit making sure the rope guide cutout side is inserted first and the ends are sliding on guide rails freely Fasten the rope gate assembly together using the previously removed hardware Torque hardware to compress lockwashers Diagram 3J Free end of wire rope projects from face of drum by several inches f Install slide the reinforcement bracket studs into channel and tighten the 2 13mm flange nuts Next swing circuit board bracket closed towards plate and fasten to plate using the 4 previously removed socket head cap screws and lockwashers Torque hardware to compress lockwashers g Plug limit switch lead into circuit board limits receptacle making sure retention tab on plug is facing you h Using a clean cotton cloth wrapped around rope loosely near actuator entrance pull down on rope and press jog up button allowing rope to pass through cloth cleaning it as it is being yv Diagram 3K y ull wire rope end into recess of wrapp
40. fea ture may falsely detect varying weight as overloaded for example on a system with unbalanced or elongated tooling that sways easily during usage or a less AT LEVEL rigid supporting structure that induce much vibration The sensitivity parameter can Configure 5 HIGH be reduced to prevent false detection when operating a load at no greater than the Overload CHANGE 1 LOW Overload Limit However do not reduce the sensitivity unless it is necessary due Detection SENSITIV to actual usage A reduced sensitivity increases the time to detect a legitimate Sensitivity overload condition that may result in damages or failure to the unit By default Detection Sensitivity is set at 5 HIGH TO LEVEL 5 HIGH 1 LOW DUAL FM Float Mode feature enabled Record tooling weight for the Dual Float Mode TOOL WT DUAL FM Float Mode feature enabled Record tooling and load weights for the Dual Float LORD WI Tare tooling weight for anti drop feature The minimum difference between SENT goles unloaded and loaded tool weight is 20 Ibs for G Force 25 Ibs for Easy Arm and 25 Ibs for G JibTM MENU 2 Program the auto home tracking position load must be at desired position for the SET HOME limit MENU 2 Reset above custom features including the dual Float Mode anti drop and auto RESET home features RESET Disable any custom feature e g anti drop from utilizing the blue LED as an LEDS indicator LED Config Enables the
41. for any mechanical setup such that the detection targets to multiple proximity sensors can overlap in any portion of the layout d Faulty input channels in the DO435 IO block or X67 expansion lO module Command Faults Motion Command Watchdog Timer Error 1600 ERROR_WATCHDOG_RUN_MODE Description While running through Jog Handle Float or other custom motion a processing command has taken too long to execute Reaction Lift is shut down if the excessive delay is caused by any problem in the lift Cause Remedy a Use the extended error index number to obtain the processing state when excessive delay has occurred b Please contact Gorbel amp Customer Service at 800 821 0086 or 585 924 6262 regarding this problem and the processing state information ACOPOS Drive Faults Error 9999 ERROR ACOPOS FAULT Description ACOPOS drive faults or warnings Reaction Lift is shut down for all drive faults or warnings Cause Remedy ACOPOS drive fault Please check the fault number displayed on the LCD screen for additional detail 7 11 7 18 G Force Q iQ Service Manual Gorbel Inc Command Warnings Error 10000 WARNING_LIFT Description Starting index to non critical warnings Reaction Not Used Cause Remedy Not Used Command Warnings Process and Display Mode Error 10400 WARN_MULTP_PROCESS_REQUEST OBSOLETE Description More than two features are attempting to display messages in the LCD at the same time
42. handle Refer to the pictures below for the location of the serial number label 101355 1 A Actuator Label Handle Label 7 1 7 11 G Force Q iQ Service Manual Gorbel Inc Troubleshooting Section I Functional Failure Table 1 unctiona Possible uspect Component s ocation orrective Action case rn J pm Handle mother Damaged defective mother board 0 4 0 5 Replace slide or pendant handle 0 No DC power to Blown fuse F on main PCB Replace F fuse on actuator Note The LCD handle screen will go into anale failure N A screen saver mode Failure Broken or damaged coil cord or 0 65 thru 10 69 after 17 minutes of onnector me oose connector any applicable cable 8 3 thru 8 onnection ncorrect cable rive tau PU failure o o e o 9 o o gt Qo D Repair or replace handle Repair or replace coil cord Repair or tighten connector 8 3 thru 8 5 eplace cable with correct part Reter to Drive Fault tables Replace P E 2 U O w D ystem Handle mother board reads network THHHHHHHE communication Any CAN bus cab THHHHHHHI to the handle is lost oil cord or pendant cable CPU failure ar ded Ad or defective power cable Drive power Damaged or defective drive cable Handle mother Damaged or defective mother board DC power Damaged or detective 24 VDC power Repair wiring replace DC power Drive LED Damaged or defective LEDs on the Replace the ACOPOS drive able or oose or
43. hidden during inspection and maintenance procedures require special attention when lubricating ropes The object of rope lubrication is to reduce internal friction and to prevent corrosion Wire Rope Replacement Criteria 1 No precise rules can be given for determination of the exact time for rope replacement since many factors are involved Once a rope reaches any one of the specified removal criteria it may be allowed to operate to the end of the work shift based on the judgment of a qualified person The rope shall be replaced after that work shift at the end of the day or at the latest time prior to the equipment being used by the next work shift 2 Removal criteria for the rope replacement shall be as follows e in running ropes any visible broken wires diagram 3 e wear of one third the original diameter of outside individual wires e kinking crushing birdcaging or any other damage resulting in distortion of the rope structure evidence of heat damage from any cause reductions from nominal diameter greater than 1 64 4 mm for 1 4 6 35 mm diameter rope 3 Broken wire removal criteria applies to dE wire rope operating on steel sheaves and drums However results of internal testing have shown that rope replacement follows the same criteria regardless of sheave or drum material 4 Attention shall be given to end d connections Upon development of any gt WIRES PER STRAND broken wires adjacent to
44. meas ures incoming 24VDC or output that is turned on to provide 24VDC is displayed in each screen as numerical numbers 1 8 iQ Unit with Custom or Reconfigured Program Third Expansion Input Output Block Diagnostic Mode displays the status of the eight configurable inputs and I O BLK3 outputs on the LCD screen The inputs statuses are displayed in the first screen DIAGNOSE followed by those for the outputs The IO Point number of the input that meas ures incoming 24VDC or output that is turned on to provide 24VDC is displayed in each screen as numerical numbers 1 8 SRV MENU Reset all programmed features in this menu such as the upper and lower cycle limits and the service indicator time limit if the feature is available Does not clear RESET the run time and cycle counts Record the current unit system configuration settings such as unit type and RECORD capacity setting factory overload settings loadcell calibration parameters virtual CONFIG limit software package enabling flag for Q unit burn in status and all the custom feature setup parameters Special Unit ZERO Set loadcell bias signal with no weight attached to define a zero value requires MENU Hardware Set loadcell signal slope coefficient with a lifted weight equal to the rated capacity Configurations CALIBRAT of the unit below the wire rope Any different lifting weight will result in false LOD COEF calibration and inaccuracy such as weight readout feature r
45. mechanical problem and correct it 7 11 7 20 G Force Q iQ Service Manual Gorbel Inc Error 10408 WARN_PROG_OVER_RANGE_OVLD_SHUTDOWN OBSOLETE Description One of the calibrated factory overload settings returned from the overload programming sequence is greater than the acceptable range from the normal shutdown value for this unit The acceptable range of this parameter is empirically determined and selected for different models and capacities Reaction Handle LCD displays the warning while unit is allowed to continue to run The over range warning indicates the potential error in programming the parameter without altering the value The sample value is still retained Cause Remedy The actuator characteristics are profiled such that while no actuators are expected to be identical the characteristics are expected to be similar within a tolerance range The possible causes of this warning are a The pickup weight does not match the rated capacity b The geartrain mechanism may be exerting excessive drag or binding such that the resultant actuator characteristic is significantly different from the tolerance range Inspect for any mechanical problem and correct it Command Warnings Other Status Error 10500 WARN_STATUS_PLC_BATTERY_ERROR Description The PLC memory retention battery power level is low or faulty Reaction Handle LCD displays the warning while unit is allowed to continue to run Cause Remedy 1 P
46. over the top portion of the handle shaft Slide the compression spring up over the top portion of the handle shaft Slide the second bearing sleeve up over the top portion of the handle shaft Slide the grip assembly off the top portion of the handle shaft Note There are a total of 12 ball bearings seated in 3 separate grooves in the handle shaft These are normally coated with grease and should remain in place however they can fall out if the amount of grease has decreased over time Procedure 6B Handle Grip and Shaft Assembly Reassembly a Install the grip assembly over the top portion of the handle shaft and position the grip assembly so that the ball bearings can be installed into the grooves of the handle shaft from the top of the grip assembly Slide the second bearing sleeve down over the top portion of the handle shaft Slide the compression spring down over the top portion of the handle shaft Slide the first bearing sleeve down over the top portion of the handle shaft Slide the spring sleeve down over the top portion of the handle shaft to the hex jam nut Install the hex ham nut from the handle shaft Install the spring pin into the hex jam nut and handle shaft 10 47 7 11 G Force Q iQ Service Manual Gorbel Inc Note Numbers in Handle Transducer Feature Parentheses are Gorbel Part Numbers Grip Assembly 74234 BA lt N A Shaft DUMP 74201 Hex Standoff 6mm Hex 742
47. screen or by flashing LED If the board has become inoperative a factory default warning message may be displayed on the LCD screen Cause Remedy A fault specifically a CAN bus alarm can occur if the CAN controller board does not communicate with the PLC correctly is in a fault state falsely removed configuration memory error etc Additional error information may be available after the warning message Reboot the unit with the E stop to clear the fault if it is not repetitive Problem can result from faulty handle board noise or data corruption in the CAN communication wires or any cut wires Replace the handle coil cord actuator interface board and CAN communication wires in the actuator until the fault is corrected Error 11805 WARN LCD FAULT BUS OFF Description Handle LCD board CAN bus controller has been turned off unintentionally If a WARN LCD FAULT _ NOT ACTIVE warning does not occur together with this then the bus line is turned off only briefly Reaction Warning message on this fault may be on screen or by flashing LED If the board has become inoperative a factory default warning message may be displayed on the LCD screen Cause Remedy A fault specifically bus off exception can occur if the handle CAN controller does not communicate with the PLC correctly or at all Reboot the unit with the E stop to clear the fault if it is not repetitive Inaccurate communication can result from faulty handle board noise or data co
48. the output connector to the cover opening Install the air extension and nylon washer into the collector shaft Assemble the slip ring PCB to the collector shaft with 2 M2 Phillips head machine screws PHMS Install the output connector nut on the slip ring PCB Slide the swivel sub assembly onto the collector shaft Carefully align connectors using the alignment grooves in the cover Install the M16 x 2 MM hex head cap screw HHCS and M16 Belleville washer onto the G360 assembly Note the orientation of the Belleville washer concave side down 10 74 G Force Q iQ Service Manual Gorbel Inc ag 2x Collector O Rin HHCS M16 x 2mm Pitch w Channel gt i 74269 74281 Belleville Washer M16 DIN 2093 Grp 2 XA 65098 T Note Numbers in Parentheses are Sliding Handle Swivel Sub Assembly Gorbel amp Part Numbers 74249 2x PHMS M2x0 4 6 SEMS Split Lock _ 65073 PCB Slip Ring Aux Out 74282 B A Output Connector Nut Collector Shatt J 4 74280 i Spring Pin MMx24 65102 j G360 Collector Label Standalone Swivel Cover P 74284 74283 CR K _ 3x Lockwasher M3 Nylon Washer 563 ID 031 Thk Dl 65051 65104 gt 1 4 NPT Air Extension Output DN8 00 8x SHCS M3 x 0 5 12 74240 SES 65012 Diagram 1A G360 with Air Assembly and Disassembly
49. the photo sensor area when in program mode Breaking the photo sensor will drop the unit out of program mode and you will need to start over again When making changes in program mode do not break the beam of the photo sensor until the new setting has been completed The display must be allowed to flash three times before the handle is gripped Breaking the sensor beam before the dis play flashes three times will cancel the change and drop the unit out of program mode and you will have to start over Press and hold this but ton for approximately three seconds until the unit enters program mode Once in program mode this button is used to select the desired menu Press and release this button to advance to the next menu If you happen to accidentally pass by a menu it will come around again if you continue to press and release this button When the unit is not in program mode press and release this button to initiate float mode When the unit is in float mode use this button to select the desired item within the menu by pressing and releasing to advance to the next selection If you stay on a menu item selection for approximately three seconds the display will blink three times and the change will be made Keep advancing through the menu items quickly until you are certain of the change you want to make Otherwise you may accidentally make an undesired change 5 3 7 11 G Force Q iQ Service Manual Gor
50. virtual limit positions are cleared and reset to default Error 6 ERROR_FACTORY_OBJ_SIZE_MISMATCH Description At startup stored default factory configuration does not match the version lift program used Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 7 ERROR_FACTORY_OBJ_LOCATE Description At startup the query command to locate the default factory configuration is returned with an error Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default 7 9 7 11 G Force Q iQ Service Manual Gorbel Inc Error 8 ERROR_NO_FACTORY_SETTINGS Description At
51. with bracket to the tooling Assure that the mounting arrangement does not affect the operating function of the slide handle 5B 11 Connect the extension cable from the G360 to the remote mounted slide handle Securely clamp the remote mount coil cord extension cable to the tooling as needed CAUTION All cables used in a remote mounted handle configuration must be properly clamped and or strain relieved to prevent premature failure of the G Force or customer tooling CAUTION Take care to avoid looping excess cable at locations where the loop could catch on foreign objects 5B 12 Continue to Step 6 on page 3 9 7 11 3 4 G Force Q iQ Service Manual Gorbel Inc Step 5C Suspended Pendant Handle Installation 5C 1 5C 2 5C 3 5C 4 5C 5 5C 6 5C 7 5C 8 5C 9 Assure that the coils of the pendant handle coil cord are centered around the pendant handle wire rope Remove the eyebolt from suspended pendant 12777 cable assembly using the threaded connector r 2 Thread the eyebolt into the bottom of the actuator Actuator Connector a keder caye M assembly as shown diagram 5E Cable Asom Suspended Pendant f Cable Assembly Reattach the suspended pendant cable assembly to the eyebolt via the threaded connector Adjust the suspended pendant cable assembly so that there is a service loop in the wiring cable and there is no tension in the wire cable Diagram 5E Assembly of Suspended Pendant
52. your system does not appear to be functioning properly the following statements will help you identify which section of this chapter to refer to A If you are unfamiliar with how the system is supposed to operate read the G Force Operational Guidelines Lift Functionality and Program Mode sections of the G Force Q and iQ Series Installation and Operation Manual If the system has a functional failure such as the system does not move in one direction Float Mode does not work or you have a blank LCD screen on the control handle refer to Troubleshooting Section I Functional Failure Table in this chapter of the Service Manual If you have a message or fault displayed on the LCD screen on the control handle refer to Troubleshooting Section II System Fault Diagnostic Chart in this chapter of the Service Manual If there is something visually wrong such as a damaged wire rope damaged coil cord or something obviously broken or out of position refer to Chapter 10 Parts and Assembly or Chapter 11 Preventative Maintenance in this Service Manual to identify the correct orientation or replacement criteria for any component If none of the above statements described your problem contact your Gorbel distributor first or Gorbel amp Inside Sales at 800 821 0086 for assistance Please have your system serial number available when you call It can be found on a label on the bottom of the actuator or on the bottom of the control
53. 0 kg End Support Frame Removal and Replacement 10 19 7 11 G Force Q iQ Service Manual Gorbel Inc 7 11 End Support Frame 76502 11x Lockwasher M5 High Collar 65062 7x SHCS M5 x 20mm Lg 65001 4x SHCS M5 x 12mm Lg 65002 2x FHCS M5 x 10mm Lg 65004 4x Front Cover Mounting Bracket 79219 Note Numbers in Bearing Retainer Ring Parentheses are 76512 Gorbel Part Numbers Diagram 12B 660 Ib 300 kg End Support Frame Removal and Replacement 10 20 G Force Q iQ Service Manual Gorbel Inc Procedure 13A Load Cell Removal a b C Turn power off by disconnecting AC power to the system Remove front cover Refer to Procedure 1A Remove rear cover Refer to Procedure 2A Disconnect load cell cable from J4 on the main PCB and open cable clamp to free cable and connector for removal Remove the M12 hex head cap screw HHCS and M12 lockwasher that secures the load cell to the main middle section through the opening towards the rear of the main middle section Note Be careful not to damage any wiring as you pull the load cell cable through the main middle section since there is other wiring present Remove the load cell pin from the load cell as required Procedure 13B Load Cell Replacement a b g Note Install the load cell actuation pin and into the bottom of the load cell Position the load cell with the pin attached in place from the rear of the main midd
54. 1 REPLACE WIREROPE C a Cycle Count after wire rope replacement 11800 11801 11802 CHK HNDL ELECTRIC Cycle E stop 11803 11804 11805 CHK LCD ELECTRIC Cycle Power 11806 11807 11808 CHK I O MODULE Cycle Power 11000 65534 65534 Cycle E stop Cycle E stop stop Drive Faults 5034 7045 7046 ENCODER ERROR Cycle E stop Reprogram Position All Other Drive Faults 1 64506 Cycle E stop or Power 7 7 7 11 G Force Q iQ Service Manual Gorbel Inc LED Chart The chart below shows the status of LED lights in different states D Program State Sub State Blue Red LCD Text Display Enaacad Displays E STOP ENGAGED This state can also be E used for LL u if the E stop is turned off P intentionally Overwrites fault warning or service warning messages to allow correction of the cause of the messages Displays Programming PROGRAM MODE various menu screens and selection D displays if unit is in command or drive fault followed Fault Mode or by a fault number and a corrective message Unit is shut Drive Fault down until a corrective action is taken or cycling the E stop or main AC power LCD displays unit is in warning fault followed by a fault Warning off Fast Flash number and a corrective message Unit is still allowed to run but warning messages overwrite other normal running messages defined in the latter cases Service Displays warnings for parts replacement 5 i Fast Flash Off recommend
55. 11 46mm The double length coil cord assembly is used on systems with a trolley Teas saddle greater than 1 4 27m and will measure approximately EC 16 4 415 93mm 4 2 Feed the wire rope from the actuator assembly through the center of the coil cord assembly ezm CAUTION The connectors on the coil cord are keyed The connector must be nip j aligned correctly before it threads into place i i hid 4 3 Use the actuator assembly hardware to fasten the coil cord Diagram 4B Double assembly to the actuator diagram 4C Adjust the coil cord in the Length Coil Cord clamps so that the coil cord connector is conveniently located on Assembly the proper side of the actuator assembly Note The orientation of the coil cord i j s must be correct so that the connector is located properly diagram 4D 4 4 Thread the coil cord connector into AA po wy the actuator connector diagram 4D ata E EE gt Ze js 4 5 Ensure that the coils of the coil cord agate are centered around the wire rope ROW acusrorassety when properly installed cot coro ASENELY n EMBLY 4 6 Use the 16mm shoulder bolt and M12 jam nut to retain the coil cord footer i the thimble in th Diagram 4C Coil Cord Assembly Diagram 4D Coil Cord Assembly ome TAINO IA the w re rope Installation at the Actuator Installation Bottom Note The shoulder bolt and black center not shown jam nut will be used to retain the handle or collector in the ne
56. 17 7 11 G Force Q iQ Service Manual Gorbel Inc Command Faults Non Motion Watchdog Timer Error 600 ERROR_WATCHDOG_NON_MOTION Description At startup the stored configuration variable in memory does not match the version lift program used Reaction Not Used Cause Remedy Not Used Command Faults Motion Control Error 1000 ERROR_STARTUP_DRIVE_NOT_READY OBSOLETE Description Not Used Reaction Not Used Cause Remedy Not Used Error 1001 ERROR_READY_MODE_CONTROLLER_NOT_READY OBSOLETE Description Not Used Reaction Not Used Cause Remedy Not Used Command Faults Custom Motion Control Error 1100 ERROR_MULTP_MOTION_REQUEST Description Not Used Reaction Not Used Cause Remedy Not Used Error 1101 ERROR_MORE_THAN_ONE_VL_TARGETS_DETECTED Description If multiple virtual limit VL set iQ feature is enabled with Option A see error 324 for more information only one digital input can turn on at a time to select a VL set This error is triggered when the unit detects that multiple inputs are turned on at the same time Reaction Lift is shut down to prevent unit from falsely responding to a wrong set Cause Remedy a Check for any electrical problem on the switches or devices connected to the input channels to falsely turn on at the same time b Check for the electrical connection to the input channels of the lift DO435 IO block in the actuator or X67 expansion lO module c Check
57. 28 4 4 NPT Thread 2x Spring Bearing P 12x Hardened Precision Ball 6mm 74212 74227 N amp Coiled Spring Pin M4x9 5mm 65087 Am Compression Spring 73019 Spring Sleeve 74213 Hex Jam Nut M24x3 0 B n Hole 74226 Diagram 6 Handle Grip and Shaft Assembly and Disassembly 7 11 10 48 G Force Q iQ Service Manual Gorbel Inc Note Numbers in BHCS M6 x 16mm Lg Parentheses are 65075 Gorbel Part Numbers Lockwasher M6 ZNPL 03370 Remote Mounted Slide Handle G FORCE RM SLIDE HANDLE Bracket Remote Mount 74270 Flatwasher M16 ZNPL 01310 Lockwasher M16 ZNPL 00212 HHCS M16x2 0 35 Gr 8 8 ZNPL 65066 Remote Mounted Slide Handle Bracket 10 49 7 11 G Force Q iQ Service Manual Latch Hook Assembly 74199 Option Latch Hook If the latch hook assembly is ordered with the in line slide handle bracket 74273 the latch hook hardware will replace the bracket hardware flatwasher lockwasher and HHCS 7 11 Gorbel Inc Note Numbers in Parentheses are Gorbel Part Numbers In Line Slide Handle G FORCE SLIDE HANDLE Bracket In Line Slide Handle 74273 Flatwasher M16 ZNPL 01310 Lockwasher M16 ZNPL 00212 HHCS M16x2 0 35 Gr 8 8 ZNPL 65066 In Line Slide Handle Control Bracket 10 50 G Force Q iQ Service Manual Gorbel Inc 74271 Bracket Auxiliary Controls 74272 Bracket
58. 4 78563 Diagram 9 Power Supply Removal and Replacement 10 15 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 10A CPU Power Supply Mounting Bracket Removal a Turn power off by disconnecting AC power to the system b Remove rear cover Refer to Procedure 2A Remove CPU assembly Refer to Procedure 8A C d Remove power supply Refer to Procedure 9A D Disconnect slack spring Th Free any wiring harnesses required g Remove 6 M5 socket head cap screws SHCS and 6 M5 lockwashers Procedure 10B CPU Power Supply Mounting Bracket Replacement a Position CPU power supply mounting bracket against actuator casting Install 6 M5 socket head cap screws SHCS and 6 M5 lockwashers a Reconnect slack spring 2 p Reinstall power supply Refer to Procedure 9B D Reinstall CPU assembly Refer to Procedure 8B mh Reposition any wiring harnesses as required Reinstall rear cover Refer to Procedure 2B EE Restore AC power to the system Note Numbers in Parentheses are Gorbel amp Part Numbers CPU Power Supply Mounting Bracket 76526 6x SHCS M5 x 12mm Lg 65002 6x Lockwasher M5 High Collar 65062 Rubber Grommet 3 8 79255 Diagram 10 CPU Power Supply Mounting Bracket Removal and Replacement 7 11 10 16 G Force Q iQ Service Manual Gorbel Inc Procedure 11A Motor Set Removal a b C Turn power off by disconnecting AC power to t
59. 50 C 50 C 5 506 50 C 5 506 50 C 5 506 50 C Operating Humidity 35 90 35 90 35 90 35 90 35 90 35 90 35 90 35 90 Range Non Condensing Virtual Limits Upper Limit Power Limit Speed Optional Standard Optional Standard Optional Standard Optional Standard Reduction Weight Display Accuracy 1 Rated 1 Rated 1 Rated 1 Rated 1 Rated 1 Rated 1 Rated 1 Rated option with Float Mode Capacity Capacity Capacity Capacity Capacity Capacity Capacity Capacity I O Actuator Number of Inputs Type 8 Sinking 8 Sinking 8 Sinking 8 Sinking Number of Number of Outputs Type Type NA Ea FET amp FET FET amp FET FET Esc FET Bzana Current Channel Amps Module Maximum Guren N A 0 5 N A 0 5 N A 0 5 N A 0 5 Amps Handle with I O Module Number of Inputs Type 8 Sinking 8 Sinking 8 Sinking 8 Sinking Number of Number of Outputs Type Type NA BN FET Ee FET SET FET amp FET FET reee tej Current Channel Amps Module Maximum Current Amps 2 1 7 11 G Force Q iQ Service Manual Gorbel Inc Chapter 3 Installation Procedure Step 1 Unpacking the G Force m TIP Packing list can be found in plastic pocket attached to shipping box 1 1 Carefully remove all items from the box Important Save shipping box and all packing materials 1 2 Verify that all components listed on the packing slip are included 1 3
60. 6mm shoulder bolt thereby capturing the wire rope G360 SHAFT coil cord footer and G360 swivel diagram 5B page 3 3 5B 5 Thread the coil cord connector into the G360 connector diagram LOCKING PIN PILOT HOLE 5B page 3 3 5B 6 Thread M12 jam nut onto the Diagram 5C Tooling Installation 16mm shoulder bolt 5B 7 Check that the coils of the coil cord are centered around the wire CMS rope when properly installed EX Head Cap Sie 2X M16 5B A pilot hole is provided for the locking pin Attach tooling to duc LoCkwash r G360 utilizing M16 thread The tool bolt rod thread should Side Hande Flatwasher be beyond pilot hole of shaft when fully engaged Using a Configuration 21 drill bit drill through the tool bolt rod thread and out 3 the other side of G360 shaft Hammer pin into place thereby locking tooling to G360 diagram 5C Remote 5B 9 Assemble the remote mounted slide handle inside the remote 221 M Mount Slide mount bracket using the hardware provided diagram 5D HAL J Bande Note This step is best completed on a workbench prior to mounting handle to tooling Remote mounted G Force handles must be mounted at both the top and bottom of the handle assembly Failure to mount the Diagram 5D Remote Mounted Slide Handle Exploded View remote mounted handle at top and bottom can result in poor performance and or premature component failure 5B 10 Attach the remote mounted handle
61. AIRHOSE EXT ASSEMBLY 2x Strain Relief Clamp 65105 2x Adapter DN8 1 4 NPT EIS 74238 DA _ 64x Nylon Air Hose Coiled 74237 Hose Swivel 90 DN8 1 4 NPT Note Numbers in l 74243 Parentheses are Gorbel Part Numbers Diagram 6 Extended Length Air Hose Assembly G FORCE AIRHOSE EXT ASSEMBLY For replacement of entire Airhose Assembly use part name G FORCE AIRHOSE EXT ASSEMBLY 10 73 7 11 G Force Q iQ Service Manual Gorbel Inc Removal amp Replacement Procedures G360TM Procedure 1A G360 Disassembly Procedure a Remove M16 x 2 MM hex head cap screw HHCS and M16 Belleville washer from G360 assembly Note the orientation of the Belleville washer concave side down b Slide the swivel sub assembly off the collector shaft Note Set aside the swivel sub assembly with the PCBs facing upward to avoid damaging them C d Remove output connector nut from the slip ring PCB Remove the 2 M2 Phillips head machine screws PHMS that secure the slip ring PCB to the collector shaft Remove the air extension and nylon washer from collector shaft Remove 3 M3 socket head cap screws SHCS and 3 M3 lockwashers from the collector shaft and slide the collector shaft out of the cover Procedure 1B G360 Reassembly Procedure a 7 11 Slide the collector shaft into the cover and secure it using the 3 M3 socket head cap screws and 3 M3 lockwashers Note the alignment of
62. At startup found found configuration setting s for the multiple virtual limit VL sets standard iQ feature These conditions include 1 Option A specifies the number of inputs directly linked to a VL set For example default standard set all inputs off custom set 1 input 1 custom set 2 input 2 etc The value cannot be greater than 4 for more than 5 VL sets Option B specifies the number of inputs to create a binary indexing format to link to VL set For example a value 3 represents 3 digit binary where the first input is the least significant bit and they can index up to a total of 8 VL sets Option B cannot be greater than 4 for more than 16 VL sets 2 Option A and B cannot both be zero 3 Either Option A or B must be non zero 4 The starting input channel number must be set Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy a Use the extended error index number to identify which Q iQ feature contains the faulty setting Use the VB Configurator program not yet available as of July 2010 to correct the false setting b Run the Gorbel supplied installation CD i e Gorbel amp G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions ar
63. Chapter 7 Troubleshooting e Troubleshooting Procedure c sees EE ok ee KK ee KRI R KK KK 7 1 e Troubleshooting Section I Functional Failure Table 7 2 e Troubleshooting Section Il System Fault Diagnostics Chart 7 4 e Q iQ Unit System Motion and Feature Command Fault List 7 8 Chapter 8 Electrical Schematics llle 8 1 Chapter 9 Adjustments e Limit Switch Adjustment 4 2 pne x Papi KIR K K K K EC GE 9 1 e Wire Rope Replacement Adjustment 00000 RR KK 9 3 e Linear Transducer Adjustment 2c teer KK KK KK KK Rr EE RD 9 4 s Slack Spring Adjustment ot ga we k akla ee ROE el we a ES 9 5 Chapter 10 Parts and Assembly PACINO i 60 d ay ln sa ada f rd eal ms tA Aas ud a RB ged Bed et ea 10 2 SINGING Hande A5 easet d AWAL A AR eR ee eh ys DRE Day 10 40 e Pendant Handle 4 uci kk kk kK hae em heed KI K K ebm tha Ben 10 53 e Soll COrds Key ela n eray na cod E d d O e EU EE 10 67 ARCUP Di Zale Meet et aoe waite les UBEME 10 74 PEC Batte lt 2 sia Se areas OSE oe kee UE una MEE S eds A ar 10 80 Chapter 11 Preventative Maintenance nananana 11 1 Chapter 12 Recommended Tools amp Parts 0 0000 ce eee eee 12 1 Gorbel Inc 7 11 G Force Q iQ Service Manual Gorbel Inc Chapter 1 Safe Hoist Operating Guidelines General There is no one single factor that is more important for minimizing the possibil
64. Diagram 1 5 If you are returning the system to Gorbel for service upgrading etc mark the box clearly with the RMA Return Material Authorization number supplied by Gorbel Inside Sales 800 821 0086 and include a copy of the RMA in the box whenever possible Do not send any components back to Gorbel without an RMA 4 1 7 11 G Force Q iQ Service Manual Gorbel Inc Chapter 5 Control and Programming Controls Interface Features The jog switch push buttons and communications connector are protected by a cover Diagram 1 To access the jog switch push buttons and communications connector loosen the M4 screw and slide the shield back towards the wire rope Note Do not fully unthread the M4 screw When finished slide the 3 shield back into place and re tighten the M4 screw Jog Switch Push Buttons The jog switch buttons allow qualified personnel to replace the wire rope on the unit To effectively operate the jog switch buttons all electrical cables must be connected and power on Depressing the Up jog switch button will enable the motor and cause the system to reel the wire rope into COMMUNICATION CONNECTOR JOG UP PUSH BUTTON the actuator and onto the drum pulley Depressing the Down jog switch button Sr J will enable the motor and cause the l system to pay out the wire rope from the JOG DOWN PUSH BUTTON actuator and off of the main pulley Jog Ma SHCS a switch push buttons override a
65. Force Q iQ Service Manual Gorbel Inc After this pop up window closes the status of the retrieval may be followed in the gauge below the button and in the Status and Messages window at the bottom of the screen Step 3 BRE Status of Step 4 Step 4 Optional You may select a Q iJ version to get Version Selected gt None Step 5 Step 5 Status and Messages 10 10 2007 8 24 35 4M Connecting to serial number 10 10 2007 8 24 35 AM Connected to Drive T ask 10 10 2007 8 24 35 4M Connecting to Drive T ask 10 10 2007 8 24 35 AM CPU RuntimeV ersion V2 40 10 10 2007 8 24 35 AM Connected to CPU a 1n4n 2nf17 8 74 37 amp M Cannectina ta CPI I lt gt When the retrieval process is complete this will be indicated by a green success label next to the progress gauge Step 3 Retrieve and Store Current Settings lili li E li li i i li i i B Step 4 completed 7111 6 4 G Force Q iQ Service Manual Gorbel Inc Step 4 This step involves choosing the location of the update file that you need to run for the G Force unit The location of this file may be on the CD that contained the Gorbel Q iQ Update Utility sent separately on a CD or delivered via the internet In any case contact Gorbel to ensure that the correct update package is being utilized After confirmation select the PIL file and click the Open button in the file dialog window Select Configuration File for PLC Configuration Tool Look in L
66. G 1 5G 2 5G 3 5G 4 7 11 The air hose assembly comes attached to the wear ring and coil cord mounting plate Once the handle installation is complete the air hose should be installed Remove two of the screws and lockwashers holding the reinforcement plate to the underside of the actuator leaving the spacers in place and insert them through the air hose bracket and reattach to the underside of the actuator Tighten all hardware At the handle or G360 insert the male swivel fitting at the end of the air hose into the female end of the elbow in the footer and tighten Connect the bulkhead fitting on the underside of the actuator to shop air and check for leaks G Force Q iQ Service Manual Gorbel Inc Step 6 Electrical Power Connection m TIP Do not connect main power until all assembly is complete Standard 6 1 Prior to final wiring inspect the entire system to ensure that all connections are seated properly and are without kinks or bends Verify the following connections a Coil cord to handle or G360 collector b Coil cord to actuator assembly c Extension cables if included 6 2 Connect a 220 VAC single phase power source through a disconnect switch by others to the festooned power cabling not provided with G Force W oltages outside this range may result in unexpected motion and or premature controls failure 6 3 Wire the female receptacle provided to the end of the festooned power cable
67. Gorbel Inc 4x HHCS M12 x 30mm Lg 65020 4x Lockwasher M12 ZNPL 00206 _ 2x Steel Wheel _ 0501 16 4x Aluminum Wheel A0501 16 6x Spacer 75336 4x Flatwasher M6 65060 4x SHCS M6 x 16mm Lg 00190 Trolley Body 76573 Trolley Components for 250 Series Aluminum Track Universal Adapter Trolley 77879 7 11 Universal Trolley Adapter Note Numbers in Parentheses are Gorbel Part Numbers G Force Q iQ Service Manual Gorbel Inc Note Numbers in Parentheses are Gorbel Part Numbers l 2x M8 Nylock Nut 65103 Load Plate Brace 76761 330 Ib 150 kg Model Only Load Plate Brace Note Numbers in Parentheses are 2x M8 Nylock Nut M8 ZNPL Gorbel Part Numbers 65103 Load Plate Brace 76522 660 Ib 330 kg Model Only Load Plate Brace Note 165 Ib 75 kg models do not use this component 10 27 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 14A Drum Gate Removal a b C Turn power off by disconnecting AC power to the system Remove the front cover Refer to Procedure 1A Remove the 4 M5 button head cap screws BHCS and 4 M5 lockwashers that secure the PCB ACOPOS support bracket assembly to the end support frame Disconnect limit switch cable assembly from main PCB in order to swing the ACOPOS drive assembly into the open position for access to the drum gate area Loosen the 2 M8 nylock nuts and remove the lo
68. If any items are missing or were damaged during shipping please contact Gorbel Inside Sales immediately at 800 821 0086 or 585 924 6262 Step 2 Pre Assembly Tools Required 2 1 Read entire Operator s Manual before beginning installation of the G Force 2 2 Tools and materials typically needed to install assemble a G Force are as follows 5mm Allen wrench e 19mm hex socket e 8mm Allen wrench Plastic cable tie straps e 2 5mm Allen wrench e Ladders man lifts 6mm Allen wrench 1320 Ib only 14mm wrench or hex socket 1320 Ib only e 3mm Allen wrench 1320 Ib only Snap ring pliers 1320 Ib only Step 3 Actuator Assembly Installation WARNING DO NOT lift the actuator by grabbing the blue plastic end covers To lift the actuator grab the handle slots in the trolley hig 3 1 The standard G Force will come with the wheels M pre assembled to the actuator trolley diagram 3A When a Gorbel G Force is to be used on a non Gorbel bridge system a universal adapter trolley is required diagram 3B Note The customer must provide two 2 hoist trolleys when the unit will 3 run in a non Gorbel bridge system a Diagram 3A Standard Actuator Assembly 3 2 Ensure the power cord from the actuator is facing the 4 d festooning side of the bridge monorail Remove the c0 end stop from the bridge and install the G Force amp Ms actuator into the track Immediately reinstall the end stop Verify that the G
69. Lg 00194 Note Numbers in 9 es Ball Bearing 6908 Parentheses are Gearbox Planetary 4 1 Double Seal Gorbel amp Part Numbers 74037 74019 660 Ib 300 kg 7 11 10 36 G Force Q iQ Service Manual Gorbel Inc Gearbox Planetary 40 1 With Key 74035 Hex Nut M6 01764 5x SHCS M6 x 20mm Lg 00186 Note Numbers in Parentheses are 4x Lockwasher M6 ZNPL Gorbel Part Numbers 03370 660 Ib 300 kg Load Plate 76503 Drum Gate Threaded 76565 Drum Pulley 76501 2x Bearing Spacer 79209 2x Ball Bearing 6824 2RS 74011 Note Numbers in Note Thread drum gate 76504 onto drum Parentheses are so the wire slot matches up to the wire rope Gorbel Part Numbers anchor point on the drum pulley 76501 660 Ib 300 kg 10 37 7 11 G Force Q iQ Service Manual Gorbel Inc 4x Spacer r 83260 Reinforcement Plate 83252 4x M8 Lockwasher 00195 a p ae 4x M8 SHCS 2x 3 8 Lockwasher __ 236 01355 P ne 4x 3 8 Hexnut 02158 3 U Bolt 83265 Note Coil cord and associated components not shown for clarity Note Numbers in Parentheses are Gorbel Part Numbers 1320 Ib 600 kg Reeved G Force Reinforcement Plate Assembly T 2x M6 Lockwasher ee Wear Ring Bracket Nemo mr c 2x M6 SHCS 65032 76708 ses 1 7 Wear Ring 2x Lockwasher 03370 2x SHCS 65028 Coil Cord Coil
70. Manual Gorbel Inc iQ Actuator Input Output Module Functionality Settings see chart 1 page 5 3 for instructions on navigating and setting menu functions When this input is turned on the G Forcee switches Second to a second independent set of virtual limits See done the same as the standard chart C for instructions on setting each of these limit set but with this input on sets uture expansion no Functionality may be assigned via custom default functionality programming to meet application requirements IM assigned Contact your Gorbele dealer for more details uture expansion no Functionality may be assigned via custom default functionality programming to meet application requirements if assigned Contact your Gorbele dealer for more details uture expansion no Functionality may be assigned via custom default functionality programming to meet application requirements Dm i Contact your Gorbele dealer for more details O y optional expansion 8 that input is on output 5 on the iQ actuator point input output block input output module is on and vise versa Description optional expansion 8 that input is on output 6 on the iQ actuator point input output block input output module is on and vise versa indicator based on hours of use and set at the factory and Joutput is in the SERVICE may be used to turn on an external service indicatorIMENU items CLEAR RUN supplied by others TIME or SRV WARN OFF
71. NE_CAPACITY_INVALID Description At startup found the stored configuration setting has an invalid capacity selection value Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy A critical configuration setting of the unit is corrupted or falsely set Please contact Gorbel Customer Service at 800 821 0086 or 585 924 6262 for further instruction Error 310 ERROR_CONTROL_DATABASE_NOT_FOUND Description At startup found the stored configuration setting has an invalid index value to the control setting database Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Please contact Gorbel Customer Service at 800 821 0086 or 585 924 6262 Error 320 ERROR MULTI FEATURES PER UNIT CONFIGURATION Description At startup found multiple Q iQ feature configuration settings are set to use the same digital input channel Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy a Use the extended error index number to identify which Q iQ feature contains the faulty setting Use the VB Configurator program not yet available as of July 2010 to correct the false setting b Run the Gorbel supplied installation CD i e Gorbel amp G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option
72. O RESET configuration setup i SRV MENU a Service Menu SERVICE UP CYCLE Program upper limit for the cycle count Maintenance and MENU SRV MENU m Service Features LO CYCLE Program lower limit for the cycle count Chart 4 continued from pages 5 7 amp 5 8 and continued on page 5 10 amp 5 11 Program Mode Menu and Selection Settings 5 9 7 11 G Force Q iQ Service Manual Gorbel Inc Program Mode Menu LCD Text Feature Description Enable disable displaying of usage data When enabled text display cycles DISPLAY between system time run time cycle counts and the software version number SYS INFO once per second CLEAR Reset cycle count to zero COUNT CLEAR Reset run time to zero RUN TIME i Reset the warning or the time limit of the Maintenance Service Indicator feature SRV WARN OFF Does not reset the current run time Note The warning can also be reset by selecting CLEAR RUN TIME SRV WARN Configure the time limit of the Maintenance Service Indicator feature on I O point 500 HRS 7 see diagram F to 500 hours SRV WARN Configure the time limit of the Maintenance Service Indicator feature on I O point 1000 HRS 7 see diagram F to 1000 hours SRV WARN Configure the time limit of the Maintenance Service Indicator feature on I O point 1500 HRS 7 see diagram F to 1500 hours CFG MENU When the LCD screen asks to enter a key code click the Menu button three times followed by a
73. O PILTest 2 Q R1001 Project Only pil Recent Desktop 5 My Documents My Computer J File name G_R1001 Project Only pil I z My Network Files of type pil files pil The selected file name will then be displayed in the program window Step 4 Get latest Qi version Optional You may select a JI version to get Version Selected gt C Documents and Settingskirpre Desktop P I PILT est Q_R1001 Project Only pil 6 5 7 11 G Force Q iQ Service Manual Gorbel Inc Step 5 With the update program selected it is now time to run the software update Upon clicking the Run Q iQ Software Update button the PVI Transfer program will open in a separate window This update can take up to 10 15 minutes but the program will show the current progress so that status of the update can be monitored At this time do not make any adjustments to the G Force unit or press any buttons in the PVI Transfer or Gorbel Q iQ Update Utility windows Process 0 Current command BEBNEEBEEBEEEEEEEEENE 0 Overall progress MEBEBBEEBEEBEEEEERE W armstart SUCCESSFUL 25 Download burtrap br ROM CHECK Download burtrap br ROM CHECK SUCCESSFUL 26 Download gcloader br ROM CHECK Download gcloader br ROM CHECK SUCCESSFUL 27 Download uscan br ROM CHECK Download uscan br ROM CHECK SUCCESSFUL 28 Download dataobj br SYSROM
74. OS assembly and align four holes with brackets attached to the actuator casting b Install 4 M5 button head cap screws BHCS and 4 M5 lockwashers c Restore AC power to the system Note Numbers in gt Parentheses are AS T EZ 4x Lockwasher M5 Gorbel amp Part Numbers AN i 65062 4x BHCS M5 x 20mm Lg Flanged 65008 Front Cover 76530 Nylock Nut M4 ZNPL 65096 Jog Button Cover 76532 Flatwasher M4 ZNPL 65081 BHCS M4 x 16mm Lg 65068 Diagram 1 Front Cover Removal and Replacement 10 3 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 2A Rear Cover Removal a Turn power off by disconnecting AC power to the system b Remove 4 M5 button head cap screws BHCS and 4 M5 lockwashers c Carefully slide rear cover away from actuator casting Procedure 2B Rear Cover Replacement a Carefully slide rear cover over motor CPU and power supply and align holes with the actuator casting b Install 4 M5 button head cap screws BHCS and 4 M5 lockwashers c Restore AC power to the system 4x Lockwasher M5 High Collar 65062 4x BHCS M5 x 20mm Lg Flanged Back Cover Assembly 65008 76531 Note Numbers in Parentheses are Gorbel Part Numbers Diagram 2 Rear Cover Removal and Replacement 7 11 10 4 G Force Q iQ Service Manual Gorbel Inc lt lt SHSS M12 x 12mm Lg Bolt Hole Plug 65088 Note Numbers in Parenthese
75. Output Fault indicator Is output turns on when a command fault or drive ault occurs It does not turn on due to a command arning Chart 1 iQ Actuator Input Output Module Standard Functionality POWER ON LED P INPUT LED DK 12345678 O n M 00000000 OUTPUT LED coMERTENT LO elal ly l l b ly 0 J we sao CP INTERFACE STD ON K MODEL cpu o 00000000 CE HEHEHEHINEEM T TTEKEKIKIEKIN Diagram 5 Actuator CPU Input Output Block 8 5 7 11 G Force Q iQ Service Manual Gorbel Inc zk alanda K k 8 Point Input Output Block Functionality ee d Function Description ettings see chart 1 page 5 3 for instructions on navigating and setting menu functions tM g Float ee rom one pre aise load weight to another These two located in SETTINGS MENU 2 DUAL TOOL WT and eights must remain fixed otherwise some drifting can occur if DUAL FM LOAD WT The desired load weight must be he weight is different than the programmed value nput Anti drop feature This input Is typically wired to a clamp request pushbutton When thelSee Point 3 Settings description 2 Clamp request input is on Output 7 see I O Point 7 turns on and Output 8 turns off regardless of the Ame loading state Output Anti drop feature Programming to tare weight Is located at Unclamp request hen the input is on Output 8 see I O Point 8 turns on only if MENU 2 ANTIDROP TOOL WT The empty ae Anti
76. Shoulder Bolt 5D 7 Check that the coils of the coil cord are centered around the wire rope when properly installed 5D 8 A pilot hole is provided for the locking pin Attach tooling to G360 utilizing RUE M16 thread The tool bolt rod thread LAY should be beyond pilot hole of shaft when fully engaged Using a 21 drill bit drill through the tool bolt rod thread and out the other side of G360 shaft Hammer pin into place thereby locking tooling to G360 diagram 5H 5D 9 Attach the pendant handle bracket directly to the tooling Assure that the mounting arrangement does not affect the operating function of the pendant handle Note If necessary a collar clamp mounting bracket option can be used to attach the pendant handle to the tooling diagram 5I LOCKING PIN 5D 10 Connect the extension cable from the G360 to the remote mounted pendant handle Securely clamp the remote mount coil cord extension cable to the tooling as needed CAUTION All cables used in a remote mounted handle configuration must be properly clamped and or strain relieved to prevent premature failure of the G Force or Take care to avoid looping excess cable at locations where the loop could catch on foreign objects 5D 11 Continue to Step 6 on page 3 9 7 11 3 6 Gorbel Inc Wire Rope Coil Cord Footer M12 Jam Nut G360 Swivel STRAIN RELIEF CLAMP MUST BE USED TO PREVENT DAMAGE TO G360 Diagram 5G G360 Should
77. Switch adjustment may be necessary The Limit Switch Assembly is located inside the actuator on the right side behind the Gorbel logo on the center casting You must remove the Front Cover to access this area Refer to diagram 1 below Diagram 1 Upper Limit Switch Adjustment The bottom allen head screw adjusts the upper limit Use a 5mm allen head wrench to perform the adjustment Turning the screw clockwise raises the stop point of the wire rope Counterclockwise lowers the stop point of the wire rope A full turn is approximately 3 inches of wire rope travel Refer to diagram 2 on page 9 2 9 1 7 11 G Force Q iQ Service Manual Gorbel Inc Upper Limit Switch M6 Adjusting Screw Diagram 2 Lower Limit Switch Adjustment The lower limit is a default of the wire rope replacement position When this switch is actuated there should be approximately two full turns of wire rope left on the drum There is no adjustment for this position The switch provides protection for the hardware inside the actuator Refer to diagram 3 below Lower Limit Switch Diagram 3 7 11 G Force Q iQ Service Manual Gorbel Inc Wire Rope Replacement Adjustment for the Lower Limit Switch ln order to determine whether this adjustment needs to be performed you must push the upper allen head screw in until it bottoms out against the body of the Limit Switch Actuator as illustrated in diagram 4 below and press the Jog Dow
78. ad plate brace if your unit is a 330 or 660 Ib 150 or 300 kg model Remove the 2 M6 socket head cap screws SHCS and 2 M6 lockwashers from the drum gate and slide the drum gate off the load plate Procedure 14B Drum Gate Replacement 7 11 a Slide the drum gate into position on the load plate and install the 2 M6 socket head cap screws SHCS and 2 M6 lockwashers Position the load plate brace if equipped with one and tighten the 2 M8 nylock nuts Swing the ACOPOS drive assembly into the closed position and connect the limit switch cable assembly to the main PCB Install the 4 M5 button head cap screws BHCS and 4 M5 lockwashers that secure the PCB ACOPOS support bracket assembly to the end support frame Install the front cover Refer to Procedure 1B Restore AC power to the system 10 28 G Force Q iQ Service Manual Gorbel Inc 2x Lockwasher M6 ZNPL 03370 2x SHCS M6 x 80mm Lg 65031 Drum Gate Clearance Note Numbers in 76537 Parentheses are Gorbel Part Numbers Diagram 14A 165 Ib 75 kg and 330 Ib 150 kg Clearance Drum Gate Removal and Replacement 2x BHCS M5 x 12mm Lg 65000 Apply Blue Loctite Retainer 3 16 Rope 75337 Wire Rope Assembly 79258 Note Numbers in Parentheses are Gorbel Part Numbers Diagram 14B 165 Ib 75 kg and 330 Ib 150 kg Clearance Drum Gate Removal and Replacement 10 29 7 11 G Force Q iQ Service Manual G
79. aged parts are noticed 4 Establish a regular schedule of inspection and maintain records for all hoists with special attention given to hooks load cables brakes and limit switches Check operation of brakes for excessive drift Never lift loads over people etc Check for damaged hooks and load cable Keep load cable clean and well maintained Check the load cable for improper seating twisting kinking wear or other defects before operating the hoist Make sure a load clears neighboring stockpiles machinery or other obstructions when raising lowering or traveling the load 11 Center hoist over the load before operating 12 Avoid swinging of load or load hook when traveling the hoist Be sure the load attachment is properly seated in the saddle of the hook Balance load properly before handling Avoid hook tip loading Pull in a straight line so that neither hoist body nor load cable are angled around an object Take up slack slowly Know the hand signals for hoisting cross travel and crane travel if working with cab operated hoists or cranes Operators should accept signals of only those persons authorized to give them CONAN 13 14 15 16 7 11 G Force Q iQ Service Manual Gorbel Inc G Force Operational Guidelines All operators should read the G Force Installation and Operation Manual before operating the unit Please follow the instructions contained in this manual for your
80. al type of problem encountered User may attempt basic troubleshooting checkup or repair For example if the fault category is CAN Communication check all the cable wiring and connectors for loose connections If the fault category is Motor Regen and Junction Temperature user can let the unit cool down before reusing the unit Another approach may be referencing Troubleshooting Section I Functional Failure Table for similar failure condition and perform the suggested corrective action s Users should contact their dealer or Gorbel amp Inside Sales for additional support and any questions about the encountered problem corrective action or replacement parts 7 11 7 6 G Force Q iQ Service Manual Gorbel Inc Corrective Action Summary Use the following table to identify the appropriate corrective action for the specific faulted condition Fault Category LCD Error Displayed LCD Error Message Error LCD Error Message Corrective Action Action 1 9 100 105 110 122 300 310 DOWNLOAD PROGRAM EIL Power 200 201 203 204 CHK PLC HARDWARE Cycle Power Command Faults 202 205 206 CHK DRIV STATUS Cycle Power ee EXTD S NNNN Cycle E stop BER L Ten 10401 10402 10403 10004 CONTACT GORBEL Cycle Power 10500 REPLACE BATTERY Cycle Power 11000 RELEASE SWITCHES Service is Required 11002 RE PROGM OVERLOAD Follow Overload Program Instructions moos CHK HNDL HARDWARE Cycle Power Command Warnings 11700 1170
81. an end connection the rope should be reterminated or replaced Reterminating shall not be attempted if the resulting rope length will be insufficient for proper operation CORE STRAND Diagram 3 19x7 Preformed Wire Rope Composition 5 Replacement rope and connections shall have strength rating at least as great as the original rope and connection furnished by the hoist manufacturer A rope manufacturer or a qualified person shall specify any deviation from the original size grade or construction 11 7 7 11 G Force Q iQ Service Manual Gorbel Inc Chapter 12 Recommended Tools and Parts ToolName J Name DD NENNEN Allen Wrenches Dan red 2 5mm 3mm 4mm 5mm 6mm T Type 230mm long are preferred 8mm 10mm Metric Sockets Drive sizes are typically 1 4 and 3 8 inch 5 5mm 7mm 8mm 10mm 19mm depending on socket size Ratchet Handles and Extensions User User preference Metric Combination Wrenches 10mm should be ratcheting type mE Afin ommo LockRing Pliers LockRing Pliers Pliers small and medium sizes and medium sizes Screwdrivers flat and Phillips Smal and medm sios _ precision type Long Nose Pliers 8 inch is typical Spare Parts Kits Gorbel Part Number Basic Kit ontact Inside Sales or speci Ic part numbers and applications Hardware Ki ontact Inside Sales or speci Ic part numbers and applications f Contact Inside Sales for specific part Swivel Kit e numbers and applicat
82. and should be removed b If correct modules are installed at least one of them cannot be identified possibly due to a faulty component Replace as necessary Error 207 ERROR_HW_MOTOR_PAR_SETUP_FAULT Description At startup the configuration of the motor settings of the unit is returned with an error Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 208 ERROR_HW_MISMATCH_PLC_VS_SOFTWARE Description At startup found the identified PLC model does not match the installed software version A Q or iQ software version must be installed into the corresponding PLC type Reaction Lift program terminates processing to prevent running with an incorrect software program Cause Remedy Check if the installed PLC controller is of model CP470 or CP474 as labeled on its front cover i Replace the module if an installation error has indeed occurred ii Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and re install the correct software version Q or iQ
83. ation can be found in Chapter 6 Software Update in this manual Gorbel Q iQ Update Utility Please select one of the following options Download Q iQ Software and Retain Existing Configurations Download Q iQ Software and Reset to Factory Default Confi T onfigurations Replace PLC Battery Reset Existing Configurations to Factory Default 711 10 80 G Force Q iQ Service Manual Gorbel Inc Procedure 2 CPU Battery Replacement These procedures should be followed if the unit experiences a Command Warning 10500 if the PLC memory retention battery power level is low or faulty or if instructed to by a Gorbel Customer Service Representative a f Typically battery replacement resets all configuration and features settings back to default unless memory retention procedures are performed prior to the replacement Please check the Software Update chapter for information on using the Replace PLC Battery option to record the settings Skip this step if not available If the previous step cannot be performed please reference the Program Mode Overview section for accessing the configuration menu LCD display CONFIGUR MENU if available accessibility may not be available on order units Choose RECORD CONFIG selection to save the latest configuration settings into nonvolatile memory Feature settings will not be recorded Skip this step if not available Turn power off using the external circuit brea
84. ations and those that require immediate Warning attention e g wire rope replacement or PLC low battery RV M diagnostic purposes it is shown before Service Warnings Service Mode Slow Flash Slow Flash uch as cycle count warnings Multiple diagnostic messages are likely to be displayed here such as output a live handle connection pushbutton states only a pecial Jog Mode is running etc 7 Startup Before Ready BETIR ie UNIT POWER UP Unit is starting up power up Process Mode aM executing necessary settings and self diagnostics 10 a Slow Flash n unit is overloaded factory or user defined while Indicates unit maintains still for an extensive time while 10 b Still Motion Previous Slow Flash jrunning in a Run Mode application such as handle mode Float Mode etc ndicates Float Mode control exceeded the over speed 19 e Run Mode OverSpeesd Slow Flash limit and the unit is shutting down j Displays run mode specific message such as RUN tiende Mode LUE JOG HANDLE PENDANT or CUSTOM Displays run mode specific messages such as RECORD DATA and RUN MODE FLOAT The first Float Mode en E message indicates when the unit is collecting loadcell data to perform Float Mode 11a Display 1 On Off pisplays custom feature messages for a custom motion Custom Display2 Display2 On On feature Run Mode that also requires using LEDs for Mir Feature N Display3 Slow Flash Off jndication More information may
85. ator 2 Follower UP2 DN2 JOG SWTH G Force Logo Button Float Mode Operator Present Switch Chart 6 Custom Diagnostic Mode for Systems Equipped with Dual Actuator Feature 7 11 5 12 G Force Q iQ Service Manual Gorbel Inc Active Diagnostic Mode Messages Continued I O Status LCD Display Message Any of the eight I O Points configured as Digital Inputs Any of the eight I O Points configured as OUTPUTS 12345678 Digital Outputs Only the Output s turned on to send 24VDC displays its I O Point number Chart 7 Diagnostic Mode Messages for iQ Actuator Input Output Module or the Expansion 8 Point Input Output Block Virtual Limits Warnings WARNINGS If the upward speed reduction point is being used to reduce the impact of engaging the load on the fly i e catching the load with a hook while the G Force is already in motion in the upward direction care must be taken to ensure the speed reduction takes place before the load is engaged Please program the Upper Slow Down Reduction point at least half an inch to an inch below the exact point of pick up Note Setting the upper and lower virtual limits to the same position will cause the unit to not travel in either direction 5 13 7 11 G Force Q iQ Service Manual Gorbel Inc iQ Actuator Input Output Module Functionality Settings see chart 1 for Assigned Function Description instructions on navigating aint and setting menu functions t
86. ator program not yet available as of July 2010 to correct the false setting b Run the Gorbel supplied installation CD i e Gorbel amp G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default 7 11 7 16 G Force Q iQ Service Manual Gorbel Inc Error 333 ERROR X67 3 IO MASK SETUP Description At startup unit detects an error while configuring the third X67 spare IO module based on the configuration setting Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy a Use the extended error index number to identify which Q iQ feature contains the faulty setting Use the VB Configurator program not yet available as of July 2010 to correct the false setting b Run the Gorbel supplied installation CD i e Gorbel amp G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 334 ERROR X67 4 IO MASK SETUP Description Not Used Reaction Not Use
87. ayed to confirm the Lockout was successful If Program Mode is requested after the Lockout has been enabled the LEDs will flash twice to indicate Program Mode is not accessible and PROGRAM LOCKED will be displayed again To Unlock Program Mode 1 Press both the G Force logo button and the MENU button simultaneously for five seconds 2 The LCD will display UNLOCK CHECK while both buttons are being depressed 3 After five seconds PROGRAM UNLOCKED will be displayed to confirm the Lockout was successful 5 sec to activate Both buttons for LOCKOUT PROGRAM No CHECK 5 sec LOCKED UNLOCK PROGRAM Yes CHECK 9 sec UNLOCKED Chart 3 Lockout Feature Process E las Safety Program Mode If the G Force has detected a fault or is running in SERVICE MODE only a limited set of menus are accessible For example if the G Force records a fault when Program Mode is activated the LCD will display LIMITED PRG MODE rather than PROGRAM MODE Safety Program Mode can be navigated just as Program Mode would be however the only menus available are V LIMITS MENU Virtual Limits menu option SPEED MENU Lift Speed adjustment e RESPONSE MENU Lift Responsiveness Acceleration adjustment e SERVICE MENU Customize and manage maintenance and service features 7 11 5 6 G Force Q iQ Service Manual Gorbel Inc Program Mode Menu LCD Text Feature Description UPPER LIMIT Program the uppe
88. b Remove the 2 pushbutton shafts from the pendant handle housing Note The E stop button assembly is removed and installed from the inside of the housing There are two parts that make up the E stop assembly The switch part is disconnected from the inside first The pushbutton is then held in place by a nut that needs to be removed from the inside Procedure 10B E Stop Assembly and Pushbutton Replacement a Install the 2 pushbutton shafts into the pendant handle housing b Install the faceplate and face seal Refer to Procedure 9B ______ Housing Note Numbers in 74302 Parentheses are Gorbel Part Numbers 2x LED Light Tube 2x Pushbutton Shaft d 74309 74320 Pushbutton E Stop Assembly PA 78804 Diagram 10 E Stop Assembly Pushbutton and Light Tube Removal and Replacement 7 11 10 62 G Force Q iQ Service Manual Gorbel Inc Top Guard 74335 9x Lockwasher M6 ZNPL 03370 Flatwasher M6 ZNPL 65060 lt One Signal Pilot Valve Block PO E 9 4 88881M 7x BHCS M6 x 10mm Lg 65076 ea Side Guard Valve Option Side Guard LOLO 74329 74313 PAd Right Angled Lever 88605 Pneumatic Mounting Plate Left Right Lever Shaft 105 74317 74315 2x BHCS M6 x 16mm Lg 65075 Single Valve Option Right Side Top Guard 74335 7x BHCS M6 x 10mm Lg 9x Lockwasher M6 ZNPL 65076 03370 Flatwasher M6 ZNPL 65060 T Side Guard a 7
89. b Assembly Assembly and Disassembly 10 43 7 11 G Force Q iQ Service Manual Housing Sub Assembly 74247 10 74248 10 Operator Present Sensor 78615 LCD Window 74223 S Handle Bottom gt 74209 i NOTE LOCATION OF NUT AND WASHER 2x Handle Pushbutton 74215 4x SHCS M5x8 55 65067 Gorbel Inc 2x External Snap Ring 6mm 65065 Bumper 74207 Pd A 4x Lockwasher M5 High Collar 65062 Note Numbers in Parentheses are Gorbel amp Part Numbers Diagram 4B Housing Sub Assembly Assembly and Disassembly 7 11 10 44 G Force Q iQ Service Manual Gorbel Inc Procedure 5A LVDT Sub Assembiy Removal a Remove the swivel or remote mount cap sub assembly Refer to Procedure 1A or 2A b Remove the housing sub assembly Refer to Procedure 3A c Access the LVDT adjustment screw from the opening below the upper portion of the handle grip assembly Turn the screw clockwise until the LVDT is clear of the grip assembly Note Keep track of the approximate number of turns required to remove the assembly It will help approximate the starting position for the replacement process Procedure 5B LVDT Sub Assembly Replacement a Insert the LVDT sub assembly into the top opening in the upper portion of the handle grip assembly Turn the screw counterclockwise from the bottom until the LVDT sub assembly is positioned close to its original position Note The f
90. band into the load plate Install the drum gate Refer to Procedure 14B Install the end support frame Refer to Procedure 12B Install the ACOPOS support bracket with electrical shield main PCB and ACOPOS servo drive still attached Connect all cable assemblies to the main PCB Refer to Procedure 7B Install the front cover Refer to Procedure 1B Restore power to the system 10 31 7 11 G Force Q iQ Service Manual Gorbel Inc Drum Cover Band 76703 Drum Cover 76702 Note Numbers in Parentheses are 2x SHCS M6 x 110mm Lg Note Apply Blue Gorbel Part Numbers 65037 Loctite to Threads Diagram 15A 165 b 75 kg and 330 Ib 150 kg Drum Cover and Band Removal and Replacement Drum Cover 76513 Drum Cover Band 76509 Note Numbers in Parentheses are 2x SHCS M6 x 90mm Lg Note Apply Blue Gorbel Part Numbers 65030 Loctite to Threads Diagram 15B 660 b 300 kg Drum Cover and Band Removal and Replacement 7 11 10 32 G Force Q iQ Service Manual Gorbel Inc Procedure 16A Limit Switch Assembly Removal a b Turn power off by disconnecting AC power to the system Remove front cover Refer to Procedure 1A Disconnect the limit switch cable assembly from the main PCB J11 Remove the access plug from the main middle section Remove the M6 button head cap screw BHCS and M6 lockwasher from the outside end of the limit SWITCH assembly Remove the limit SWITCH assembly fr
91. be found in the Custom BN Ea description section D READY or response Display 1 4 Displays custom feature messages for a custom feature zo Custom Display 2 hat also requires using LEDs for indication while the unit Feature N Display 3 Slow Flash Off jis idling in Ready Mode More information may be found Display 4 Slow Flash lin the Custom Feature description section 7 11 7 8 G Force Q iQ Service Manual Gorbel Inc Q iQ Unit System Motion and Feature Command Fault List Software Version R1 07 0 Command Faults Unit Configuration Setting Error 1 ERROR_SERIAL_NUM_OBJ_SIZE_MISMATCH Description At startup the stored PLC serial number in memory does not match the version the lift program uses or it may be corrupted Reaction Lift program terminates processing to prevent running with an unconfigured or potentially faulty PLC unit Cause Remedy Please contact Gorbel Inside Sales at 800 821 0086 or 585 924 6262 Error 2 ERROR_SERIAL_NUM_OBJ_LOCATE Description At startup the query command to locate the stored PLC serial number is returned with an error Reaction Lift program terminates processing to prevent running with an unconfigured or potentially faulty PLC unit Cause Remedy Please contact Gorbel Inside Sales at 800 821 0086 or 585 924 6262 Error 3 ERROR_SERIAL_NUM_OBJ_READ Description At startup the query command to retrieve the stored PLC serial number is returned with an error
92. bel Inc Press amp Hold MENU Button Click G Force Logo Button 2 sec to activate Q iQ Only PROGRAM V LIMITS MODE MENU N iQ or Q with software option JU Set Various Virtual Limits Select Maximum Hoist Speed Select Handle Control Response Program Common Q amp iQ Custom Features SETTINGS gt Program iQ Features MENU 2 N LED S Configure Blue LED MENU Indicator Optional Configure Dual Actuator System DUAL ACT 1 MENU SERVICE S Select Maintenance and MENU Service Features Activate Through Y MENU ENABLE CONFIGUR MENU Chart 1 Program Mode Process User Accessible Hardware Configurations 7 11 5 4 G Force Q iQ Service Manual Gorbel Inc SETTINGS MENU i PRESET bo CHANGE ers 7 Je SAN i SUB MENU i O i OVLDLMT i O i OPFORCE i O i SENSITIV i daran P ode WEN 2 mj mimi mmi d dmi 2 mk i 3 4 repel n d e up P 4 i PRESET i SUB MENU i Chart 2 Program Mode Main Menu Solid Border and Sub Menu Dotted Border Layouts 5 5 7 11 G Force Q iQ Service Manual Gorbel Inc Lockout Feature chart 3 To prevent tampering in Program Mode a Lockout Feature is available To Lockout Program Mode 1 Press both the G Force logo button and the MENU button simultaneously for five seconds 2 The LCD will display LOCKOUT CHECK while both buttons are being depressed 3 After five seconds PROGRAM LOCKED will be displ
93. d Cause Remedy Not Used Error 335 ERROR X67 5 IO MASK SETUP Description Not Used Reaction Not Used Cause Remedy Not Used Error 336 ERROR X67 6 IO MASK SETUP Description Not Used Reaction Not Used Cause Remedy Not Used Error 337 ERROR X67 7 IO MASK SETUP Description Not Used Reaction Not Used Cause Remedy Not Used Command Faults Process and Display Mode Error 4400 ERROR PROC DISP Description General Process and Display Mode faults Reaction Not Used Cause Remedy Not Used Command Faults Other Status Error 500 ERROR STATUS Description Starting index to other faults Reaction Not Used Cause Remedy Not Used Error 501 ERROR BOTH TRAVEL LIMITS AT HOMING Description At startup both the upper and lower limit switches or the upper limit and slack switches are triggered This can inhibit the ACOPOS drive from properly setting its position Reaction Lift program terminates processing because the drive cannot properly configure its position Cause Remedy a if both the upper and slack switches are engaged pull down on the wire rope to remove slack and recycle power on the unit b Check for any mechanical binding that could engage both the upper and lower limit switches or upper limit and slack switches c Check and correct if the limit switch cable is connected to the interface board d Check for bad electrical connection or shorted wires from the switches 7
94. d slide retainer off of support plate rope end toward you Set retainer and screws in front cover diagram 3G Note 165 and 330 Ib units use two 5mm button head cap screws BHCS n Grasp wire rope with right hand where it exits actuator Keep rope from bending while pushing rope upward to unseat the stop sleeve from the anchor channel If this does not work use a medium screwdriver flat sliding it upward between rope and drum to progressively pry rope out of anchor channel while still pushing up on rope Remove rope from actuator through opening at bottom once unseated diagram 3H Diagram 3E Loosen flange nuts to remove reinforcement bracket Retainer Diagram 3F a j Diagram 3H Remove two M6 socket head cap Diagram 3G B m ve Ee k fiom acta ior screws from the drum gates Remove M8 socket head cap e through opening at bottom screws and slide retainer off rope end towards you 10 7 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 3B Wire Rope Assembly Replacement a Insert end of wire rope assembly upward through coil cord bracket with right hand With left hand grab free end and bend rope to form loop tightly enough to insert loop portion into groove of drum diagram 3l At this point free end will project from face of drum by several inches diagram 3J b By pulling downward with right hand and holding rope in groove with left hand rope end can then be pulled into recess in drum
95. e cleared and reset to default Error 325 ERROR DUAL ACTUATOR SETTING ON Q UNIT Description At startup found Dual Actuator feature is falsely configured on the Q system This is an iQ only feature and is not currently available for iQ Easy Arm system Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy a Contact Gorbel Inc regarding the purchased unit to determine if a mismatched order CPU model or software version has been installed It may be necessary to send the unit back to Gorbel Inc for proper reconfiguration b Run the Gorbel supplied installation CD i e Gorbel amp G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Note Please do not perform this action if the fault is caused by a 7 15 7 11 G Force Q iQ Service Manual Gorbel Inc Error 326 ERROR_MISSING_INPUT_CHANNEL Description At startup found an iQ feature is misconfigured specifically a required digital input channel location is missing Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Handle displays this command fault followed by an extended error index numbe
96. e fault if it is not repetitive Inaccurate communication can result from faulty handle board noise or data corruption in the CAN communication wires or any cut wires Replace the handle coil cord actuator interface board and CAN communication wires in the actuator until the fault is corrected 7 11 7 24 G Force Q iQ Service Manual Gorbel Inc Error 11803 WARN_LCD_FAULT_NOT_ACTIVE Description Handle LCD board CAN bus controller has triggered a fault and becomes inactive Reaction Warning message on this fault may be on screen or by flashing LED If the board has become inoperative a factory default warning message may be displayed on the LCD screen Cause Remedy A fault specifically an inactive node can occur if the handle LCD board CAN bus controller does not communicate with the PLC correctly and exceeds the allowable wait period of the master node Reboot the unit with the E stop to clear the fault if it is not repetitive Inaccurate communication can result from faulty handle board noise or data corruption in the CAN communication wires or any cut wires Replace the handle coil cord actuator interface board and CAN communication wires in the actuator until the fault is corrected Error 11804 WARN LCD FAULT CAN IO ALARM Description Handle LCD board CAN bus controller has triggered an alarm status Additional error information may be available following the warning Reaction Warning message on this fault may be on
97. e holding the handle or G360 loop the pulley through the wire rope and slip the pulley and side spacers down between the plates diagram 5L page 3 8 Align the holes in the plates with the spacers and the bearings insert the pulley pin and install the snap ring on the pulley pin m WEAR RNG 76764 2X 03370 S 4 2X 65112 2X 65028 2X 03370 2X 79150 CO IL CORD 2X 79150 2X 65032 83253 79150 W RE RO PE ASSEM BLY 65032 Diagram 5J Assembly of Wire Rope to 1320 Ib Actuator Assembly 4X 83260 83252 83265 Diagram 5K Attaching U bolt and Reinforcement Plate to Actuator Assembly Using the supplied cap screws and lockwashers attach the coil cord mounting plate to the top of the handle or G360 Attach the coil cord Turck connector to the mating connector in the top of the handle or G360 and use the supplied cap screw to attach the strain relief clamp to the side plate so there is a small service loop at the connector 5E 10 Continue to Step 6 on page 3 9 7 11 G Force Q iQ Service Manual Gorbel Inc Step 5F 1320 Ib Suspended Pendant Handle Installation 5F 1 5F 2 5F 3 5F 4 5F 5 5F 6 5F 7 5F 8 5F 9 With the actuator hanging from rail or other support structure thread the free end of the wire rope through the wear ring bracket and use the NALA supplied hardware to attach the bracket to the Wate actuator diagram 5J page 3 7 65006 ENAP
98. e or pendant handle moves in the mother board up direction inear transducer failure 0 4 oll cora or B O Repair or replace coil cord or roken conductor 8 4 Down limit switch Limit switch failure Replace down limit switc O alsely programmed lower virtual limit eck reset virtual limits under dual VL setup alsely activating a custom feature that None Avoid this condition tops all downward movement oat Mode loadcell maximum capacity None Decrease load reached o o Q o D o o gt Qo i N J o D 5 o o 5 CO c o PES o O eo Cj C O 0 Unit only Handle failure Hanale mother board failure 41 10 5 Heplace slide or pendant hand moves in the mother board down direction inear transducer failure Replace linear transducer oil cord or B Repair or replace coil cord or pendant cable pendant cable Actuator wiring Broken conductor Repair or replace cable Replace up limit switc eck reset virtual limits e Ps Co CO Ps UJ o D 5 o o 5 c o ze o Co O imit switch failure O alsely programmed upper virtual limit under dual VL setup alsely activating a custom feature that tops all upward movement oat Mode loadcell maximum capacity reached None Avoid this condition None Decrease load 1 92 e Handle linear Linear transducer failure to drop after transducer inear transducer adjustment Adjust lin
99. ear transducer handle is Handle mother Damaged defective handle mother Replace slide or pendant hand released PCB board mother board Handle operator Damaged operator present sensor 0 40 Replace operator present present sensor falsely keep unit running ensor Motor brake amaged detective motor brake 0 18 Replace motor Operation ustom feature input to Auto Move None Avoid this condition alsely turned on Replace linear transducer O Bl eo 1 Is eo 1 92 A amaged defective actuator PCB not functioning Drive module amaged detective arive module Module cable Damaged defective drive cable able oose or disconnected cable 860 connection andle linear Linear transducer failure Replace actuator main PCB Replace ACOPOS drive module Replace the cable Replace motor drive cable 9 Q o zi o D 7 Co Qol co eo noticeably transducer faster in one direction than the other E U 0 eplace or reform coil cord no smooth ring is binding position bracket and or weight inside actuator readout is opening inaccurate 7 3 7 11 G Force Q iQ Service Manual Gorbel Inc H unctiona Possible uspect Component s ocation orrective Action Faure causes gege referenco ommunication Any communication interruption between 8 eck all applicable failure he E stop switch and the servo drive onnections handle coil cord Engaged G360 Message stop switc stop switc 0 4
100. ece cee hee HHHH HH HH BEND 10 67 BGO 10 74 NUM MI ere a aa E a e a e Ka p aaeei 10 80 CAUTION Many of the removal replacement procedures in this section require AC power to be removed rom the actuator You must disconnect the AC power plug from the AC source in order to do this or use a disconnect if equipped with one Using the e stop button will not accomplish this because it does not interrupt AC power to the actuator 10 1 7 11 G Force Q iQ Service Manual Gorbel Inc Removal and Replacement Procedures ACTUATOR Plug 79274 2x Gorbel Label 76550 3x G Force Label 83178 Note Numbers in oe i Capacity Label Parentheses are mu See Table Below for P N Gorbel Part Numbers G Force Actuator Labels Q300kg 76555 iQ 300 kg 76552 Q 660 Ib 76561 iQ 660 Ib 76558 Q 150 kg 76556 iQ 150 kg 76553 Q 330 Ib 76562 iQ 330 Ib 76559 Q 75 kg 76557 iQ 75 kg 76554 Q 165 lb 76563 iQ 165 Ib 76560 Q 600 kg iQ 600 kg q 1320 b 95268 iq 320 b 89768 7 11 10 2 G Force Q iQ Service Manual Gorbel Inc Procedure 1A Front Cover Removal a Turn power off by disconnecting AC power to the system b Remove 4 M5 button head cap screws BHCS and 4 M5 lockwashers c Carefully slide front cover away from actuator casting Procedure 1B Front Cover Replacement a Carefully slide front cover over ACOP
101. ed instead of the tare value to generate the corresponding overload detection parameters Please activate weight readout WEIGHT READ ON_ under SETTINGS MENU in PROGRAM MODE and ensure that the lifted weight does not exceed the maximum limit before selecting TARE OVLD LMT This warning does not negatively affect system performance because overload parameters are set to the maximum allowable settings User can cycle the E stop switch on the handle to clear the warning Error 11007 WARN_UO_BELOW_MIN_LIMIT Description This warning is triggered when User Programmable Overload attempts to tare a weight less than 25 of the rated capacity Reaction The tare weight is rejected and 25 of the rated capacity is used to set up the overload detection parameters Cause Remedy When TARE OVLD LMT selection from USR OVLD SUB MENU CHANGE OVLD LMT in PROGRAM MODE is selected unit tares the current lifted weight and applies overload settings proportional to this weight This warning is triggered when the lifted weight is below the minimum 25 rated capacity limit To prevent overload limit being set below the minimum when this error occurs the 25 rated capacity value is applied instead of the tare value to generate the corresponding overload detection parameters Please activate weight readout WEIGHT READ ON_ under SETTINGS MENU in PROGRAM MODE and ensure that the lifted weight is not below the minimum limit before selecting TARE OVLD LMT This warnin
102. ed onto the drum Continue loading rope onto drum drum face using jog button until 3 drum revolutions are completed i Remove screwdriver from between actuator and wear ring j Install front cover onto actuator making sure all 4 screws are aligned with tabs before threading k If using coil cord make sure rope is inserted down through the middle of the coils Attach wire rope to handle weighted hook or end effector in reverse order of disassembly Diagram 3L Retainer plug on end of wire rope m Reset virtual limits and or slow down settings Should be fully seated in recess 7 11 10 8 G Force Q iQ Service Manual Gorbel Inc Procedure 4A Electrical Shield Removal a Turn power off by disconnecting AC power to the system b Remove front cover Refer to Procedure 1A c Remove 3 M3 socket head cap screws SHCS and M3 lockwashers d Remove 3 shield standoffs e Remove electrical shield Procedure 4B Electrical Shield Replacement a Position the electrical shield and align 1 shield standoff with the corresponding hole in the actuator main PCB b Install 1 M3 socket head cap screw SHCS and M3 lockwasher Do not tighten hardware completely c Install the other 2 shield standoffs M3 socket head cap screws SHCS and M3 lockwashers d Tighten all hardware carefully to avoid damaging the electrical shield e Install the front cover Refer to Procedure 1B f Restore AC power
103. els Ext is 320 Ext he latter feature that triggers the fault Multiple iQ features are configured to use the same digital output channel Ext is 321 Ext he latter feature that triggers the fault An iQ feature input channel is set outside the allowable range Ext is the feature 322 Ext hat triggers the fault An iQ feature output channel is set outside the allowable range Ext is the feature hat triggers the fault hile executing a Jog Handle Float or other custom motion a processing command is taking too long to execute Ext is the state of execution when this error is generated Please contact Gorbel Inc with this error number P A fault has been triggered while configuring the spare I O block Please follow the recommended remedy for this fault such as resetting configurations to factory default id A fault has been triggered while executing a command to process the stored system configuration or unit serial number in the CPU memory Please contact Gorbel Inc with these error numbers 20614 Error while saving the data object in Flash memory 7 27 7 11 G Force Q iQ Service Manual Gorbel Inc Command Fault E 78076 oun 7 11 Extended NE Error S Description Command Fault and Extended Fault Supplement Information An alarm fault has been triggered while processing one of the electrical components connected in the communication line including the handle board LCD display spare I O block and
104. ent 7 11 10 34 G Force Q iQ Service Manual Planetary Gearbox EPL84 35 1 With Key 76713 BHCS M6 x 20mm Lg 65075 Nylock Nut M6 M 65090 2x Bearing Spacer 79209 2x Ball Bearing 6824 RS Note Numbers in 74011 Parentheses are Gorbel amp Part Numbers 165 Ib 75 kg Nylock Nut M6 65090 Note Numbers in Parentheses are Gorbel Part Numbers 330 Ib 150 kg 10 35 Gorbel Inc Note BHCS 65075 should provide slide fit for limit switch assembly do not fully thread into load plate Load Plate Drum Gate Threaded 79223 76705 Ball Bearing 6908 Double Seal Drum Pulley 65075 76751 Note Thread drum gate 76705 onto drum so the wire rope slot matches up to the wire rope anchor point on the drum pulley 76751 BHCS M6 x 16mm Lg 65075 Ball Bearing 6908 Double Seal 74019 7 11 G Force Q iQ Service Manual Gorbel Inc Note Numbers in Planetary Gearbox EPL118 70 1 76714 Parentheses are Load Plate Gorbel Part Numbers 76701 Drum Pulley 76753 Drum Gate Threaded 76705 2x Bearing Spacer 79209 2x Ball Bearing 6824 RS 74011 Note Thread drum gate 76705 onto drum so the wire rope slot matches up to the wire rope anchor point on the drum pulley 79155 330 Ib 150 kg 8x Lockwasher M5 8x SHCS M5 High Collar x 30mm Lg 65062 65003 4x Lockwasher M8 ZNPL 00195 4x SHCS M8 x 25mm
105. equires Float Mode option This step must be performed after zero load bias PRESET Access predefined sets of Q iQ feature configurations including factory default SUB MENU setup Chart 4 continued from pages 5 7 thru 5 9 amp continued on page 5 11 Program Mode Menu and Selection Settings 7 11 5 10 G Force Q iQ Service Manual Gorbel Inc Program Mode Menu LCD Text Feature Description Input Dual Float Mode Input Anti Drop Output Anti Drop Input Auto Home Input External device control combine with Actuator I O Module point 5 Input External device control combine with Actuator I O Module point 6 Output mimic OPS Output mimic stack PRESET qt cbr d bir c Input Dual Float Mode Input Anti Drop Clamp Input Anti Drop Unclamp Input Auto Home Input External device control combine with Actuator I O Module point 5 Input External device control combine with Actuator I O Module point 6 Output Anti Drop Clamp Output Anti Drop Unclamp PRESET SUB MENU 2 PRESET Preset Feature SUB MENU Configuration List 1 2 3 4 5 6 7 8 I Input Dual Float Mode Input Anti Drop Clamp Input Anti Drop Unclamp Input Auto Home Output Handle Operator Present Sensor Status Output Slack or Down Travel Limit Switch Status ode Anti Drop Clamp PRESET 3 j9o N 9 t1 5 N The e adi device eo rol feature previously on l O5 and 6
106. er Bolt and Coil Cord G360 SHAFT PILOT HOLE Diagram 5H Tooling Installation REMOTE MOUNTED PENDANT HANDLE Diagram 5l Remote Mounted Pendant Handle with Collar Clamp Mounting Bracket Option G Force Q iQ Service Manual Gorbel Inc Step 5E 1320 Ib Inline Slide amp Remote Mounted Handle Installation 5E 1 5E 2 5E 3 5E 4 5E 5 5E 6 5E 7 5E 8 5E 9 With the actuator hanging from rail or other support structure thread the free end of the wire rope through the wear ring bracket and use the supplied hardware to attach the bracket to the actuator Thread the free end of the wire rope through the coil cord assembly so it hangs below the coil cord mounting plate and attach the wear ring bracket using the supplied hardware diagram 5J Insert Turck connector on coil cord into mating connector on the underside of the actuator Grab the free end of the wire rope and loop it up towards the underside of the actuator ensuring there are no twists or kinks in the rope Feed the U bolt through the wire rope thimble and insert the U bolt into the appropriate holes in the reinforcement plate Using supplied hexnuts securely tighten U bolt to the plate diagram 5K Attach the plate to the underside of the actuator using the supplied cap screws lockwashers and spacers as shown and ensure hardware is now completely tightened If an air hose is being installed leave hardware loose for now Whil
107. erated when system attempts to program the load cell coefficient as commanded through PROGRAM MODE CONFIGUR MENU CALIBRAT LOD COEF and resulted in an invalid setting number Reaction Handle LCD displays the warning while unit is allowed to continue to run The invalid coefficient is cleared and all previously programmed weights for Q and iQ features are reset Cause Remedy Load cell calibration procedure composed of three steps 1 zero the empty handle and any clevis or hook 2 pick up a maximum capacity with and set the load cell coefficient and 3 set unit in stack and set a true zero weight This error is generated when performing 2 The possible causes can be a Step 1 is not correctly performed with an empty handle b The pickup weight does not match the rated capacity c The programming sequences are not followed correctly d Problem with the load cell electronics This may include a damaged load cell loose load cell cable connection to the actuator main interface board or to the servo drive 7 19 7 11 G Force Q iQ Service Manual Gorbel Inc Error 10405 WARN_PROG_OVER_RANGE_LOADCELL_BIAS Description The sampled minimum load cell signal bias is greater than the acceptable range from the normal bias value for this unit The acceptable range of this parameter is empirically determined and selected for different models and capacities Reaction Handle LCD displays the warning while unit is allowed
108. etain Existing Configurations option to clear the faulty memory and retain the latest configuration settings e g if unit configured for Float Mode and Q iQ feature settings e g virtual limit positions For custom iQ units all custom feature settings such as position or weight settings are not retained and are reset to default settings as specified for the unit Error 113 ERROR_SAVE_UNIT_OBJ_FREE Description Prior to saving the current unit specific configuration setting into memory an error has occurred while determining the available free memory space to store into PLC Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Retain Existing Configurations option to clear the faulty memory and retain the latest configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions For custom iQ units all custom feature settings such as position or weight settings are not retained and are reset to default settings as specified for the unit Error 114 ERROR_SAVE_UNIT_OBJ_CLEAR Description Prior to saving the current unit specific configuration setting into memory the program found limited memory space available for storage A clear memory command is executed but an error is returned
109. g does not negatively affect system performance because overload parameters are set to the minimum allowable settings User can cycle the E stop switch on the handle to clear the warning Error 11008 WARN SLIDE PENDANT TYPE OI MISMATCH Description Slide or pendant handle sends a unique signal to the PLC to differentiate the handle type This error is generated if handle type signal changes from slide to pendant or vice versa while the unit is running Reaction Unit is stopped with a warning display Cause Remedy Replace the slide or pendant handle mother board Command Warnings Custom Motion Control Error 11100 WARN MULTP MOTION REQUEST Description Not Used Reaction Not Used Cause Remedy Not Used Command Warnings Motion Command Watchdog Timer Error 11600 WARN WATCHDOG MOTION Description Not Used Reaction Not Used Cause Remedy Not Used 7 23 7 11 G Force Q iQ Service Manual Gorbel Inc Command Warnings Maintenance Services Error 11700 WARN_REPLACE_WIREROPE_RECOMMEND Description When cycle count and lower limits are set cycle count can increment This warning is triggered if the cycle exceeds 15000 counts Reaction N A Cause Remedy This is a warning indicator to check wire rope condition under the most severe operating conditions for signs of wear and tear and it can vary based on the actual usage Please examine the wire rope and replace if necessary After replacement activate Program M
110. general corrosion broken or cut strands number distribution and type of visible broken wires see next section on rope replacement When such damage is discovered the rope shall either be removed from service or given an inspection as detailed in the next section Periodic Inspection The inspection frequency shall be determined by a qualified person and shall be based on such factors as expected rope life as determined by experience on the particular installation or similar installations severity of environment percentage to capacity lifts frequency rates of operation and exposure to shock loads Inspections need not be at equal calendar intervals and should be more frequent as the rope approaches the end of its useful life A designated person shall perform periodic inspections This inspection shall cover the entire length of rope The individual outer wires in the strands of the rope shall be visible to this person during the inspection Any deterioration resulting in appreciable loss of original strength such as described below shall be noted and determination shall be made as to whether further use of the rope would constitute a hazard points listed in previous section on frequent inspection reduction of rope diameter below nominal diameter due to loss of core support internal or external corrosion or wear of outside wires severely corroded or broken wires at end connections severely corroded cracked ben
111. gram 5 Handle Base Bracket Removal and Replacement 10 57 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 6A Rear Cover Removal a Remove handle base bracket Refer to Procedure 5A b Remove the 6 M3 button head cap screws BHCS and 6 M3 lockwashers that secure the rear cover c Remove rear cover and rear cover gasket Procedure 6B Rear Cover Replacement a Position rear cover gasket and rear cover on pendant handle assembly b Install the 6 M3 button head cap screws BHCS and 6 M3 lockwashers that secure the rear cover c Install handle base bracket Refer to Procedure 5B Rear Cover Gasket 74311 Rear Cover 74310 Pd E 6x Lockwasher M3 ZNPL 65051 6x BHCS M3 x 8mm Lg 65080 Note Numbers in Parentheses are Gorbel Part Numbers Diagram 6 Rear Cover Removal and Replacement 7 11 10 58 G Force Q iQ Service Manual Gorbel Inc Procedure 7A Pendant Mother and Pendant Daughter Board Removal a Remove handle base bracket Refer to Procedure 5A b Remove the rear cover Refer to Procedure 6A c Remove the external nuts from the pendant daughter board d Remove the 2 M3 button head cap screws BHCS and 2 M3 starwashers from the pendant mother board e Slide the pendant mother and daughter boards out from the pendant handle body Procedure 7B Pendant Mother and Pendant Daughter Board Replacement a Slide the pendant mother and daughter board
112. gram 5 Main PCB Removal and Replacement 10 10 G Force Q iQ Service Manual Gorbel Inc Procedure 6A Cooling Fan Removal a Turn power off by disconnecting AC power to the system b Remove rear cover Refer to Procedure 2A c Unplug connector from cable assembly d Remove 4 M4 button head cap screws BHCS and M4 lockwashers and remove cooling fan Procedure 6B Cooling Fan Replacement a Position cooling fan on underside of CPU power supply mounting bracket b Install 4 M4 button head cap screws BHCS and M4 lockwashers c Connect cable assembly d Install rear cover Refer to Procedure 2B e Restore AC power to the system Note Numbers in Parentheses are Gorbel Part Numbers Cooling Fan 78815 4x Lockwasher M4 ZNPL 65052 4x BHCS M4 x 25mm Lg All 660 Ib 300 kg models and certain 65015 150 Ib 75 kg and 330 Ib 150 kg models Diagram 6 Cooling Fan Removal and Replacement 10 11 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 7A ACOPOS Support Bracket amp ACOPOS Servo Drive Removal Note If only the ACOPOS servo drive needs to be removed it will not be necessary to perform all the following steps Perform steps a b e f g and j only a b C Turn power off by disconnecting AC power to the system Remove front cover Refer to Procedure 1A Remove electrical shield Refer to Procedure 4A Remove main PCB Refer to Procedure 5A Re
113. gram Mode Note The warning is cleared through Program Mode or cycling the power or E stop if the warning is not repetitive 3 ACOPOS Drive fault describes faults detected in the drive that result in a shutdown and a drive fault message displayed on the LCD screen The recovery from these may require the cycling off on of the E stop switch or AC power source Note The latter must be done by disconnecting the AC power cord using an electrical disconnect device or a circuit breaker It is also possible that the fault clearance may require a more specific corrective action such as reloading system software see Chapter 6 replacing the wire rope checking certain external input output modules or some other service related task If necessary check with your Gorbel distributor or contact Gorbel Inside Sales at 800 821 0086 for assistance Q iQ Unit Fault Error Warning Categories Command Faults These are faults detected by the PLC while executing a command and will result in unit shutdown with the command fault message on the LCD Non Motion Watchdog Timer Command Warnings Allows unit to continue to operate with warning message on the LCD the whole time until the warning is cleared through processed steps such as clearing the cycle counts through Program Mode Sub Catego Warning Examples 1 Process and Display Mode Multiple processes controlling LCD displays 2 Other Status PLC battery low power 3 Non Motion Watchdog
114. he G Force All tooling related questions should be directed to the tooling manufacturer or supplier 3 9 7 11 G Force Q iQ Service Manual Gorbel Inc Step 8 Float Mode and Final Steps m TIP Gorbel Inside Sales is available from 7am to 7pm Eastern Time Monday Thursday and 7am to 5pm Eastern Time Friday 8 1 Float Mode may be activated by simply pressing the G Force logo button on the left hand side of ELGAYTINDICAT ORD L pi the handle diagram 8A Below is a simple exercise to practice if you are not familiar with the Bees CO RON Float feature This exercise assumes an in line FLOAT MODE OPTION slide handle is being used A Grasp the handle grip and lift an object Diagram 8A Float Mode Button Slide Handle weighing at least 20 Ibs 9 kg toa comfortable height in front of you B Let go the of the handle grip C Press the G Force logo button on the handle Note Do not hold onto the load Applying an upward or downward force on the handle or load while initiating Float Mode will give the unit a false reading and cause excessive drift D After Float Mode is initialized the blue LED light will turn on and the handle with payload should not be moving The LCD will display RUN MODE FLOAT E Now grasp the load F To move the load down put vertical pressure on the load downward towards the floor To move the load up lift up on the load towards the ceiling Note The direction and s
115. he system Remove rear cover Refer to Procedure 2A Remove resolver and motor power cables from motor set Disconnect slack spring from slack spring bracket Remove 4 M6 socket head cap screws SHCS and 4 M6 lockwashers from motor set Carefully pry motor set away from gearbox assembly Procedure 11B Motor Set Replacement a Align key on motor set shaft with gearbox assembly and push motor set into gearbox assembly with mounting holes properly aligned Position slack spring bracket on left side of motor set and secure motor set with 4 M6 socket head cap screws SHCS and 4 M6 lockwashers Note Do not tighten hardware completely until all 4 screws have been installed and are hand tight Connect slack spring to slack spring bracket Connect resolver and motor power cables to motor set Reinstall rear cover Refer to Procedure 2B Restore AC power to the system Note Numbers in Parentheses are Gorbel amp Part Numbers 4x SHCS M6 x 25mm Lg 65028 4x Lockwasher M6 ZNPL 00370 Slack Spring Bracket 79211 36 Frame Motor Set 78560 Diagram 11A 165 Ib 75 kg Motor Set Removal and Replacement 10 17 7 11 G Force Q iQ Service Manual Gorbel Inc Hex Nut M8 65101 To be used as Spacer Slack Spring Bracket 79211 SHCS M6 x 40mm Lg 65033 37 Frame Motor Set 78561 4x Lockwasher M6 ZNPL 00370 Note Numbers in 3x SHCS M6 x 25mm Lg Parentheses are 65028 Gorbel
116. ice Manual Gorbel Inc ACOPOS Servo Drive 110 230 VAC 1 Phase Notes Numbers li 78550 includes 78551 78552 78553 Parentheses are Gorbel Part Numbers Ground Warning Label AC110 Card 78551 77072 AC122 Card 78552 AC131 Card 78553 Te PCB ACOPOS Support Bracket Assy 79218 3x Nylock Nut M6 ZNPL 65090 AT N 6x Lockwasher M5 High Collar 65062 6x SHCS M5 x 12mm Lg 65002 ACOPOS Pivot Bracket 79215 Diagram 7 ACOPOS and Support Bracket Removal and Replacement 10 13 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 8A CPU Assembly Removal a Turn power off by disconnecting AC power to the system b Remove rear cover Refer to Procedure 2A c Disconnect 3 cable assemblies from the CPU d If this is an iQ model it may be necessary to disconnect any I O wiring from the I O module e Remove 2 Phillips head screws and lift CPU off mounting bracket Procedure 8B CPU Assembly Replacement a Position CPU on mounting bracket b Install 2 Phillips head screws c Connect 3 cable assemblies to CPU and any l O wiring if necessary d Reinstall rear cover Refer to Procedure 2B e Restore AC power to the system Note Numbers in Slack Spring Parentheses are ae 2 79237 Gorbel Part Numbers aO S O Slack Spring Eye Bolt wh WAY 79210 Nylock Nut M6 ZNPL 65090 Hexnut M6 ZNPL 01764 Power Supply 150W 78811 5x Fla
117. ify which Q iQ feature contains the faulty setting Use the VB Configurator program not yet available as of July 2010 to correct the false setting b Run the Gorbel supplied installation CD i e Gorbel amp G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 323 ERROR_OUTPUT_CONFIGURATION_OUT_OF_BOUND Description At startup found a Q iQ feature input channel configuration setting is outside the allowable range Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy a Use the extended error index number to identify which Q iQ feature contains the faulty setting Use the VB Configurator program not yet available as of July 2010 to correct the false setting b Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 324 ERROR_FALSE_SETTING_CUS_MULTIPLE_VL_SETS Description
118. ine adjustment can be done using a diagnostic procedure after the handle is completely reassembled and power is applied to the system Refer to Chapter 5 SERVICE MENU SRV MENU ACT DIAG for this diagnostic b Replace the housing sub assembly Refer to Procedure 3B c Replace the swivel or remote mount cap sub assembly Refer to Procedure 1B or 2B 10 45 7 11 G Force Q iQ Service Manual 2x Lockwasher M16 ZNPL _ 00212 Housing Sub Assembly 74247174248 Grip amp Shaft Sub Assembly 74245 2x HHCS M16 x 2 33mm CL 8 8 Gorbel Inc Note Numbers in Parentheses are Gorbel Part Numbers 74230 ___ 2x Flatwasher M16 ZNPL 01310 Remote Mount Cap Sub Assembly 74252 see inset Handle Transducer Sub Assembly 74246 Remote Mount Slide Handle Cover 74224 Hex Standoff 6mm x 12mm PN M SHSS M6 x 1 8 PCB Slide Auxiliary Out 65099 y 74233 b N PHMS M3x0 5 20 ZNPL 65082 M Lockwasher M3 ZNPL 65051 Connector Nut Diagram 5 Handle Transducer Sub Assembly Removal and Replacement 7 11 10 46 G Force Q iQ Service Manual Gorbel Inc Procedure 6A Handle Grip and Shaft Assembly Disassembly a b C d e f g Remove the spring pin from the hex jam nut and handle shaft Remove the hex ham nut from the handle shaft Slide the spring sleeve up over the top portion of the handle shaft Slide the first bearing sleeve up
119. ing is pressed into the swivel casting Procedure 2B Swivel Sub Assembly Reassembly Procedure a b Press the bearing into the swivel casting Install the primary slip ring PCB into the swivel casting by installing the input connector nut 3 M2 Phillips head machine screws PHMS 4 nylon Phillips head machine screws PHMS and 12 flatwashers Install the secondary slip ring PCB into the swivel casting Be very careful to not deform the contacts on the PCB Install the Delrin spacer washer onto the swivel sub assembly Install the C ring onto the swivel sub assembly Check to see that the assembly moves freely Install the swivel sub assembly into the G360 assembly Refer to Procedure 1B 10 77 7 11 G Force Q iQ Service Manual Note Numbers in Parentheses are Gorbel Part Numbers Slide Handle Swivel 74206 Input Connector Nut PCB Slip Ring Secondary _ 74236 C Ring 31 75mm _ 65074 Gorbel Inc Ball Bearing 6005 NSE 74221 _ PCB Slip Ring Primary 74235 ____ 3x PHMS M2 x 0 4 6 SEMS Split Lock 65073 4x Nylon PHMS and Flatwashers ____ Washer Spacer Delrin 74218 Diagram 2 Swivel Sub Assembly Disassembly and Reassembly 7 11 10 78 G Force Q iQ Service Manual Gorbel Inc Note Numbers in Parentheses are Suspended Pendant Swivel Assembly Shaft Gorbel Part Numbers 74290 Sleeve Clevis Suspended Pendan
120. installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 204 ERROR_HW_MISMATCH_PLC_MODULE Description At startup found the identified modules for CP474 PLC model do not match the known modules for this controller Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy a Confirm the adapter module AF101 and the digital IO module DO435 are installed with the CP474 controller b If AF101 and DO435 modules are present either one of them can be at fault Replace as necessary Error 205 ERROR_HW_MISMATCH_DRIVE OBSOLETE Description At startup found an unknown ACOPOS drive Reaction N A Cause Remedy Please contact Gorbel Inside Sales at 800 821 0086 or 585 924 6262 Error 206 ERROR_HW_MISMATCH_DRIVE_MODULE Description At startup found the identified ACOPOS plug in modules do not match the known models for this system Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy The designed plug in modules are AC110 AC122 and AC131 If this error occurs a At least one unknown module is installed
121. into the PLC Note Due to incorrect software installation earlier the stored feature configurations may be faulty Therefore it is also recommended to choose the Reset Factory Default Configurations option when installing the updated software All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default 7 13 7 11 G Force Q iQ Service Manual Gorbel Inc Command Faults Control Parameter Database Error 300 ERROR_MACHINE_STYLE_INVALID Description At startup found the stored configuration setting has an invalid machine style i e G Force Easy Arm etc value Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy A critical configuration setting of the unit is corrupted and falsely set Please contact Gorbel Customer Service at 800 821 0086 or 585 924 6262 for further instruction Error 301 ERROR_MACHINE_EA_VERSION_INVALID Description At startup found the stored configuration setting has an invalid Easy Arm span and height version value Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy A critical configuration setting of the unit is corrupted and falsely set Please contact Gorbel Customer Service at 800 821 0086 or 585 924 6262 for further instruction Error 302 ERROR_MACHI
122. ions 12 1 7 11
123. is disabled therefore its corresponding outputs on Actuator I O Module I O points 5 and 6 are disabled as well A O Lo V I ji DEFAULT Reset feature assignments back to factory default equivalent to PRESET 2 Indicates this feature is only available on iQ units Additional details are available in the Input Output Functionality section This menu is hidden unless the optional feature is purchased and installed Two 2 virtual limit sets are available with a standard iQ unit More virtual limit sets are possible with custom programming The minimum distance between any two Virtual Limits is 1 1 2 1 4 and 1 8 for any 75Kg 150Kg 300Kg and 600Kg actuators correspondingly with the exception that the gap between the Upper and Lower Virtual Limits must be greater than 1 The motion control position accuracy to any Virtual Limit is as follows 1 4 for G Force amp Easy Arm G Jib 150Kg 1 16 for G JibTM 300Kg 1 8 for G Force 300Kg 1 16 for G Force amp 600Kg Note that the actual total accuracy is motion control accuracy plus any mechanical component accuracy constraints For example if mechanical component accuracy is 1 4 the total cumulated accuracy is 1 2 for G Force amp 75Kg unit Chart 4 continued from pages 5 7 thru 5 10 Program Mode Menu and Selection 5 11 7 11 G Force Q iQ Service Manual Gorbel Inc Active Diagnostic Mode Messages Button Switch or Sensor LCD D
124. isplay Message Iternately displays 1 FLOAT BUTTON 2 WEIGHT NNN LBS Weight Readout Value 3 SIGNAL NNNNN Actual Load Cell Signal Iternately displays 1 HANDLE SWITCH 2 STROKE NNN MAX Handle Position to Maximum Stroke 3 SIGNAL NNNNN Actual Handle Position Signal HANDLE N AUX INPUT Handle Controller Auxiliary Input N is the handle number in a multi handle controller application e g 1 or 2 Chart 5 Standard Diagnostic Mode Messages G Force amp Logo Button Float Mode Operator Present Switch Button Switch or Sensor LCD Display Message Alternately displays 1 FLOAT BUTTON 2 WEIGHT NNN LBS Weight Readout Value 3 SIGNAL NNNNN Actual Load Cell Signal Iternately displays 1 HANDLE SWITCH 2 STROKE NNN MAX Handle Position to Maximum Stroke SIGNAL NNNNN Actual Handle Position Signal Handle Controller Auxiliary Input N is the handle number in a multi handle controller application e g 1 or 2 Upper Limit Switc Actuator 1 Leader TRAV LMT Actuator 2 Follower TRAV LMT ower Limit or Slack Switc Actuator 1 Leader DN1 TRAV LMT Actuator 2 Follower DN2 TRAV LMT oth Limit Switches Actuator 1 Leader UP1 DN1 TRAV LMT Actuator 2 Follower UP2 DN2 TRAV LMT og Up Button Actuator 1 Leader UP1 JOG SWTH Actuator 2 Follower UP2 JOG SWTH og Down Button Actuator 1 Leader DN1 JOG SWTH Actuator 2 Follower DN2 JOG SWTH Both Jog Buttons Actuator 1 Leader UP1 DN1 JOG SWTH Actu
125. ity of personal injury to the operator and those working in the area or damage to property equipment or material than being familiar with the equipment and using Safe Operating Practices Hoists trolleys are designed for lifting and transporting of material only Under no circumstances either during initial installation or in any other use should the hoist be used for lifting or transporting personnel No operator should be permitted to use the equipment that is not familiar with its operation is not physically or mentally fit or has not been schooled in safe operating practices The misuse of hoists can lead to certain hazards which cannot be protected against by mechanical means hazards which can only be avoided by the exercise of intelligence care and common sense Safe Operating Practices also involve a program of periodic inspection and preventative maintenance covered in a separate section Part of the operator s training should be an awareness of potential malfunctions hazards requiring adjustments or repairs and bringing these to the attention of supervision for corrective action Supervision and management also have an important role to play in any safety program by ensuring that a maintenance schedule is adhered to and that the equipment provided for the operators is suitable for the job intended without violation of one or more of the rules covering safe operating practices and good common sense The Safe Operati
126. ker device Follow Actuator Procedure 2A on page 10 4 to remove the rear cover Locate the battery cover of the CPU Q Model iQ Model Touch the mounting rail or ground connection not the power supply in order to discharge any electrostatic charge from your body 10 81 7 11 G Force Q iQ Service Manual Gorbel Inc g Remove the cover from the lithium battery holder using a screwdriver h Remove the battery from the holder by pulling the removal strip don t use insulated tools because of the risk of short circuiting The battery should not be held by its edges Insulated tweezers may also be used for removing the battery Correct Incorrect i Insert the new battery with correct polarity The removal strip should be pulled to the right of the battery holder and the side of the battery should be facing left In order to be able to remove the battery again in the future the removal strip must be on the right side of the battery Removal Strip Lithium Battery j Now wrap the end of the removal strip over the top of the battery and insert it underneath the battery so that it does not protrude from the battery holder k Replace cover Insert the lower edge of the cover in the battery holder opening Press the upper end of the cover home firmly Note Lithium batteries are considered hazardous waste Used batteries should be disposed of accordingly 7 11 10 82 G Force Q iQ Service Manual
127. lded 78622 Hex Jam Nut M12x1 75 ZNPL 65064 2x BHCS M4 x 0 7 x 16 Lg 65068 2x Strain Relief Clamp 74232 Plug Air DN8 1 4 NPT 74241 Coil Cord Footer 74205 Clevis Bolt 74222 Diagram 4 165 Ib 75 kg and 330 Ib 150 kg Double Length Coil Cord Assembly G FORCE COILCORD EXT ASSEMBLY For replacement of entire Coil Cord Assembly use part name G FORCE COILCORD EXT ASSEMBLY 7 11 10 70 G Force Q iQ Service Manual Gorbel Inc Drawing Not To Scale 48 gt 12 gt Compressed Coil Male X Pendant Cable 74324 This cord is intended to stretch from 48 to 114 Pendant Cable Electrical Portion Only G FORCE PENDANT CABLE For replacement of entire Cable Assembly use part name G FORCE PENDANT CABLE 10 71 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 3 Standard Air Hose Assembly G FORCE AIRHOSE ASSEMBLY Note Numbers in Parentheses are Gorbel Part Numbers 2x Strain Relief Clamp 65105 2x Adapter DN8 1 4 NPT 74238 x 238 15 z 82x Nylon Air Hose Coiled CENTER A 74237 TO CENTER Hose Swivel 90 DN8 1 4 NPT 74243 Diagram 5 Standard Air Hose Assembly G FORCE AIRHOSE ASSEMBLY For replacement of entire Airhose Assembly use part name G FORCE AIRHOSE ASSEMBLY 7 11 10 72 G Force Q iQ Service Manual Gorbel Inc Procedure 4 Extended Length Air Hose Assembly G FORCE
128. le section Install the M12 hex head cap screw HHCS and M12 lockwasher that secure the load cell to the main middle section Connect the load cell cable connector J4 on the main PCB and secure the cable with the corresponding clamp Install the front cover Refer to Procedure 1B Install the rear cover Refer to Procedure 2B Restore AC power to the system f you are replacing the load cell you will have to perform specific load cell diagnostic procedures described in the Configuration Menu Contact Gorbel Customer Service Support for assistance 10 21 7 11 G Force Q iQ Service Manual HHCS M12 x 25mm Lg 65022 Lockwasher M12 ZNPL 00206 Load Cell 165 75kg Capacity 78806 Load Cell Pin 76763 Note Numbers in Parentheses are Gorbel Part Numbers Gorbel Inc Cord Connector 76505 Threaded Plug 77860 75 KG IQ CERTIFIED Hex Socket Plug 1 2 NPT 65089 Cord Connector 77861 75 KG Q CERTIFIED Diagram 13A 165 Ib 75 kg Q and iQ Load Cell Removal and Replacement 7 11 10 22 G Force Q iQ Service Manual HHCS M12 x 25mm Lg 65022 Lockwasher M12 ZNPL 00206 Load Cell Pin 76763 Load Cell 660 300 kg 74014 Load Cell 330 150 kg 150 300 KG IQ 78807 Note Numbers in Parentheses are Gorbel amp Part Numbers Gorbel Inc Cord Connector 76505 Threaded Plug 77860 150 300 KG IQ CERT Cord Connector 77861 Hex
129. lease contact Gorbel Customer Service at 800 821 0086 or 585 924 6262 for replacement battery When the battery is replaced any unsaved configuration or Q iQ feature settings are lost and revert back to the last saved or factory configured settings Be sure to follow the instructions prior to taking out the battery 2 Replace the battery as soon as possible When the battery power has depleted any unsaved settings are lost when the power to the unit is recycled and unit uploads the last saved or factory configured settings upon power up Error 10501 WARN_MAX_NUM_RECORDING_REACHED OBSOLETE Description Not Used Reaction Not Used Cause Remedy Not Used Command Warnings Non Motion Watchdog Timer Error 10600 WARN_WATCHDOG_NON_MOTION Description Not Used Reaction Not Used Cause Remedy Not Used Command Warnings Motion Control Error 11000 WARN_BOTH_TRAVEL_LIMITS_ENGAGED Description Both the upper and lower travel limit switches are engaged at motion startup i e handle pendant float mode etc This warning can only trigger after the unit has powered up and is different from error 501 Reaction Motion not started and handle display warning on the LCD Cause Remedy a If both the upper and slack switches are engaged pull down on the wire rope to remove slack and recycle power on the unit b Check for any mechanical binding that could engage both the upper and lower limit switches or upper limit and
130. left side of the block when placed in the orientation as shown in the diagram The running software version can be checked through DISPLAY SYS INFO selection under SERVICE MENU in PROGRAM MODE Diagram 5 Handle Input Output Block 5 15 7 11 G Force Q iQ Service Manual Gorbel Inc Chapter 6 Software Update Gorbel G Force Q iQ units are shipped out of the factory with the latest released software The software will be continuously improved by adding new Q or iQ features expanded feature capabilities bug fixes or even a new product line When a software update or a standard release version is ready it can be deployed into an existing unit with the Gorbel Q iQ Update Utility program The program can connect to the unit retrieve and store its current settings upload the new software version and restore the original settings This program MUST BE used to update the software for the users and followed through properly Any alternative method may corrupt the unit configuration and result in an inoperable unit Gorbel G Force Software Update Instructions The following instructions pertain to running the Gorbel Q iQ Update Utility for Gorbel G Force units Installation Upon insertion of the CD the installation program should start automatically If it does not navigate to the CD in Windows Explorer and run the program called GorbelUpdate msi At this point if you do not have the NET 2 0 Framework installed on your co
131. ll motion Diagram 1 Actuator Controls Interface Display as viewed from control from a handle or tooling bottom of actuator WARNING The jog switch buttons are for system maintenance and load testing use only and should not be manipulated during normal operation of the G Forcee Operation of the jog switch buttons during normal operation increases the risk of personal injury to the operator Service Mode This operation mode is similar to the safe mode of a PC In this state all handle motion control and Q amp iQ custom features are disabled all digital outputs are turned off and only basic jog up jog down LCD display and safety program mode are available It allows a minimum safe operation on a unit with a damaged handle broken I O electronics or other damaged peripheral control components that would make it dangerous to run the unit if the component is used The unit is still inoperative if actuator components such as the drive motor or jog switches are damaged To activate service mode with the handle E stop pushbutton released and the LCD screen displaying LIFT READY press and hold both jog pushbuttons on the actuator for ten seconds Both the blue and red LEDs flash once per second and the LCD displays SERVICE MODE when the operation mode is ready Communications Connector This connector is the communications port for the G Force amp With the program kit option provided by Gorbel users may connect to the G Force am
132. llation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Command Faults Hardware ID Error 200 ERROR_HW_ID_PLC_QUERY Description An error has occurred while identifying the PLC type and connected add on modules if any Reaction N A Cause Remedy a Check if a PLC model CP470 or CP474 is properly installed If CP474 is used check if the other expansion cards such as DO435 are correctly attached b Run the Gorbel supplied installation CD i e Gorbel amp G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 201 ERROR HW ID EXCESS PLC MODULE Description The PLC has identified more add on modules than the maximum limit of 5 Reaction N A Cause Remedy a Check if PLC model CP470 has any add on modules Check if PLC model CP474 has a DO435 add on module Reboot the unit Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and
133. ma GORBEL service A C LA S S AB OVE G Forcee Gorbel Dealer Gorbel Customer Order No Serial No Date Month Year G Force Q iQ Service Manual Index Page Chapter 1 Safe Hoist Operating Guidelines lille 1 1 Chapter 2 Technical Specifications kk kK KK KK KK eee eee eee 2 1 Chapter 3 Installation Procedure e Step 1 Unpacking the G Force 0 KK KK KK KK KS 3 1 e Step 2 Pre Assembly Tools Required 0 05 3 1 e Step 3 Actuator Assembly Installation 000 3 1 e Step 4 Coil Cord Installation 000 0 ees 3 2 e Step 5 Handle Installation webs KK RR RR RR RR tme KK 3 3 e Step 6 Electrical Power Connection 0000 eee eee 3 9 e Step7 Initial Power Up oi as kk kK KK KK KK KRI aX ARS 3 9 e Step 8 Float Mode and Final Steps kk kK KK KK RR RR KK 3 10 e Step 9 Expansion I O Block Mounting Instructions Option 3 12 Chapter 4 Removal Procedure KK KK KIRI K KK KI K KI KIRI KK KIR KK 4 1 Chapter 5 Control and Programming e Controls Interface Features kk kk kk KK KK gn Rn 5 1 e Program Mode Overview kk ra D kk kk KK KK KK KK KK KK lea EP 5 2 e iQ Actuator Input Output Module Functionality 5 14 e Expansion 8 Point Input Output Block Functionality 5 15 Chapter 6 Software Update kK KK KK KK KK KK KK ee 6 1
134. move 2 M5 button head cap screws BHCS and M5 lockwashers from top portion of PCB ACOPOS support bracket Remove 2 M5 button head cap screws BHCS and M5 lockwashers from lower portion of support bracket Disconnect all external cable assemblies from the ACOPOS drive Remove 2 M6 nylock nuts from hinge pins Lift PCB ACOPOS support bracket with ACOPOS drive still attached off hinge bracket Separate the ACOPOS servo drive from the PCB ACOPOS support bracket assembly by removing the 2 M6 nylock nuts from the underside of the upper portion of the PCB ACOPOS support bracket assembly Procedure 7B ACOPOS Support Bracket amp ACOPOS Servo Drive Replacement a 7 11 Attach ACOPOS servo drive to PCB ACOPOS support bracket with the 2 M6 nylock nuts Position PCB ACOPOS support bracket with ACOPOS servo drive attached onto hinge bracket and install 2 M6 nylock nuts Swing ACOPOS assembly into its normal operating position and install all the cable assemblies to the ACOPOS servo drive Install 2 M5 button head cap screws BHCS and M5 lockwashers into top portion of PCB ACOPOS support bracket Install 2 M5 button head cap screws BHCS and M5 lockwashers into lower portion of PCB ACOPOS support bracket Install main PCB Refer to Procedure 5B Install electrical shield Refer to Procedure 4B Install front cover Refer to Procedure 1B Restore AC power to the system 10 12 G Force Q iQ Serv
135. mputer this is included with most XP and Vista computers you will be prompted to download and install this before proceeding With the NET 2 0 Framework installed you will be prompted to install the Gorbel Q iQ Update Utility on your computer i Gorbel Q iQ Update Utility Welcome to the Gorbel Q iQ Update Utility Setup oF Wizard The installer will guide you through the steps required to install the Gorbel O iQ Update Utility software on your computer WARNING This computer program is protected by copyright law and international treaties Unauthorized duplication or distribution of this program or any portion of it may result in severe civil or criminal penalties and will be prosecuted to the maximum extent possible under the law Cancel 6 1 7 11 G Force Q iQ Service Manual Gorbel Inc Click the Next buttons until the software installation is complete and then click Close at the following screen i Gorbel Q iQ Update Utility Gorbel Q Q Update Utility has been successfully installed Click Close to exit Please use Windows Update to check for any critical updates to the NET Framework Starting the Program Now that the program is installed you may run the program from the icon on your desktop o Gorbel Q iQ Update Utility You may also run the program using the Start Menu from the Gorbel Inc group n Xung eM l x Gorbel Q iQ Update Utility f ri GorbelInc Using the Program
136. n Button until the drum stops and the Wire Rope Retaining Plate is approximately at the 2 3 o clock position as shown in diagram 5 below If the drum does not reach this position when it stops turn the upper allen head screw 1 2 turn counterclockwise with a 5 mm allen head wrench Jog the wire rope up one full turn and repeat the process all over again Caution If the wire rope retaining plate rotates past the 4 o clock position release the Jog Down Button immediately or internal damage may occur Press the Jog Up Button until the drum makes one full rotation and adjust the Lower Limit Switch by turning the upper allen head screw one full turn clockwise Retaining Diagram 5 9 3 7 11 G Force Q iQ Service Manual Gorbel Inc Linear Transducer Adjustment If there is motion drift in the system when the Operator Present Sensor is activated and the handle grip is not moved in either direction the Linear Transducer will need to be adjusted The adjustment can be monitored by using DIAGNOSTIC MODE in the PROGRAM MENU 1 Press and hold the MENU button right side of handle for two seconds to activate Program Mode 2 Release MENU button Both the red and blue LED will illuminate and PROGRAM MODE will be displayed for one second Note If system is equipped with the Virtual Limits Package the VIRTUAL LIMITS menu will appear first 3 Press the MENU button to scroll until you reach the SERVICE MENU Press the G Force log
137. n and set aside Using a 3mm hex wrench remove the 4 button head screws on front cover two on each side of unit Remove front cover from actuator and set aside upward to use as a bowl to hold future parts Note Be careful not to contact circuit board Going in the down direction unspool rope from drum using jog down button while keeping tension on wire rope with other hand wearing a glove Continue until lower limit is engaged Insert a medium sized screwdriver between the white colored wear ring and the actuator black casting where the wire rope exits the actuator right side This will keep the slack switch disengaged while jogging down the remainder of the rope diagram 3A Face the unit with circuit board on your left and wire rope on the right Note The next two steps must be done at the same time g Using a long screwdriver or hex wrench reach through front of actuator and locate upper socket head cap screw head facing you underneath the lower limit switch Fully push the screw in until it cannot move anymore it is spring loaded Keep pressure on it diagram 3B Using your right hand press the jog down button while watching the drum rotate two full turns in the clockwise direction The drum should stop automatically with the wire rope retainer visible in the 3 o clock position on the drum 10 6 Diagram 3A Insert screwdriver between the white wear ring and the actuator casting where the rope exi
138. ng Practices shown are taken in part from the following publications American National Standard Institute ANSI Safety Standards for Cranes Derricks Hoists e ANSI B30 2 Overhead and Gantry Cranes ANSI B30 16 Overhead Hoists Do s and Don ts Safe Operation of Hoists The following are Do s and Don ts for safe operation of overhead hoists A few minutes spent reading these rules can make an operator aware of dangerous practices to avoid and precautions to take for his own safety and the safety of others Frequent examinations and periodic inspections of the equipment as well as a conscientious observance of safety rules may save lives as well as time and money DON TS HOISTS 1 Never lift or transport a load until all personnel are clear and do not transport the load over personnel 2 Do not allow any unqualified personnel to operate hoist 3 Never pick up a load beyond the capacity rating appearing on the hoist Overloading can be caused by jerking as well as by static overload Never carry personnel on the hook or the load Do not operate hoist if you are not physically fit Do not operate hoist to extreme limits of travel of cable without first checking for proper limit switch action Oak 1 1 7 Avoid sharp contact between two hoists or between hoist and end stop 8 Do not tamper with or adjust any parts of the hoist unless specifically authorized to do so 9 Never use the load cable as a sling
139. nnector carefully Some are secured with hardware some are quick disconnect type 7 11 11 4 G Force Q iQ Service Manual Gorbel Inc 14 Servo Drive Heat Sink Clean this area 17 Linear Transducer Position Check the only if the operating environment is Linear Transducer by using the Diagnostic especially dusty Use compressed air and Menu as described in Chapter 9 Adjust safety glasses only if necessary HEAT SINK INSIDE 15 Cooling Fan if equipped Clean this area 18 Trolley Wheels Check for excessive wear if it appears to be dirty Use compressed air and or contamination and safety glasses 16 Sliding Handle The ball bearings on the 19 Crane or supporting structure Check for slide mechanism should be lubricated with wear or excessive contamination inside the white lithium grease Use bridge Check lock washers and other the grease sparingly and hardware for proper tightness wipe any excess off immediately BALL BEARINGS 12 11 5 7 11 G Force Q iQ Service Manual Gorbel Inc Wire Rope Inspection 1 7 11 Frequent Inspection The operator or other designated person should visually inspect all ropes at the start of each shift These visual observations should be concerned with discovering gross damage such as listed below which may be an immediate hazard distortion or the rope such as kinking crushing unstranding birdcaging main strand displacement or core protrusion
140. nother three clicks on the G Force Logo button to access the ENABLE Configuration Menu Standard Diagnostic Mode displays all handle pushbuttons sliding gripper or STANDARD v RR ce pendant lever position load cell weight reading and limit switches status on the DIAGNOSE LCD screen SERVICE iQ Actuator Input Output Module Diagnostic Mode displays the status of the eight MENU LIFT l O configurable inputs and outputs on the LCD screen The inputs statuses are DIAGNOSE displayed in the first screen followed by those for the outputs The I O Point Continued number of the input that measures incoming 24VDC or output that is turned on to provide 24VDC is displayed in each screen as numerical numbers 1 8 Service Menu Maintenance and Service Features Continued y the status of the eight configurable inputs and outputs on the LCD screen The I O BLK1 inputs statuses are displayed in the first screen followed by those for the outputs DIAGNOSE The I O Point number of the input that measures incoming 24VDC or output that is turned on to provide 24VDC is displayed in each screen as numerical numbers 1 8 iQ Unit with Custom or Reconfigured Program Second Expansion Input Output Block Diagnostic Mode displays the status of the eight configurable inputs and I O BLK2 outputs on the LCD screen The inputs statuses are displayed in the first screen DIAGNOSE followed by those for the outputs The I O Point number of the input that
141. nus The LCD will display the corresponding programmable menus e V LIMITS MENU Virtual Limits menu option SPEED MENU Lift Speed adjustment RESPONSE MENU Lift Response acceleration adjustment SETTINGS MENU Programmable Features on both the Q and iQ units e SETTINGS MENU 2 Programmable Features on iQ units only iQ only LED MENU Program the LED lights Q only SERVICE MENU Customize and manage maintenance and service features e CONFIGUR MENU Special unit features and hardware configurations Once you have reached the menu you would like to enter press the G Force logo button 5 The first programmable feature in that menu will be displayed Chart 4 pages 5 7 thru 5 11 displays a full list of all the menus and programmable features under each menu 6 To move to the second programmable feature press the G Force logo button again 7T Note If the MENU button is pressed after Step 4 the selection is cleared and the LCD displays the next program menu 8 Once the desired feature is selected wait three seconds 9 After displaying the feature text for three seconds the request is executed The LCD will flash the feature text several times to indicate the command is being executed 10 After the command is executed the system returns to standard operation and the LCD displays LIFT READY 5 7 11 5 2 G Force Q iQ Service Manual Gorbel Inc Handle Operation Make sure to keep fingers clear of
142. o a second independent set of virtual limits See done the same as the standard chart 3 for instructions on setting each of these limit set but with this input on sets uture expansion no Functionality may be assigned via custom default functionality programming to meet application requirements assigned Contact your Gorbele dealer for more details uture expansion no Functionality may be assigned via custom default functionality programming to meet application requirements assigned Contact your Gorbele dealer for more details uture expansion no Functionality may be assigned via custom default functionality programming to meet application requirements assigned Contact your Gorbele dealer for more details O that input is on output 5 on the iQ actuator input output module is on and vise versa that input is on output 6 on the iQ actuator input output module is on and vise versa based on hours of use and set at the factory and Joutput is in the SERVICE may be used to turn on an external service indicatorIMENU items CLEAR RUN supplied by others TIME or SRV WARN OFF Output Fault indicator Is output turns on when a command fault or drive ault occurs It does not turn on due to a command arning Chart 8 iQ Actuator Input Output Module Standard Functionality Diagram 4 Actuator CPU Input Output Block 7 11 5 14 G Force Q iQ Service Manual Gorbel Inc Expansion 8 Point Input Output Block Functi
143. o button left side of the handle several times until the readout displays SERV MENU ACT DIAG Wait approximately 2 seconds 4 DIAG MODE will appear on the display Block the Operator Present Sensor beam with your hand but do 2mm Allen Wrench not move the slide portion of the ca handle at all 4 5 HANDLE SWITCH STROKE MAX 96 Diagram 6 will appear on the display with a number It should be between 3 and 3 6 To decrease the number on the display turn the LT Adjustment Screw counter clockwise To increase the number on the display turn the LT Adjustment Screw clockwise Use a 2mm Allen head wrench for the adjustment Try increments of one revolution at a time 7 Recheck the number on the display by blocking and unblocking the OPS at least five times 7111 9 4 G Force Q iQ Service Manual Gorbel Inc Slack Spring Adjustment Slack spring adjustment is necessary if one or more of the following conditions apply When wire rope continues to pay out from actuator when end effector handle tooling is being supported and down travel is commanded When slack wire rope deflection exceeds 3 inches when end effector is supported When tooling is added to a G360 assembly When an air line coil hose assembly is added between the end effector and actuator When changing from a pendant handle to a slide handle or vice versa occurs When chatter or erra
144. ockwashers Note Numbers in Parentheses are Gorbel Part Numbers Lever Shaft 67 74314 Green Lever P d 88601 Vs Red Lever 88602 Diagram 3 Lever Shaft Removal and Replacement 10 55 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 4A Lever Removal a Remove either side guard Refer to Procedure ZA b Remove the lever shaft Refer to Procedure 3A c Remove both levers from the pendant handle Procedure 4B Lever Replacement a Position both levers on the pendant handle b Install the lever shaft Refer to Procedure 3B c Install the side guard Refer to Procedure 2B Note Numbers in Parentheses are Gorbel Part Numbers Lever Shaft 67 74314 _Green Lever 88601 Red Lever 88602 Diagram 4 Lever Removal and Replacement 7 11 10 56 G Force Q iQ Service Manual Gorbel Inc Procedure 5A Handle Base Bracket Removal a Disconnect handle base bracket from clamp collar or tooling if necessary b Remove 2 M6 button head cap screws BHCS and 2 M6 lockwashers Procedure 5B Handle Base Bracket Replacement a Install 2 M6 button head cap screws BHCS and 2 M6 lockwashers b Reattach the handle base bracket to clamp collar or tooling if necessary Note Numbers in Parentheses are Gorbel Part Numbers Handle Base Bracket 88401 Rubber Grip 88402 2x Lockwasher M6 ZNPL 03370 2x BHCS M6 x 16mm Lg 7 65075 Dia
145. ode detects load cell signal drops below a minimum level indicating an electronics problem Reaction Handle LCD displays the warning message and Float Mode is terminated Cause Remedy This fault is typically triggered when the load cell cable or signal wire s is disconnected or damaged Check for a loose or damaged load cell cable to the main circuit board in the actuator b loose or damaged intermedium cable P N 78613 to the main circuit board or the load cell analog signal wire s on this cable to the drive c damaged main circuit board for processing the load cell sensor d damaged load cell sensor 7 11 7 22 G Force Q iQ Service Manual Gorbel Inc Error 11006 WARN_UO_EXCEED_MAX_CAPACITY Description This warning is triggered when User Programmable Overload attempts to tare a weight larger than the maximum limit The maximum limit is set at 101 of the rated capacity plus 12 lbs to account for the handle weight Reaction The overloaded tare weight is rejected and the maximum limit is used to set up the overload detection parameters Cause Remedy When TARE OVLD LMT selection from USR OVLD SUB MENU CHANGE OVLD LMT in PROGRAM MODE is selected unit tares the current lifted weight and applies overload settings proportional to this weight This warning is triggered when the lifted weight exceeds the maximum limit To prevent overload limit being set above maximum limit when this error occurs the maximum limit is appli
146. ode with a handle browse to SRV MENU and click to CLEAR COUNT selection to reset the cycle count to 0 Error 11701 WARN_REPLACE_WIREROPE_REQUIRED Description When cycle count and lower limits are set cycle count can increment This warning is triggered if the cycle exceeds 20000 counts Reaction N A Cause Remedy This is a warning indicator to check wire rope condition under the most severe operating conditions when replacement may be necessary and it can vary based on the actual usage Please examine the wire rope and replace if necessary After replacement activate Program Mode with a handle browse to SRV MENU and click to CLEAR COUNT selection to reset the cycle count to 0 Command Warnings Fault Warning Error 11800 WARN_HANDLE_FAULT_NOT_ACTIVE Description Handle digital IO CAN bus controller has triggered a fault and becomes inactive Reaction The digital inputs such as the OPS sensor Menu and Float pushbuttons are disabled Cause Remedy A fault specifically an inactive node can occur if the handle CAN bus controller does not communicate with the PLC correctly and exceeds the allowable wait period of the master node Reboot the unit with the E stop to clear the fault if it is not repetitive Inaccurate communication can result from faulty handle board noise or data corruption in the CAN communication wires or any cut wires Replace the handle coil cord actuator interface board and CAN communication wires in the act
147. oil Cord Once the wire rope coil cord footer and slide handle swivel are aligned replace the 16mm shoulder bolt thereby capturing the wire rope coil cord footer and slide handle diagram 5A 5A 5 5A 6 5A 7 installed 5A 8 Continue to Step 6 on page 3 9 Thread the coil cord connector into the slide handle connector diagram 5A Thread the M12 jam nut onto the 16mm shoulder bolt Check that the coils of the coil cord are centered around the wire rope when properly Step 5B Remote Mounted Slide Handle Installation 5B 1 Ensure the wire rope is still fed through the center of the coil cord Hold the G360 swivel just below the coil cord assembly 5B 2 Center the coil cord footer between the ears of the G360 swivel Note Make sure the fin of the coil cord footer is on the opposite side of the G360 connector 5B 3 Remove the 16mm shoulder bolt from the coil cord footer and wire rope and allow the coil cord footer and wire rope to slide down into the G360 swivel Wire Rope Coil Cord Footer 16 mm Shoulder Bolt M12 Jam Nut COIL CORD HAS BEEN G360 Swivel REMOVED FOR CLARITY STRAIN RELIEF CLAMP MUST BE USED TO PREVENT DAMAGE TO G360 Diagram 5B G360TM Shoulder Bolt and Coil Cord 3 3 7 11 G Force Q iQ Service Manual Gorbel Inc Step 5B Remote Mounted Slide Handle Installation Continued 5B 4 Once the wire rope coil cord footer and G360 swivel are aligned replace the 1
148. om the load plate inside the main middle section Procedure 16B Limit Switch Assembly Replacement a Position the limit switch assembly on the load plate by locating it on the inside M6 button head cap screw BHCS The lower projection of the slide must be engaged in recess in threaded gate Install the M6 button head cap screw BHCS and M6 lockwasher on the outside end of the limit switch assembly Connect the limit switch cable assembly to the main PCB J11 Install the access plug into the main middle section Install the front cover Refer to Procedure 1B Restore AC power to the system 10 33 7111 G Force Q iQ Service Manual Gorbel Inc Note Numbers in Parentheses are Limit Switch Assembly 79259 Gorbel Part Numbers Note Slide limit switch assembly into place on load plate The M6 BHCS will retain one end and the M6 SHCS shown below will retain the other BHCS M6 x 16mm Lg 65075 Lockwasher M6 ZNPL 03370 Diagram 16A 165 Ib 75 kg and 330 Ib 150 kg Limit Switch Assembly Removal and Replacement jean pit Limit Switch Assembly 7650 3 2 79274 Note Slide limit switch into place on load plate The M6 SHCS will retain one end and the M6 BHCS shown below will retain the other BHCS M6 x 16mm Lg 65075 Lockwasher M6 ZNPL 03370 Note Numbers in Parentheses are Gorbel Part Numbers Diagram 16B 660 b 300 kg Limit Switch Assembly Removal and Replacem
149. on ncorrect cable 8 0 Replace with correct cable Operator error Virtual limits set incorrectly eck reset virtual limits able oose or disconnected cable 86 8 4 Reconnect retighten cable connection pomeston o o ACOPOS D ee drive fault to identity cause e g 8 thru 24 ollow the recommended input drive fluctuation remedy for each fault drive overcurrent drive or motor over temperature broken or loose motor cable broken or loose encoder cable P PU P PU locked up In error state 0 15 Replace the P PU failure stop switc e failure gt 0 Q 2 Q 5 e 2 e Col Col Col ZZ j gt a lt 7 11 7 2 G Force Q iQ Service Manual Gorbel Inc unction Possible uspect Component s ocation orrective Action Failure Cause s 5 Opt a U not ption not oadcell not installed inside actuator 0 0 ontact your Gorbel distributor move up or installed or option down in Float oftware not configured 6 eload software Mode oadcell cable Loadcell cable to main PCB 8 4 econnect or replace loadce disconnected or damaged 0adce oadcell s damaged or defective Replace loadce oadacell pin Oaacell pin Is damaged detective epatr replace loadcell pin Handle Pushbutton or switch is broken 60 eplace pushbutton or handle pushbutton imother board able oose or disconnected cable 86 8 4 Repair or replace the cable connection 4 Unit only Handle failure Handle mother board failure 0 Replace slid
150. onality poime AssioredFuncion Deeiplon navigatngandseting menu functions Point navigating and setting menu functions nput Dual load weight W Mode load weights programmed are Float Mode rom one pre aed load weight to another These two located in SERINGS MENU 2 DUAL TOOL WT and eights must remain fixed otherwise some drifting can occur if DUAL FM LOAD WT The desired load weight must be he weight is different than the programmed value w2 from the G Force when performing each nput Anti drop feature Clamp request nput Anti drop feature Unclamp request hen the input is on Output 8 see I O Point 8 turns on only if IMENU 2 ANTIDROP TOOL WT The a Mis Anti Drop algorithm determines i suspended load is at or below including handle controller and other accessories he set weight ANTIDROP TOOL WT If Output 8 turns on ithout a pickup part must be suspended solely by the Output 7 is turned off ire rope when tarring The minimum difference between unloaded and loaded tool weight is 20 Ibs for G Force 25 Ibs for Easy Arm and 25 Ibs for G Jib products nput Auto Home When this input Is toggled momentarily turned on then off again e Auto Home position programming s located at he G Force automatically travels to the set home position in the SETTINGS MENU 2 MENU 2 SET HOME Move the ertical travel Tracking stops when obstruction is detected i e G Force to the desired position in the vertical t
151. op sub assembly from the handle bottom Use caution the ribbon cable and ground wire will still be connected e All the sub assembly internal components can be removed or replaced using the exploded view drawings as a reference Procedure 4B Housing Sub Assembly Reassembly a All the sub assembly internal components can be removed or replaced using the exploded view drawings as a reference b Once all the internal components have been positioned properly slide the handle bumper in place on the handle bottom and join the handle top sub assembly with the handle bottom Make sure the ribbon cable and ground wire are connected properly Install the 4 M5 socket head cap screws SHCS and 4 M5 flatwashers Install the housing sub assembly and swivel or remote cap sub assemblies as required Refer to Procedures 3B and 1B or 2B E Stop Pushbutton Assembly E Stop Body with Nut _ Top Handle Cast 78804 X YE 74208 Emergency Stop Label _ ji 74225 2x Light Pipe N Handle Plug M20 Thread Y 74217 3x PHMS M2x0 4 6 S MS Split Lock 65073 y lt a ESD Ground Wire a E Not Shown Pa 65109 PA 78804 O Ring 10mm ID 1mm Thick di uS op Pushbutton Assembly Slide Mother Board PCB_ 78802 E 7C E Stop Leads with Connector Not Shown Note Numbers in Parentheses are Slide Daughter Board PCB Remote 78808 Gorbel amp Part Numbers Slide Daughter Board PCB CAN 78803 Diagram 4A Housing Su
152. orbel Inc Wire Rope Termination Plate 76545 2x Lockwasher M8 ZNPL 00195 2x SHCS M8 x 25mm Lg 00194 Wire Rope Assembly 79245 Drum Gate Clearance 76510 2x Lockwasher M6 High Collar i 65053 Note Numbers in 2x SHCS M6 x 80 mm Lg l Parentheses are 65031 Gorbel Part Numbers Diagram 14C 660 Ib 300 kg Clearance Drum Gate Removal and Replacement 7 11 10 30 G Force Q iQ Service Manual Gorbel Inc Procedure 15A Drum Cover and Drum Cover Band Removal a b C e Turn power off by disconnecting AC power to the system Remove front cover Refer to Procedure 1A Remove ACOPOS support bracket with electrical shield main PCB and ACOPOS servo drive still attached Disconnect only cable assemblies from the main PCB as necessary Refer to Procedure 7A Remove end support frame Refer to Procedure 12A Remove the drum gate Refer to Procedure 14A Note Use caution during the next step The drum cover band will be in tension f g Remove the 2 M6 socket head cap screws SHCS and 2 M6 lockwashers that secure the drum cover band to the load plate Slide both the drum cover band and drum cover off the drum pulley Procedure 15B Drum Cover and Drum Cover Band Replacement a Position the drum cover band inside the drum cover and slide the assembly over the drum pulley Install the 2 M6 socket head cap screws SHCS and 2 M6 lockwashers for the drum cover
153. ould be situated near the center of the circular opening without any contact Readjust the bracket or replace it d Problem with the load cell electronics This may include a damaged load cell or loose load cell cable connection to the actuator main interface board or to the servo drive e The actuator PCB board which processes the load cell signal may be damaged or out of spec Replace the PCB board Error 10407 WARN_PROG_OVER_RANGE_OVLD_LIMIT OBSOLETE Description One of the calibrated factory overload settings returned from the overload programming sequence is greater than the acceptable range from the normal limit value for this unit The acceptable range of this parameter is empirically determined and selected for different models and capacities Reaction Handle LCD displays the warning while the unit is allowed to continue to run The over range warning indicates the potential error in programming the parameter without altering the value The sample value is still retained Cause Remedy The actuator characteristics are profiled such that while no actuators are expected to be identical the characteristics are expected to be similar within a tolerance range The possible causes of this warning are a The pickup weight does not match the rated capacity b The geartrain mechanism may be exerting excessive drag or binding such that the resultant actuator characteristic is significantly different from the tolerance range Inspect for any
154. p to upload software programs or use the G Force Visual Basic program 5 1 7 11 G Force Q iQ Service Manual Gorbel Inc Program Mode Overview Software Version R1 07 0 Program Mode is used to control and adjust all of the features on the Q and iQ series G Force Before entering Program Mode review the Program Mode Menu outline Chart 4 pages 5 7 through 5 11 M LCD DISPLAY EMERGENCY STOP BUTTON FLOAT INDICATOR LED BLUE j FAULT INDICATOR LED RED EE DEPAY G FORCE LOGO BUTTON G FORCE LOGO BUTTON FLOAT MODE OPTION FLOAT MODE OPTION E MENU BUTTON j M I MENU BUTTON T n PROGRAM MODE FLOAT INDICATOR LED BLUE T b Diagram 2 Slide Handle G Forcee Logo Float Mode MENU NA BK LU and Emergency Stop Buttons and LEDs EMERGENCY STOR BUTTON DOWN LEVER LOWER UP LEVER RAISE Diagram 3 Pendant Handle G Forcee Logo Float Mode MENU and Emergency Stop Buttons and LEDs Entering Program Mode chart 1 page 5 4 1 Press and Hold the MENU button right hand side of handle for two seconds to activate Program Mode 2 After two seconds release the MENU button The red and blue LEDs will illuminate and PROGRAM MODE will be displayed for one second Then the first menu will be displayed e Q unit SPEED MENU default Note If the Virtual Limits Package has been ordered the Virtual Limits Menu V LIMITS will appear first iQ unit V LIMITS MENU 3 Press the MENU button to toggle between me
155. peed of travel is now being controlled by the amount of force that the operator exerts directly onto the load The higher the force exerted on the load the faster the unit moves Note An over speed detection routine checks if Float Mode reaches 90 of the maximum fully loaded lifting speed and shuts the unit down It safely limits the maximum speed of travel in Float Mode G Run the unit up and down several times at least 20 times in each direction to assure proper operation Float Mode should provide a smooth feel CAUTION Actuating the operator present switch while in Float Mode will cause the unit to exit Float H Repeat this exercise until you become comfortable with Float Mode 7 11 3 10 G Force Q iQ Service Manual Gorbel Inc Step 8 Float Mode and Final Steps Continued NEVER remove the load from the G Forcee while still in Float Mode The control system will interpret the removal of the load as operator intent to lift the load Therefore the unit will begin to drift up The speed of the unit drift directly correlates to the weight that was removed from the unit The heavier the weight the faster the unit will travel In Float Mode the live load weight CANNOT be increased or decreased because this will cause unwanted motion Float Mode must be reinitiated each time the weight of the live load is changed If external forces are applied to the load while Float Mode is being initiated the G Forcee will calculate a
156. pter 8 Electrical Schematics Diagram 1 Q Q Block 8 1 7 11 G Force Q iQ Service Manual Gorbel Inc Diagram 2 Q iQ System Schematic 7 11 8 2 Gorbel Inc G Force Q iQ Service Manual ovssZ Aanassy 31avo 1984 AT18W3SSV 318V2 ye82 ATSWASsv 318V29 s0982 AlgWassv 31avo z 982 ATSWASsv 3118V90 11984 AT8W3SSV 318VO 01984 AT18W3SSV 318V2 60982 ATaWassy 318VO 20982 ATSNASSv 318V2 80984 ATaWassy 318VO SJequinN Wed GjieqJos 9Je seseuuaJeg Ul SJOqUInN 9JON Diagram 3 Cable Interconnect 474 CPU and Drive 7 11 8 3 Gorbel Inc G Force Q iQ Service Manual SIOQUINN Wed I9qQJ09 aie seseuuaJeg UI SJequinN 9 ON 1982 A18W3SSV 3 18v29 1299 aosewe 13 s s4 vanszivs o4 oce vanoszve sarya sease fas nszi vo zatia wsewnNuvd oNuvs asna 10984 A18W3SSV 318V29 t0982 A18A3SSV 318V2 0982 ATaWassy 318VO 90982 ATSWASSv 23118V0 80984 AT8A3SSV 318VO 01984 A18WN3SSV 318Vv29 21984 A18W3SSV 318V2 60982 AT18W3SSV 318VO 11982 AT8A3SSV 318V2 20984 AT18W3SSV 318VO 10984 AT18A3SSV 318VO 00984 A18A3SSV 318V2 iQ Actuator PCB tQ Diagram 4 Cable Interconnec 8 4 7 11 G Force Q iQ Service
157. r referencing the iQ feature with the faulty setting Cause Remedy a Use the extended error index number to identify which Q iQ feature contains the faulty setting Use the VB Configurator program not yet available as of July 2010 to correct the false setting b Run the Gorbel supplied installation CD i e Gorbel amp G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configure for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 327 ERROR MISSING OUTPUT CHANNEL Description At startup found an iQ feature is misconfigured specifically a required digital output channel location is missing Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Handle dis plays this command fault followed by and extended error index number referencing the iQ feature with the faulty setting Cause Remedy a Use the extended error index number to identify which Q iQ feature contains the faulty setting Use the VB Configurator program not yet available as of July 2010 to correct the false setting b Run the Gorbel supplied installation CD i e Gorbel amp G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to
158. r virtual limit load must be at desired position for upper limit Virtual Limits ES Program the lower virtual limit load must be at desired position for lower limit IE Men LOWER J Program the lower slow down reduction point load must be at position where Software SLOW DN slow down begins when raising load RESUME will resume normal speed when raising load RESET SPD MENU g SPD 100 RESPONSE Set the lowest handle control response corresponding to about 75 of the highest Lift responsiveness setting Responsiveness RESPONSE HEA Set the medium handle control response corresponding to about 85 of the Acceleration MENU RESIUMT highest responsiveness setting Setting Pun Pun Set the highest handle control responsiveness setting ZERO j i WT DISP Record and tare out the handle weight for weight readout calculation WEIGHT READ ON_ READ OFF DISPLAY j Q amp iQ Custom SETTINGS METRIC Ecos n of the weight readout display between pounds English and kilo Features MENU ENGLISH 9 ns Metri FM SETUP SUB MENU Access Float Mode Configuration Setup Sub Menu SETTINGS Reset above Custom Features i e reset tarred handle weight weight readout off ENABLE R DISABLE Enable or Disable running Float Mode related features such as Standard Float FLOAT MO Mode Remote Mount Float Mode Trigger Dual Float Mode Weights etc SUB MENU FM SETUP juo Float Mode Anti Recoil Configuration Sub Menu Float
159. ravel Q iQ G Force stops at 10 25 lbs depending on unit capacity before selecting the position setting in this menu IS Input controls input 5 on the actuator input output module E used in hen this input is on output 5 on the iQ actuator input output conjunction with module is on and vise versa actuator output 5 is Input controls input 6 on the actuator input output module control used in hen this input is on output 6 on the iQ actuator input output conjunction with module is on and vise versa actuator output 6 is on and remains latched on when the input is released It can be turned off by Input 3 see I O Point 3 indame Control nism of an end effector tooling It turns on when Input 3 see I O Point 3 is on and the Anti Drop algorithm determines the sus pended load is at or below the set weight ANTIDROP TOOL WT If it is not turned on the input can be held momentarily do not hold on indefinitely until the tooling is unloaded then the output is urned on Once the output turns on it remains latched on when he input is released It is always turned off with Input 2 see I O Point 2 G Force must have Float Mode feature enabled for this feature to work Chart 9 Expansion 8 Point Input Output Block WARNING Please be aware that software versions prior to R1 07 0 use I O block model X67BC7321 while those with R1 07 0 and newer require the X67BC7321 1 model The model number can be ound at the
160. red if the tare weight is outside this range Overload Limit is capped at one of these bounds range of the maximum and minimum limits for Overload Limit Clicking the G Force SET LIMIT Logo pushbutton decrements the limit from the maximum down to the minimum one LBS NNNN lb at a time The button can be pressed and held to decrease the count at a faster rate Once the minimum value is reached click the pushbutton to restart from the setup screen otherwise the minum limit is applied after the pushbutton is released Chart 4 continued from page 5 7 amp continued on pages 5 9 thru 5 11 Program Mode Menu and Selection Settings 7 11 5 8 G Force Q iQ Service Manual Gorbel Inc Program Mode Menu LCD Text Feature Description Startup prompt screen displaying the programmed Operating Force Limit Operator s push and pull force is an extra loading to the system especially when Configure AT FORCE handle is mounted on the tooling This sub menu allows one to set a Force Limit to Operating Force CHANGE LBS NNNN account for different user s operating force thus reducing chance of false overload Limit for Moving OP FORCE detection The limit should not be set larger than necessary as it reduces detection a Load in Air capability By default the limit is set at 15 Ibs MEA Set Operating Force Limit to between 5 and 25 Ibs in 1 Ib increments Startup prompt screen displaying the programmed Detection Sensitivity This
161. rentheses are Gorbel Part Numbers _ 2x Bumper G Force Trolley 77320 4x Nylock M6 65090 2x End Axle A0501 24 6x Snap Ring 2001 12 Center Axle A0501 24 C H 1 Note C H 1 is either of 2 holes off center C H 2 is center hole with slot to edge Gorbel Inc 4x HHCS M12 x 30mm Lg 65020 4x Lockwasher M12 ZNPL 00206 2x Spacer 75336 6x Steel Wheel 0501 16 4x Flatwasher M6 65060 4x SHCS M6 x 16mm Lg 00190 Trolley Body 76573 Trolley Components for 500 Series Steel Track Note Numbers in Parentheses are Gorbel amp Part Numbers _ 2x Bumper G Force Trolley 77320 4x Nylock M6 65090 2x End Axle A1001 24 6x Snap Ring 2001 12 Center Axle A0501 24 C H 1 Note C H 1 is either of 2 holes off center C H 2 is center hole with slot to edge 4x HHCS M12 x 30mm Lg 65020 4x Lockwasher M12 ZNPL 00206 6x Aluminum Wheel A0501 16 6x Spacer 77865 4x Flatwasher M6 65060 4x SHCS M6 x 16mm Lg 00190 Trolley Body 76573 Trolley Components for 500 Series Aluminum Track 7 11 G Force Q iQ Service Manual Note Numbers in Parentheses are Gorbel Part Numbers _ 2x Bumper G Force Trolley 77320 4x Nylock M6 65090 2x End Axle A1001 24 6x Snap Ring 2001 12 Center Axle A0501 24 C H 1 Note C H 1 is either of 2 holes off center C H 2 is center hole with slot to edge
162. reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 331 ERROR X67 1 IO MASK SETUP Description At startup unit detects an error while configuring the first X67 spare IO module based on the configuration setting Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy a Use the extended error index number to identify which Q iQ feature contains the faulty setting Use the VB Configurator program not yet available as of July 2010 to correct the false setting b Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 332 ERROR X67 2 IO MASK SETUP Description At startup unit detects an error while configuring the second X67 spare lO module based on the configuration setting Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy a Use the extended error index number to identify which Q iQ feature contains the faulty setting Use the VB Configur
163. rom faulty handle board noise or data corruption in the CAN communication wires or any cut wires Replace the handle coil cord actuator interface board and CAN communication wires in the actuator until the fault is corrected Error 11809 WARN CANIO FAULT Description The CAN bus controller fault checking routine has experienced an error or the detected failed CAN bus board has a node number outside the designed range of the system Reaction N A Cause Remedy In the system application there is an exception fault checking routine on all CAN bus controller boards if the system is running constantly This warning occurs if the routine itself experiences a fault such as unconfigured bus node or even application User should reboot the unit with the E stop to clear the fault if it is not repetitive Similar to other CAN bus controller warnings replace the handle coil cord actuator interface board and CAN communication wires in the actuator until the fault is corrected If the problem cannot be resolved contact Gorbel amp Customer Service at 800 821 0086 or 585 924 6262 for further diagnostic and troubleshooting information 7 11 7 26 G Force Q iQ Service Manual Gorbel Inc Q iQ Unit Command Fault Extended Error List Software Version R1 06 3 Command Extended Error E Fault E S Description Command Fault and Extended Fault Supplement Information Multiple iQ features are configured to use the same digital input chann
164. rror 104 ERROR_SERIAL_NUM_OBJ_CREATE_DUMMY Description A temporary PLC serial number variable is created prior to saving but an error has occurred while the command is executed Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Please contact Gorbel Inside Sales at 800 821 0086 or 585 924 6262 Error 105 ERROR_SERIAL_NUM_OBJ_COPY Description While copying the temporary PLC serial number into memory an error has occurred while the command is executed Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Please contact Gorbel Inside Sales at 800 821 0086 or 585 924 6262 7 11 7 10 G Force Q iQ Service Manual Gorbel Inc Error 110 ERROR_SAVE_UNIT_OBJ_SIZE_MISMATCH Description Prior to saving the current unit specific configuration setting into memory when checking the last stored version with this version they are not compatible Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Retain Existing Configurations option to clear the faulty memory and retain the latest configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit position
165. rruption in the CAN communication wires or any cut wires Replace the handle coil cord actuator interface board and CAN communication wires in the actuator until the fault is corrected Error 11806 WARN SPAREIO FAULT NOT ACTIVE Description An X67 spare IO block CAN bus controller connected to the handle has triggered a fault and become inactive Reaction Standard iQ features operating through this spare IO block are either disabled or outputs turned off Cause Remedy A fault specifically an inactive node can occur if an X67 spare IO block CAN bus controller does not communicate with the PLC correctly and exceeds the allowable wait period of the master node Reboot the unit with the E stop to clear the fault if it is not repetitive Inaccurate communication can result from faulty handle board noise or data corruption in the CAN communication wires or any cut wires Replace the handle coil cord actuator interface board and CAN communication wires in the actuator until the fault is corrected Error 11807 WARN SPAREIO FAULT CAN IO ALARM Description An X67 spare IO block CAN bus controller connected to the handle has triggered an alarm status Additional error information may be available following the warning message Reaction Standard iQ features operating through this spare IO block are either disabled or outputs turned off Cause Remedy A fault specifically a CAN bus alarm can occur if the CAN controller board does not comm
166. s For custom iQ units all custom feature settings such as position or weight settings are not retained and are reset to default settings as specified for the unit Error 111 ERROR_SAVE_UNIT_OBJ_CHECK Description Prior to saving the current unit specific configuration setting into memory an error has occurred when checking if a stored version exists Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Retain Existing Configurations option to clear the faulty memory and retain the latest configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions For custom iQ units all custom feature settings such as position or weight settings are not retained and are reset to default settings as specified for the unit Error 112 ERROR_SAVE_UNIT_OBJ_DELETE Description Prior to saving the current unit specific configuration setting into memory the last stored version is first deleted An error has occurred during the delete command Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and R
167. s are W Gorbel Part Numbers i Note iQ Model Shown Starwasher M4 External Tooth 4x Panduit Push M 65056 Wing Mounts 6 4 mm 76518 A 2x Hex Nut M4 ZNPL 65057 Strain Relief Clamp 65105 Flat Washer M4 ZNPL 65081 3x Panduit Latching Nylock Nut M4 ZNPL Wire Clip 6 4mm 65096 76516 8x Panduit Latching Note Numbers in Wire Clip 9 6mm Parentheses are 76517 Gorbel Part Numbers 10 5 7 11 G Force Q iQ Service Manual Procedure 3A Wire Rope Assembly Removal Gorbel Inc Warning Wire rope replacement is to be performed by qualified maintenance personnel only Make sure the replacement rope is same length and diameter 3 16 or 1 4 as rope 7 11 a currently on actuator unit i Ensure there is no load on handle weighted load hook pendant or end effector ii If using slow down setting clear reset on handle or pendant handle menu screen If using virtual limits clear reset on handle or the pendant handle s menu screen iii Remove end tool Slide handle Using a 19mm socket and ratchet remove the nut from the handle s socket head shoulder screw then use an M8 hex wrench and remove unthread Socket head shoulder screw from handle This will detach it from wire rope thimble Set handle down on bench or table to support it and not stretch coil cord Pendant handle Remove the weighted hook or end effector from rope removing the clip and pi
168. s into the pendant handle body b Install the 2 M3 button head cap screws BHCS and 2 M3 starwashers to secure the pendant mother board inside the pendant handle body c Install the external nuts on the pendant daughter board d Install the rear cover and rear cover gasket Refer to Procedure 6B e Install the handle base bracket Refer to Procedure 5B lt ag PCB Pendant Daughter Board gt 74319 Remote 74304 CAN _ PCB Pendant Mother Board 2 d 74303 2x Starwasher External M3 65084 2x BHCS M3 x 20mm Lg 65009 Note Numbers in Parentheses are Gorbel Part Numbers Diagram 7 Pendant Mother and Daughter Board Removal and Replacement 10 59 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 8A Plunger Assembly Removal a Remove either side guard Refer to Procedure 2A b Remove the lever shaft Refer to Procedure 3A c Remove both levers Refer to Procedure 4A d Remove the M4 button head cap screw BHCS and M4 large OD washer e Slide both plunger assemblies out of pendant handle housing f Remove the plunger springs from plunger assemblies g Remove the plunger tips from plunger assemblies Procedure 8B Plunger Assembly Replacement a Install the plunger tips into the plunger assemblies b Install the plunger springs into the pendant handle housing c Install both plunger assemblies into the pendant handle housing d Install the M4 but
169. safety and for optimum trouble free operation of your G Force jj t YT f Read amp follow all Check Wire Rope for Center G Force over Avoid swinging of load instruction amp warning improper seating twisting the load before lifting or load hook when information on or attached kinking wear or defects a load Do not end traveling with the to the G Forcee before operating or side load G Forcee i 2 Check the coil cord for The operator s hand should Float Mode Press the G Forcee The wire rope should never be improper seating twisting not leave the handle grip at logo button with only the load weight more than 15 out of vertical kinking wear or defects any time the G Forcee is in hanging from unit Applying while the G Forcee is in use The before operating use excluding Float Mode What is Trolley Saddle The distance from bottom of wheels to floor Maximum Trolley Saddle is 14 Do not impact the G Forcee Maximum Trolley Saddle for the The maximum available wire Questions about G Forcee into end stops repeatedly or at G Forcee with standard in line slide rope travel for the G Force is Call your local Gorbele a speed faster than a normal handle is 14 See above drawing 11 For H5 duty cycle the distributor or Gorbele Customer walking pace for Trolley Saddle definition maximum working stroke is 8 Service at 800 821 0086 7 11 1 2 G Force Q iQ Service Manual
170. screw HHCS and M16 Belleville washer from the top of the swivel assembly b Slide the swivel assembly off the top of the handle shaft Procedure 1B Swivel Sub Assembly Replacement a Slide the swivel assembly onto the top of the handle shaft b Install the M16 custom hex head cap screw HHCS and M16 Belleville washer onto the top of the handle shaft Hardware Kit 74251 Note Numbers in see inset Parentheses are Gorbel Part Numbers Swivel Sub Assembly 74249 Housing Sub Assembly Air Extension O Ring 74242 Air Extension Output DN8 1 4 NPT option f 74240 Linear Transducer Sub Assembly 74246 HHCS M16 x 2mm Pitch 2x Collector O Ring with Channel x 74269 74281 Grip amp Shaft Sub Assembly 74245 Flatwasher M16 ZNPL 01310 Belleville Washer M16 Lockwasher M16 ZNPL 65098 00212 Hexnut re APL wT 65063 External Snap Ring 25 4mm Hook Latch Assembly 65069 74199 Diagram 1 In Line Slide Handle Swivel Sub Assembly Removal and Replacement 7 11 10 40 G Force Q iQ Service Manual Gorbel Inc Procedure 2A Remote Mount Cap Sub Assembly Removal Note This procedure assumes the handle has already been removed from a remote mount bracket or similar mounting device a Remove M16 hex head cap screw HHCS flatwasher and lockwasher from the top of the handle assembly b Slide the remote mount cap off the handle shaft Note the orientation of the internal elec
171. select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default If problem persists replace the component b c d o e Error 202 ERROR HW ID DRIVE NOT READY Description At startup 10 seconds after power cycling the system the ACOPOS drive is still not ready for operation Reaction Lift program terminates processing to prevent running with incorrect configuration setup Cause Remedy PLC is not communicating with the ACOPOS drive due to i Loose or disconnected communication CAN cable s in the system ii PLC CAN communication component is not working iii ACOPOS AC110 CAN communication card is not working iv Interface circuit board has bad CAN cabling connection 7 11 7 12 G Force Q iQ Service Manual Gorbel Inc Error 203 ERROR_HW_MISMATCH_PLC Description At startup found the identified PLC model type does not match any of the known models for this system Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Check if the installed PLC controller is of model CP470 or CP474 as labeled on its front cover i Replace the module if an installation error has indeed occurred ii Run the Gorbel supplied
172. slack switches c Check and correct if the limit switch cable is connected to the interface board d Check for bad electrical connection or shorted wires from the switches 7 21 7 11 G Force Q iQ Service Manual Gorbel Inc Error 11001 WARN_UNCONTROLLED_MODE_SWITCH Description The current running control mode RUN MODE is switched to another unexpectedly rather than handled properly such as Float Mode switching to Handle Mode because of grabbing a slide handle Furthermore a slide handle or pendant handle sends a unique signal to the PLC to differentiate the handle type This is further used to check that if a handle is identified as a slide or pendant type but the identifier signal is switched to another type such that a miss matched handle type is detected Reaction Handle LCD displays the warning while unit is allowed to continue to run Cause Remedy When a control mode is started the handle LCD displays the type of RUN MODE the unit is running at e g HANDLE PENDANT or FLOAT MODE a When the handle controller is used if the LCD displays correctly its type i e HANDLE or PENDANT but this error is triggered while the unit is running or the LCD displays the incorrect type at any time that does not match the actual handle type the handle motherboard may be damaged and should be replaced b For all other cases please contact Gorbel Inc to describe the symptoms and if the problem is reoccurring Error 11002
173. startup the default factory configuration setting does not exist in memory This check only takes place when unit specific configuration cannot be found or a deleted factory setting command is performed Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 9 ERROR_UNIT_OBJ_READ Description At startup the retrieval of the stored unit specific or default factory configuration setting in memory is returned with an error Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy Run the Gorbel supplied installation CD i e Gorbel G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Command Faults Supplemental Tools Error 100 ERROR_DUMMY_SERIAL_NUM_OBJ_CHECK Description
174. t Clevis Pin 1 2 Dia 1 1 2 Lg ZNPL Swivel Assembly 74293 l 74292 Cotter Pin Snap Ring Internal 47mm Basic 65086 Ball Bearing 6005 NSE 74221 Snap Ring External 25mm HD 65085 Suspended Pendant Swivel Assembly Housing 74291 Flatwasher M16 ZNPL 01310 Lockwasher M16 ZNPL 00212 Hexnut M16x2 0 ZNPL 65063 Latch Hook Assembly Metric Option 74199 Suspended Pendant Swivel Assembly 10 79 7 11 G Force Q iQ Service Manual Gorbel Inc Removal amp Replacement Procedures CPU BATTERY Procedure 1 Optional Retain Q iQ Custom Feature Settings Q iQ custom feature settings like the programmed weight of the handle tooling for zeroing the weight readout on the handle LCD display programmed positions like the virtual limits etc are temporarily stored in the PLC memory powered by the PLC battery As a result these memories are cleared and reset to default when the battery is replaced Users can reprogram these features to use them again If available an alternative to reprogramming the features is to use the Gorbel amp Q iQ Update Utility Use this utility to save the settings onto a PC then follow Procedure 2 to replace the bat tery Use the utility again to upload the settings from the PC back into the PLC After a power reboot the unit will be back online as before Choose the Replace PLC Battery option in the utility program as shown below More inform
175. t worn or improperly applied end connections Special care should be taken when inspecting sections of rapid deterioration such as the following sections in contact with saddles equalizer sheaves or other sheaves where rope travel is limited Sections of rope at or near terminal ends where corroded or broken wires may protrude sections subject to reverse bends Sections of rope that are normally hidden during visual inspection such as parts passing over sheaves G Force Q iQ Service Manual Gorbel Inc Wire Rope Maintenance 1 Rope should be stored to prevent damage contamination and deterioration 2 Rope shall be unreeled or uncoiled in a manner to avoid kinking of or inducing a twist in the rope 3 Before cutting rope means shall be used to prevent unlaying of the strands 4 During installation care should be observed to avoid dragging of the rope in dirt or around objects that will scrape nick crush or induce sharp bends AUTION Rope should be maintained in a well lubricated condition Gorbel recommends using chain and cable penetrating oil for lubrication Lubricant applied as part of a maintenance program shall be compatible with the original lubricant PreLube 6 Lubricant applied shall be of the type that does not hinder visual inspection Immediately after inspection lubricant shall be applied before rope is returned to service Those sections of rope that are located over sheaves or otherwise
176. t 90 of unit loaded speed SUB MENU Over Force Detection Unit terminates if user s operating force exceeds the maximum force limit or a dropped weight is detected by evaluating the force profile Different from Over Speed Detection unit can run at the maximum Float Mode speed a Maximum force limit defaults at 35 Ibs b A dropped weight profile assumes the operator has both hands off the weight tooling as the unit speeds upward Detection ability may reducer if user attempts to stop the unit or if the tooling swings heavily c If the total lifted weight e g tool and part is less than the maximum force limit Over Speed Detection is applied Float Mode Anti FM ANTI Recoil RECOIL Configuration Setup MX FORCE 45 45 LBS Set Anti Recoil Over Force Detection maximum force limit between 15 and 45 Ibs Unit reset to the default setup according to the configured detection method For DEFAULT example unit configured with Over Force Detection defaults to 35 Ibs maximum SETTINGS force limit dropped weight profile checkup and conditional Over Speed Detection UNLOAD STOP option is turned off for both methods Startup prompt screen when this sub menu is accessed Please activate weight USR OVLD readout while setting an overload limit to ensure that the load cell is properly cali SETUP brated and the desired overload limit is within the acceptable range Please see WEIGHT READ ON under SETTINGS MENU for additional de
177. t Washer M4 ZNPL 65081 5x Lockwasher M4 ZNPL 65052 3x SHCS M4 x 10mm Lg 2x SHCS M4 x 16mm Lg 76304 65018 Q CPU 2003 470 78562 iQ CPU 2004 474 78563 Diagram 8 CPU Assembly Removal and Replacement 7 11 10 14 G Force Q iQ Service Manual Gorbel Inc Procedure 9A Power Supply Removal a Turn power off by disconnecting AC power to the system b Remove rear cover Refer to Procedure 2A c Disconnect input and output wiring from the power supply d Remove 3 M4 socket head cap screws SHCS and 3 M4 lockwashers from bottom of power supply e Slide power supply out of CPU power supply mounting bracket Procedure 9B Power Supply Replacement a Position power supply inside the CPU power supply mounting bracket b Install 3 M4 socket head cap screws SHCS and 3 M4 lockwashers into bottom of power supply c Connect input and output wiring Refer to System Schematic if necessary d Reinstall rear cover Refer to Procedure 2B e Restore AC power to the system Note Numbers in Slack Spring Parentheses are gt EUN 79237 Gorbel Part Numbers 5 fo mos Slack Spring Eye Bolt E NR S 79210 Nylock Nut M6 ZNPL 65090 Hexnut M6 ZNPL 01764 Power Supply 150W 78811 5x Flat Washer M4 ZNPL 65081 5x Lockwasher M4 ZNPL 65052 i 3x SHCS M4 x 10mm Lg 2x SHCS M4 x 16mm Lg 76304 65018 Q CPU 2003 470 78562 iQ CPU 2004 47
178. tails SUB MENU CHANGE NP Program an overload limit OLVD LMT USR OVLD User SUB MENU CHANGE Configure operating force limit for moving a load in air Programmable OP FORCE Overload Setup CHANGE i BS SENSITIV Configure overload detection sensitivity DEFAULT Apply factory default settings Overload limit is set as the maximum limit which is SETTINGS 10196 of the rated capacity plus 12 Ibs to account for a handle weight The operat ing force limit is set at 15 Ibs and detection sensitivity is set to 5 High Startup prompt screen displaying the programmed overload limit User Overload feature adjusts the detection and over limit parameters proportional to programmed Overload Limit The over limit when overload is triggered is at M above the Overload Limit plus the Operating Force Limit see CHANGE OP FORCE section for info An over limit is roughly set at G Force amp 12096 x Overload Limit OP FORCE East Arm 105 x Overload Limit OP FORCE g supported by the wire rope as the Overload Limit This value can be monitored Proaram an CHANGE through the Weight Readout feature without zeroing the reading see SETTINGS g a TARE MENU For G Force and Easy Arm 165 Ib units the maximum limit is 175 Ibs Overload Limit OVLD LMT OVLD LMT CHANGE OVLD LMT For all other capacities the maximum limit is 101 of the rated capacity plus 12 lbs for a handle weight The minumum limit is 25 of the rated capacity A warning is trigge
179. the overall CAN communication Please check the Specific extended fault description for possible corrective actions Note Standard iQ system uses adapter module 1 without any screw in module hereas adapter module 2 or screw in module s may be used on a custom system Setup The error numbers are listed for completeness whereas certain errors do not apply to some components e g S 16904 cannot occur with E 11804 LCD display dle time has passed for designed aigital output module 4352 Adapter module 1 4368 Adapter module 2 Output set even though no output Is defined 4608 Adapter module 1 4624 Adapter module 2 Output level incorrect short circuit on a digital output module 4864 Adapter module 1 4880 Adapter module 2 Idle time has passed for designed analog output module 8448 8467 8448 8451 Screw in module 1 4 on Adapter module 1 8464 8467 Screw in module 1 4 on Adapter module 2 Voltage monitoring has found an error 16384 Adapter module 1 16400 Adapter module 2 rror flag for digital input module set often triggered on spare I O module 16640 Adapter module 1 16656 Adapter module 2 Error flag for digital output module set often triggered on spare I O module 16896 16927 16896 Adapter module 1 16904 16911 I O Channel 1 8 16912 Adapter module 2 16920 16927 I O Channel 1 8 20480 20736 20992 21248 21504 Invalid channel or value 798720 798739 798720 798723 Screw in module 1
180. tic travel down operation occurs when using an unloaded G360 or a weighted hook traveling downward from top of travel up limit spring is too tight Unloaded G360 equipped hoist may encounter this type of operation until tooling is added Slack Spring Adjustment Procedure T 4 Use an M3 hex wrench to remove all screws securing the blue rear cover to actuator Place screws in cover and set aside Locate slack spring over the motor next to casting diagram 7 Spring is held in place by a motor bracket on one end and an eyebolt on the other end Using a 10mm open end wrench loosen the nut closest to the eye inside on bolt diagram 8 Diagram 7 Diagram 8 If chatter or erratic operation of hoist while traveling down is encountered the end effector or tooling on wire rope is not heavy enough to overcome the spring tension Loosen the outside nut one half turn and test the hoist operation full stroke up and down between each half turn adjustment of eyebolt but until chattering is eliminated 9 5 7 11 G Force Q iQ Service Manual Gorbel Inc 5 All other conditions will require the outside nut to be adjusted by turning clockwise tightening to increase tension to the slack spring Before tightening of this nut be sure there is enough free travel of the eyebolt inside nut loose 6 Using the applications end effector handle unloaded end tool travel downward resting end effector on floor If rope con
181. tinues to pay out from actuator beyond two seconds after reaching floor remove hand from handle or release down button pendant Turn the outside nut clockwise one half turn tightening it Test again by traveling up removing handle or tooling from floor and travel down again resting on floor Continue adjusting and testing this until rope travel stops within two seconds of effector resting Supported on floor and deflection of rope is 3 4 inches Tighten inside nut clockwise until jammed against sheet metal while keeping eyebolt stationary 7 Correct slack adjustment occurs when a deflection of the wire rope is 3 4 inches when in slack mode and rope travel stops diagram 9 3 4 ann 8 4 Diagram 9 7 11 9 6 G Force Q iQ Service Manual Gorbel Inc Chapter 10 Parts amp Assembly This chapter provides the Gorbel part numbers for all capacity G Force Q and iQ models as well as the removal and replacement instructions for most of the components inside the actuators and control handles In most cases the Gorbel part numbers for all three capacity G Forces are the same Where there are differences separate pages are used to illustrate the differences All Gorbel part numbers are shown in parentheses and bold print Index fuo P 10 2 Slide Handle nianie eS e deer era cee EGER Ee bee Gt 10 40 Pendant Aande nenese 2 oes het coton temor Poe pas eoe ace aque 10 53 GOL DIOS uu E d
182. to continue to run The over range warning indicates the potential error in programming the parameter without altering the value The sample value is still retained Cause Remedy The load cell minimum signal bias is sampled during procedure steps 1 and 3 see Warning 10404 However the normal bias value selected is based on step 3 when the unit is in slack Therefore if a handle tooling or additional parts are tare in step 1 this warning will be triggered Ignore this warning if it is triggered in step 1 If this warning is triggered while the unit should be in slack the possible causes can be a The unit may appear to be in slack while a loading plate is still exerting pressure to the load cell This may be due to some binding or drag in the rotary geartrain mechanism Ensure the unit is in slack such that the rotary geartrain mechanism is pushed back i e push up onto the white plastic wear ring at the bottom of the unit and the unit cannot move down with a handle controller b The metal mounting bracket of the white plastic wear ring onto the geartrain mechanism may be bent such that the wear ring cannot move back far enough and is touching the cast body housing opening prematurely When the unit is loaded the wear ring should be situated near the center of the circular opening without contact The bracket may be bent if it is offset near a particular side significantly Readjust the bracket or replace it c Problem
183. to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default Error 321 ERROR MULTI FEATURES PER OUTPUT CONFIGURATION Description At startup found multiple Q iQ feature configuration settings are set to use the same digital output channel Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy a Use the extended error index number to identify which Q iQ feature contains the faulty setting Use the VB Configurator program not yet available as of July 2010 to correct the false setting b Run the Gorbel supplied installation CD i e Gorbel amp G Force Q iQ Software Downloader and select the Download Q iQ Software and Reset to Factory Default Configurations option to reset any faulty settings All configuration settings e g if unit is configured for Float Mode and Q iQ feature settings e g virtual limit positions are cleared and reset to default 7 11 7 14 G Force Q iQ Service Manual Gorbel Inc Error 322 ERROR_INPUT_CONFIGURATION_OUT_OF_BOUND Description At startup found a Q iQ feature input channel configuration setting is outside the allowable range Reaction Lift program terminates processing to prevent running with an incorrect configuration setup Cause Remedy a Use the extended error index number to ident
184. to the system Note Numbers in 3x M3 Shield Standoff Parentheses are Z Si 8mm OD x 3 1mm x 16mm Lg Gorbel Part Numbers 25 D 76575 Electrical Shield 76521 3x Lockwasher M3 ZNPL 65051 4 3x SHCS M3 x 25mm Lg 65013 Diagram 4 Electrical Shield Removal and Replacement 10 9 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 5A Main PCB Removal a b C d e Turn off power by disconnecting AC power to the system Remove front cover Refer to Procedure 1A Remove electrical shield Refer to Procedure 4A Unplug cable assemblies from J1 through J14 on main PCB Note the color coding for cable assemblies that connect to J6 J7 and J8 Remove 2 M3 socket head cap screws SHCS and M3 lockwashers Note Use caution when handling the main PCB to avoid any damage Procedure 5B Main PCB Replacement a b Install 2 M3 socket head cap screws SHCS and M3 lockwashers Connect cable assemblies to J1 through J14 on the main PCB Check the color coding for J6 J7 and J8 Install the electrical shield Refer to Procedure 4B Install the front cover Refer to Procedure 1B Restore AC power to the system Note Numbers in Parentheses are Gorbel amp Part Numbers 7 11 Actuator Main PCB 78801 2x Lockwasher M3 ZNPL 65051 Metal Loop Strap 1 2 ID 1 76525 ai 2x SHCS M3 x 12mm Lg E 65012 Nylock Nut M5 ZNPL 65070 Hex Standoff 01007 Dia
185. ton head cap screw BHCS and M4 large OD washer to secure the plunger assemblies in the pendant handle housing e Install both levers Refer to Procedure 4B f Install the lever shaft Refer to Procedure 3B g Install the side guard Refer to Procedure 2B Note Numbers in Parentheses are Gorbel Part Numbers 2x Plunger Assembly 74323 Washer M4 Large OD 65081 2x Plunger Spring 99913 wee y BHCS M4 x 8mm Lg 65077 2x Plunger Tip 74321 Apply Blue Loctite 242 Diagram 8 Plunger Assembly Removal and Replacement 7 11 10 60 G Force Q iQ Service Manual Gorbel Inc Procedure 9A Faceplate and Face Seal Removal a Remove the 10 M2 Phillips screws PHMS and 10 M2 lockwashers from the faceplate b Remove the faceplate and face seal from the pendant handle housing Procedure 9B Faceplate and Face Seal Replacement a Install the faceplate and face seal into the pendant handle housing b Install the 10 M2 Phillips screws PHMS and 10 M2 lockwashers for the faceplate Face Seal 74306 Faceplate 74305 10x Lockwasher M2 ZNPL 65055 SEMS Split Lock Note Numbers in 65073 Parentheses are Gorbel Part Numbers Diagram 9 Faceplate and Face Seal Removal and Replacement 10 61 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 10A E Stop Assembly and Pushbutton Removal a Remove the faceplate and face seal Refer to Procedure 9A
186. top portion of the pendant handle b Install the 4 M6 button head cap screws BHCS and 4 M6 lockwashers ___ Top Guard 74335 8x Lockwasher M6 ZNPL l M 03370 poe BHCS M6 x 10mm Lg 5 65076 _2x Side Guards 74313 Note Numbers in Parentheses are Gorbel Part Numbers Diagram 1 Top Guard Removal and Replacement 10 53 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 2A Side Guard Removal a Remove the 2 M6 button head cap screws BHCS and 2 M6 lockwashers from each side of the pendant handle b Remove the 2 side guards from the pendant handle Procedure 2B Side Guard Replacement a Position the 2 side guards on each side of the pendant handle b Install the 2 M6 button head cap screws BHCS and 2 M6 lockwashers on each side of the pendant handle __ Top Guard 74335 8x Lockwasher M6 ZNPL 03370 Bak BHCS M6 x 10mm Lg 65076 2x Side Guards 74313 Note Numbers in Parentheses are Gorbel Part Numbers Diagram 2 Side Guard Removal and Replacement 7 11 10 54 G Force Q iQ Service Manual Gorbel Inc Procedure 3A Lever Shaft Removal a Remove either side guard Refer to Procedure ZA b Slide the lever shaft through each lever Procedure 3B Lever Shaft Replacement a Position both levers and slide the lever shaft through both levers b Install the side guard using the 2 M6 button head cap screws BHCS and 2 M6 l
187. trical connector located below the remote mount cap Procedure 2B Remote Mount Cap Sub Assembly Replacement a Slide the remote mount cap onto the handle shaft Note the orientation of the internal electrical connector located below the remote mount cap b Position the handle assembly into the remote mount bracket if applicable and install M16 hex head cap screw HHCS flatwasher and lockwasher onto the top of the handle assembly 2x HACS M16 x 2 33mm CL 8 8 Note N J 74230 lt ote Numbers in 2x Lockwasher M16 ZNPL Parentheses are 00212 Gorbel Part Numbers 2x Flatwasher M16 ZNPL 01310 Remote Mount Cap Sub Assembly 74252 see inset External Snap Ring 65069 Housing Sub Assembly 74247 74248 Handle Transducer Sub Assembly 74246 Remote Mount Slide Handle Cover 74224 Hex Standoff 6mm x 12mm ink 65099 PCB Slide Auxiliary Out 74233 B a Grip amp Shaft Sub Assembly PHMS M3x0 5 20 BN lt 65082 M Lockwasher M3 ZNPL 65051 Connector Nut Diagram 2 Remote Mounted Sliding Handle Remote Mount Cap Sub Assembly Removal and Replacement 10 41 7 11 G Force Q iQ Service Manual Gorbel Inc Procedure 3A Housing Sub Assembly Removal a Remove swivel sub assembly or remote mount cap assembly Refer to Procedure 1A or 2A accordingly b Remove air extension output and O ring if equipped with this option c Remove snap ring and any shim washers d
188. ts the actuator Diagram 3B Locate socket head cap screw head and fully push it in until it can not move anymore G Force Q iQ Service Manual Gorbel Inc i From the limit switches is a gray colored lead that plugs into the circuit board Its connected location is approximately 2 inches down the right side of the circuit board labeled limits Gently pull out the plug lead to disconnect the plug from board diagram 3C j Using a 3mm hex wrench remove 4 M5 button head cap 7 JDisgram SERR screws that fasten the swiveling circuit board bracket to the Gently pull out the grey limit switch wiring lead to disconnect plug from front support plate 2 screws are located on the top and 2 board are on the bottom of bracket Set screws in plastic front cover Swing bracket out towards you and to the left diagrams 3D k Using 13mm open end wrench loosen but do not remove the 2 flange nuts and remove reinforcement bracket diagram 3E 330 Ib 150 kg and 660 Ib 300 kg units only Using an M5 hex wrench remove 2 M6 socket head cap screws from the drum gates Slide the unthreaded gate out towards you Place gate and hardware in front cover acis Mrs P Remove four socket head cap diag ram 3P screws two on top two on bottom a that fasten the swiveling m Using an M6 hex wrench remove the 2 M8 socket head circuit board bracket to the front cap screws from the rope retainer an
189. uator until the fault is corrected Error 11801 WARN HANDLE FAULT CAN IO ALARM Description Handle digital IO CAN bus controller has triggered an alarm status Additional error information may be available following the warning Reaction The digital inputs such as the OPS sensor Menu and Float pushbuttons are disabled Cause Remedy A fault specifically a CAN bus alarm can occur if the CAN controller board does not communicate with the PLC correctly is in a fault state falsely removed configuration memory error etc Additional error information may be available after the warning message Reboot the unit with the E stop to clear the fault if it is not repetitive Problem can result from faulty handle board noise or data corruption in the CAN communication wires or any cut wires Replace the handle coil cord actuator interface board and CAN communication wires in the actuator until the fault is corrected Error 11802 WARN HANDLE FAULT BUS OFF Description Handle digital IO CAN bus controller has been turned off unintentionally If a WARN HANDLE FAULT NOT ACTIVE warning does not occur together with this then the bus line is turned off only briefly Reaction The digital inputs such as the OPS sensor Menu and Float pushbuttons are disabled Cause Remedy A fault specifically bus off exception can occur if the handle CAN controller does not communicate with the PLC correctly or at all Reboot the unit with the E stop to clear th
190. uipped Look for any obvious external damage or wear caused by the Wire Rope or other external causes Make sure the Air Hose is secured properly with the correct clamps 4 Load Hook and or tooling by others Check that the Load Hook is secured properly to the handle or swivel Make sure lock washers are compressed completely and any other associated hardware is secure Monthly Tasks Tools may be required as well as a clean dry cloth and compressed air 5 Slack Switch Adjustment Using the Handle lower the Wire Rope until it goes slack There should be no additional movement downward once it is slack If the Wire Rope continues to pay out stop immediately and refer to Chapter 9 Jii of this manual to perform the Slack Switch Adjustment Check the Coil Cord and Air Hose Clamps on the Wear Ring to insure the Wear Ring is moving freely inside the Actuator opening B RBEL SLACK ADJUSTMENT HARDWARE WEAR RING f t 3 iP a 7 11 11 2 G Force Q iQ Service Manual Gorbel Inc 6 Wire Rope Expose any much of the Wire Rope as possible and wipe it off with a clean dry cloth Use the Jog Buttons to pay out as much of the Wire Rope as possible 7 Operator Present Sensor sliding handle only Use a gentle puff of compressed air or a soft cloth to clean the sensor Do not apply any pressure to the lens or do anything that may scratch it OPERATOR PRESENT SENSO NOTE PHOTO ENHANCED
191. unicate with the PLC correctly is in a fault state falsely removed configuration memory error etc Additional error information may be available after the warning message Reboot the unit with the E stop to clear the fault if it is not repetitive Problem can result from faulty handle board noise or data corruption in the CAN communication wires or any cut wires It can also be triggered if a channel in the X67 spare lO module is configured as an output but 24Vdc is sent to this channel for example due to miss wiring Check and correct any wiring into a false channel or false custom feature configuration Replace the handle coil cord actuator interface board and CAN communication wires in the actuator until the fault is corrected 7 25 7 11 G Force Q iQ Service Manual Gorbel Inc Error 11808 WARN_SPAREIO_FAULT_BUS_OFF Description An X67 spare IO block CAN bus controller connected to the handle has been turned off unintentionally If a WARN SPAREIO FAULT NOT ACTIVE warning does not occur together with this then the bus line is turned off only briefly Reaction Standard iQ features operating through this spare IO block are either disabled or outputs turned off Cause Remedy A fault specifically bus off exception can occur if the X67 spare IO block CAN controller does not communicate with the PLC correctly or at all Reboot the unit with the E stop to clear the fault if it is not repetitive Inaccurate communication can result f
192. with the load cell electronics This may include a damaged load cell or loose load cell cable connection to the actuator main interface board or to the servo drive d The actuator PCB board which processes the load cell signal may be damaged or out of spec Replace the PCB board Error 10406 WARN_PROG_OVER_RANGE_LOADCELL_COEF Description The sampled maximum load cell signal coefficient is greater than the acceptable range from the normal coefficient value for this unit The acceptable range of this parameter is empirically determined and selected for different models and capacities Reaction Handle LCD displays the warning while unit is allowed to continue to run The over range warning indicates the potential error in programming the parameter without altering the value The sample value is still retained Cause Remedy The load cell maximum signal coefficient is sampled during procedure step 2 see Warning 10404 When this parameter is calibrated the unit is expected to be loaded with a weight corresponding to the capacity of the unit The possible causes can be a Step 1 of the calibration procedure see Warning 10404 is not correctly performed b The pickup weight does not match the rated capacity c The metal mounting bracket of the white plastic wear ring onto the geartrain mechanism may be bent such that the wear ring is pressing against the cast body housing opening When the unit is loaded the wear ring sh
193. xt step 4 7 If applicable connect air hose coil cord to supply line from the actuator assembly The air hose coil cord is provided with two 2 1 4 NPT male swivel fittings located at both ends of the air hose 4 8 For standard in line slide handle installation go to Step 5A page 3 3 For remote mounted slide handle installation go to Step 5B page 3 3 For suspended pendant handle installation go to Step 5C page 3 5 For remote mounted pendant handle installation go to Step 5D page 3 5 For 1320 Ib in line slide or remote mounted handle installation go to Step 5E page 3 7 For 1320 Ib suspended pendant handle installation go to Step 5F page 3 8 7 11 3 2 G Force Q iQ Service Manual Gorbel Inc Step 5A Standard In Line Slide Handle Installation 5A 1 Ensure the wire rope is still fed through the center of the coil cord Hold the slide handle just below the coil cord 5A 2 Center the coil cord footer between the ears of the slide handle swivel Note Make sure the fin of the coil cord footer is on the opposite side of the slide handle connector Wire Rope Coil Cord Footer 16 mm Shoulder Bolt M12 Jam Nut Slide Handle Connector 5A 3 Remove the 16mm shoulder bolt from the coil cord footer and wire rope and allow the coil cord footer and wire rope to slide down into the slide handle Swivel 5A 4 dar COIL CORD 7 HAS BEEN REMOVED FOR CLARITY Diagram 5A S ide Handle Shoulder Bolt and C

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