Hirschmann PAT IFLEX5 Manuel utilisateur

www.hirschmann.com

HIRSCHMANN

P/N 031-300-190-154 REV I 05/22/2017

LOAD MOMENT INDICATOR

iFLEX5

SERVICE MANUAL

Service Manual iFLEX5

NOTICE

Hirschmann Electronics, Inc. makes no warranty of any kind with regard to this material, including, but

not limited to, the implied warranties of merchantability and/or its fitness for a particular purpose.

Hirschmann will not be liable for errors contained in this manual or for incidental or consequential

damages in connection with the furnishing, performance, or use of this manual. This document

contains proprietary information, which is protected by copyright, and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another language without

the prior written consent of Hirschmann.

Hirschmann reserves proprietary rights to all drawings, photos and the data contained therein. The

drawings, photos and data are confidential and cannot be used or reproduced without the written

consent of Hirschmann. The drawings and/or photos are subject to technical modification without

prior notice.

All information in this document is subject to change without notice.

MANUAL REVISIONS

REV

DATE

NAME

DESCRIPTION

04/10/02

CSH

ECN 02-122

06/03/02

ECN 02-122

06/15/02

ECN 02-122

06/24/02

ECN 02-122

07/01/02

ECN 02-122

12/04/02

CSH

ECN 02-179

07/29/03

CSH

ECN 03-088

06/05/06

ECN 05-110

11/6/08

ECN 08-173

05/22/17

ECN 17-078

Service Manual iFLEX5

TABLE OF CONTENTS

1General Information.................................................................................................................1

2Warnings...................................................................................................................................1

3Description Of The System...................................................................................................... 2

3.1 DESCRIPTION OF SYSTEM FUNCTION...........................................................................................2

3.2 DESCRIPTION OF ACAN BUS SYSTEM.........................................................................................2

3.3 DESCRIPTION OF THE SYSTEM COMPONENTS...............................................................................3

4What’s Wrong?.........................................................................................................................4

4.1 IHAVE AN ERROR CODE INDICATED ON THE CONSOLE ...................................................................4

4.2 THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE ............................................4

4.3 THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH.........................................4

4.4 THE DISPLAYED SLEWING DOES NOT MATCH THE ACTUAL SLEWING ANGLE ....................................4

4.5 THE DISPLAYED LOAD DOES NOT MATCH THE ACTUAL LOAD..........................................................4

4.6 THE CONSOLE DISPLAY IS BLANK.................................................................................................4

4.7 IHAVE AN A2B PROBLEM............................................................................................................4

4.8 IHAVE ACAN-BUS PROBLEM ....................................................................................................4

4.9 INEED TO IDENTIFY A SPARE PART...............................................................................................4

4.10 IHAVE NOTICED WATER IN SOME PART OF THE SYSTEM.................................................................4

5Angle Sensing .......................................................................................................................... 5

5.1 ANGLE SENSING ERROR -FLOW CHART........................................................................................6

6Length Sensing ........................................................................................................................ 8

6.1 LENGTH SENSING ERROR -FLOW CHART.....................................................................................9

7Pressure Sensing................................................................................................................... 11

7.1 PRESSURE SENSING ERROR -FLOW CHART ................................................................................11

8Slewing Sensing.....................................................................................................................12

8.1 SLEW SENSING ERROR -FLOW CHART........................................................................................13

9Load sensing.......................................................................................................................... 14

9.1 LOAD SENSING ERROR -FLOW CHART ........................................................................................14

10 No console display................................................................................................................. 15

11 A2B Problem........................................................................................................................... 16

12 cann-bus communication...................................................................................................... 17

12.1 E61.........................................................................................................................................17

12.1.1E61 - Flow Chart .............................................................................................................18

12.2 E62.........................................................................................................................................19

12.3 E63.........................................................................................................................................19

12.4 E64.........................................................................................................................................19

12.4.1E64 - Flow Chart .............................................................................................................20

12.5 E65.........................................................................................................................................20

13 Troubleshooting a sensor problem using the display......................................................... 21

14 iFLEX5 Boom Control System (BCS).................................................................................... 24

14.1 RT9000E /RT800E BASICS.....................................................................................................24

14.1.1Terminology:...................................................................................................................24

14.1.2Components:...................................................................................................................24

14.1.3Manual / Auto Mode:.......................................................................................................24

14.2 TELE SEQUENCE:.....................................................................................................................26

Service Manual iFLEX5

14.3 IFLEX5 BCS DIGITAL INPUTS:..................................................................................................26

14.4 RT9000E /RT800E IFLEX5 BCS DIGITAL OUTPUTS:...............................................................27

14.5 IFLEX5 BCS ANALOG INPUTS AND PWM OUTPUTS: .................................................................29

14.6 IFLEX5 BCS TEST DISPLAY:....................................................................................................31

14.7 BOOM OUT OF SEQUENCE:.......................................................................................................32

14.8 TELE ROD DRAIN VALVE:..........................................................................................................32

14.9 TELE TWO STAGE RELIEF VALVE:.............................................................................................32

14.10 HYDRAULIC LUFFING BOOM EXTENSION:.............................................................................33

15 Drawings................................................................................................................................. 34

15.1 COMPONENTS OF THE LMI SYSTEM PAT IFLEX5.......................................................................34

15.2 BLOCK DIAGRAM......................................................................................................................35

15.3 ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM ..................................................................36

15.3.1Central Unit to Crane and Console Wiring Diagram ....................................................36

15.3.2Cable Reel (length/angle sensor) Wiring Diagram .......................................................37

15.3.3Boom Extension Anti-two Block Wiring Diagram ........................................................38

15.4 MAIN CENTRAL UNIT CONNECTOR.............................................................................................38

15.5 ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL SYSTEM..........................................................39

15.5.1Central Unit to Crane Interface Wiring Diagram...........................................................39

15.5.2Console and Sensor Wiring Diagram............................................................................40

15.5.3Cable Reel (LWG520/0002) Wiring Diagram..................................................................42

15.5.4Luffer Extension Wiring Diagram..................................................................................43

16 Spare Part Listings................................................................................................................. 44

16.1 CENTRAL UNIT, IFLEX5 PART NO. 021-020-060-003..........................................................44

16.2 GRAPHIC CONSOLE ASSY, VERTICAL PART NO. 050-350-061-356 .................................45

16.3 GRAPHIC CONSOLE ASSY, PART NO. 050-350-061-376...................................................46

16.4 CABLE REEL, LWG508 PART NO. 068-508-060-001...........................................................47

16.5 CABLE REEL, LWG521 PART NO. 068-521-060-002...........................................................49

16.6 CABLE REEL, LWG152 PART NO. 067-152-060-056...........................................................50

16.7 PRESSURE TRANSDUCER BLOCK,DAV314/0014 PART NO. 044-314-060-014 ........................51

16.8 CABLE ASSEMBLY 11M,PART NO. 031-010-101-007 .........................................................51

16.9 WIRING HARNESS STANDARD, PART NO. 031-010-100-549 .............................................51

16.10 WIRING HARNESS BOOM CONTROL, PART NO. 031-010-100-554..............................52

16.11 CABLE ASSEMBLY, 14M PART NO. 031-010-100-555...................................................52

16.12 TRS05 REPEATER, RADIO WINDSPEED KIT 031-300-104-087.....................................53

17 Service Screen For Sensor Calibration ................................................................................ 54

17.1 ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION ..................................................54

17.2 ZERO-SETTING THE TRANSDUCER INPUTS .................................................................................55

17.3 ZERO-SETTING THE SLEWING INPUTS ..............................................................................55

17.4 LENGTH SENSOR CALIBRATION PROCEDURE .............................................................................56

17.4.1Cable Reel LWG508 Adjustment Procedure .................................................................56

17.4.2Length Sensor Adjustment Procedure..........................................................................57

17.4.3Cable Reel Length Cable Replacement Procedure ......................................................58

17.5 ANGLE SENSOR CALIBRATION PROCEDURE...............................................................................59

17.6 ZERO-SETTING THE SLEW POTENTIOMETER ..............................................................................61

18 Error Codes ............................................................................................................................62

19 Troubleshooting Moisture..................................................................................................... 72

19.1 WATER INGRESS ......................................................................................................................72

19.2 CONDENSATION........................................................................................................................73

General Information

1 GENERAL INFORMATION

This service manual is designed to assist a service or maintenance person in identifying system

problem areas or malfunctions. A digital voltmeter with the capability to measure current will be

required, along with standard maintenance and service tools. NOTE: Knowledge of how to use a

voltmeter to measure both voltage and current is assumed.

REFERENCE:

For system operation, refer to the consoles operator’s manual 031-300-190-147.

2 WARNINGS

The LMI is an operational aid that warns a crane operator of approaching overload conditions and

over hoist conditions that could cause damage to equipment and personnel.

The device is not, and shall not be, a substitute for good operator judgment, experience and use of

accepted safe crane operating procedures.

The responsibility for the safe crane operation shall remain with the crane operator who shall ensure

that all warnings and instructions supplied are fully understood and observed.

Prior to operating the crane, the operator must carefully and thoroughly read and understand the

information in this manual to ensure that he knows the operation and limitations of indicator and

crane.

Proper functioning depends upon proper daily inspection and observance of the operating

instructions set forth in this manual. Refer to Section 6. Pre-Operation Inspection and Calibration

Verification of the operator’s manual.

The LMI can only work correctly, if all adjustments have been properly set. For correct

adjustment, the operator has to answer thoroughly and correctly all questions asked during

the setup procedure in accordance with the real rigging state of the crane. To prevent

material damage and serious or even fatal accidents, the correct adjustment of the LMI has

to be ensured before starting the crane operation.

Service Manual iFLEX5

3 DESCRIPTION OF THE SYSTEM

3.1 DESCRIPTION OF SYSTEM FUNCTION

The iFLEX5 system is a CAN bus system made up of a central microprocessor unit, operating

console, length/angle sensor, pressure transducers, and anti-two block switches. All components and

sensors are equipped with CAN bus controllers.

The PAT Load Moment Indicator system operates on the principle of reference/real comparison. The

real value, resulting from the pressure measurement is compared with the reference data, stored in

the central processor memory and evaluated in the microprocessor. When limits are reached, an

overload warning signal is generated at the operator’s console. At the same time, the aggravating

crane movements, such as hoist up, telescope out and boom down, will be stopped.

The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity and

dimensions are stored in memory chips in the central processor unit. This data is the reference

information used to calculate the operating conditions.

Boom length and boom angle are registered by the length/angle sensor, mounted inside the cable

reel, which is mounted on the boom. The boom length is measured by the cable reel cable, which also

serves as an electrical conductor for the anti two-block switches.

The crane load is measured by pressure transducer block attached to the piston and rod side of the

hoist cylinders.

The interactive user guidance considerably simplifies the input of operating modes as well as the

setting of geometry limit values.

3.2 DESCRIPTION OF A CAN BUS SYSTEM

CAN stands for “Controller Area Network”. Its intended use is as a serial bus system for a network of

controllers. Each controller connected through a CAN chip is called a "node" and is mostly used to

acquire data from a sensor. All nodes are connected to a common bus and all nodes are able to

simultaneously read the data on that bus. Also, all nodes are able to transmit data on that bus

however only one node at a given time has write access to the bus. If the message is relevant, it will

be processed; otherwise it is ignored. The unique identifier also determines the priority of the

message. The lower the numerical value of the identifier, the higher the priority.

The cable bus is a twisted pair of shielded wire. Data can be transmitted in blocks from 0-8

bytes at a maximum transfer rate of 1 Mbit/s for networks up to 40 meters. For longer network

distances the maximum transfer rate must be reduced to 50 Kbit/s for a 1 km network distance.

CAN will operate in extremely harsh environments and the extensive error checking

mechanisms ensure that any transmission errors are detected.

Description Of The System

3.3 DESCRIPTION OF THE SYSTEM COMPONENTS

Pressure Transducer: The pressure transducer converts hydraulic pressure into an electric signal.

A pressure transducer block houses two transducers, CAN bus converter board, and two bus

connectors. One pressure transducer is connected to the piston side of the lift cylinder and the other

to the rod side.

The Length-Angle Transducer: The length-angle sensor (LWG), often referred to as the “cable reel”,

is a combination of two transducers in one box, installed on the base section of the boom. It

measures the length and the angle of the boom.

A reeling drum drives a potentiometer, which is the length transducer. Part of the length transducer

circuit is the length cable on the drum, which is a multi-conductor cable. It is connected to the anti-

two-block switch at the boom head and to a slip ring body in the LWG.

The angle transducer is a potentiometer driven by a weighted pendulum that is oil damped. Both

length and angle transducer are connected to a CAN bus controller board, which is connected to the

bus system.

Anti-Two-Block Switch: The anti-two-block switch monitors the load block and it’s relationship with

the head of the boom. In working condition the switch is closed. When the load block strikes the

weight the circuit opens, disengaging a relay output to the lock out solenoid valves, where applicable.

To check the cable for damage, (short circuit to ground) there is a 4.7k resistor between ground and

the contact of the switch, to give a signal back to the central unit. The weight at the anti-two-block

switch keeps the switch closed until the load block strikes it.

Console: The graphic console displays all geometrical information such as length and angle of main

boom, working radius and head height of the boom. It also displays the actual load and the maximum

load permitted by load chart. Furthermore, it has an alarm horn, a warning light for overload, and a

pre-warning light. The graphic display allows for a simple interactive configuration setup, as well as

sensor calibration (zero adjustment), and troubleshooting sensor output screen. The console has a

warning light for anti-two-block conditions and an override switch for overload or anti-block condition.

Refer to Operator’s Handbook for detailed operation of the console.

Central Unit: Inside the central unit there is a CPU and connection board. The board has a hard

mounted connector for power, ground, bus controller, and slew indication. The board has a green

LED, indicating relay energized and a communication LED that flashes through red, yellow, and green

colors.

Slew Potentiometer: This component is not supplied by PAT/Hirschmann. It is part of the electrical

swivel (slip ring assembly). The potentiometer has two wipers which are used to determine the

slewing angle (rotational positioning) of the super structure in relation to the carrier. The slew input to

the central unit is not a CAN signal, but rather two 4..20mA analog signals.

Service Manual iFLEX5

4 WHAT’S WRONG?

So, what’s wrong? Assuming you are reading these pages because of some kind of problem with the

PAT system, let us try to guide you quickly to solving the problem. In most cases, your problem will

fall under the following categories:

4.1 I HAVE AN ERROR CODE INDICATED ON THE CONSOLE

Please go to section Error Codes!

4.2 THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE

Start in section Angle Sensing to check the indicated angle.

4.3 THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH

Start in section Length Sensing to check the indicated length.

4.4 THE DISPLAYED SLEWING DOES NOT MATCH THE ACTUAL SLEWING ANGLE

Refer to section Slewing Sensing to check the slew sensor.

4.5 THE DISPLAYED LOAD DOES NOT MATCH THE ACTUAL LOAD

Please note that the indicated load is calculated by the system from the geometry information in the

computer, the operator’s selections, and all the sensor inputs. If the load display is off, it can therefore

be due to an error in any or several of these inputs! Refer to section Load sensing to narrow down the

source of your problem.

4.6 THE CONSOLE DISPLAY IS BLANK

If the console does not show any sign at all (no lights, no buzzer, no display), the problem is either in

the wiring between console and central unit, or the console itself. Refer to section No console display

for further troubleshooting.

4.7 I HAVE AN A2B PROBLEM

Please go to sectionA2B PROBLEM

4.8 I HAVE A CAN-BUS PROBLEM

Please go to section CAN-Bus Communication!

4.9 I NEED TO IDENTIFY A SPARE PART

Please go to the Spare Part Listings!

4.10 I HAVE NOTICED WATER IN SOME PART OF THE SYSTEM

Please go to section Troubleshooting Moisture!

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