Page 1
Load Switch
LS 804
Original
Manual
A.S.T. - Angewandte System Technik GmbH, Mess- und Regeltechnik
Marschnerstraße 26 D-01307 Dresden
Phone (03 51) 44 55 30 Fax (03 51) 44 55 555
www.ast.de vertrieb.dd@ast.de
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Manual Load Switch LS 804
List of Contents
1. General description .............................................................................................. 1
2. Functional description ......................................................................................... 1
3. Dimensions ........................................................................................................... 2
4. Electrical connection ............................................................................................ 3
4.1. Connection diagram ................................................................................................ 3
4.2. Voltage supply 24 V DC .......................................................................................... 3
4.3. Sensor inputs I a – I d ............................................................................................. 4
4.3.1. LS 804.01 ........................................................................................................... 4
4.3.2. LS 804.02 ........................................................................................................... 5
4.4. Switching inputs IN1 to IN16 ................................................................................... 6
4.5. Analogue outputs Vout and Iout .............................................................................. 7
4.6. Output relays and error relays K1 to K6 and Error1 and Error2 .............................. 7
4.7. Digital interfaces LAN, CAN and RS485/232 .......................................................... 7
4.7.1 Pin assignment / CAN interface .............................................................................. 8
4.7.2 Pin assignment / RS485 interface / optional RS232 interface ................................. 8
5. Operation and display LS 804 .............................................................................. 9
5.1. Functions of keys .................................................................................................... 9
5.1.1. Function keys ..................................................................................................... 9
5.1.2. Cursor keys ........................................................................................................ 9
5.2. LED indicators....................................................................................................... 10
5.2.1. LEDs "SP1" and "SP2" ..................................................................................... 10
5.2.2. LED "Error" and error displays .......................................................................... 11
5.3. Matrix display - 4 x 20 characters ......................................................................... 12
5.3.1. Operating display / sensor signals a to d and switching contacts ..................... 12
5.3.2. Operating display / network for browser accessing ........................................... 13
5.3.3. Operating display for load spectrum recorders ................................................. 14
5.4. Configuration via keypad ...................................................................................... 15
5.4.1. Limits ................................................................................................................ 15
5.4.2. Adjustment ........................................................................................................ 16
6. Configuration via web browser ......................................................................... 17
6.1. Status (information) ............................................................................................... 17
6.2. Settings (scaling, interfaces, password) ................................................................ 18
6.3. Adjustment (load calibration) ................................................................................ 20
6.3.1. Adjustment status ............................................................................................. 22
6.4. Limits (K1 to K6) ................................................................................................... 23
6.5. Load spectrum recorders (LSR) ............................................................................ 25
6.6. Configuration / Config ........................................................................................... 26
7. Maintenance / Error messages .......................................................................... 27
7.1. Status of relays K1 to K6 ...................................................................................... 27
7.2. Status of relays Error1 and Error2 ........................................................................ 28
8. Instructions in the event of failure .................................................................... 29
8.1. Error overview ....................................................................................................... 29
8.1.1. Error overview / Sensor errors .......................................................................... 29
8.1.2. Error overview: hardware failure / adjustment errors ........................................ 29
8.2. Sensor errors ........................................................................................................ 30
8.3. Adjustment errors .................................................................................................. 30
8.4. Communication errors / Logic units L1/L2 ............................................................. 31
9. Technical data ..................................................................................................... 32
10. Project planning assistance .............................................................................. 33
11. EC declaration of conformity ............................................................................. 34
Subject to technical changes, Status: 07.06.2017 1
A.S.T. - Angewandte System Technik GmbH, Mess- und Regeltechnik
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Manual Load Switch LS 804
1. General description
The "LS 804 Load Switch” is a configurable switching device.
Based on DIN ISO 13849, the design and architecture of the LS 804 load switch unite to bring
about a high level of safety integrity. The appliance meets PerformanceLevel PL c.
Up to a total of four sensors can be linked up to the device. The LS 804.01 is capable of processing
sensors with a strain-gauge signal in mV/V, whereas the LS 804.02 processes sensors with a standard
signal of 4-20 mA. Sensors processing a standard signal of 4-20 mA can be fed from the LS 804 applying
24 V DC.
The mode of operation on the device is set by configuration via a web browser in addition to individual
setting and adjustment on the keypad. Depending on the number and type of the connected load sensors,
individual, cumulative, differential and partial loads can be monitored.
Outputting of the freely parameterisable load shut-off points takes place via six relays ("K1" to "K6") with
N/O contacts. Allocation of the relays to the load signals is freely configurable. In addition, the device
incorporates two error relay outputs "Error1" and "Error2". These error relays are not freely programmable
and generate a “0” status in the event of a system error occurring. The use of force-guided relays on the
SLS 801 serves to ensure maximum system safety.
Two analogue outputs and two digital interfaces are provided for further application of the load signals on
overriding systems.
2. Functional description
CAUTION! Any operating processes or adjustments performed on the keypad of the LS 804 via
the web browser as well as changes made to the limit-set function by means of switching inputs
IN1 to IN8 will render the switching function inoperative for the duration of this work and the
resetting phase as well as for a few seconds afterwards.
Sensor a
Signal a
Sensor b
Signal b
Sensor c
Signal c
Sensor d
Signal d
I a
I b
I c
I d
L1
(Ch 1)
L2
(Ch 2)
Lastschalter LS 804
K1
K2
K3
K4
K5
K6
Error 1
Error 2
Verb indung
Überwachung L1/ L2
Überwachung
Figure 1 – Block diagram LS 804
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Speisespannung
- 24 VDC -
Eingänge
- digital -
Ausgänge
- analog -
Anzeige
LED
Tas ta tu r
Ethernet
CAN
RS485
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Manual Load Switch LS 804
2
Monitoring not only takes place of output relays "K1" to "K6" and error relays "Error1" and "Error2”, but
also of the load sensors with respect to cable rupture and short-circuiting. In the event of system errors
occurring, the error relays will switch off. A sensor error on any input does not automatically lead to loss
of function on the overall system. As a result of this functionality feature, a high level of safety is attained
along with maximum possible availability.
The LS804 is designed with several peripheral interfaces.
- The two analogue outputs 0-10 V / 4-20 mA for sensors a to d or selected total formation.
- Connection: LAN (RJ-45)
- Connection X1: CAN
- Connection X2: RS485 / optional RS232
3. Dimensions
Dimensions: 102 mm x 105 mm x 205 mm / 1 kg
Weight: Approx. 1kg
Fastening on mounting rail TS35
Connection Voltage supply 1.5 mm
Switching outputs (relays)) 1.5 mm
Analogue outputs 1.0 mm
Switching inputs 1.0 mm
204
2
screw terminals
2
screw terminals
2
screw terminals
2
screw terminals
,5
4
SP1
LAN
LAN
CAN RS 485
Figure 2- Dimensions LS 804
SP2 Error Run
F2F1
F3
OK
LS 804
105,4
73,6
75,4
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Manual Load Switch LS 804
4
5
0
415
0
425
0
4. Electrical connection
4.1. Connection diagram
1
Power
+24 VDC
CAN RS 485
2
3
0 V
+24 VDC
0 V
PE
6
PE
7K1
8
9
K2
11
12
13
1
161717
1
K3
K4
K5
18
K6
21
19
Error 1
22
2
Error 2
23
AG 2
2
AG 2
Vout 2
262728293
AG 1
AG 1
lout 2
Vout 1
lout 1
LS 804
Error Run
LAN
LAN
SP1
SP2
OK
F2F1
F3
IN1
70
IN2
69
IN3
68
IN4
IN1...4R
67
66
IN5
65
IN6
64
IN7
63
IN8
IN5...8R
61
62
IN9
60
IN10
59
IN11
58
IN12
57
IN9...12R
56
IN13
55
IN14
54
IN15
53
IN16
IN13...16R
51
52
+EX a
50
+ SI a
49
-SI a
48
-EX a
47
SHI a
46
+EX b
45
+SI b
44
-SI b
43
-EX b
42
SHI b
41
+EX c
40
+ SI c
39
-SI c
38
-EX c
37
SHI c
36
+SI d
+EX d
34
35
-SI d
33
-EX d
SHI d
31
32
Figure 3 – Position and designation of connections
4.2. Voltage supply 24 V DC
The operating voltage is 18-36 V DC, this being based on a maximum power consumption of 15 VA.
Operational readiness is indicated by means of an LED next to the 24 V AC connections.
Conductors of up to 1.5 mm
After the operating voltage has been applied, the green LED “Power” indicator will light up next to terminal
1 as well as the “Run” LED.
2
can be connected up to terminal blocks 1 to 6.
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Manual Load Switch LS 804
g
g
g
4.3. Sensor inputs I a – I d
A total of four sensor connections are available.
Conductors of up to 1.0 mm
2
can be connected up to terminal blocks 31 to 50.
4.3.1. LS 804.01
The LS 804.01 is designed for DMS sensors with a signal output range extending from -5mV/V to
+5mV/V. The bridge resistors may be from 350 Ω ... 1000 Ω.
Input stages "I 1a" and "I 1b" serve to feed the DMS sensors with 5 V, input stages "I c" und "I d"
supplying the DMS sensors with 3.3V.
F2F1
CAN RS 485
F3
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
+EX a
+ SI a
Signal a
-SI a
-EX a
SHI a
a
-SI b
+SI b
+EX b
b
nal b
Si
Figure 4– Sensor inputs I a – I d (LS 804.01)
-SI c
-EX c
-EX b
SHI b
+ SI c
+EX c
SHI c
c
Si
nal c
-SI d
+SI d
+EX d
-EX d
SHI d
d
Si
nal d
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Manual Load Switch LS 804
4.3.2. LS 804.02
The LS 804.02 is designed for DMS sensors having an integrated or external DMS amplifier with a
standard signal output 4-20mA.
The LS 804.02 feeds the amplifiers with 24V DC, max. 25 mA. The input signal range without error
message extends from 2 mA to 22 mA.
The "0V" connections of the respective sensors are bridged internally. If sensors with three conductors –
"UB", "OUT" and "OV" – are available, connections 32, 37, 42 und 47 must be left free.
CAN RS 485
50
49
0V a480V a
UB a
OUT a
F2F1
47
46
SHI a
45
44
43
42
41
0V b
0V b
UB b
OUT b
SHI b
F3
UB c
40
39
38
37
36
0V c
0V c
OUT c
SHI c
35
34
32
31
UB d
0V d330V d
OUT d
SHI d
a
Signal a
b
Signal b
c
Signal c
d
Signal d
Figure 5– Sensor inputs I a – I d (LS.804.02)
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Manual Load Switch LS 804
0
C
0
0
0
0
4.4. Switching inputs IN1 to IN16
Sixteen optocoupler inputs are arranged in four groups each group being made up of four inputs. Limit
sets can be accessed to by means of inputs IN1 to IN8.
A static signal on the relevant input provides access to the corresponding limit set: Via IN1, set “1” is
defined as the current set. If no signal is present, the LS 804 will operate with the limit set last displayed
in Chapter 6.4 Limits (K1 to K6). If, by accident, more than one input is occupied by a signal, the LS 804
will utilise that input having the lowest number.
For the load spectrum recorder, inputs IN13 and IN16 are employed for switching the “Raise/Lower”
signals (signals a to d). A signal applied to input IN12 generates the RESET function on the device in the
event of an error occurring; also refer to Chapter 7 Maintenance / Error messages.
Static signal
on
IN1 Accessing to limit set 1
IN2 Accessing to limit set 2
IN3 Accessing to limit set 3
IN4 Accessing to limit set 4
IN5 Accessing to limit set 5
IN6 Accessing to limit set 6
IN7 Accessing to limit set 7
IN8 Accessing to limit set 8
IN9 ((unoccupied))
IN10 ((unoccupied))
IN11 ((unoccupied))
IN12
RESET function in the event of error (FATAL ERROR); also refer to Chapter on LED
IN13 Start up / Load spectrum recorders / Sensor a (signal for Raise/Lower)
IN14 Start up / Load spectrum recorders / Sensor b (signal for Raise/Lower)
IN15 Start up / Load spectrum recorders / Sensor c (signal for Raise/Lower)
IN16 Start up / Load spectrum recorders / Sensor d (signal for Raise/Lower)
Reaction on LS 804
“Error”.
Table 1 – Inputs
Return of the keying pulse "direct" or "+24 V DC" or "0 V" is set by means of jumpers INx...xR.
Conductors of up to 1.0 mm
IN1 70
IN2 69
IN3 68
IN4 67
IN1...4R 66
V
2
can be connected up to terminal blocks 51 to 70.
V
+24VD
70
IN1
24V
67
68
69
IN2
IN3
66
IN4
IN1...4R
V
+24VDC
24V
V
70
IN1
IN2
66
IN3
IN4
IN1...4R
V
67
68
69
+24VDC
Switching signal "0V" Switching signal "24V" Switching signal "Zero potential"
Figure 6 Examples illustrating return of keying pulse via jumpers (0V, 24V, zero potential)
Note: The jumper settings in Fig. 6 apply to all groups IN1…IN4 / IN5…IN8 / IN9…IN12 /
IN13…IN16.
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Manual Load Switch LS 804
70
IN1
69
IN2
68
IN3
67
IN4
66
IN1...4R
+24VDC
0V0V0V
+24VDC
65
IN5
64
IN6
63
IN7
62
IN8
61
IN5...8R
60
IN9
58
57
59
IN10
56
In12
IN11
IN9...12R
+24VDC
0V
+24VDC
53
54
55
IN13
IN14
IN15
Switching signal "pushbutton" for input 1 … 16
Figure 7 - Examples illustrating return of keying pulse via jumpers (pushbutton)
4.5. Analogue outputs Vout and Iout
The LS 804 features two analogue outputs AnalogOut1 and AnalogOut2, both of which are capable of
being configured as voltage or current outputs (Vout1 / Iout1 or Vout2 / Iout2) – 0-10 V or 4-20 mA. The
analogue output stages can be freely assigned to the input signals and their respective linkages, e.g.
selected total formation (also refer to Chapter 6.2 Settings (scaling, interfaces, password).
The maximum load of the current outputs may be 500 Ω; the minimum load resistance for the voltage
outputs must be 1 kΩ. Conductors of up to 1.0 mm
2
can be connected up to the terminal blocks.
52
IN16
4.6. Output relays and error relays K1 to K6 and Error1 and Error2
The LS 804 is equipped with a total of eight switching outputs.
Six output relays – K1 to K6 – are freely adjustable within the scope of different applications with respect
to input signals and their respective linkages (also refer to Chapter 6.4 Limits (K1 to K6)).
No access is provided to the two error relays Error1 and Error2. These are only triggered in the event of
system errors occurring on the facility, sensor errors included.
The switching relays are force-actuated working contacts; their switching status can be indicated on the
display.
The maximum switching capacity (DIN EN 60947-4-1 / EN 60947-4-1) is as follows:
AC1: 250V/6A, AC15: 230V/3A, DC1: 24V/6A, DC13: 24V/5A/0,1Hz, UL 508: B300 / R300.
Conductors of up to 1.5 mm
2
can be connected up to terminal blocks 7 to 22.
4.7. Digital interfaces LAN, CAN and RS485/232
On the basic version of the LS 804 provision is made for three interfaces for data exchange or data
transmission.
LAN (RJ-45): Parameterisation of LS 804 via a browser.
X1 (9-Pin-SUB-D): CAN interface.
X2 (9-Pin-SUB-D): RS485 interface / optional RS232 interface.
Cyclical output of measured values as ASCII string.
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Manual Load Switch LS 804
4.7.1 Pin assignment / CAN interface
PIN Function
1 (( unoccupied ))
2 (( unoccupied ))
3 CAN-L
4 CAN-GND
5 (( unoccupied ))
6 (( unoccupied ))
7 CAN-H
8 (( unoccupied ))
9 (( unoccupied ))
Table 2– X1 – Pin assignment / CAN interface
4.7.2 Pin assignment / RS485 interface / optional RS232 interface
PIN Function
1 (( unoccupied ))
2 (( unoccupied ))
3 485-B
4 (( unoccupied ))
5 485-GND
6 (( unoccupied ))
7 (( unoccupied ))
8 485-A
9 (( unoccupied ))
Table 3 – X2 – Pin assignment / RS485 interface
PIN Function
1 (( unoccupied ))
2 232-TX
3 232-RX
4 (( unoccupied ))
5 232-GND
6 (( unoccupied ))
7 (( unoccupied ))
8 (( unoccupied ))
9 (( unoccupied ))
Table 4 – X2 – Pin assignment / optional RS232 interface
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Manual Load Switch LS 804
5. Operation and display LS 804
5.1. Functions of keys
5.1.1. Function keys
The LS 804 device is set to the operating or programming status by means of function keys F1, F2 and
F3.
Note: The functions of the respective keys F1 to F3 are indicated in the bottom line of the display
matrix.
5.1.2. Cursor keys
Further displays and operations take place by actuating the cursor keys.
Simultaneous pressing of keys:
and Information on network addresses (also refer to Chapter 5.3.2 – Operating display /
network for browser accessing).
and Adjustments menu for sensors and switching points (also refer to Chapter 5.4–
Configuration via keypad).
and Operating display / Service life (also refer to Chapter 5.3.3– Operating display for load
spectrum recorders).
Note: The cursor keys are only pressed simultaneously in the operating display for sensor
signals (also refer to Chapter 5.3.1– Operating display / sensor signals a to d and switching
contacts)).
and /or Return to operating display / Sensor signals takes place according to the
information indicated in the display.
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Manual Load Switch LS 804
5.2. LED indicators
Power
LS 804
Error Run
LAN
SP1
SP2
OK
F2F1
CAN RS 485
Figure 8– Position of LEDs
Power: 24 V DC supply voltage
Run: LS 804 ready for operation
Caution! The LS 804 cannot be returned to the operating status (LED Run lights up
green) until the causes of failure have been eliminated and the device has been restarted by
means of the Reset key. or input IN12.
SP1/SP2 signalises at least one open contact "K1" to "K6" in each case.
Error System error: At least one error relay "Error1" or "Error2" is open.
F3
5.2.1. LEDs "SP1" and "SP2"
The LEDs "SP1" and "SP2" signalise that at least one contact "K1" to "K6" is open. These correspond to
the settings specified in Chapter 6.4 Limits (K1 to K6) and can be queried by means of the operator
actions specified in Chapter 5.3.1 Operating display / sensor signals a to d and switching contacts.
LED SP1: This references to sensor a to d when K1, K3, K4 and K5 trigger.
LED SP2: This references to sensor a to d when K1, K3, K4 and K6 trigger.
Note: The LEDs SP1 or SP2 will send a signal if any exceeding or falling-below of the switching
thresholds has been detected (refer to Chapter6.4 Limits (K1 to K6)).
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Manual Load Switch LS 804
5.2.2. LED "Error" and error displays
LED Error indicates a system error. At the same time an error message will appear in the display
according to the following example:
F A T A L - E R R O R !
C h 1 : S F : 0 D / H W : 0 9
C h 2 : S F : 2 D / H W : 0 0
I P F l a g s R e s e t
Figure 9 – Error display
Pressing the
key facilitates switching between L1/L2 and the measured-value display.
Pressing key
Actuating keys
Flags makes it possible to display selected error flags.
or facilitates swapping between the display of the SF flags and HW flags
(hardware flags).
In the HW-flag display mode additional displaying of the flag values is possible indicating voltage supply
errors/sensor errors (V-Exc-Flags 1/2).
S F - F l a g s
a : 0 b : 0 c : 0 d : 0
E x i t
Figure 10 – SF flags
H W - F l a g s
a : 1 b : 0 c : 0 d : 0
V - E x c : 1
V - E x c E x i t
Figure 11 – HW flags
Pressing
V-Exc and the keys or makes it possible to display flags indicating voltage supply
errors (V-Exec-Flags 1) as well as individual sensor errors (V-Exc-Flags 2).
V - E x c - F l a g s 1
1 2 V : 0 5 V E / V : 0
3 . 3 V E : 0 3 . 3 V V : 0
E x i t
Figure 12 – Flags indicating voltage supply errors (V-Exc-Flags 1)
V - E x c - F l a g s 2
S e n s a : 0 S e n s b : 0
S e n s c : 0 S e n s d : 0
E x i t
Figure 13 – Flags indicating sensor errors (V-Exc-Flags 2)
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Manual Load Switch LS 804
Key to the different flags:
12V: Voltage supply/relay
5V E/V: Voltage supply/sensor supply voltage / Channel 1 (L1/Ch1)
3.3V E Sensor supply voltage / Channel 2 (L2/Ch2)
3.3V A Supply voltage / Channel 2 (L2/Ch2)
Sens a: Sensor a (calibration/signal out of specification or wire breakage)
Sens b: Sensor b (calibration/signal out of specification or wire breakage)
Sens c: Sensor c (calibration/signal out of specification or wire breakage)
Sens d: Sensor d (calibration/signal out of specification or wire breakage)
Further information on error messages/causes and their elimination will be found described in
Chapter 8 Instructions in the event of failure occurring.
5.3. Matrix display - 4 x 20 characters
The four-line matrix display serves to indicate operating statuses and signals as well as acting as a
display when configuring the LS 804.
Die 4-zeilige Matrixanzeige dient sowohl der Anzeige von Betriebszuständen und Signalen als auch der
Anzeige bei der Konfiguration des LS 804.
5.3.1. Operating display / sensor signals a to d and switching contacts
Following application of the operating voltage and the connection of operable sensors, sensor signals a
and b will be displayed.
R u n - C h 1
a : 3 . 2 t
b : 1 . 7 t
S u M c / d R e l
Figure 14 – Operating display / sensor signals
Using cursor keys
Pressing key
Load spectrum recorder is active! (also refer to 5.3.3 - Operating display for load spectrum recorders).
Actuating key
K1 closed; “K5: 1“ – K5 open) and the error relays Error1 and Error2.
K 1 : 0 K 4 : 0 E 1 : 0
K 2 : 0 K 5 : 1 E 2 : 0
K 3 : 0 K 6 : 0
E x i t
or facilitates switching back and forth to and from the % display.
c/d the display will switch to the values of the sensors c and d.
Rel serves to display the status of the output relays K1 to K6. (Example: “K1: 0“ –
Figure 15 – Operating display / Switching contacts
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Manual Load Switch LS 804
5.3.2. Operating display / network for browser accessing
Information on the network addresses and other details can be obtained from the operating display of the
sensor signals by pressing keys
and simultaneously.
L S 8 0 4 - I n f o r m a t i o n
I P S c a l e E x i t
Figure 16 - LS804 – Information
Actuating key
IP serves to display network information including the IP address of the device, by
means of which it is possible to access to the LS 804 via a browser.
N e t w o r k : D H C P O N
I P : 1 9 2 . 1 6 8 . 1 0 0 . 2 0
N M : 2 5 5 . 2 5 5 . 2 5 5 . 0
G W : 1 9 2 . 1 6 8 . 1 0 0 . 1
Figure 17 – Network information
Default-IP: 192.168.1.10
DHCP default ON
The IP address can be assigned automatically from a linked-up DHCP server if the value "DHCP = On"
has been set (also refer to Chapter 6.2. Settings (scaling, interfaces, password)).
If no DCHP server is found in the network, the IP address will have been set to the above value.
Default login data (if default): Login:admin) / Password: admin (refer to Chapter 6.2).
Pressing the
Key
key returns the user to menu "LS804 – Information".
Scale indicates the 100% values (nominal characteristics) of sensors a to d (also refer to
Chapter 6.2 Settings (scaling, interfaces, password)).
Actuating
or brings about a display change of sensors a/b and c/d.
In addition the LS 804 variant (mV / mA) will be displayed as well as the current limit set.
M e a s . s c a l e s e t t i n g s
V a r : m V / L s : 2
a: 1 0 0 . 0 t
b: 2 0 . 0 t
Figure 18 – Scaled values for signal a and signal b
Actuating the button returns the user to menu " LS804 – Information".
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Manual Load Switch LS 804
5.3.3. Operating display for load spectrum recorders
Load spectrum recorders (LSR) are provided for displaying the service life of the individual sensors a to d,
computed in accordance with FEM Directive 9.755.
For this purpose, a signal is evaluated second-by-second, proportional to the load 0…100% of the
relevant hoist unit when this is operated and saved in a totalizing memory.
The contents of this totalizing memory constitute the actual useful life S. This can be displayed both in
hours as actual useful life S and as a percentage % as consumed useful life V = S/D.
Note: All inputting of the theoretical useful life D and the starting value for actual useful life S is
carried out employing a web browser (Chapter 6.5 Load spectrum recorders (LSR)).
Note: The service life is computed for each sensor individually and cannot be made up of
several input signals.
Pressing
(also refer to Chapter 6.5 Load spectrum recorders (LSR)).
L S 8 0 4 - L S R
S e n s o r a : -
S e n s o r b : R U N
S e n s a S e n s b E x i t
Figure 19 Operation display – Load spectrum recorders
Fig. 19 indicates that the totalized service life in respect of sensor b. The given example indicates an
operating signal arriving from hoist unit b). No operating signal is shown to be coming from sensor a (e.g.
hoist unit a).
Exiting of the display is carried out by pressing the
Actuating
In the given example pressing key
service life in respect of sensor a (hoist unit a).
L S R - S e n s o r a
D [ h ] : 1 2 0 0
S [ h ] : 1 2 3
V [ % ] : 1 0 . 2
and switches the system to the operation display containing the service-life indicator
key.
or brings about a display change of sensors a/b and c/d.
Sens a makes it possible to access to information on the
Figure 20 - Service-life display – Sensor a
Exiting of the display is carried out by pressing the
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key.
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5.4. Configuration via keypad
Note: Where configurations are triggered via the web browser, the respective setting options are
blocked by LCD / keypad so as to prevent operating errors.
Pressing
and triggers change to the Adjustments Menu governing the sensor signals.
In menu LS804 – Functions it is possible to carry out readjustments to the sensor signals a to d in respect
of zero load (0%) and full load (100%) as well as changes to the switching points. A precondition for this
is that the configuration has previously been carried out via the web browser.
L S 8 0 4 - F u n c t i o n s
L i m . A d j . E x i t
Figure 21– Function menu
Lim.: Menu for setting the limits on the current limit set (refer to 5.4.1 Limits)
Adj.: Adjustments Menu for setting the zero load and final value (refer to 5.4.2 Adjustment).
5.4.1. Limits
In the "Limit" menu, the display on the LS 804 only shows the values of the current limit set. This will have
previously been accessed to by means of an input signal or determined in accordance with Chapter 6.4
Limits (K1 to K6) with the "Limit set" function. On the LS 804 it is possible to deposit up to 8 limit sets.
Depressing
or serves to trigger selection of the limit.
Actuating
or brings about a change in the values of the relevant limit.
must be pressed to complete the changes to the display!
If this is not done, it will not be possible to access to information on other switching points using keys
or
.
1 : O L [ N ] + a
1 4 0
R e l : 1
Display: Limit No. with measurement unit & sensor config.
Value for limit or period of delay
Allocated relays
K1 to K6.
R e a d E x i t
Figure 22 – Display of switching point (where overloading occurs of 140% in respect of sensor a, relay 1
(K1) will be switched off with a time lag).
1 : D e L a y [ m s ]
5 0 0
R e L : 1
R e a d E x i t
Figure 23 - Display of switching point (where a switching condition is met for signal a, relay 1 (K1) will be
switched off if that switching condition is not met after 500 milliseconds).
Note: Allocation of the switching relays K1 to K6 can only be set via a web browser! (Refer to
Chapter 6.4 Limits (K1 to K6)).
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5.4.2. Adjustment
Sensors a to d can be accessed to in the Adjustments Menu.
The sensor signals a and b can be adjusted in accordance with the following illustration (Fig. 25):
Using cursor keys
sensors c and d.
A d j u s t m e n t
A d j u s t m e n t O K !
S e n s a S e n s b E x i t
Figure 24– Adjustments menu for selecting sensor a or b
A d j u s t m e n t - S e n s a
2 0 0 N
1 0 0 %
> 0 < 1 0 0 % E x i t
Figure 25– Adjustments menu for sensor a
>0<: Adjustment of zero load >0<. A precondition is that the signal of sensor a is load-free.
or facilitates switching back and forth to and from the display containing
100%: Adjustment of full load 100%. The signal of sensor a must generate a 100% load!
Caution! When actuating the keys >0< and 100% the values are only set
temporarily. The values are not saved until the Adjustments menu is quitted by pressing
Exit!
Exit: Exiting of Adjustments menu and prompting to save adjustment "Save Adjustment?"
Adj.: Repetition of adjustment process.
Yes: Saving of readjusted temporary values.
No: Exiting of menu without saving the adjusted temporary values.
The same process is carried out in respect of adjustments to sensors c and d.
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6. Configuration via web browser
The configuration routine is accessed to via the browser by means of the IP address specified under
Chapter 5.3.2 Operating display / network for browser accessing (Figure 17 – Network information).
The LS 804 load switch has been operably tested under the following browsers/operating systems:
- WindowsXP Web-Browser Chrome, Firefox, Opera, Internet-Explorer
- Windows7/8/10 Web-Browser Chrome, Firefox, Opera
6.1. Status (information)
After the configuration routine has been accessed to via the browser, the following image will appear:
Figure 26 – Status information (LS804.01)
The "Channel information" section contains the display for sensors a to d as well as the cumulative loads
a/b, c/d and a-d along with additional system information.
In the event of an error occurring, the causes of failure can be determined by actuating the “Error Status”
link (also refer to Chapter 7.2 Status of relays Error1 and Error2).
Actuating the "Relay status" link will display the status of the contacts K1 to K6 (also refer to Chapter 7.1
Status of relays K1 to K6).
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6.2. Settings (scaling, interfaces, password)
By accessing to the “Settings” window it is possible to display and modify the current data.
Any changes made to the settings are written into the device by pressing the button.
Figure 27 – Settings, basic settings
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Manual Load Switch LS 804
Measurement scale settings
Entry of 100% values in respect of sensors a to d. This might be for example the rated loads of hoist unit
a and b. The values can only be entered as whole numbers. Any of the sensors can be disabled at will.
Note: Where changes are made to the individual sensors, the LS 804 will automatically switch
over to the Adjustments Mode after the “OK” button has been pressed.
Analogue out settings
The analogue outputs can be configured either as voltage or current outputs. The reference value for
signal is the 100% value entered above when selecting signal a to d or, when selecting Sum, the 100%
value of the relevant sum.
CAN settings (X1)
When setting the cyclical value output – “Values out” to ON – outputting of the following values takes
place on the CAN interface together with the configured interval – “Values out interval”.
Output-interval settings are possible from 50…5000 ms.
Two CAN telegrams with different CAN IDs are sent with the float values of sensors a and b or sensors c
and d.
ID send (base):
DLC B0 B1 B2 B3 B4 B5 B6 B7
8
a_float a_float a_float a_float b_float b_float b_float b_float
ID send (base+1):
DLC B0 B1 B2 B3 B4 B5 B6 B7
8
c_float c_float c_float c_float d_float d_float d_float d_float
RS485/RS232 settings (X2)
When setting the cyclical value output – “Values out” to ON – outputting takes place of the following
formatted ASCII telegram on the serial interface cyclically with the configured interval – “Values out
interval”.
"a:%s b:%s c:%s d:%s Sab:%s Scd:%s Sabcd:%s\r\n"
In the configured scaling these values are transmitted with decimal places and unit of measurement.
Output-interval settings are possible from 1…240 s (4 Min.).
Security settings
Factory default Security settings (Login admin), when set
Username/Login (not changeable) admin
Password admin
Master password 1803
An existing password is deleted by erasing the contents of fields Password and Password confirmation
and then entering the Master password.
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6.3. Adjustment (load calibration)
This is where adjustment of the LS 804 to the sensors essentially takes place.
Accessing to the “Adjustment” window will display the current data on "Sensor characteristics".
Figure 28 – Adjustment, setting the LS 804 according to sensor characteristics (LS 804.01)
Figure 29 – Adjustment, setting the LS 804 according to sensor characteristics (LS 804.02)
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Manual Load Switch LS 804
Button
Release of "Adjustment" feature for changes and calibrations. The header "Adjustment
active" will appear.
Saving of entered values for sensor characteristics.
Saving of entered values – and calibrations where applicable – from the temporary memory
buffer on the device.
Exiting this menu without taking over the entered values; the current data will be retained.
An adjusted characteristic is deleted and the factory default setting adopted. The appliance
needs the be re-adjusted!
Table 5 – Buttons Adjustment
Sensor characteristics
Indication of characteristics for sensors a to d at maximum anticipated load signal.
Load calibration
Calibration of sensors a to d takes place here.
Note: No functioning of the LS 804 will be possible unless the sensors (load calibration) are
adjusted. Incorrect adjustment or no adjustment at all will unleash the following message: Adj. not
OK!"
Further information on adjustment status will be found under 6.3.1 Adjustment status !
Caution! Adjusted values (load calibration) will not be taken over by the LS 804 until the SAVE
button is pressed! As long as the values have not been taken over the following message will
appear: "Adj. not saved!" !
Adjustment status
Refer to 6.3.1 Adjustment status.
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6.3.1. Adjustment status
Via the „Adjustment status“ link it is possible to check whether all necessary steps have been performed
and completed for adjustment.
Figure 30 – Adjustment status – Adjustment completed
Figure 31 – Adjustment status – Adjustment wrong
Meaning of various flags:
1 = OK / 0 = not OK
NullP: Adjustment zero point Button > 0 <).
EndP: Adjustment final point or adjustment with load (Button Load).
Justage Done: Completion of adjustment (Button Save).
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6.4. Limits (K1 to K6)
Accessing to the "Limit set" window will display the current settings in respect of switching points K1 to K6
for that particular limit set currently in use.
Figure 32 – Limits
"Enable change with dig. Inputs" allows the disabling or enabling of the limit switching by means of digital
inputs 1 ... 8.
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Button
Release of "Limits" for changes. The header "Limits active" will be displayed.
Accessing to a limit set as that currently due to be edited.
Repeated reading of limit sets and display of current values. Corresponds to Start
button.
Saving of displayed limit set in a temporary memory buffer.
Saving of limit sets placed from the temporary memory buffer on the device and
takeover of current limit set to the LS function.
Exiting of this menu without taking over the limit values.
Table 6 – Buttons Limits
Up to a total of eight limit sets can be defined under "Limits".
Allocation of the contacts to the sensors takes place on flexible lines. Depending on the allocation, the
contacts will open if overload conditions prevail (Type - Overload/Ovl) and/or if underload conditions
prevail (Type - Underload/Unl).
Any number of individual sensors or cumulative/differential loads can be monitored.
A time lag of up to 5 seconds can be entered for the opening action (inputtung in ms). If the signal falls
back below the switching point within this delay period, the Open command will be cancelled.
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6.5. Load spectrum recorders (LSR)
Accessing to the “LSR” page will display the following image:
Figure 33 – Load spectrum recorders (LSR)
Theoretical values
Theoretical useful life D (Useful life) is entered in the Theoretical values field in respect of signals a to d
as well as the starting values pertaining to actual useful life S (Start value) of the respective sensors.
The values are saved by pressing the
button.
Runtime values
The Runtime values field displays the following:
Mode: RUN if one sensor is active (Raise/Lower) i.e. the useful life will be computed
S(run) [h]: Actual useful life
V=S(run)/D [%]: Consumed useful life
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6.6. Configuration / Config
Accessing to the "Config" window makes it possible to document the current settings.
For this purpose it is necessary to press the button marked “Generate current config file”. This then
creates config.txt and config.bin files including the date and time stamp of the PC.
This config.txt file documents all relevant settings/data for operating the LS 804
The config.bin binary file is suitable for recovering the settings.
Caution! When settings undergo any change on the LS 804 the files config.txt and config.bin will
be deleted and afterwards need to be recreated.
Saving the config.txt and config.bin files is performed by the user in the usual way.
Figure 34– Config.
It is possible to select a binary file by means of the button “Datei auswählen“/“Select file“ and to send it to
the LS 804 by pressing the “Send“ button. A check is carried out of the device type and checksum of the
binary file. After the binary file has been successfully loaded without any errors, the settings can be saved
on the LS 804 by means of the button “Write config to device“
Caution! After the binary file “config.bin“ has been saved on the LS 804, the sensors will need to
be adjusted and saved (refer to Chapter 6.3 Adjustment (load calibration)). The limit values will
also need to be saved (refer to Chapter 6.4. Limits (K1 to K6)).
Note: The length of the file name for recovery of the settings must not be allowed to exceed 31
characters.
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7. Maintenance / Error messages
7.1. Status of relays K1 to K6
The status of relays K1 to K6 as well as Error1 and Error2 is queried by means of the browser, Chapter
6.1 Status (information), link “Relay status”. The relay-flags window that opens displays the status of the
contacts corresponding to the settings specified in Chapter 6.4 Limits (K1 to K6).
Figure 35 – Relay flags (0 - closed, 1 - open: Switching condition met in accordance with Chapter 6.4).
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7.2. Status of relays Error1 and Error2
In the event of a system failure or similar circumstances occurring causing the LED Error to light up red,
the error-flags window can be opened by means of the browser, Chapter 6.1 Status (information), link
“Error status”.
Figure 36– Error-Status (0 - closed, 1 - open: Error message)
Where a system error occurs, all relays (K1 to K6 and Error1 / Error2) will be de-energised!
Caution! The LS 804 can only be returned to the operating state (LED Run lights up green) after
the causes of failure have been eliminated and the device has been started up with key
Reset or input IN12.
-
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8. Instructions in the event of failure
The most probable causes of failure – “Sensor errors” (Chapter 8.2. Sensor errors and “Adjustment
errors” (Chapter 8.3) – will be found specified in Table 7 and Table 8. Allocation to Ch1 and Ch2 is of no
importance.
8.1. Error overview
Note: Any error flags that are set are always identified by “1“, the non-fault state being indicated
by a “0”.
8.1.1. Error overview / Sensor errors
Code Failure Remedy
HW:x1
(SF:20)
HW:x2
(SF:20)
Table 7 – Examples of sensor errors
Sensor a: Sensor error / Very high overload. Check cable connection for short-circuiting or
rupture. Check sensors.
Sensor b: Sensor error / Very high overload. Check cable connection for short-circuiting or
rupture. Check sensors.
8.1.2. Error overview: hardware failure / adjustment errors
Code Failure Remedy
HW:x8 Supply voltage(s) for sensors / Sensor
errors.
HW:x3Adjustment has not attained completion for
sensor a and b or c and d.
HW:x2Adjustment has not attained completion for
sensor b or d.
HW:x1Adjustment has not attained completion for
sensor a or c.
Table 8– Examples of hardware failure/adjustment errors
The applicable SF-values for all errors listed in Table 8 are always optional SF=xx.
Note: Communication errors involving logic units L1/L2 are atypical and are shown as SF=00 /
HW=00 (refer to Chapter 8.4.).
The following chapters contain information on errors that occur along with their respective indications in
the LCD display as well as on the status website.
Check cable connection for short-circuiting or
rupture. Check sensors. Check supply voltages.
Carry out adjustment (Chapter 6.3 Adjustment).
Carry out adjustment (Chapter 6.3 Adjustment).
Carry out adjustment (Chapter 6.3 Adjustment).
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8.2. Sensor errors
This type of error can be caused for example by wire breakage on +SI b (terminal 44).
The error is identified by SF=xx / HW=02.
F A T A L - E R R O R !
C h 1 : S F : 0 0 / H W : 0 2
C h 2 : S F : 2 0 / H W : 0 0
I P F l a g s R e s e t
Figure 37 – Sensor error / Sensor b – display (error display)
Actuating key
Flags and keys or makes it possible to display the respective sensor errors
(HW flags). Any additional error occurring on the sensor supply system can be displayed by pressing key
V-Exc.
H W - F l a g s
a : 0 b : 1 c : 0 d : 0
V - E x c : 0
V - E x c E x i t
Figure 38 – Sensor error / Sensor b – display (HW flags)
8.3. Adjustment errors
This type of error is caused by the device not having been adjusted or following deletion of an adjustment
or as a result of the adjustment of sensors a to d not having been carried out or completed.
The error is identified for example by SF=xx / HW=01.
R u n - A d j . n o t O K !
a : 2 0 . 4 t
b : 1 . 5 t
E r r c / d R e s e t
Figure 39 – Adjustment error / Start – display (measured-value display)
By actuating key
Err it is possible to display the error information on the individual sensors a to d
(refer to Chapter 7.1).
H W - F l a g s
a : 1 b : 0 c : 1 d : 0
E x i t
Figure 40 – Adjustment error / Display (error display)
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Figure 41– Adjustment error / Start – Status
After the adjustment function has been accessed to, the LCD will indicate whether adjustment is
erroneous or free of errors.
A d j u s t m e n t
A d j u s t m e n t n o t O K !
E x i t
Figure 42 – Adjustment erroneous
A d j u s t m e n t
A d j u s t m e n t O K !
E x i t
Figure 43 – Adjustment free of errors
8.4. Communication errors / Logic units L1/L2
This type of error is caused by faults occurring in communication with the logic units L1/L2 (Ch1/Ch2).
The error is identified by an error message SF=00 / HW=00.
S t a r t - E R R O R !
C h 1 : S F : 0 0 / H W : 0 0
C h 2 : S F : 0 0 / H W : 0 0
R e s e t
Figure 44 – Communication error – Display (Error display)
Figure 45 – Communication error – Status
If the error continues to occur after a “Reset”, this points to a hardware defect on one or both of the logic
units L1/L2.
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9. Technical data
Sensor inputs
LS 804.01
for DMS sensors
LS 804.02
for 4 ... 20mA sensors
Input signal range (+Si/-Si)
Impedance range for DMS bridge.
Supply voltage for DMS bridge (+Ex/-Ex)
Voltage supply
Operating voltage
Power consumption
Connection terminals
Switching inputs Schalteingänge IN 1 ... 16
Optocoupler groups 4 x 4
Return lines using plug-in jumpers“IN___R”
Connection terminals
Switching outputs K1 ... 6 and Error 1...2 LED display
Normally open contacts, force-guided
Switching voltage / switching current
Switching capacity
Service life – electrical
Service life – mechanical
Connection terminals
Analogue outputs
2x current outputs / max. load
OR
2x voltage outputs / min load
Connection terminals
Digitale Schnittstellen
VDC
LED display
VDC
W
mm²
mm²
Switching
cycles
mm²
mA / Ω
V / kΩ
mm²
-5.0mV/V ... +5.0mV/V
Bridge resistance: 350 ... 1000 Ω
5.0 / 3.3
18 ... 36
max. 15
Screw terminal up to 1.5
“direct” or “+24VDC” or “0V
Screw terminal up to 1.0
DC1: 24V/2A DIN EN 60947-4-1 and 60947-5-1
60mW ... 50 W(VA)
100,000 switching cycles
> 10 mill. switching cycles
Screw terminal up to 1.5
4mA ... 20mA/ 500Ω
0V ... 10V/ 1kΩ
Screw terminal up to 1.0
4mA ... 20mA
Max. load: 25mA/sensor
24 ± 10%
Ethernet
CAN
RS485
Load spectrum recorders - LSR
Input values
Time basis
Output values
Display / keypad
Display
Lamps
Keypad
Ambient conditions
Working temperature range
Storage temperature range
Interference immunity
Interference emission
Vibration resistance
Impact resistance
Design data
Weight
Dimensions (W x H x D)
Mounting
Environmental protection EN 60529
RJ45 / parameterisation
h
h
4-line LED display, 16 characters per line
°C
°C
Metal housing for standard rail mounting
kg
mm
S: starting value, consumed useful life 1/3600
Indication in display and website
Membrane keypad: Cursor cross, three function keys F1 ... F3
-20 ... +60, relative humidity <95% at 40°C
-25 ... +70, relative humidity <95% at 40°C
9-pole SUB-D
9-pole SUB-D
D: Theoretical useful life
7 LED status displays
DIN EN 61000-6-2
DIN EN 55011-B
DIN EN 60068-2-6
DIN EN 60068-2-27/-29
102 x 105 x 205
on mounting rail TS35
1
IP 40
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10. Project planning assistance
Settings (scalings) Sensor a Sensor b Sensor c Sensor d
Signal used
Meas. scale set.
Final Value (100% Load)
AnalogOut 1/2
Analogue output 1
Analogue output 2
Type
(4…20mA od. +/-10V)
(a,b,c,d, Ʃa+b, Ʃc+d, Ʃa-d)
Signal
Adjustment (adjustment) Sensor a Sensor b Sensor c Sensor d
Sensor
characteristics
Load calibration
Input sensitivity
(mV/V oder mA)
Zero load (no entry)
Test load
Limits
(switching points)
Term
(+/- a/b/c/d)
Type
(Ovl Unl)
Value
(Unit)
Delay
(ms)
K1 K2 K3 K4 K5 K6
Limit 1
Limit 2
Limit 3
Limit 4
Limit 5
Limit 6
Limit 7
Limit 8
LSR (load spectrum recorders) Sensor a Sensor b Sensor c Sensor d
Theoretical useful life D (h)
Starting value / actual useful life S (h)
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11. EC declaration of conformity
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