Hirschmann iVISOR mentor QVGA Service Manual

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iVISOR

mentor QVGA

Contents

Service Manual

Edition 2/2009 Rev. A

The order code for this document is 24 183 69 1012e (Generic)

General information

Important notes

Service menus

Troubleshooting

Appendix: Wiring Diagrams …

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TABLE OF CONTENTS

1. General information ........................................................................... 3

2. Important notes.................................................................................. 5

3. Sensor calibration.............................................................................. 6

3.1 Zero-setting the pressure signals......................................................... 8

3.2 Zero-setting the slewing signal........................................................... 10

3.3 Length sensor calibration procedure .................................................. 12

3.4 Angle sensor calibration procedure.................................................... 15

4. Troubleshooting............................................................................... 19

4.1 General information............................................................................ 19

4.2 Error code list ..................................................................................... 20

Revision History ................................................................................. 26

Appendix: Wiring, Drawings, Spare Parts

The manufacturer reserves the right to modify the contents of this manual without notice. Hirschmann will not be liable for errors contained in this manual or for incidental or consequent ial damages in co nnection w ith t he 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 w ithout 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 use d or reproduced without the written consent of Hirschmann. The drawings and/or photos are subject to technical modification without prior notic e.

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

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Configuration Setup

1. GENERAL INFORMATION

This manual describes the service menus of the iVISOR mentor QVGA load moment indicator (LMI)

and assists a service or maintenance person in identifying system malfunctions.

NOTE: Knowledge of system and CAN bus wiring is assumed. REFERENCE: Refer to Operator’s manual 24 183 19 1012e (Generic) for detailed operation of

the mentor QVGA.

The iVISOR mentor QVGA load moment indicator system comprises a central microprocessor unit

with an integrated display and control console together with various sensors to record the measured values. The system components are connected via CAN bus.

Components of the iVISOR mentor QVGA LMI system

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Configuration Setup

Components:

CPU/Console: The iVISOR mentor QVGA load moment indicator comprises a central

microprocessor unit with an integrated display and operating console together with various sensors to record measured values. The system components are connected via CAN bus. The iVISOR mentor QVGA displays all geometrical information such as length and angle of main boom, working radius and tip height of the boom. It also displays the actual load and the maximum load permitted by load chart. Furthermore, it has an acoustical alarm, 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 antiblock condition.

Length-Angle Transducer: The length-angle sensor gSENS 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.

Pressure Transducer(s): A pressure transducer pSENS DAVS converts hydraulic

pressure into a CAN signal. One (or two) pressure transducer is (are) connected to the piston side of the lift cylinder and one to the rod side.

Slew Angle Sensor: The gSENS DW G sensor converts the circular motion of the upper

structure of the crane into a CAN signal.

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Configuration Setup

2. IMPORTANT NOTES

The LMI is an operating aid that warns the crane operator of imminent overloading or of the approach of the hook block to the boom head, in order to avoid possible property damage or injury to personnel.

The device is not, nor is it intended to be, a substitute for good operator judgment and/or experience, nor does it remove the need for utilizing only recognized safe procedures during crane operations.

The crane operator continues to bear ultimate responsibility for safe operation of the crane. He must ensure that he fully understands and follows the displayed notes and instructions in their entirety.

The LMI is not able to provide aid to the crane operator unless it has been properly adjusted and unless the correct load capacity chart and the correct operating code have been entered for the respective rigging configuration. The correctness of the LMI settings must be guaranteed before beginning crane work in order to avoid damage to property and severe or even fatal injuries to personnel.

This system can be equipped with an external key-operated switch located in the crane operator's cab. This key-operated switch overrides control lever function switch-off by the LMI or by the hoist limit switch system. This switch may only be used during emergency situations, and even then only by authorized personnel. Failure to observe these instructions could result in damage to property and severe or even fatal injuries to personnel.

The LMI cannot perform correctly unless it has been properly adjusted. The prerequisite for this is making conscientious and correct entries during the set-up procedure, in accordance with the actual configuration of the crane. The correctness of the LMI settings must be ensured before beginning crane work in order to avoid damage to property and severe or even fatal injuries to personnel.

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Sensor Calibration

3. Sensor Calibration

In this code-protected area, settings affecting system precision can be made by trained service personnel. For access to the calibration menus it is necessary to input a matching 5-digit code.

To start the function:

▼ Info screen

Actuate the INFO key.

to service menus

back

▼ Entry to calibration menus

abort input of service code

increase marked numeric value

reduce marked numeric value

mark the next figure, access after the last valid figure

If an invalid service code is entered, you are prompted to enter it again or to abort the input.

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Sensor Calibration

After entering the service menu you can follow the calibration procedure step by step or can select the type of calibration by scrolling with function key

. Press "ESC" to finish calibration procedure:

3.1) pressure signal piston side

… and rod side 3.2) slewing angle

signal

3.3) boom length signal

3.4) boom angle signal

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Sensor Calibration

3.1 Zero-setting the pressure signals

NOTE: The only thing adjustable for the pressure transducers is the zero point, which is the signal the

transducer outputs when there is no (zero) pressure sensed.

Ensure there is no pressure in the hydraulic line when

disconnecting the hoses from pressure transducers!

The display shows which transducer (piston-side, rod-side or force) is being zeroed and a horizontal dial marks the present pressure (or force) difference in %.

NOTE: there are two

calibration screens: for piston and for rod transducer.

NOTE: The operating range for zero-setting this value is from -1% to +1%. Press and release the “AUTO >CAL<” key multiple times until the zero-setting starts.

The indicator line must move to zero on the dial, otherwise the zero-setting of this value is not correct!

▼ Zero point adjustment, pressure piston side:

leave the service menu

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carry out zero point setting

skip calibration step / go to next menu

Sensor Calibration

▼ Zero point adjustment, pressure rod side:

leave the service menu

carry out zero point setting

skip calibration step / go to next menu

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Sensor Calibration

3.2 Zero-setting the slewing signal

NOTE: The only thing adjustable for the slew potentiometer is the zero point, which is complete when

the boom is at the 0° and 180° position of the crane.

NOTE: The range for zero-setting this value is from -10° to +10°./ ±170° to 190° Press the “AUTO >CAL<” key until the zero-setting starts. The indicator line must move to zero

on the dial, otherwise the zero-setting of this value is not correct!

▼ Zero point setting, slewing angle 0° position:

leave the service menu

▼ Zero point setting, slewing angle 180° position:

carry out zero point setting slewing angle for 0° position

skip calibration step / go to next menu

leave the service menu

carry out zero point setting slewing angle for 180° position

skip calibration step / go to next menu

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Sensor Calibration

3.3 Length sensor calibration procedure

NOTE: The length sensor can be calibrated for its zero point and its full range.

With retracted boom, the potentiometer of the length sensor has to be at its 0 position, which is all the way counter-clockwise. For extended boom, the adjustment is done by software as described below.

The length should be calibrated to be about 0.1 feet (or 0.05m for metric) accurate for retracted and extended lengths. Perform the following steps:

▼ Start screen zero point adjustment, boom length:

leave the service menu

Start length calibration

▼ Start screen min. boom length:

leave the service menu

skip calibration step / go to next menu

• Fully retract the main boom and check if indicated length is within 0.1 feet (or 0.05m for metric) of actual retracted boom length.

• If it is not

, adjust length potentiometer mechanically as described below:

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Sensor Calibration

• With boom fully retracted turn the center screw of the length pot unit counter clockwise to a soft

stop.

• During adjustment an additional button "OK" appears. Check value and set actual length as fully retracted length by pressing OK.

▼ Adjustment, min length:

leave the service menu

carry out min. boom length setting

skip calibration step / go to next menu

Afterward next calibration screen appears:

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Sensor Calibration

▼ Start screen maximum. boom length:

leave the service menu

skip calibration step / go to next menu

• Now extend main boom all the way out. Make sure you are within the allowed operating range (especially maximum radius).

• During telescoping out the boom an additional button "OK" appears.

▼ Adjustment, maximum length:

leave the service menu

carry out max. boom length setting

skip calibration step / go to next menu

• Check whether boom is fully extended, then press "OK". Afterward next calibration step (angle) appears.

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Sensor Calibration

3.4 Angle sensor calibration procedure

The angle sensor can be calibrated for its zero point, with steep boom (75°) and one or two additional angle values (40° / 65°)

Material required: calibrated inclinometer

▼ Start screen adjustment, boom angle:

leave the service menu

Start angle calibration procedure

▼ Start calibration for "zero degree" angle:

leave the service menu

skip calibration step / go to next menu

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Sensor Calibration

angle

sensor

• Boom down.

• Release adjustment screws of the angle

sensor.

• Mechanically adjust top of angle sensor housing exact parallel with boom by help of inclinometer.

• Fix adjustment screws of the angle sensor.

Having adjusted the angle sensor mechanically check value and press "OK" for the next step.

▼ Calibration for "zero degree" angle:

leave the service menu

calibrate next angle

skip calibration step / go to next menu

• Now boom up to 40°, (range is 35°- 45°)

▼ Calibration for "40°" angle:

leave the service menu

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calibrate next angle

skip calibration step / go to next menu

Sensor Calibration

When the boom angle is within the calibration range, the screen will add the ‘CHANGE ?’ / ‘SET’ and ‘OK’ text as shown below:

▼ Calibration for "40°" angle:

leave the service menu

adjust actual angle

set current angle to defined angle

• Measure the boom angle with the inclinometer and when the boom is positioned in the calibration range, compare the measured angle to the displayed angle.

• If the indicated angle is within +/- 0.1 degrees of the measured angle, confirm with ‘OK’. Otherwise, select ‘SET’ to adjust the angle.

▼ Adjust "40°" angle:

leave the service menu

increase angle value by 0.1°

Confirm

decrease angle value by 0.1°

• Once you push ‘SET’ , the screen is going to change to the angle adjustment screen. Use the ‘+’ and ‘-‘ buttons to adjust the indicated angle to match the measured angle.

• When the display shows the correct angle, press ‘OK’.

Press ESC to leave sensor adjustments and return to normal LMI screen.

• Now repeat procedure as shown for the boom angle 65° and 75°.

If values were modified a confirmation screen appears at the end:

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Sensor Calibration

▼ Confirmation screen

leave the service menu

YES, I confirm

NO, go to next menu

• When you are sure to save this calibration, press ‘OK’. Normal LMI screen appears. Otherwise press "Return" for restart the calibration procedure

Press ESC to leave sensor adjustments and return to normal LMI screen.

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Troubleshooting

4. TROUBLESHOOTING

4.1 General information

In the event of a malfunction, if the range is not reached or is exceeded or if an operating error is detected by the system, a message appears on the data display (1) starting with an “E” followed by a two-digit code which indicates the reason for the malfunction.

The error codes listed in the following table describe the various error codes which can be displayed in this system.

Faults in the microprocessor system must be dealt with only by the manufacturer’s trained customer service personnel. If faults occur, please contact Hirschmann Service USA:

www.hirschmann.com > USA > Electronic Control Systems > Contact - ECS.

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Error Code List

4.2 Error code list (System program LSQN V 1.11)

Error Code Error Cause Elimination

E01

E02

E03

E04

E05

E06

E11

Fallen below radius

range or angle range

exceeded

Radius range exceeded

or fallen below angle

range

Non-permitted slewing

zone (no load area)

Operating mode not

acknowledged or non

permitted slewing zone

Prohibited length range

Radius range exceeded

or fallen below angle

range with luffing jib

operation

Fallen below lower limit

value for measuring

channel "length main

boom"

• Fallen below the minimum radius or gone past the maximum angle specified in the respective load chart due to luffing up the boom too far

• Gone past the maximum radius or fallen below the minimum angle specified in the respective load chart due to luffing down the boom too far

• The slewing zone with load is not permitted

• A non existing operating mode has been selected

• The boom is in a non-permitted slewing zone

• Boom has been extended either too far or not far enough, e.g. if it is prohibited to go beyond a certain maximum boom length or with load curves for jibs where the main boom has to be extended to a certain length

• Length sensor adjustment has changed, e.g. the cable slid off the length sensor reel.

• Clutch between length sensor pot and drive is defective

• Maximum radius as specified in the load chart exceeded or fallen below minimum angle due to luffing down the luffing jib too far

• Length potentiometer is defective

• PDB variable for analog value not supported

• Electronic component in the measuring channel is defective

• Luff down the boom to a radius or angle specified in the load chart.

• Luff up the boom to a radius or angle specified in the load chart.

• Slew to permitted area

• Set the correct operating mode

for the operating state in question

• Slew the boom to a permitted area.

• Extend/retract boom to the correct length

• Retract boom. Check the prestress of the cable reel (cable must be taut). Open the length sensor and carefully turn the length sensor pot counterclockwise until the detent by means of a screw driver

• Replace the complete clutch including drive wheel and adjust length sensor pot as described above

• Luff the jib to a radius or angle specified in the load chart.

• Replace length potentiometer

• Setup of correct PDB variable

for analog value in DGA6.i.3

• Replace sensor unit

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Error Code List

Error Code Error Cause Elimination

E12

E13

E14

E15

E16

E17

E18

E1A

E1B

E1C

Fallen below the lower

limit value in the

measuring channel

"pressure piston side"

Fallen below lower limit value in the measuring

channel "pressure rod

side"

Fallen below lower limit

value in measuring

channel "force"

Fallen below lower limit

value in measuring

channel "angle main

boom"

Fallen below lower limit

value in measuring

channel "angle 2"

Fallen below lower limit

value "length telescope I

(+II)"

Front outrigger

overloaded

Fallen below lower limit

value in measuring

channel "slewing angle

1".

slew below allowed

range

Fallen below lower limit

value in measuring

channel "slewing angle

Fallen below lower limit

• Pressure transducer is defective.

• PDB variable for analog value not supported

• Electronic component in the measuring channel is defective.

• refer to E12 • refer to E12

• Force transducer defective

• Electronic component in the

measuring channel is defective.

• Angle potentiometer defective

• PDB variable for analog value

not supported

• Electronic component in the measuring channel defective.

• Angle potentiometer defective • Replace angle sensor

• Electronic component in the

measuring channel defective.

• Length potentiometer defective • Replace length sensor.

• Electronic component in the

measuring channel defective

• Front outrigger overloaded •

• Cable between the central unit

and the slewing angle sensor defective or loose. Water inside the plug of the angle sensor

• 1-cannel slew sensor min. value DGA 11.5.7 <> 0

• Slewing angle potentiometer is defective

• Electronic component in the measuring channel defective

• refer to E1A

• Angle potentiometer defective • Replace angle sensor

• Replace pressure transducer

• Setup of correct PDB variable

for analog value in DGA6.i.3

• Replace sensor unit

• Replace force transducer

• Replace sensor unit

• Replace angle sensor

• Setup of correct PDB variable

for analog value in DGA6.i.3

• Replace sensor unit

• Check cable as well as plugs,

replace, if need be.

• move to allowed slew range

• Replace slewing angle sensor

• Replace sensor unit

• refer to E1A

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Error Code List

Error Code Error Cause Elimination

E21

E22

E23

E24

E25

E26

E27

E2A

E2B

E2C

E31

value in measuring

channel "luffing jib

angle"

Upper limit value in

measuring channel

"main boom length" has

been exceeded.

Upper limit value in

measuring channel

"pressure piston side"

has been exceeded

Upper limit value in

measuring channel

"pressure rod side" has

been exceeded.

Upper limit value in

measuring channel

"force" has been

exceeded.

Upper limit value in

measuring channel

"main boom angle" has

been exceeded.

Upper limit value in

measuring channel "angle 2" has been

exceeded.

Upper limit value in

measuring channel

"length telescope I (+II)

has been exceeded.

Upper limit value in

measuring channel

"slewing angle 1" has

been exceeded

slew above allowed

range

Upper limit value in

measuring channel

"slewing angle 2" has

been exceeded

Upper limit value in

measuring channel

"luffing jib angle" has

been exceeded

Error in the system

program

• Electronic component in the measuring channel defective.

• refer to E11

• refer to E12

• refer to E14

• refer to E15 • refer to E15

• refer to E16 • refer to E16

• refer to E17 • refer to E17

• refer to E1A

• 1-cannel slew sensor max.

value DGA 11.5.8 <> 0

• refer to E1A

• Angle potentiometer defective

• Electronic component in the

measuring channel defective.

• The system program file is defective.

• Flash-EPROM defective

• Replace sensor unit

• refer to E11

• refer to E12

• refer to E14

• refer to E1A

• move to allowed slew range

• refer to E1A

• Replace angle sensor

• Replace sensor unit

• Upload valid system software

• Replace central unit

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Error Code List

Error Code Error Cause Elimination

E32

E37

E38

E39

E43

E47

E51

E52

E53

E56

E57

E61

Error in the power

supply

Error in the logical

program flow

System program and

crane data file do not

match.

System program and

load chart file do not

match

Error in the write/read

memory, (RAM)

Error in the monitored

write/ read memory.

The CRC verification of

the monitored write/read

memory provides an

incoherent result

Error in the crane data

file

Error in load chart file.

Wrong setup of min.

analog inputs length1,

angle1, pressure1

Error in crane data file.

Error in serial crane

data file.

Error in the CAN bus

data transfer for all CAN

units

• +UB System not present at the system start

• +UB System not present at the system finish

• Contact problems at +UB switch off/on

• System program file is

defective

• Flash-EPROM defective

• The system program in the LMI

does not match to the programming in the crane data file

• The system program in the LMI and the programming in the load chart file do not match.

• Write/read memory (RAM) or central unit defective.

• The CRC sign of the monitored write/read memory is wrong

• The buffer battery is decharged (< 2V at 1kOhm).

• Central unit defective.

• No valid data in the crane data

file.

• Flash-EPROM defective

• No valid data in the load chart

file

• Flash-EPROM defective

• Analog input not supported • Setup correct Flag in in DGA

• No valid data in the crane data

file during calibration.

• Flash-EPROM defective

• Calibration data file does not

contain valid data.

• Flash-EPROM defective

• CAN Bus cable between the

central unit and the sensor unit defective or not connected.

• Can bus port in the central unit defective

• +UB System and +UB Power must be wired separately: +UB System connected direct with the crane battery. +UB Power for switch on/off

• +UB switch off/on again

• Upload valid system software

• Replace central unit

• Upload valid system program

file or the valid crane data file

• Upload valid system program file or the valid load chart file

• Replace central unit

• Restart the LMI

• Replace buffer battery on the

central unit.

• Replace central unit

• Upload valid crane data file

• Replace central unit

• Upload valid load chart file

• Replace central unit

6.i.2

• Restore or upload valid crane data file

• Replace central unit

• Upload calibration data file by

changing data (OM, limits) and save

• Replace central unit

• Check the connection between

the central unit and the sensor units

• Replace the central unit

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Error Code List

Error Code Error Cause Elimination

E62

E63

E64

E65

E66

E67

E68

E69

E84

E85

E89

E98

EAB

EAC

Error in the can bus data

transfer of the pressure

transducer sensor unit

Error in the can bus

pressure transducer

sensor unit

Error in the can bus data

transfer of the

length/angle sensor unit

Error in the can bus

length/angle sensor unit

Error in the data of the

digital I/O MENTOR

Error in the can bus data

transfer of the digital I/O

external module

Error in the can bus data

transfer of the force

sensor unit

Error in the can bus

force sensor unit

Wrong rigging condition.

Error in the radius

determination

Operating mode

switchover with load.

LMI watchdog activated

Short circuit in the A2B

switch circuit

(not with radio A2B)

A2B switch circuit

disconnected

(not with radio A2B)

• Short circuit in a CAN Bus cable

• Cable between the central unit and the sensor unit defective.

• Can bus port in the central unit defective

• Can bus port in the sensor unit is defective

• Sensor unit is defective • Replace the sensor unit

• The analog values of the

sensor unit are invalid

• See E62 • See E62

• See E63 • See E63

• PDB variable invalid • Change system software

• PDB variable invalid • Connect digital I/O external

• See E62 • See E62

• See E63 • See E63

• The selected rigging condition

is not contained in the crane data file.

• The computed radius is too small (negative deflection)

• The operating mode on the console has been switched over with the boom loaded.

• LMI processing time limit exceeded

• Short circuit in the A2B switch

• Short circuit in the cable to the

A2B switch

• Disconnected cable in the A2B switch

• Disconnected cable to the A2B switch

• Replace Can Bus cable

• Check the cable to the sensor

unit

• Replace the central unit

• Replace the sensor unit

• Change MENTOR

CAN module

• Select another rigging condition

• Check the programming in the

crane data file.

• Check the programming in the crane data file.

• Select operating mode without load on the boom

• Reset system

• Connect PC terminal and watch

error messages

• Replace A2B switch

• Replace cable to the A2B

switch

• Connect or replace cable in the A2B switch

• Connect or replace cable to the A2B switch

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Error Code List

Error Code Error Cause Elimination

EAD

EDB

EDC

EDD

EDE

EDF

EFD

No valid A2B switch

status

Datalogger setup error

Datalogger watchdog

activated

Battery empty

Record lost

Flash block full

LMI Watchdog

extra time

• Sensor wrong function

• CAN bus delay

• Radio telegram delay module

(radio A2B)

• Radio telegram ID is invalid

• Setup of the datalogger is

cleared (ser. crane data file or battery buffered RAM)

• datalogger processing time limit exceeded

• Battery check detected a low voltage of the battery

• Not possible to save data because other task saves data at the same time

• Not possible to save any more data

• a function needs more than 0.5 sec, e.g. Flash PROM write

• Replace A2B switch

• Replace cable to the A2B

switch

• Replace battery of radio module (radio A2B)

• Setup ID in DGA12.9

• transfer data and setup

datalogger again

• Reset system

• Connect PC terminal and watch

error messages

• change battery, after this setup of RTC

• Message disappears after a few seconds

NOTE:

If an error message not included in the above list is displayed, please contact Hirschmann Service USA: www.hirschmann.com > USA > Electronic Control Systems > Contact - ECS.

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Revision History

Rev. Date Changes Name

Rev. A 2009-02-26 First edition

System software SQG2 V 3.14 LMI software LSQN V 1.11 (20090223) Graphics V 1.00 Application MQVGA V 1.00 (20090220)

Konopka

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Hirschmann iVISOR mentor QVGA Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual