Hirschmann PAT IFLEX5 Service Manual

www.hirschmann.com

HIRSCHMANN

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

LOAD MOMENT INDICATOR

iFLEX5

SERVICE MANUAL

Service Manual iFLEX5

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

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

Service Manual iFLEX5

TABLE OF CONTENTS

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

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

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

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

3.2 DESCRIPTION OF A CAN BUS SYSTEM ......................................................................................... 2

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

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

4.1 I HAVE 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 I HAVE AN A2B PROBLEM ............................................................................................................ 4

4.8 I HAVE A CAN-BUS PROBLEM .................................................................................................... 4

4.9 I NEED TO IDENTIFY A SPARE PART ............................................................................................... 4

4.10 I HAVE NOTICED WATER IN SOME PART OF THE SYSTEM ................................................................. 4

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

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

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

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

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

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

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

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

9 Load 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

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

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

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

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

12.4.1 E64 - 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

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

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

14.1.3 Manual / 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

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

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

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

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

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

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

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

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

15.5.4 Luffer 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

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

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

17.4.3 Cable 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 antitwo-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!

Angle Sensing

Terminal X21

+ 5V

Signal

GND

Pressure Transducer

iFLEX5

Angle

Sensor

CAN-Bus

Converter

Cable Reel

LED

X21 (angle)

X20 (length)

X14 (A2B)

X1 (CAN)

5 ANGLE SENSING

The System measures the angle of the main boom of the machine with an angle sensor. The angle sensor is contained within the cable reel, located on the left side of the main boom.

Block Diagram

The signal runs from the angle sensor to the Can-Bus converter board, both located in the cable reel. From there, it travels as digital information on the CAN-Bus to the pressure transducer, which acts as a T-connector to the main CAN-Bus running to the central unit.

So, what do you do when you are having a problem with your angle read-out? Start by verifying the angle display. Refer to the section “Troubleshooting A Sensor Problem Using

The Display” to call up the sensor signal on your console display. The CAN-Bus is digital and as such

will either transmit the signal correctly or not at all. If your readings are off, you have to determine what is causing the problem (reference the following flow charts).

CAN-Bus electronics in cable reel.

The angle sensor has a potentiometer built in that is driven by a pendulum. As the angle changes, so

will the pendulum and with it the potentiometer’s axle. The converter board supplies a constant

voltage of 5V to the angle sensor and in return monitors the voltage of the potentiometer. The terminal used is X21. The angle sensor is connected as follows:

5.1 ANGLE SENSING ERROR - FLOW CHART

Angle Sensing Error

First, verify the angle displayed through the console by using the sensor output screen.

Press the info button twice

Angle sensor is functioning

correctly.

Angle sensor range values:

4500mV at 0° 2500mV at 45° 500mV at 90°

Does the displayed

value differ from the

actual value?

Open the cable reel and locate the angle sensor (right) and CAN-Bus converter board (left).

Verify that the sensor is

being supplied with 5V

by measuring between

pin 5 (GND) and Pin 1

(+) of terminal X21.

Is the voltage

between the

range of 4.75

to 5.25V ?

Replace converter

board

If unplugging the angle sensor made the voltage return to

the acceptable range, replace the angle sensor. Follow

procedure for angle sensor installation and calibration.

compare

YES

Is the voltage

between the

range of 4.75

to 5.25V ?

1ST

2ND

MEASURE AGAIN

Continue with angle sensing

flow chart (next page)

Unplug angle sensor

and measure again.

2ND

Recalibrate angle

sensor. (Reference Angle sensor calibration

procedure).

Service Manual iFLEX5

Angle Sensing

Angle Sensor signal varies

Ensure the angle sensor returns a voltage

between 1.875V at 90° and 3.125V at 0°

Does the indicated angle vary by more than +/- 0.25° from

the actual angle?

Replace converter

board.

If this angle varies significantly

from your actual angle, replace

the angle sensor.

YES

Ensure correct software has been installed

and crane operator is not in error.

Verify the voltage by measuring

Between Pin 5 (GND) and Pin3

(signal) of terminal X21.

Angle Sensor Signal On Pin 3:

Angle Voltage

90 1.875 75 2.083 60 2.292 45 2.500 30 2.708 15 2.917 0 3.125

Note: Actual voltages will vary slightly.

Note: If you need to determine the angle for voltages other than

shown above, do so by using the following formula:

Angle (degrees) = 90 degrees – ((Voltage-1.875) * 72)

Service Manual iFLEX5

Terminal X20

+ (~ 4.8V)

Signal

- (~ 0.2V)

Pressure Transducer

iFLEX5

Cable Reel

Length

Sensor

CAN-Bus Converter

LED

X21 (angle)

X20 (length)

X14 (A2B)

X1 (CAN)

6 LENGTH SENSING

The system measures the length of the main boom of the machine with a length sensor. The length sensor is contained within the cable reel, located on the left side of the main boom.

Block Diagram

The signal runs from the length sensor to the CAN-Bus converter board, both located in the cable reel. From there, it travels as digital information on the CAN-Bus to the pressure transducer, which acts as a T-connector to the main CAN-Bus running to the central unit.

So, what do you do when you are having a problem with your length read-out? Start by verifying the length display. Refer to the section “Troubleshooting A Sensor Problem Using

The Display” to call up the sensor signal on your console display. The CAN-Bus is digital and as such

will either transmit the signal correctly or not at all. If your readings are off, you have to determine what is causing the problem (reference the following flow charts).

CAN-Bus electronics in cable reel. The length sensor has a potentiometer built in that is driven by a gear drive from the cable drum. As

the length changes, the cable drum will turn and with it the potentiometer’s axle. The converter board

supplies a voltage of about 4.7V to the length potentiometer and in return monitors the output voltage of the potentiometer. The terminal used is X20. The length sensor is connected as follows:

Length Sensing

Length Sensing Error

First, verify the length displayed through the

console is off by using the sensor output screen.

Press the info button twice

Length sensor is

functioning correctly.

Does the displayed

value differ from the

actual value?

Open the cable reel

and locate the length

sensor (right) and

CAN-Bus converter

board (left).

Does the indicated

length vary

significantly from the

actual length (more

than 0.3 feet)?

Replace length

sensor.

Proceed to next length sensing flow chart.

YES

Ensure the

cable reel has

5-8 turns of

preloading on

the reel.

Fully retract the boom and turn the screw of the length potentiometer with a small screwdriver counterclockwise to a soft stop, bringing the sensor voltage to 0V (+/- 0.1 Volt).

Measure voltage between

Pin 5 (-) and Pin 3 (signal)

of terminal X20 and compare.

Return to the indication screen and again compare the indicated and actual length.

YES

Press the info button twice

6.1 LENGTH SENSING ERROR - FLOW CHART

Service Manual iFLEX5

Length Sensor Signal on Pin 3

Turns

Voltage X20-5 to X20-3

Voltage GND to X20-3 0

0.00

0.16

0.46

0.62

0.93

1.09

1.40

1.56

1.87

2.03

2.34

2.50

2.81

2.97

3.28

3.44

3.75

3.91

4.22

4.38

4.68

4.84

Length Sensor varies

Replace

converter

board.

If unplugging the length sensor

made the voltage return to the

acceptable range, replace the

length sensor. Follow procedure

for length sensor calibration.

YES

1ST

2ND

Ensure the length

sensor is being

supplied with 4.7V by

measuring between

Pin 5 (-) and Pin 1 (+)

of the X20 terminal.

Is the voltage

between the

range of 4.7V

to 5.0V ?

See length sensor

signal chart below.

YES

Unplug the length

sensor and

measure again.

Is the voltage

between the

range of 4.7V

to 5.0V ?

The length sensor returns a voltage between 0.16V at 0 turns of the length pot (= fully retracted) and

4.84V at 10 turns. How many turns you get at full extension depends on the gear ratio, the boom length, the length cable used and the spooling pattern, so we cannot provide a standard table for it.

What we can give you for trouble-shooting, however is the following table that shows the expected output voltage (measured between X20-5 and X20-3 Signal) for each complete turn of the length potentiometer. Note that this does not sync to the number of turns of the cable reel, though:

Note: Actual voltages will vary slightly.

For the boom control system, the length sensors are the same as described above with the exception of cable reel internals (location of hardware, wiring, and gear wheels). Refer to the LWG520 and LG152 spare part list for these differences.

Pressure Sensing

iFLEX5

Pressure Transducer

(2)

Pressure-

Measuring

Cells

CAN-Bus

Converter

Pressure Sensing Error

First, verify the pressure displayed through the

console by using the sensor output screen.

Press the info button twice

Pressure transducers are

functioning correctly.

Does the

displayed value

differ from the

actual value?

The readout should

read 500mV (+/-

25mV) and 0 PSI.

If the reading is slightly off, small variations can be adjusted; see section Service Screen For Sensor Calibration.

Ensure that the pressure lines

are drained and disconnected.

Replace pressure transducers.

YES

7 PRESSURE SENSING

The System measures the pressure of the boom lift cylinder for both rod- and piston-side. Both sensors are contained within one box that also contains the electronics needed for amplification and creation of the CAN-Bus signal.

Block Diagram:

7.1 PRESSURE SENSING ERROR - FLOW CHART

Note: After exchanging the pressure transducer block, BOTH transducer channels need to be zeroed, see procedure Zero-Setting The Transducer Inputs.

The signal runs from the pressure transducer as digital information on the CAN-Bus to the central unit.

Service Manual iFLEX5

500

1000

1500

2000

2500

3000

3500

4000

0 45 90 135 180 225 270 315 360

SLEW ANGLE

MILLIVOLTS

Potentiometer 1 Potentiometer 2

0 45 90 135 180 -135 -90 -45 0

ANGLE

(deg)

SL ANG 1

(mv)

SL ANG 2

(mv)

717

2161

30.3

1174

2645

1680

3150

89.9

2158

3595

120.1

2641

3141

150.1

3144

2639

180

3595

2161

-150.1

3144

1681

-120.1

2642

1180

-90

2160

718

-60.1

1681

1168

-30

1172

1680

718

2161

iFLEX5

Slip Ring Assembly

Slew

Potentiomet

er with (2)

outputs

Current

Converter

Modular Slew Pot - Voltage on Service Screen

Display screen

for sensor inputs

8 SLEWING SENSING

The system measures the slewing (rotational position) of the crane’s upper with a slewing sensor. The slewing sensor is contained within the slip ring assembly.

Block Diagram

The slew potentiometer has two potentiometers built in that are driven by the slip ring axle. As the

slewing angle changes, so will the axle and with it the potentiometer’s outputs. Use the display screen by pressing ‘i’ (info) twice to show all sensor inputs.

The table to the right show measured millivolt reading for the slew potentiotmeter.

Slewing Sensing

Modular Slew Pot - Output Currents

0 90 180 270 360

Degrees

mA 2 mA 3

Slew Sensing Error

First, verify the slew angle displayed through

the console by using the sensor output screen.

Press the info button twice

Slew potentiometer is

functioning correctly.

Does the

displayed value

differ from the

actual value?

The slew unit output can be found on pins 8 and 9. In order to

measure current, however, you must disconnect a pin and

measure in line (between the cable from the slew unit and the

central unit). *The two outputs will vary as shown in chart below.

YES

Ensure that the slew pot unit

is supplied with crane voltage.

Pin 7 must carry crane

voltage and Pin 2 is GND.

You can also leave the wires connected as use your meter in

Voltage-mode to measure the output signals. In this case, you

will see the 4…20mA range as a 1.1 to 5.5 Volt range.

If the voltage or currents do not fall in line with the

charts and tables shown below, and no system errors

are present, the problem may be mechanical.

Open the slip ring unit and determine if the slew potentiometer is set correctly.

The converter board is supplied with 12V from the central unit. The potentiometer and the board output two signals between 4 and 20mA that go to the central unit. You can measure them at the 12pin crane interface connector.

8.1 SLEW SENSING ERROR - FLOW CHART

(When the crane is over front, you should see about 4mA in one channel (wire #2) and 12mA in the other channel (wire #3)).

Service Manual iFLEX5

Correct whichever

value differs

Load Sensing Error

Verify operator’s settings are correct

Verify angle, length, and pressure readings

Press the info button twice

Do the

displayed

values differ

YES

Zero pressure transducers,

calibrate angle and length

If a problem still persists,

replace the pressure

transducer block.

9 LOAD SENSING

Please note that the load displayed by the LMI is not a direct measurement, but a calculated value that is based on a lot of factors. Outside of the measured values (sensors), those include:

 Operator settings such as:

o Operating mode/configuration o Parts of Line/Reeving

 Rigging parts such as:  Hookblock weight  Sling weights, etc.  Tip height (length of load line used)  Boom weights  Boom attachments such as  Stowed jibs  Auxiliary boom nose, etc.

9.1 LOAD SENSING ERROR - FLOW CHART

No console display

Ensure that no lights, warning

lights, or backlighting is visible.

Check wiring harness

and central unit.

Open console.

Check if power is being supplied by the

central unit. Measure on the green connector

(Pin 1 is +Ub 12V and Pin 2 is GND).

Is power

being

supplied?

YES

Check fuses in console: one (F6) is located on

the connection board (mounted to the inside of

the housing) which protects the override key

switch function and the bar-gragh. The main fuse

(F1) is locate on the console processor board.

Are fuses

Replace fuse.

YES

Check for power on connector

X6 of the connection board. (Pin 1 is +Ub 12V and Pin 2 is GND).

Is power

being

supplied?

YES

Follow power from this connector to the console computer

board, connector X1. (Pin 1 is +Ub 12V and Pin 2 is GND).

Is power

being

supplied?

Connecting

cable is

loose or

defective.

YES

If voltage is present on all

pins and connector are in

place, but you still do not get

any console lighting.

Ensure TxD LED is on (located in center of

the computer board and is normally blinking

when the console is communicating).

Check fuse F1 again. Make sure all connectors are correctly in place.

Conn. Board Computer Board Pins

X6 X1 4 X10 X22 6 X7 X2 10

* X10-X22 could be plugged into X17 by mistake

Software is

defective.

Console electronics

need replaced.

If no power was

supplied on the

connection board but

was supplied on the external connector, the connection board must

be replaced.

10 NO CONSOLE DISPLAY

If the console is not showing any lights, such as warning lights, backlighting, etc. it is most likely missing power. Start with the following:

A2B problem

Ensure the

bypass

plug is

installed.

Turn power off, remove bypass plug, and

measure the resistance at the boom nose box

between terminals 1 and 3 with an ohmmeter.

Switch closed = 0 ohms (weight installed)

Switch open = 1 Megaohm (weight removed)

Are the control levers

locked out and is the

crane in an anti-two

block condition?

Lower the hook block and/or

headache ball to correct the

two-block problem. If two

hoists are in use, both hooks

must be lowered.

If wiring is

correct, replace

A2B switch.

Is the anti-two

block warning

light on?

YES

Remove wires and measure the A2B

signal in the cable reel between terminal

7 and 8 with an ohmmeter.

Switch closed = 4700 +/- 500 Ohms

Switch open = > 1 Megaohm.

YES

Are the ohmmeter

readings correct?

YES

Plug the bypass

plug into the

boom nose box

and refer to

system wiring to

check wire

connections in

boom nose box.

Check for

damaged length

cable and wiring.

If broken length

cable, refer to

system wiring.

Are the

ohmmeter

readings correct?

Are the

ohmmeter

readings correct?

Replace the

slip ring.

YES

A problem lies with either the wiring

harness, cable reel length/angle

boards, and/or the central unit.

Ensure bypass plug is plugged into the

boom nose box. Remove wires and

measure the A2B signal in the cable reel

between the X1: (brown) an X2 (red) wires

on the slip ring with an ohmmeter.

Switch closed = 4700 +/- 500 Ohms

Switch open = > 1 Megaohm.

11 A2B PROBLEM

Service Manual iFLEX5

cann-bus communication

Connector M12, 5 contacts

Pin Layout (CiA DR-303-1 7.2)

Pin 1 Shield Pin 2 + Ub Pin 3 Ground Pin 4 CAN High Pin 5 CAN Low

Pressure Transducer

E63

iFLEX5

Cable Reel

CAN-Bus

Converter

E65

E64

E61

E62

12 CANN-BUS COMMUNICATION

The System measures the length of the main boom, the angle of the main boom, the pressures of the lift cylinder, and the A2B state of the machine via a CAN-Bus connection. Since this is a digital bus connection, it is not possible to measure the signals on the bus with a multimeter. Instead, the LMI provides you with error codes that give you an indication of the bus state.

The error codes are one of the following: E61 Error in the CAN bus data transfer for all CAN units

E62 Error in the can bus data transfer of the pressure transducer sensor unit E63 Error in the can bus pressure transducer sensor unit E64 Error in the can bus data transfer of the length/angle sensor unit E65 Error in the can bus length/angle sensor unit

Block Diagram

The block diagram tries to clarify that: If the CU does not see any CAN-Bus component, it will report an E61. If it sees only the cable reel, it will report an E62 (pressure transducer missing). If it sees only the pressure transducer, it will report an E64 (cable reel missing). E63 means that the pressure transducer is available, but is reporting an internal error. E65 means that the cable reel unit is available, but is reporting an internal error.

So, what do you do when you are having a problem with one of those codes?

12.1 E61

In case of an E61, start by connecting the two cables on the transducer block together. If an E62 appears, the transducer block must be replaced. If an E61 appears, reconnect the cable from the from the central unit to the transducer block. At this point, if an E61 still appears check your cabling. You can verify that power is being supplied to the sensor by testing the CAN connectors per this layout:

Service Manual iFLEX5

E61

Connect the two cables on the Transducer block together

E61

Yes

Disconnect cables and connect cable from c/u to transducer block

E61

Yes

Ohm cable from c/u to the transducer block. If cable checks good replace c/u

Connect the cable reel can bus cable to the transducer block. Remove can bus connector at cable reel

E61

Yes

Replace can bus cable between Cable reel and transducer block

Ohm out connector in cable reel. If connector Checks good replace can bus converter board.

E62

Replace Transducer Block

E64

Measure between pins 3 and 2 for crane voltage. If you see voltage, check all pins for continuity. The central unit must be replaced if this cable is functioning correctly. If the E61 error code has become an E64, connect the cable reel can bus cable to the transducer block and remove the can bus connector at the cable reel. If this causes an E61 to appear, the can bus cable between the cable reel and transducer block must be replaced. If an E64 remains, use the Ohm-meter to check the connector in the cable reel. Either the connector has failed or the can bus converter boards must be replaced.

12.1.1 E61 - Flow Chart

+ 55 hidden pages

Hirschmann PAT IFLEX5 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual