PAT DS 150 User Manual

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User Manual IK 150 / 0031 e

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The information in this document is subject to change without notice. PAT makes no warranty of any kind with regard to this material, including, but not limeted to, the implied warranties of merchantability and fitness for a particular purpose. PAT shall not be liable for errors contained herein or for identical or consequential damages in connection with the furnishing, performance, or use of this manual. This document contains proprietary information which is protected by copyright. All rights reserved. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of PAT.

USER MANUAL

IK 150 / 0031

doc. no. 50 150 19 0031 e

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TABLE OF CONTENTS

1 General Information .................................................................................................. 3

2 Warnings..................................................................................................................... 3

3 System Description................................................................................................... 4

3.1 Operating Console ...................................................................................................... 6

4 Control Identification................................................................................................ 7

5 Pre- Operation Inspection and Calibration Verification................................... 12

6 Service and Maintenance....................................................................................... 14

7 Troubleshooting ...................................................................................................... 15

Appendix: Important Notes

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1. GENERAL INFORMATION

The PAT DS 150 Load Moment Indicator (LMI) complements the operator's know-how by providing the information, right in the cab, needed to make the demanding lifts required of modern cranes. Using various sensing devices, the PAT DS 150 Load Moment Indicator monitors all crane functions and provides the operator with a continuous reading of the crane's rated capacity. The readings continuously change as the crane moves through the motions needed to make the lift. The PAT DS 150 Load Moment Indicator also provides the operator with information regarding the length of the boom, angle of the boom and jib, working radius, rated load and the total calculated weight being lifted by the crane. If non permitted conditions are approached, the PAT DS 150 Load Moment Indicator will warn the operator by sounding an audible alarm, lighting a warning light and locking out those functions that may aggravate the crane´s condition.

2. WARNINGS

The PAT DS 150 Load Moment Indicator (LMI) is an operational aid which warns a crane operator of an approaching two blocking condition as well as approaching overload conditions which could cause damage to equipment and property, and injury to the operator or bystanders. This device is not, and should not, be a substitute for good judgement, experience and accepted safe crane operating procedures. The operator is solely responsible for the safe operation of the crane and must observe and obey all warnings and instructions supplied by PAT and the crane manufacturer. Prior to operating a crane equipped with a PAT operational aid, the operator must carefully and thoroughly read and understand the information in this manual and the crane manufacturer's manual to insure that the operator knows the operation and limitations of the operational aid and crane. Proper functioning is dependent on proper daily inspection and observance of the operating instructions set forth in this manual. We draw your attention to section 5 of this handbook.

WARNING

The display (1) will only aid the operator when the LMI is properly programmed and the proper load capacity chart and operating code are selected for the crane configuration being utilized. To prevent property damage or serious bodily injury or death to personnel, ensure the LMI is properly programmed before operating the crane.

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3. SYSTEM DESCRIPTION

The PAT DS 150 load moment indicator consists of a central microprocessor unit, operator's console and peripheral equipment to register the angles, pressures and hoist limit. The system operates on the principle of reference/real comparison. The real values resulting from the force or pressure measurement is compared with the reference data stored in the central processor memory and evaluated in the microprocessor. When limits are exceeded, an overload warning signal is generated at the operator's console. At the same time, the dangerous 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 overload conditions.

Boom length and boom angle are registerd by the length/angle sensor, mounted indide the cable reel which is mounted on the boom. The boom length is measured by the cabel reel cable which also serves as electrical conductor for the anti-two-block switch.

The crane load is measured by pressure transducers attached to the piston and rod side of the lift cylinders.

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SYSTEM COMPONENTS

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3.1 OPERATING CONSOLE

The console has 2 functions:

• terminal for input of instructions to the system by the crane operator

• display of important data and information

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4. CONTROL IDENTIFICATION

The following list will describe the controls and displays of the DS 150 safe load indicator. The numbers of the illustration (on page 6) correspond to the numbers in the following list:

(1) LC DISPLAY

The LC DISPLAY will show technical information as well as operating information to the operator. During crane operation the readout will display radius, boom length, boom angle, height of boom tip, actual and maximum load. The load moment will also be indicated at the display in form of a bargraph. In case of system malfunctions the various faults will be indicated via an error code instead of the tip height display (Described in chapter 7).

(2) BARGRAPH

This indicator displays how much of the crane rated capacity is being used. As the crane is moved through its various motions, the bargraph will constantly change on the display. The range is divided into 3 areas: A green area is the normal working area, the yellow prewarning area shows the remaining portion of the rated load capacity and the bargraph indicates the approach to the overload condition and the

red area shows that the maximum rated load capacity is exceeded.

NOTE

Operating within the red area is not permitted.

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(3) OPERATING CODE SWITCH

The operating code switch is used to set the load moment indicator (LMI) to the operating configuration of the crane.

Caution

The correct setting is of utmost importance for the proper function of the system and the crane. Therefore only operators who are thoroughly familiar with crane load capacity charts and the use and operation of the system shall set the operating code switch. To set the operating mode, the operator has to adjust the operating code switch to a code number which is printed in the load chart in accordance with the actual crane configuration.

(4) REEVING SWITCH

The REEVING SWITCH (4) provides the load moment indicator with information regarding the number of falls (parts of line) used to reeve the hook block. The switch has 16 positions which are shown under the window of the control knob when it is turned. The operator has to set the reeving switch to the actual number of falls (parts of line) being used.

Caution

The correct setting is of utmost importance for the proper function of the system and the

crane.

(5) ANTI-TWO-BLOCK WARNING LIGHT

The red ANTI-TWO-BLOCK WARNING LIGHT (5) will light up when the anti-two-block limit switch contacts open, indicating that a two-blocking condition is approaching. At the same time the audible alarm will sound. The following crane movements will be stopped subsequently: hoist up, telescope out, boom down. The term "two block" is a crane term which refers to a condition when the load handling device comes into contact with the boom head. This condition, if not prevented, may cause the wire rope to break, allowing the load to fall. Two blocking can be caused by raising the load into the boom head or lowering the boom without paying out hoist line.

(6) PREWARNING LIGHT

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The yellow LOAD MOMENT PREWARNING LIGHT (6) will light up when the load on the crane is between 90 and 100 % of the crane rating, indicating that an overload condition is approaching. This means for the operator to continue his crane operation with extreme caution.

(7) OVERLOAD LIGHT / ALARM SWITCH

This control serves a dual purpose:

• the red warning lamp lights up when the load on the crane is in excess of 100% of the crane rat-

ing, indicating that an overload condition has been reached.

• this button allows the audible alarm to be silenced for 15 seconds.

(8) TARE BUTTON

The TARE BUTTON is used to indicate the net load on the load display (ref. #1). Net load is the actual load, less lifting tackle and hook block. The tare button has to be activated before lifting. After pushing the TARE BUTTON the display of actual load will be set to zero (taring). and the display shows max. load and net load. Net load display is blinking and set to zero. After lifting a load the net load display shows the net load (pay load). The net load display will change to the normal working display when the radius is changed (either by boom angle or jib angle). Display errors can be caused by reason of environmental factors such as wind acting upon the crane and the load.

BOOM ANGLE LIMITS

This system is equipped with presets for boom angle range selection. There are limits for maximum and minimum boom angle which can be set by the operator as allowed by crane geometry. After restart the system the limits have to be set new.

(9) SETTING OF BOOM ANGLE LIMIT: MAXIMUM

After pressing this button, the actual boom angle will be stored as maximum boom angle limit. The LC Display shows the value "MAX xx °". To indicate that the maximum angle limit is activated, the lamp in the button will light up. Once this angle is reached, the lamp flashes and the buzzer will sound until the boom is moved back into a permissible angle range.

(10) SETTING OF BOOM ANGLE LIMIT: MINIMUM

After pressing this button, the actual boom angle will be stored as minimum boom angle limit. The LC Display shows the value "MIN xx °". To indicate that the minimum angle limit is activated, the lamp in the button will light up. Once this angle is reached, the lamp flashes and the buzzer will sound until the boom is moved back into a permissible angle range.

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RESET ANGLE LIMITS

To reset the boom angle limits press button (9) and (10) simultaneously. The values for angle limitation on the LC Display will be cleared.

(11) ENTER BUTTON "E"

This control has no function.

(12) BY-PASS KEY SWITCH

WARNING

Since this switch deactivates the cut-off function of the LMI system and the anti-two-block system, the following instructions shall be adhered to:

• the by-pass key should be used with discretion, as unwarranted use of it to override the

control lever lockout system can result in harm to the crane and danger to property and persons

• never use the by-pass key to either overload or operate the crane in a range not permissi-

ble

The BY-PASS KEY SWITCH (12) can deactivate the cut-off of the LMI or anti-two-block momentarily to allow the crane operator to override the control lever lockout. It can be operated only by using the matching key. The spring-loaded by-pass switch has 3 positions which are further described as follows:

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This position by-passes the anti-two-block control lever lockout which does not influence the LMI system. The red warning light (5) and the audible alarm (13) for approaching two-block condition will also come on at all times. The By-Pass Key Switch is springloaded in order to return the switch to the neutral position. To activate the switch, it therefore has to be held manually during it's operation.

This is the neutral position to which the switch returns because of it's springloaded mechanism. In this position, the by-pass switch is without influence to the LMI and anti-two-block control lever lockout.

In this position, the by-pass key switch deactivates the control lever lockout function of the LMI. All other display, indicating and alarm functions, as well as the control lever lockout function of the anti-two-block system will continue to work. The by-pass switch is springloaded in order to return the switch to the neutral position. Therefore to activate the switch, it has to be held manually during it's opera-

tion.

(13) AUDIBLE ALARM

This element is the AUDIBLE ALARM, which sounds during the following conditions: overload situation, approaching two-block condition, boom angle preset limits are reached, in case of a malfunction of the LMI system and in case of an recognised operating error. The alarm can be turned off temporarily by pushing the button (7).

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5. PRE-OPERATION INSPECTION AND CALIBRATION VERIFICATION

Prior to operating the crane, the following electrical connections must be checked to ensure that the system is properly connected for the crane configuration.

Machines with only a Main Hoist

If the crane works only with the boom and without boom extension or jib, no additional connections are necessary. However, be sure the weight of the anti-two-block switch is properly installed on the main hoist load line. With even parts of hoisting line, the weight shall be attached to the dead-end line. With odd parts of hoisting line, the weight shall be attached to the line of lowest speed. If the crane works with boom extension or jib, the connecting cable shall be installed between the junction box on the boom extension or jib and the boom junction box. The weight attached to the main hoist anti-two-block switch shall be removed. Then the weight shall be reattached to the boom extension or jib anti-two-block switch.

WARNING

Failure to re-position the anti-two-block switch weight will prevent the overhoist system from functioning properly. No weight shall be on the main hoist anti-two-block switch when the boom extension or jib is being used.

Machines with Main and Auxiliary Hoists

If the boom extension or jib is not in the operating position, the by-pass plug shall be installed in the main boom junction box. The weight of the main hoist anti-two-block switch shall be installed. If the boom extension or jib is in the operating position, the connecting cable shall be installed between the junction boxes on the boom extension or jib and the main boom. Weights shall also be attached to the anti-two-block switches on both the main boom and boom extension or jib. If the boom extension or jib is in the operating position and no load line is being used on main boom, to prevent injury or damage to equipment, the weight shall be removed from main boom switch.

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After the electrical connections have been checked to insure that the system is properly connected for the crane configuration, the following checks shall be made:

1. Check the electrical wiring connecting the various parts of the system for physical damage.

2. Check the anti-two-block switches and weights for free movement.

3. Check the spring-loaded cable reel to be sure it is free to rotate, has tension and the cable is reeled properly.

4. Check mechanical installation and electrical connection of the force transducer(s) on jibs where applicable.

WARNING

The following tests shall be performed with care to prevent damage to the machine or injury to personnel. Proper functioning of the system requires successful completion of these tests before operating the machine.

If the operator cannot see the load handling device approaching the boom nose, he shall have an assistant (signal person) watch the load handling device. The operator shall be prepared to stop the machine immediately should the LMI system not function properly as indicated by lighting the red warning light (7), sounding the audible alarm (13) and locking the crane movements, hoist up, telescope out and boom down.

Check the anti-two-block alarm light (5) and the audible alarm (13) by performing one of the following tests:

1. By manually lifting the weight attached to the anti-two-block switches. When the weight is lifted, the audible alarm (16) should sound, the anti-two-block alarm light (5) should light.

2. Slowly raise the main boom load handling device to create a potential two-block condition. When the load handling device lifts the weight, the audible alarm (13) should sound, the antitwo- block alarm light (5) should light and the motion of the load handling device should be stopped. Lower the load handling device slightly to eliminate this condition.

3. Slowly lower the boom to create a potential two-block condition. When the load handling device lifts the weight, the audible alarm (11) should sound, the anti-two-block alarm light (5) should light and the boom lowering function should be stopped. Lower the load handling device slightly to eliminate this condition.

4. Slowly extend (telesope) the boom to create a potential two-block condition. When the load handling device lifts the weight, the audible alarm (13) should sound, the anti-two-block alarm light (5) should light and the boom telescope out function should be stopped. Lower the load handling device slightly to eliminate this condition.

WARNING

If the light and audible alarm do not function as described and the crane movements are not stopped, the system is not working properly. The malfunction shall be corrected before operating the crane.

5. If the crane is equipped with a boom extension or jib, repeat the test procedure for the boom extension or jib anti-two-block switch.

6. Check that the display of the main boom length agrees with the actual boom length.

7. Check that the display of the main boom angle agrees with the actual boom angles.

8. Check that the display of the operating radius of the crane agrees with the actual radius.

9. Check the load display by lifting a load of known weight. The accuracy of the load indication shall be within the tolerance of SAE J159.

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OPERATION

After being properly programmed, the LMI is operational. Therefore, the operator shall be thoroughly familiar with all controls of the LMI and he shall properly set each switch before operating the crane. All settings shall be checked by lifting a load of known weight and comparing the load to the information displayed on the LMI. Rated loads include the weight of the hook block, slings, and auxiliary load handling devices. Their combined weights shall be subtracted from the listed load capacities as stated on the load capacity chart to obtain the net load to be lifted.

WARNING

If any of the displays reflect a deviation between displayed and actual values an authorized PAT service representative shall be called for repair of the system or reverification of the crane's LMI calibration.

WARNING

Any structural modifications or changes to the crane shall require reverification of the crane's LMI calibration.

6. SERVICE AND MAINTENANCE

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Daily maintenance of the load moment indicator consists of inspecting:

1. The electrical wiring connecting the various parts of the system. If electrical wiring is damaged, it shall be replaced immediately.

2. If the insulation is worn on the length sensor cable or cable guides are damaged, these parts shall be replaced.

3. Check the anti-two-block limit switches for freedom of movement.

4. The cable reel shall be under tension to operate properly.

5. Check the pressure transducers at the lift cylinder(s) and the connecting hoses for oil leakage.

6. Check mechanical installation and electrical connection of force transducer(s) on jibs where applicable.

Other than correcting the problems identified in the Malfunctions Table and replacing faulty mechanical parts and cables, no other repairs shall be performed by unauthorized or untrained personnel.

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7. TROUBLESHOOTING

GENERAL

In case of a malfunction of the system, the display (1) will indicate a code which identifies the system malfunction.

The error codes listed in the Malfunction Table will identify various faults which can occur with the LMI. Following the Malfunction Table are pages which explain each fault and describes the action which should be taken to correct the fault.

Faults within the electronic microprocessor must be repaired by factory trained service personnel. When these faults occur, the competent service organization must be contacted.

Malfunctions Table

Error Code Error E01 Fallen below the radius or above angle range E02 Radius range exceeded or fallen below angle range E03 Boom position is out of the permissible working area E04 Operating mode not existing E05 Prohibit length range

NOTE:

If there is any Error Code displayed on the console which is not listed in the Malfunctions Table you should call the Local Distributor.

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ERROR CODE DESCRIPTION

OPERATING ERRORS

Malfunctions in the system which are caused by range exceedings or operating errors by the crane operator himself are indicated on the display together with an explanation. These error codes are E01, E02, E03, E04 and E05 and they can normally be eliminated by the crane operator himself.

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ERROR CODE TABLE

Error Code Error Cause Elimination E01

Fallen below radius range or angle range exceeded

• 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

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

E02

Radius range exceeded or fallen below angle range

• 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

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

E04

Operating mode not acknowledged

• A non existing operating mode has been selected

• Set the correct operating mode for the operating state in question

E05

Prohibited length range

• 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

• Extend/retract boom to the correct length

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

• 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

• Clutch between length sensor pot and drive is defective

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

• Failure of +5V supply of analog part of analog board

• Check +5 V supply. Exchange main board in case of voltage failure or breakdown when loaded with 50 ohms approx.

• Cable between central unit and length sensor is defective or disconnected.

• Check cable and plugs, replace, if need be.

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Error Code Error Cause Elimination

• Defective length potentometer

• Replace length potentiometer.

E06

Radius range exceeded or fallen below angle range with luffing jib operation

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

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

E07

Faulty acknowledgment of the overload relay on the connection board. The relay should be energized, the 2nd contact however is indicated to be off, or the 2nd contact is indicated to be on while the relay should be deenergized.

• Overload relay or connection board are defective

• Processor board defective

• Replace connection board

• Replace processor board.

E08

No acknowledgment from the anti-twoblock relay

• refer to E07 • refer to E07

E10

Error in the length measurement

• With the boom retracted, the signal "main boom length" differs by more than 2 % from the programmed value for the basic length

• Check length sensor of the main boom

• With the boom retracted, the signal "length Tele I (+II)" differs by more than 2 % from the reference value 0

• Check length sensor 2.

E11

Fallen below lower limit value for measuring channel "length main boom"

• Cable between central unit

and length sensor is defective or disconnected. Water inside the plug of the length/angle sensor

• Check cable as well as

plugs, replace, if need be.

• Length potentiometer is

defective

• Replace length potentiometer

• Electronic component in the measuring channel is defective

• Replace LMI main board or processor board.

E12

Fallen below the lower limit value in the measuring channel "pressure piston side"

• Cable between the central unit and pressure transducers defective or water inside the plugs

• Check cable as well as plugs, replace, if need be.

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Error Code Error Cause Elimination

• Pressure transducer is defective.

• Replace pressure transducer

• Electronic component in the measuring channel is defective.

• Replace LMI main board or processor board.

E13

Fallen below lower limit value in the measuring channel "pressure rod side"

• refer to E12 • refer to E12

E15

Fallen below lower limit value in measuring channel "angle main boom"

• Cable between central unit and the length/angle sensor defective or loose. Water inside the plug of the length/angle sensor.

• Check cable as well as plugs, replace, if need be.

• Angle potentiometer defective

• Replace angle sensor

• Electronic component in the

measuring channel defective.

• Replace LMI main board or processor board.

E16

Fallen below lower limit value in measuring channel "angle 2"

• Cable between the central unit and the angle sensor defective or loose. Water inside the plug of the angle sensor.

• Check cable as well as plugs, replace, if need be.

• Angle potentiometer defective

• Replace angle sensor

• Electronic component in the

measuring channel defective.

• Replace LMI main board or processor board.

E17

Fallen below lower limit value "length telescope I (+II)"

• Cable between the central unit to the length sensor defective or loose. Water inside the length sensor plug.

• Check cable as well as plugs, replace, if need be.

• Length potentiometer defective

• Replace length sensor.

• Electronic component in the

measuring channel defective

• Replace LMI main board or processor board.

E19

Reference and/or supply voltage defective

• The supply voltage is falsified by one of the sensors (DAV, LWG)

• Check the voltages on the LMI main board (AGND = MP0). Check sensors, plugs and cable, replace, if need be.

• Electronic component is defective

• Replace LMI main board

• A/D converter defective. • Replace LMI main board

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Error Code Error Cause Elimination E21

Upper limit value in measuring channel "main boom length" has been exceeded.

• refer to E11 • refer to E11

E22

Upper limit value in measuring channel "pressure piston side" has been exceeded

• refer to E12 • refer to E12

E23

Upper limit value in measuring channel "pressure rod side" has been exceeded.

• refer to E12 • refer to E12

E25

Upper limit value in measuring channel "main boom angle" has been exceeded.

• refer to E15 • refer to E15

E26

Upper limit value in measuring channel "angle 2" has been exceeded.

• refer to E16 • refer to E16

E29

Reference and/or supply voltage defective.

• refer to E19 • refer to E19

E31

Error in the system program

• The system program PROM

is defective.

• Replace system program PROM (PROM No. 0)

E38

System program and data EPROM do not match.

• The system program in the LMI does not match to the programming in the data EPROM

• Replace the system program PROM or the data EPROM (PROM No. 1)

E39

System program and TLK EPROM do not match

• The system program in the LMI and the programming in the TLK EPROM do not match.

• Replace system program PROM or TLK EPROM (PROM No. 2).

E41

Error in the internal write/read memory (RAM) of the computer component 80C537

• Computer component 80C537 defective

• CPU module defective

• Processor board defective.

• Replace computer compo-

nent 80C537.

• Replace CPU module.

• Replace processor board

with CPU module.

E42

Error in the external write/read memory, 1st part (RAM)

• Write/read memory (CMOS RAM) or processor board defective.

• Replace processor board with CPU module.

E43

Error in the external write/read memory, 2nd part (RAM)

• refer to E42 • refer to E42

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Error Code Error Cause Elimination E45

Redundancy error in the A/D conversion

• The A/D converter on the processing board and the redundant A/D converter in the CPU 80C537 provide different results.

• Replace processor board.

E46

Error in the A/D converter uPD 7004 of the processor board.

• No acknowledgment of the A/D converter uPD 7004

• Replace processor board.

E47

Error in the monitored write/ read memory.

The CRC verification of the monitored write/read memory provides an incoherent result

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

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

• Processor board defective.

• Restart the LMI

• Replace buffer battery on

the LMI main board

• Replace processor board.

E48

Cyclic RAM test: error in the internal write/read memory (RAM) of the computer component 80C537

• Computer component 80C537 defective

• CPU module defective

• Processor board defective.

• Replace computer compo-

nent 80C537.

• Replace CPU module

• Replace processor board

with CPU module.

E51

Error in the crane data EPROM or EEPROM.

• No valid data in the crane data EEPROM.

• Memory module wrongly bridged.

• Crane data EPROM defective

• Load crane data EEPROM containing valid data.

• Bridge memory module acc. to memory type

• Replace crane data EPROM

E52

Error in load chart PROM.

• Memory module wrongly bridged.

• Load chart EPROM defective.

• Bridge memory module acc. to memory type.

• Replace load chart EPROM

E56

Error in crane data EEPROM.

• Memory module wrongly bridged.

• Crane data EEPROM defective

• Bridge memory module acc. to memory type

• Replace crane data EEPROM

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Error Code Error Cause Elimination E57

Error in serial crane data EEPROM.

• Serial crane data EEPROM does not contain valid data.

• Memory module defective

• Write data on the serial

crane data EEPROM (by means of test program or on-line function), then restart the LMI

• Replace memory module.

E58

Error in the serial analog data EEPROM.

• No valid data in the serial analog data EEPROM.

• LMI main board defective.

• Write data on the serial

analog data EEPROM by means of the test program, then, restart the LMI

• Replace LMI main board.

E69

Error in the load chart EPROM

• Memory module wrongly bridged

• Bridge memory module acc. to memory type

The number of the selected EPROM base and the programmed value are not identical

• Load chart EPROM defective

• Replace load chart EPROM

• Base number not pro-

grammed

• Program the correct base number (1 for base 1, 2 for base 2)

• Load chart EPROM wrongly programmed

• Check base programming in the load chart EPROM.

E71

Faulty acknowledgment of relay K1 on the connection board

• Relay K1 or connection board defective.

• Replace connection board.

Relay should be energized but the 2nd contact is signaled to be off or the 2nd contact is signaled to be on whereas the relay should be deenergized.

• LMI main board is defective • Replace LMI main board.

E72 ... E77

Faulty acknowledgment of relays K2...K7 on the connection board.

• refer to E71 • refer to E71

E85

Error in the radius determination

• The computed radius is too small (negative deflection)

• Check the programming in the data EPROM.

E89

Operating mode switchover with load.

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

• Select operating mode without load on the boom

E91

No data transmission form the console to the central unit

• 24 V supply of the console is interrupted

• Check 24 V at terminal X1 of the console electronics

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Error Code Error Cause Elimination

• Interruption or accidental ground in the line between console electronics and central unit

• Check the connection console electronics - central unit. In case of an accidental ground, the transmitter module of the console electronics might be damaged. Therefore, replaces the console electronics.

• Transmitter/receiver module is defective

• Exchange console electronics or LMI main board resp.

E92

Error in the data transmission from console to central unit

• Loose connection in the line between console electronics and central unit

• Transmitter/receiver module is defective

• Check the connection between console electronics and central unit

• Exchange console electronics or LMI main board resp.

E93

Error in the data transmission from the central unit to the console

• refer to E92 • refer to E92

E94

No data transmission from the central unit to the console

• Interruption or accidental ground in the line central unit

- console

• Check line to the console (in case of accidental ground, replace console electronics, too).

• 5 V supply of the computer in the central unit is missing

• Check connection to the power unit

• 5 V supply is too low • Exchange the LMI main board

• Transmitter/receiver module

is defective

• Replace console electronics or LMI main board

• Computer module is defective

• Replace processor board.

• Electro-magnetic interfer-

ences (e.g. when switching contactors or valves)

• Eliminate the source of interferences by inverse diodes or varistors.

E95

Error in the console EPROM

• The console EPROM is defective.

• Replace the console EPROM

E96

Error in the internal RAM of the console.

• The CPU of the console is defective.

• The console main board is defective.

• Replace the CPU of the console

• Replace the console main board.

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Error Code Error Cause Elimination E97

Error in the external RAM of the console

• The external RAM of the console is defective.

• The console main board is defective.

• Replace the external RAM of the console.

• Replace the console main board.

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PAMPHLET 1 Cut-off Values for Boom Cranes with Variable Capacity depending

on Variable Radius

The crane cut-off values are calculated by us on the basis of the load charts and construction drawings supplies by the crane manufacturers.

These theoretical cut-off values must be checked by testing the crane with weighed test loads in all operating modes and at least in the following equipment conditions depending on the crane type.

• Cranes with fixed boom length during operation:

Minimum, medium and maximum radius with shortest, medium and longest boom length as well as with shortest, medium and longest jib length with these boom lengths.

• Cranes with variable boom length during operation:

Minimum, medium and maximum radius at each length step as well as with all jibs.

PAMPHLET 2 Important notes for crane operators

The LMI is an operational aid which warns a crane operator of approaching overload conditions and also warns of overhoist conditions which could cause damage to equipment and personnel.

The device is not, and shall not, be a substitute for good operator judgement, experience and use of accepted safe crane operating procedures. The responsibility for the safe operation of the crane 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 the crane/SLI manual to ensure that he knows the operation and limitations of the indicator and crane.

Proper functioning is dependent upon proper daily inspection and observations of the operating instructions set forth in the manual.

WARNING

This system can be equipped with an override key on the central micro-processor unit. This key switch bypasses cut-off functions of the load moment indicator device. The switch may only be used by authorized personnel during emergency situations. Failure to follow this instruction may result in property damage and/or personal injury.

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PAMPHLET 3 Important notes for crane users

In the Federal Republic of Germany, the directives of the Union of German Engineers VDI (Verein Deutscher Ingenieure) 3570 are effective for the construction of safe load indicators. There, too, it is directed to the significant and the limits of the safe load indicator.

"Safe load indicators shall, during crane operation, hinder accidents, endangering of persons, things, the load, the crane due to overload within the limits possible. User and crane operator must take into account that a safe load indicator cannot realize all dangers in time and that a malfunction by nonperceptible influences indeed is possible. Therefore they are not dispensed from circumspection and the responsibility to the observance of the operating instructions and the load of the crane. Safe load indicators are not intended for regular operation. They shall only respond in emergency cases. The capacity of the hoisting appliance shall not be reduced by safe load indicator".

Instructional Pamphlet VDMA

for safe load indicators (load moment limiting devices) on boom cranes

The boom crane delivered to you has a safe load indicator (overload cut-off device) according to §24 of the accident prevention regulation UVV "boom cranes" which will cut off the hoist and boom hoist unit of the crane when exceeding the admissible safe load. The opposite movement must remain possible in order to be able to relieve the crane of the load after the safe load indicator has reacted, e.g. it must be possible to lower the load when the hoist was cut off.

Installation of a safe load indicator (overload cut-off device) has the purpose to prevent the crane from lifting a load which would endanger its stability. Hence the safe load indicator (overload cut-off device) is an emergency switch which, in the event of overload, cuts off all movements increasing the load moment thus avoiding a possible damage or accident.The following must be observed for the safe load indicator to comply with its function as a safety device.

1. Safe load indicators (overload cut-off devices) must not be used operationally to cut off the hoist or boom hoist unit. The crane operator must in any case previously make sure that the load to be lifted will not exceed the lifting capacity of the crane. Superheavy loads exceeding the lifting capacity of the crane must not be lifted even with a safe load indicator installed. The unit must not be loaded beyond the respectively admissible load.

2. Freeing loads which are stuck may only be effected in agreement with the crane manufacturer and with cranes especially equipped for this purpose. During these jobs it is not allowed to use the safe load indicator (overload cut-off device) as an operational unit for force measurements.

3. The built-in safe load indicator must be regularly serviced and checked as to its functional safety before starting operation. According to the accident prevention regulation UVV "boom cranes" §35 maintenance of the crane also includes regular checks of the safe load indicator.

4. Generally, the safe load indicator does not adjust automatically to the various operating conditions of the crane. When changing the operating condition of the crane, the operator is therefore responsible of changing the safe load indicator over to the new load or load moment range as well. For this purpose, observe the manufacturers operating instructions for the safe load indicator installed. Safe operation of the device and accident-free operation of the crane depend to a high extent on careful observance of this instruction. Maladjusted safe load indicators, e.g. set to a high load moment with retracted outriggers, are much more dangerous than cranes without a safe load indicator since the crane operator is given a wrong feeling of safety which might be the cause of serious accidents.

5. When changing the crane over to various operating conditions, the safe load indicator installed must be changed over to the new load or safe load ranges resp. by the crane operator, e.g.:

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a) when extending or retracting the outriggers (changing over to high or little load moment); b) when changing the boom length by:

- extending or retracting (telescoping) manually;

- mounting or dismounting intermediary parts;

c) when slewing or pivoting the crane to the range of greater or smaller stability moment (changing over to high or lit-

tle load moment);

d) when passing into another load capacity range by several parts of line in the cables of the hoist or boom hoist unit.

6. It must be strictly pointed out that due to wrong operation of the crane it might not be possible for the safe load indicator to respond or resp. that the engine might not be cut off quickly enough. In this case you cannot exclude an accident inspite of a safe load indicator installed. In particular, this applies to:

- underhooking the load or the load handling accessories;

- excessive retardation forces,

- loads falling into the line,

- diagonal pull,

- moving the crane to an area of higher gradient,

- yielding ground,

- wind pressure.

7. If there is a device available to switch off or bridge the safe load indicator (load moment limiting system), it must only

be used with regard to special measures of precaution and in presence of the crane superintendence, for instance when testing the crane and for special applications provided for by the crane manufacturer. The safe load indicator must not be switched off or bridged operationally under no circumstances in order to lift loads which exceed the respectively admissible loading capacity of the crane.

Careful observance of the regulations contained in this instructional pamphlet and in the operating instructions of the crane manufacturer is the precondition for the safe function of the safe load indicator (overload cut-off device).

In all cases of doubt consult the operating instructions of the manufacturer. Should this be not sufficient, it is necessary to inquire at the company concerned.

Unauthorized interventions in the mechanism of the safe load indicator will void the warranty.

Publisher: VDMA Fachgemeinschaft für Hebezeuge und Fördermittel

im Verein Deutscher Maschinenbau Anstalten e.V. Düsseldorf - Oberkassel

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PAMPHLET 4 Instructions to ensure the electromagnetical compatibility (EMC)

with electronic systems under the effect of electromagnetic fields

Electromagnetic fields increasingly affect electronic systems and can thus cause malfunctions for whose elimination we shall indicate some preventive measures according to today's state of engineering below:

1. The preventive measures are mainly based upon the idea to shield the electronic circuits from irradiated

high frequency interferences:

- All components will have metal housings outside with grounding possibility;

- The cables used will have braided shields. The shield applied must be highly conductive as to the surface of all junction areas;

- Coupling of crane ground and electronic ground at only one point of the system.

2. The general measures listed in item 1, however, cannot ensure complete protection against electromagnetic fields in individual cases because the size and the type of the effect depends on the local conditions.

The influencing factors, inter alia, are as follows:

- Particularly unfavourable arrangement of the antenna as to the system;

- Very high transmitter powers;

- Impossible to observe the measures of item 1 consistently by reason of local conditions;

- Long cables;

- Interferences coupling into the supply lines.

With unfavourable conditions you can therefore not do without taking any measures exceeding the preventive ones experimentally on site, taking into account the principles mentioned in item 1, e.g.:

• Adding filters or short-circuiting the interfering frequencies by means of capacitors;

• Making or removing ground connections;

• Using double shielded cables (guarded shield system).

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PAMPHLET 5 Notes for Protection of Labour During Repair of Display and Oper-

ating Consoles

Caution: LCD displays contain fluid chemicals.

Therefore, you have to proceed carefully when:

• operating devices with LCD displays

• storing or carrying them (risk of fracture)

• clearing spare or unusable LCD displays

Possible risks are chemical reactions because of skin contact with broken LCD displays. In case of contact with chemicals, carefully clean the parts of body affected with soap. Caution in case of open wounds.

PAMPHLET 6 Installation instructions for display and operator's console without

closed metal housing

In order to avoid radio interferences, high frequency devices and systems subject to the general approval the Federal Minister of the Post Office and Telecommunication published in the gazette no. 163/1984 as order no. 1045/1984 and no. 1046/1984 have to observe the limits and requirements stipulated.

In case of display and operator's console without closed metal housing (panel-mounted) type, the cable shield must be applied via a bare clamp on the panel directly in front of the console.

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MANUFACTURER'S CERTIFICATE

This is to certify that

Unit: Electronic Measuring System

Type: DS 150

Description: Load Moment Indicator

is radio shielded according to the provisions of Decree No. 1046/1984, General Approval in accordance with the Law on Operation of High Frequency Equipment, Gazette of the Federal Minister of Post and Communications, Edition 1984, No. 163 dated December 14, 1984 and DIN VDE 0871/6.78 "Interference Suppression of High Frequency Equipment for Industrial, Scientific, Medial (ISM) and Similar Purposes", limit class B.

The German Federal Post has been informed that this unit is put into service and is entitled to inspect the series for compliance with the regulations.

PAT GmbH