Académique Documents
Professionnel Documents
Culture Documents
Type:
LHM 550
Serial number:
141082
141082 / 001
1
141082 / 001
Owner¶s Guide
Read instructions completely before installing.
COOLING, HEAT/COOL AND HEAT PUMP SERIES
ADDRESS _______________________________________________________________
SOME SUGGESTIONS
1. To avoid installation difficulties, read 3. When possible, install unit on a shaded side of
instructions completely before starting. This the house or building.
publication contains information pertinent to the
installation and operation of your new room air 4. Make sure that wall mounting area (or
conditioner. window, if window installation is chosen) is
structurally sound enough to support the unit.
2. This unit can be installed in a double-hung
window or through a wall. For both installations, 5. Room air conditioners are designed to fit
you must first remove the chassis from the easily into standard double-hung windows.
casing, install the casing first and then reinsert However, some window frame design variations
the chassis. require modification to the window for safe,
proper installation. If assistance is needed,
please call your local Carrier Distributor. If there
is no distributor in your area, call
1-800-CARRIER (227-7437).
CONTROL PANEL AND OPERATING INSTRUCTIONS
See Fig. 1 for reference throughout this section
Your Carrier unit is equipped with an electronic 3. Timer operation active display
panel that controls the functions of the unit. This
section explains how to best use these functions
to suit your specific needs. The panel is located
behind the control door. To open, use the Finger
Tab to swing door downward.
To indicate the operating status of your unit the
following displays are used:
REMEMBER:
(A) Up arrow will move time forward NOTE: The value displayed reflects the temperature
in (1) minute increments. closest to the unit. The value may not reflect the
(B) Down arrow will move time backward average temperature of the entire room.
in (1) minute increments.
(C) Holding button down will allow the time FILTER
to change at a faster pace
When the unit has operated for 200 hours, the clean
When the clock indicates the correct time, push the filter indicator will light. This indicates that the filter
SET CLOCK button again and the clock will start. needs to be checked and cleaned if necessary. After
cleaning, push the SLEEP and the TURBO buttons
NOTE: The SET CLOCK will not work while simultaneously to reset the operating hours. The
programming the automatic timer, or when the timer indicator will turn off.
mode is activated.
NOTE: More frequent cleaning may be necessary
ACTIVATE TIMER depending on indoor-air quality. See Energy-Saving
(AUTOMATIC TIMER) Tips section for filter removal and cleaning procedures.
Your Carrier unit comes equipped with a timer program ENGLISH/METRIC DISPLAY
that allows you to select times the unit will turn on and
off. The unit has been pre-programmed at the factory Your Carrier unit can display temperatures and
with an On and Off time. To activate the timer function, setpoints in Fahrenheit or Celsius. To change, press
push the ACTIVATE TIMER button. The display will the MODE and FAN buttons at the same time. To
show the current on and off time. The arrow indicates change back, press MODE and FAN buttons again.
³IN TIMER OPERATION´. To deactivate the timer
option push the ACTIVATE TIMER button. To change
on or off times see Set Timer.
FAN SELECTION SET TEMP/TIME (INCREASE AND
DECREASE SETPOINT)
The FAN SELECT BUTTON allows you to choose the
speed of the fan. When the button is pressed, an Setpoint is the room temperature you want the unit to
arrow on the display alternates between AUTO, HIGH, maintain. To change the setpoint one degree, push the
MED and LOW. The arrow indicates the selected fan UP OR DOWN ARROW buttons. The setpoint cannot
speed. The Auto Fan setting will automatically select be increase above 80 F (26.5 C) or decrease below 65
the speed that will best maintain the room at the F (18.5 C). (To change display form Deg F to Deg C
desired temperature. see English/Metric display, Page 6).
· Power failure
Notes: 1. If circuit breaker is tripped or fuse is blown will drip onto pedestrians or neighboring property,
more than once, contact a qualified electrician. install the enclosed external drain. See instruction on
2. If unit is installed where condensation drainage page 12.
Carrier
Room Air Conditioner
Full Warranty
ONE-YEAR WARRANTY ± CARRIER warrants to the user that this product will CARRIER WILL NOT BE RESPONSIBLE FOR:
be free from defects of workmanship under normal use and maintenance for a
period of one year from the date of original purchase. CARRIER, through an 1. Damage due to failure to perform normal maintenance as outlined in the Owner¶s
independent servicing dealer or service station, will either repair or replace a Guide.
defective product (as decided solely by CARRIER) free of charge to the user.
CARRIER may replace any defective part with either a new or remanufactured part 2. Instruction on methods of control and use of air conditioning unit after initial
at CARRIER¶s sole option. installation.
EXTENDED FOUR-YEAR WARRANTY ON SEALED REFIGERATION SYSTEM 3. Damage or repairs needed as a consequence of faulty installation or application.
ONLY ± During the second through fifth years after date of original purchase, This is the responsibility of the installer.
CARRIER further warrants to the user that the compressor, condenser,
evaporator, and connecting tubing will be free from defects in material or 4. Failure to start due to voltage conditions, blown fuses, open circuit breakers, or
workmanship under normal use and maintenance. CARRIER will either repair or any other damages due to the inadequacy or interruption of electrical service.
replace (as decided solely by CARRIER) any defective compressor, condenser,
evaporator, or connecting tubing free of charge to the user, including a recharge 5. Damage or repairs needed as a consequence of any misapplications, abuse,
of refrigerant for the system if necessary. However. THIS LIMITED WARRANTY unauthorized alternation, improper servicing or operation.
DOES NOT INCLUDE costs incurred for diagnosing, removing, installing, shipping,
or transporting the product or any parts. User is responsible for these costs; 6. Damage as a result of floods, winds, fires, lightning, accident, corrosive
however, SUCH COSTS MAY BE COVERED by a separate warranty or service environments, or other conditions beyond the control of CARRIER.
agreement provided by the seller or another third party, such agreement being
separate and distinct from this factory warranty. 7. Any parts not supplied or designated by CARRIER.
LIMITATION OF WARRANTIES ± ALL IMPLIED WARRANTIES (INCLUDING 8. CARRIER products installed outside the continental U.S.A., Alaska, Hawaii, and
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR Canada.
PURPOSE) ARE HEREBY LIMITED IN DURATION TO THE PERIOD FOR WHICH
THE APPLICABLE PRODUCT COMPONENT IS EXPRESSLY WARRANTED HEREIN. 9. Shipping damage or damage as a result of storing or transporting the unit.
Some states do not allow Limitations on how long an implied warranty lasts, so
the above limitations may not apply to you. THE EXPRESS WARRANTIES MADE IN
THIS WARRANTY ARE EXCLUSIVE AND MAY NOT BE ALTERED; ENLARGED, or
CHANGED BY ANY DISTRIBUTOR, DEALER, OR OTHER PERSON WATSOEVER.
CARRIER WILL NOT BE RESPONSIBLE FOR ANY SPECIAL, INCIDENTAL OR
NATURE WHATSOEVER. Some states do not allow the exclusion of incidental or
consequential damages, so the above limitation may not apply to you. All work
provided for by this warranty shall be performed during normal working hours. All
replacement parts, whether new or remanufactured, assume as their warranty
period only the remaining time period for which the applicable component is
expressly warranted herein.
CARRIER CORPORATION
IF YOUR UNIT DOES NOT WORK, FOLLOW THESE STEPS IN ORDER:
1. CHECK THE THINGS YOU CAN DO YOURSELF. These 3. CONTACT THE NEAREST CARRIER DISTRIBUTOR
include being sure the air conditioner is plugged in SERVING YOUR AREA. (See Telephone Yellow
firmly in an appropriate receptacle, checking the Pages.)
fuse or circuit breaker and ensuring its replacement
or resetting, if necessary, and rereading the 4. CONTACT CARRIER IF A SATISFACTORY SOLUTION
instruction book to ensure all controls are set IS NOT REACHED IN STEPS 2 AND 3.d
properly. By doing this you can save money. Many
unnecessary calls result in the serviceman doing Carrier Air Conditioning
what the owner can do for himself. Consumer Relations Department
P.O. Box 4808
Carrier Parkway
2. CONTACT YOUR DEALER OR THE CARRIER Syracuse, New York 13221
AUTHORIZED SERVICE CENTER. You may find this Telephone: 1-800-CARRIER (227-7437)
name on the product, on your invoice or in your From Canada: (315) 432-7885
Homeowner¶s Packet.
141082 / 001
No.:
B-E 07 467
Page 1 from 9
Type: G5F15/26-HVDR-37-36-3-R36D
Special: --
*CTVOCPP-ÑPKI
S t ro m zuf üh ru n gs A G
Leitungstrommeln - Schlauch - Seil - Sondertrommeln - Schleifringkörper
Postfach 1260 76677 Graben-Neudorf Telefon: 07255 / 7120-0
Siemensstraße 6 76676 Graben-Neudorf Telefax: 07255 / 5038
www.hukag.com
E - Mail: info@ hukag.com
No.:
Maintenance Instruction and Spare Parts List
Type: G5F15/26-HVDR-37-36-3-R36D B-E 07 467
Page 2 from 9
List of Contents
Note that there is enough seal between the round plate and
the bottom of the terminal box. Optionally this must be ac-
complished by the customer side locally. Control the sealing
in regular intervals and renew it every 3-5 years.
You receive this necessary sealant H&K-Sikaflex 221 over
our spare part sales.
Note: The 1st, slip ring () nearest the axle is always earth Ũ.
7.0 Maintenance
a.) Wear Part
The brush holders/collector and slip rings/plane slip rings are subject to a natural wear and
are depending upon need to be replaced. The brush bearing surfaces are to be cleaned
and the mobility of the pendulum brush holders are to examine (with wire brush holding the
pressure * is to the slip rings to examine), if necessarily should take place a cleaning or an
exchange (during 2/3 wear of the brush coals). After cleaning of the slip rings these should
be injected with contact spray. You receive the for this necessary special spray over our
spare part sales. It is to be made certain that the slip rings are always clean and no brush
coal dust at the slip rings set (flash over). After running in (after commissioning for the first
time after 3 months) of the brush coals the brush coal dust in the slip ring area is to be re-
moved. You have to made weekly maintenance in the running-in period (approx. 4-8
weeks) after commissioning. That’s important to ensure correct function further on. After-
wards in regular intervals (every 6 months and / or depending upon turnings of the slip
rings) repeat this procedure. If you fall into no pattern, please you request a maintenance
plan from us (with description of your data e.g. turnings, layer duration, travel speed). The
inserted grooved ball bearings are by the factory plentifully provided with camp fat, so that
a greasing is necessary only in larger time intervals. It is to be made certain by the cus-
tomer that the steel flange is closely screwed on and the cable entry is well after IP54
(IP65) sealed.
Pressure* = when easy one-sided taking from 3-4 mm off should set itself the hook again
well on the slip ring course. If this effected can take place re-bent and/or must an ex-
change.
The electrical connection must be done according to VDE 0100 - 0113 resp. IEC-Nr.: 204-
1:1992 or CENELEC.
According the EC recommendation 89/382/EEC, we point out that rotating parts have to be
secured against danger of accident.
Notice
According the EC recommendation 89/392/EEC, we point out that rotating parts have to be
secured against danger of accident.
9.0 Enclosure
General security advices for motor driven cable reeling drums B+E 00 049
Screws / tightening torque B+E 00 069
Maintenances instruction for hydraulic motor B+E 00 060
Maintenances instruction for hydraulic air multiple disc brake B+E 00 06
When ordering spare parts, please state our order- and our serial number, to avoid wrong
deliveries. The order- and our serial number are on the type plate on the drum.
Safety References
– The cable reeling drum is built and is reliable in service delivered after the newest
state design. Arbitrary changes, which impair the working reliability, are not permissi-
ble. That concerns also protection device, which is appropriate as contact protection.
– The cable reeling drum may be used and operated only in the context of the condi-
tions specified in the achievement and supply contract.
– The operator has to ensure that with the assembly, the commissioning , servicing and
maintenance as well as the repair assigned persons consider the manual. Make sure
that they read and understood it in all points to prevent:
• dangers for life and health of the user and other persons.
• To guarantee the working reliability of the device.
• loss of use and environmental pollutions by wrong handling.
- for transport, assembling and disassembly, the operation as well as servicing and
maintenance, the relevant regulations are to be considered to the industrial safety
and to environmental protection.
- the cable reeling drum may only maintained or repaired by authorized, trained and in-
structed personnel.
- work on the cable reeling drum may be accomplished only in the switched off condi-
tion.
- The changed oil has to be filled into suitable container. Possibly developed oil on the
floor are to be eliminated immediately with an oil bonding agent. Strongly oil-soaked
cloths has to be kept in suitable containers. The waste oil is just like the oil bonding
agent and the cleaning cloths to be thrown according to the relevant environmental-
protection regulations.
- rotary drive components, like clutches, gear wheels or belt drives must be secured
against danger of accidents.
- at the cable reeling drum appropriate references, e.g. identification plate, rotation ar-
row etc. are to be considered. They must be free by colour and dirt. Missing ones de-
scribe have to be replaced.
No.:
B 00 069
page 1 from 2
Maintenance instruction
Screws/tightening torque
*CTVOCPP-ÑPKI
Stromzuführungs AG
Cable reeling drum – Hose – Special drums – Slip ring bodies
p.o.box 0100 76674 Graben-Neudorf phone: +0049-7255 / 7120-0
Siemensstraße 6 76676 Graben-Neudorf fax: +0049-7255 / 5038
www.hukag.com
E - Mail: info@hukag.com
No.:
Maintenance instruction B 00 069
Screws/tightening torque
page 2 from 2
Note: Unserviceable screws should be replaced by new ones of the same property class
and type.
Maintenance Instruction
and Spare Parts List
for
Replacement of the Springs Type LT
*CTVOCPP-ÑPKI
Stromzuführungs AG
Cable Reeling Drum – Hose – Special Drums – Slip Ring Bodies
p.o.box 0100 76674 Graben-Neudorf phone: +0049-7255 / 7120-0
Siemensstraße 6 76676 Graben-Neudorf fax: +0049-7255 / 5038
www.hukag.com
EMail: info@hukag.com
No.:
Maintenance Instruction and Spare Parts List B-00 090
Type: LT parallel or in serial
page 2 from 8
List of Contents
Attention: The springs are made of rolled flat steel. The consequences of this
properties are, that they want to go back to its primitive state. So you have to look
and be carefully about the danger of accidents by using this kind of springs.
Disconnect the main power cable from the slip rings and pull the cable out of the hollow
shaft. The winding cable can remains on the drum body if it is secured against automatic
unwinding. Otherwise it must be uncoil completely from the drum body.
Remove the reeling drum from the fixing flange by loosen the screws (customer side).
Now remove the cable gland (1), the circlip ring (2) and the fixing flange from the hollow
shaft and the feather key. Remove the shield (7) with the spring housing (10), the ball
bearing (8) and the bearing cover (9) by unscrewing of the fixing nuts (5 and 6). The ball
bearing (8) should not be removed from the shield (7).
Attention! If the shield (7) is lifting up itself from the spring housing (16) by loosen-
ing one of the last nut you have to tighten it immediately. After that please contact
us for specify the next procedure.
The springs (12) were now visible and can be replaced out of the spring housing (10),
with the spacer plate and with their bandage.
Handle with care!
If you have a cable reeling drum with more springs you have to repeat the procedure until
all springs are took out of the spring housing.
Attention! The new springs should be handle with care. Never remove the spring
bandage because this could cause very serious accidents.
The new springs must be placed into position with the bandage on. It is also important to
ensure that the inner eyelet of the spring engages properly in the groove of the takener
(14) which is fixed on the hollow shaft. After that you have to grease the new spring well.
Further take into consideration that all springs have the same direction of rotating. Con-
sider the type designation for example LT300/… on the type plate. After that you have to
grease the springs well. Now you can assemble the cable reeling drum in reverse order.
Attention! The hollow shaft (15) has to be proper cleaned and the shield (7) with the ball
bearing (8) must be slide easier on it.
01 cable gland 1
02 circlip ring 1
03 fixing flange 1
04 nut M6 4
05 nut M6 8
06 nut M8 3
07 shield 1
08 ball bearing 1
09 bearing cover 1
10 spring housing 1
11 spacer plate
12 spring 1
13 spacer plate 1
14 takener (hollow shaft) 1
15 spring bolt 1
16 spring housing 1
Attention: The springs are made of rolled flat steel. The consequences of this
properties are, that they want to go back to its primitive state. So you have to look
and be carefully about the danger of accidents by using this kind of springs.
Disconnect the main power cable from the slip rings and pull out the cable of the hollow
shaft. The winding cable can remains on the drum body if it is secured against automatic
unwinding. Otherwise it must be uncoil completely from the drum body.
Remove the reeling drum from the fixing flange by loosen the screws (customer side).
Now remove the cable gland (1), the circlip ring (2) and the fixing flange from the hollow
shaft and the feather key. Remove the shield (7) the spring housing (10), the ball bearing
(8) and the bearing cover (9) by unscrewing of the fixing nuts (5 and 6). The ball bearing
(8) should not be removed from the shield (7).
Attention! If the shield (7) is lifting up itself from the spring housing (16) by loosen-
ing one of the last nut you have to tighten it immediately. After that please contact
us for specify the next procedure.
The springs were now visible and can be replaced out of the spring housing (16) with the
spring housing (10), the spacer plate and with their bandage.
Attention! This applies only for cable reeling drum types LT220 and LT530.
During the replacement of the spring you have to press down the takener (14) by
using an screwdriver for example. Otherwise the inner eyelet of the lower spring
can jump out of the spring housing (10).
A circlip ring is constructional handled that by the other cable reeling drum types.
Attention! The new springs should be handle with care. Never remove the spring
bandage because this could cause very serious accidents.
The new springs must be placed into position with the bandage on. It is also important to
ensure that the inner eyelet of the spring engages properly in the groove of the Takener
(14) which is fixed on the hollow shaft. Pay
attention by the last spring, because you
don’t see it correctly, that the spring bolt
engages properly in the outer eyelet of the
spring. Otherwise you have a malfunction
of the spring (see pic.).
Further take into consideration that one
spring should be placed with inverted
direction to the other to cause a serial
effect. Consider the type designation on the
type plate LT300 …/H (H = in serial) for
example. After that you have to grease the
spring well. Now you can assemble the cable
reeling drum in reverse order. Attention!
The shield (7) with the ball bearing (8) must
be slide easier on it.
01 cable gland 1
02 circlip ring 1
03 fixing flange 1
04 nut M6 4
05 nut M6 8
06 nut M8 3
07 shield 1
08 ball bearing 1
09 bearing cover 1
10 spring housing 1
11 spacer plate
12 spring 1
13 spacer plate 1
14 takener 1
15 spring bolt 1
16 spring housing 1
17 hollow shaft
Maintenance Instruction
for
Hydraulically Released
*CTVOCPP-ÑPKI
S t ro m zuf üh ru n gs A G
Cable Reeling Drum - Hose - Rope - Special Drums - Slip Ring Bodies
p.o.box 0100 76674 Graben-Neudorf phone: +49-7255 / 7120-0
Siemens Street 6 76676 Graben-Neudorf fax: +49-7255 / 5038
www.hukag.com
E - Mail: info@hukag
Nr.:
Maintenance Instruction B-E 00 061
Hydraulically Released Spring-applied
Multi-plate Brakes series 0-022-..0/..9 Seite 2 von 7
141082 / 001
A
1
6
2
5
3
B C
D E
2
1
00520266.eps
Strictly follow the Instructions for Use
Any use of the apparatus requires full understanding and strict observation of these
instructions.
The apparatus is only to be used for purposes specified here.
Maintenance
The apparatus must be inspected and serviced regularly by trained service personnel.
Repair of the apparatus may only be carried out by trained service personnel.
We recommend that a service contract be obtained with Dräger Safety and that all repairs
also be carried out by them.
Only authentic Dräger spare parts may be used for maintenance.
WARNING
Indicates a potential hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a potential hazardous situation which, if not avoided, could result in physical
injury or damage to property.
It may also be used to alert against unsafe practices.
NOTICE
Indicates additional information on how to use the apparatus.
Intended Use
PARAT C is a smoke hood designed for single use, which provides respiratory protection
against smoke and most hazardous combustible gases. It is designed for an escape
period of at least 15 minutes.
WARNING
Do not use the smoke hood at temperatures below -10 oC. The filter does not work
properly at low temperatures!
PARAT C with CO-P2 filter complies with EN 403:2004 (M) for mobile hoods or
EN 403:2004 (S) for stationary hoods. Only use the smoke hood for the purpose of
escaping in an emergency. Do not use during regular operations!
DANGER
The smoke hood is suitable for single use only. Dispose after use.
The smoke hood does not provide protection against oxygen deficiency!
Failure to observe this can lead to death or severe bodily injuries.
The nose cup fits all adults and children from the age of four.
What is What?
(Figure A)
1 hood 4 pull cord
2 nose cup 5 filter
3 adjustable strap 6 exhalation valve
Explanation of Symbols
Important! Strictly follow the Instructions for Use.
03
Date of manufacture (see explanations under
http://www.draeger.com/ST/internet/pdf/ 9021650_01_2005_MUL036.pdf)
Use
WARNING
Only use hood if it is undamaged and the seal on the filter is still intact!
z Open packaging and remove smoke hood.
PARAT C twin pack:
Grip lid of the twin box at the top, pull forwards and remove smoke hood.
PARAT C single pack:
Open packaging and remove smoke hood.
PARAT C soft pack:
Open zipper and remove smoke hood.
PARAT C traveller pack:
Remove retaining clip, open box and remove smoke hood.
PARAT C box:
Lift lever with the index finger, then the rubber band will open.Open packaging and
remove smoke hood.
z Opening the filter (Figure B):
Hold smoke hood with one hand. Grip the two red pull cords with the other hand and
pull the sealing plugs completely out of their holes.
DANGER
Before using the smoke hood, ensure that the filter opening is free, since breathing will
otherwise be impaired!
z Put aside the packaging, pull cords and seal plugs.
z Using both thumbs, push the filter out of the hood from inside (Figure C).
z Grip the collar with both hands and open it wide.
z Put the chin into the smoke hood first (Figure D1).
z Pull the hood over the head (Figure D2).
Ensure that nose and chin are positioned inside the nose cup. If required, take hold
of the filter and move the nose cup so that it is positioned snugly around the mouth
and nose.
Ensure that the hair is covered completely by the smoke hood.
NOTICE
There is no need to remove spectacles.
z Tighten the adjustable strap until the nose cup is positioned snugly around the mouth
and nose, holding the filter with the other hand (Figure E).
z If it is not possible to tighten the adjustable strap, hold mask firmly in position using
the hand.
WARNING
Full beards can cause leaks and put the wearer of the hood at risk!
If the smoke hood is used by children, an adult should make sure that the nose cup is
positioned correctly around the chin and nose.
z Breathe calmly!
Breathing is slightly more difficult. The breathing air becomes noticeably warmer: this
is an indication of correct operation of the filter.
z Find an escape route to an emergency exit. If this is not possible, wait for the arrival
of the fire brigade! Knock on walls or stand at a window so that the rescuers can find
you.
Maintenance
The maximum lifetime of the smoke hood is 12 years from the date of manufacture.
The smoke hood must be maintained by qualified trained personnel only.
Replace filter and valve disc of an unused smoke hood if
– the sealing plugs of the filter for the smoke hood have been removed.
– the sealing is damaged.
– the expiry date shown on the box has been exceeded.
For this purpose, use spare-part kit R 57302.
Storage
Store the hood in the box in a cool and dry place. Do not expose to direct sunlight and
temperatures above 50 oC.
Disposal
Dispose of filter and hood in accordance with the applicable local waste disposal
regulations.
Order List
Name and Description Part No.
PARAT C single pack: R 52 817
PARAT C traveller pack: R 52 818
PARAT C twin pack: R 52 845
Seal D 12 378
Seal wire T 13 028
PARAT C soft pack: R 53 555
PARAT C box: R 54 461
Spare-part kit R 57 302
99
4
141082 / 001
OPERATING
INSTRUCTIONS
VERSION
001 − 15.11.2006
LIEBHERR
RADIOREMOTECONTROL
INDEX
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 5
1.3. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 7
2. OPERATING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 8
3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 23
LIEBHERR
RADIOREMOTECONTROL
LIEBHERR
RADIOREMOTECONTROL
1. GENERAL
−1.5− LIEBHERR
RADIOREMOTECONTROL
. IMPORTANT NOTE!
You need to fully charge the battery before using it for the first time!
A battery’s operating time depends on its age and the ambient temperature. Over time older batteries lose
their capacity. At temperatures below 0°C the battery does not achieve its full capacity.
− Only recharge the battery when it is completely discharged, i.e. when the red
display is flashing on the transmitter and/or the audible signal is emitted.
− Do not keep the battery in your tool box or in your trouser pocket.
− Store batteries at room temperature (approximately 20°C).
− Always use the protective caps supplied when keeping the batteries.
Batteries stored for a long period of time should be charged before they are used.
− Only type FuB10AA and FuB 10XL batteries should be charged on the FLG 11 0B charger.
− Do not operate the charger in potentially explosive areas.
− The charger must be operated only at the mains voltage stated on its base.
− The charger should be operated only in closed indoor rooms.
− Operate the charger at room temperature and protect it from
overheating, dust and humidity.
− The mains plug must be removed without fail before the device is opened.
− Do not cover the charger while it is in operation.
− Unplug the charger from the mains supply when it is not in use.
− The appliance must be taken out of operation if a fault occurs on the appliance or on the power cable.
− Do not make any technical changes to the charger or the power cable.
− Any repairs must be effected only by a specialist technician.
−1.6− LIEBHERR
RADIOREMOTECONTROL
1.3. MAINTENANCE
The radio equipment requires almost no maintenance. Nevertheless you should take note of the following:
− Make sure that the switches operate smoothly.
Dirt of all kinds can hinder and even prevent switches from actuating.
− Regularly check the corrugated bellows on the operating controls for seal.
Any faulty corrugated bellows must be replaced immediately because penetrating
dirt and dampness can affect the operation of the controls.
− The transmitter batteries must be charged and discharged regularly.
− Never clean the transmitter with a high pressure cleaner.
− If necessary, clean the transmitter with a brush or a soft cloth.
− Make sure that no metal components are located above the antenna.
− Make a daily visual check of the antenna.
− If the antenna is damaged, immediately cease radio controlled operation.
. IMPORTANT NOTE!
In the event that problems occur with your radio equipment, please contact your
LIEBHERR Customer Services point
−1.7− LIEBHERR
RADIOREMOTECONTROL
2. OPERATING CONTROLS
Selections
Strut
Folding spars
Drive mode
−1.8− LIEBHERR
RADIOREMOTECONTROL
D E C
A Selections Function
B Selections Function
C Selections Function
D Selections Function
Turn rotary platform counter−
Crane operation
clockwise
E Selections Function
Turn motor swing gear
Motor swing gear
counter−clockwise
−1.9− LIEBHERR
RADIOREMOTECONTROL
D C
E
A Selections Function
B Selections Function
C Selections Function
D Selections Function
E Function
Horn
−1.10− LIEBHERR
RADIOREMOTECONTROL
Toggle switch
Selections Function
Strut 1 retract
Strut 1 extend
Toggle switch
Selections Function
Strut 2 retract
Grab descend
Strut 2 extend
Toggle switch
Selections Function
Grab raise
Spreader telescope in
−1.11− LIEBHERR
RADIOREMOTECONTROL
Toggle switch
Selections Function
counterbalance spreader
Spreader
to black flipper switches
Counterbalance spreader
Spreader
to white flipper switches
Toggle switch
Selections Function
Strut 3 retract
Strut 3 extend
Toggle switch
Selections Function
Strut 4 retract
Magnet switch on
Strut 4 extend
−1.12− LIEBHERR
RADIOREMOTECONTROL
"Free−wheel rotator"
"Bypass" button
−1.13− LIEBHERR
RADIOREMOTECONTROL
"Lighting" button
−1.14− LIEBHERR
RADIOREMOTECONTROL
−1.15− LIEBHERR
RADIOREMOTECONTROL
In the event that there is a fault on the crane which would normally appear on the crane’s screen in the
form of a text message, this is now simply indicated by a flashing stop light on the control console screen.
No text messages are displayed on the control console screen.
The page displays in flashing and beep mode if a fault occurs on the crane (text
message on the crane screen).
If the connection between the transmitter and the receiver is lost for a short period (less than 8 seconds),
all the master switches and toggle switches must be put back to their home positions, so that further
movement can take place. This requirement to set all switches to home is displayed to the operator in the
form of a STOP symbol which remains on the screen until all the master switches and toggle switches
have been set to home position.
. IMPORTANT NOTE!
As soon as a STOP symbol appears on the control console screen, radio operation must cease
immediately! The error message on the crane screen must be read out!
−1.16− LIEBHERR
RADIOREMOTECONTROL
Maximum load
Pos9 Pos10 Pos11
Progress
Crab steering
Normal steering
Position 2:
−1.17− LIEBHERR
RADIOREMOTECONTROL
Position 3:
Position 4:
Folding spar in position, strut on floor and no pressure at wheel sets; symbol active;
Folding spar in position and folding spar or strut are moving; symbol flashes;
Folding spar not in position, strut on floor and no pressure at wheel sets;
symbol active;
Folding spar not in position and strut or folding spar are moving;
symbol flashes;
Position 5:
Folding spar in position, strut on floor and no pressure at wheel sets; symbol active;
Folding spar in position and folding spar or strut are moving; symbol flashes;
Folding spar not in position, strut on floor and no pressure at wheel sets;
symbol active;
Folding spar not in position and strut or folding spar are moving;
symbol flashes;
Position 6:
Drive mode has been selected; load, slewing gear position or unload position not in drive range
(Selection not possible); symbol flashes;
Drive mode active; load, slewing gear or unload position is now out of drive range;
Symbol flashes;
−1.18− LIEBHERR
RADIOREMOTECONTROL
Position 7:
Folding spar in position, strut on floor and no pressure at wheel sets; symbol active;
Folding spar in position and folding spar or strut are moving; symbol flashes;
Folding spar not in position, strut on floor and no pressure at wheel sets;
symbol active;
Folding spar not in position and strut or folding spar are moving;
symbol flashes;
Position 8:
Folding spar in position, strut on floor and no pressure at wheel sets; symbol active;
Folding spar in position and folding spar or strut are moving; symbol flashes;
Folding spar not in position, strut on floor and no pressure at wheel sets;
symbol active;
Folding spar not in position and strut or folding spar are moving;
symbol flashes;
Position 9:
Position 10:
Position 11:
Engine symbol (for function see 3.4 "Starting and stopping the unit")
−1.19− LIEBHERR
RADIOREMOTECONTROL
Pos6
Pos8
Wind symbol
Pos9 Pos10 Pos11
Magnet operation
Magnet switched on
−1.20− LIEBHERR
RADIOREMOTECONTROL
Position 2:
Position 3:
Slack rope winch 1 and 2 or slack rope due to load threshold; symbol flashes;
Beep signal on slack rope winch 1 and winch 2 active;
Difference in rope length too great or bypass key is pressed in service mode winch 1 or winch 2;
Symbol flashes;
−1.21− LIEBHERR
RADIOREMOTECONTROL
Position 4:
Position 5:
Position 6:
Position 7:
Position 8:
Position 9:
Position 10:
Position 11:
Engine symbol (for function see 3.4 "Starting and stopping the unit")
−1.22− LIEBHERR
RADIOREMOTECONTROL
3. OPERATION
. IMPORTANT NOTE!
If during a procedure the radio connection is interrupted briefly, the transmitter and receiver react
by indicating what is known as the "home position requirement".
This means that you must release all operating controls such as the small master switches or
push−buttons, so that they all return to the home position. Only once this has been done will the crane
or machine react again to radio commands! This prevents uncontrolled movement of the crane or
machine once the radio connection is restored.
If you are working with a radio control unit for the first time, at first you will probably miss the physical
contact with the crane to which you are accustomed at the control stand inside the crane. If at first
the reaction of the crane appears different, it is because you do not feel the crane movements quite
so perceptibly as when you are actually on the crane.
−1.23− LIEBHERR
RADIOREMOTECONTROL
. IMPORTANT!
Make sure that the battery poles are in the correct positions.
− The remote controls are selected at the 4T−S01 switch (side panel of switch cabinet).
− Use the master key at the side of the operating console to switch on the transmitter.
− Once the connection between the transmitter and receiver has been made, the horn image is displayed.
. IMPORTANT NOTE!
The horn symbol also appears when the radio connection is switched back on
after an interruption longer than 4 seconds, or after an emergency stop.
. IMPORTANT NOTE!
If there is a fault at the crane (text message), the screen shows a flashing stop symbol and it also
beeps. Error messages cannot be output on the screen. For this reason any faults must be rectified
immediately!
The screen in the rotary platform cabin or turret cabin is active while the radio remote control
is switched on and the crane control system is operational.
−1.24− LIEBHERR
RADIOREMOTECONTROL
. IMPORTANT NOTE!
When the switch is operated, the crane’s ignition is automatically switched on!
Warning! A danger exists when the radio remote control is switched on!
The radio remote control system is active as soon as radio operation is
enabled by actuating the switch on the control cabinet!
If any of the controls are inadvertently activated when the radio remote
control is switched on, a function will be triggered.
− Make sure that all the control and operation elements are at
resting position when you switch on!
− Make sure that you have read and understood all the safety
regulations in 1.1 and 3.1!
−1.25− LIEBHERR
RADIOREMOTECONTROL
3.2.3. TROUBLESHOOTING
ATTENTION!
Do not continue working with a faulty radio control system!
−1.26− LIEBHERR
RADIOREMOTECONTROL
Once the crane control system has been switched on, unlike in the crane cabin, the most recently used
operating mode is not automatically reselected.
To select the operating mode, once the crane control system is operational, you need to set the rotary
switch to the required position. If it is already at the required position, you need to
leave that position, and reselect it.
. IMPORTANT NOTE!
Make sure that the motor is running, and all master switches and toggle switches are at home
setting (home position requirement).
If the required operating mode is available in the crane’s current position, it is activated. In normal lift and
heavy lift operation, a difference is made between the two options by means of the signal placed.
The operating mode depends on the signal placed (e.g. slewing gear, spreader,
etc.) and the position of the crane.
(e.g. supported, rotary gear position, etc.)
In order to fold down the boom, on the selector knob, select crane operation, hook. Then hold down the
bypass key to activate fold down operation. This remains active all the while the bypass key is kept
depressed. If it is released for longer than 1 second, the fold down operation is deselected. This means
that it is necessary to start again at the selector switch and bypass key if you wish to continue the fold
down operation.
The bypass key must be kept held down. If the bypass key is released for more
than 1 second −> operating mode is deselected− > start again.
−1.27− LIEBHERR
RADIOREMOTECONTROL
The bypass key must be kept held down so that the required winch.
can be driven.
In spreader mode it is possible to bypass the load threshold and the signal it has triggered by holding
down the bypass key. This makes it possible to lower further if this is needed. It can be very helpful to
bypass the load threshold when constructing or dismantling the spreader from the crane. In spreader
mode it is possible to lower only up to this load threshold.
The bypass key must be kept held down in order to bypass the load threshold or
the signal it has triggered.
In grab and motor grab mode a ’stop lowering’ command is triggered via a load threshold, and this is
displayed by means of the slack rope symbol. In order to be able to bypass this stop command, the
bypass key has to be held down. This can be very helpful when re−suspending loads.
The bypass key must be kept held down in order to bypass the load threshold.
−1.28− LIEBHERR
RADIOREMOTECONTROL
Once the console has been switched on, the top right−hand corner of the screen displays a symbol
indicating that the engine is heating up. Once this symbol has disappeared, the engine can be started.
The diesel engine is started at the engine key.
When the diesel engine is running, an engine symbol appears at the bottom right−hand corner of the
screen, either flashing or constant. This depends on whether you are starting the electro−drive or the
diesel engine in Eco mode or not.
Start the unit by briefly pressing the engine key. While the engine is starting, the engine symbol at the
bottom right−hand of the screen is flashing. When everything is ready for operation, the engine symbol
stops flashing and becomes solid.
Start the diesel engine by briefly pressing the engine key. If the diesel engine is at idle power, this is
indicated on the screen by a flashing engine symbol at the bottom right edge of the screen. If you briefly
press the engine key again, the diesel engine switches to full power. When everything is ready for
operation, the engine symbol on the screen stops flashing and becomes solid. If you press the key again,
the diesel engine returns to idle power.
If you briefly press the engine key, the engine goes to full or idle power.
To switch off the diesel engine, you have to hold down the engine key for more than 2 seconds.
Press engine key for more than 2 seconds − > engine stops.
−1.29− LIEBHERR
RADIOREMOTECONTROL
If the emergency switch is pressed on the control console, it has the same effect as the emergency switch
on the crane, i.e. it switches off the crane completely, including the control system.
However,to switch the control unit back on, you need to release not only the emergency off switch as in
the crane, but you also need to switch the control console back on using the key−operated switch.
Once the emergency off button has been pressed and then released again, the
control consol must be switched back on with the key.
The crane control system must then be switched back on at the horn key. This is displayed on the screen
by means of the horn symbol.
3.6.1. INTERRUPTION FOR LONGER THAN 0.5 s AND LESS THAN APPROX. 8 s
If an interruption to the radio connection occurs for more than 1 second but less than 8 seconds, the
interrupted connection symbol displays on the screen.
The mechanisms are blocked and movements are braked down for an integration period.
When the radio connection is restored, the movements are not automatically restored. This can only
happen once all the master switches and toggle switches have been returned to their home positions.
Until the master switches and toggle switches have been reset to their home positions, the stop symbol is
constantly displayed on the screen.
Once the home position requirement is met, you can restart movements.
If the interruption to the radio connection was for more than 8 seconds, the radio control system receiver
automatically triggers a passive emergency off signal. Like a normal emergency stop, this switches off the
entire crane, including the control system.
The interrupted connection symbol is displayed on the screen all the while the connection is interrupted.
Once the connection has been restored the horn symbol is displayed on the screen and the crane control
system can be switched on again by pressing the horn key.
−1.30− LIEBHERR
5
141082 / 001
DOCUMENTATION
Schwenkwerk-Typ / Slewing Unit Type:
SW 144 DISK
Bestell-Nr. / Order-no.:
2308.0453
Version / Version:
EC00407
Ident-Nummer / Identification-no.:
10514223
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Sortier-Nr. Blatt-Nr.
A 16.0138-1 D 1-1
I n h a l t s v e r z e i c h n i s
Blatt-Nr. Sortier-Nr.
Maschinenkarte / Technische Daten
1.0 Sicherheit
1.1 Zu diesem Dokument 2-1 A 16.0200-1 D
1.2 Zielgruppe 2-1 A 16.0200-1 D
1.3 Bestimmungsgemäße Verwendung 2-1 A 16.0200-1 D
1.4 Grundlegende Sicherheitshinweise 2-2 A 16.0200/2-7 D
1.4.1 Warnhinweise 2-2 A 16.0200-2 D
1.4.2 Sicherheitszeichen 2-2 A 16.0200-2 D
1.4.3 Organisatorische Maßnahmen 2-3 A 16.0200-3 D
1.4.4 Personalauswahl und -qualifikation 2-4 A 16.0200-4 D
1.4.5 Maßnahmen durch den Betreiber 2-4 A 16.0200-4 D
1.4.6 Maßnahmen durch den Bediener 2-5 A 16.0200-5 D
1.4.7 Maßnahmen zu Wartung, Instandhaltung und 2/5-6 A 16.0200/5-6 D
Instandsetzung
1.4.8 Sicherheitshinweise zu Elektrik 2/6-7 A 16.0200/6-7 D
1.4.9 Sicherheitshinweise zu Hydraulik 2-7 A 16.0200-7 D
1.4.10 Umgang mit Ölen, Fetten und anderen 2-7 A 16.0200-7 D
chemischen Substanzen
3.0 Betriebsanleitung
3.1 Hinweise für den sicheren Betrieb 8/1-2 A 16.0619/1-2 D
3.2 Inbetriebnahme
3.2.1 Montageanleitung - Erst-Inbetriebnahme 8/3-4 A 16.0619/3-4 D
3.2.2 Tägliche Inbetriebnahme 8-5 A 16.0619-5 D
3.3 Betrieb
3.3.1 Hinweise für den Betrieb 9-1 A 16.1218 D
3.4 Außerbetriebnahme 9-1 A 16.1218 D
3.5 Wieder-Inbetriebnahme 9-1 A 16.1218 D
3.6 Transport 9-1 A 16.1218 D
Originalbetriebsanleitung
6DO]JLWWHU0DVFKLQHQEDX$* 7HOHIRQ (PDLO 9RUVWDQG 6LW]GHU*HVHOOVFKDIW6DO]JLWWHU%DG
:LQGPKOHQEHUJVWUDH SHLQHU#VPDJGH 6HEDVWLDQ+%UDQGHV9RUVLW]HQGHU 5HJLVWHUJHULFKW
6DO]JLWWHU*HUPDQ\ 7HOHID[ ,QWHUQHW -UJHQ%LDOHN $PWVJHULFKW%UDXQVFKZHLJ
ZZZVPDJGH 9RUVLW]HQGHUGHV$XIVLFKWVUDWHV 5HJLVWHUQXPPHU
ZZZSHLQHUGH 8OULFK'HFNHU +5%
30.09.2010
P
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Sortier-Nr. Blatt-Nr.
A 16.0138-2 D 1-2
I n h a l t s v e r z e i c h n i s
Blatt-Nr. Sortier-Nr.
4.0 Instandhaltung 10-1 A 16.1222-1 D
4.1 Pflege und Wartung 10-2 A 16.1222-2 D
4.1.1 Wartungsübersicht 10-2 A 16.1222-3 D
4.1.2 Wartungsintervall nach den ersten 10-2 A 16.1222-4 D
50 Betriebsstunden
4.1.3 Wartungsintervall nach den ersten 10-2 A 16.1222-4 D
500 Betriebsstunden
4.1.4 Wartungsintervall wöchentlich 10-2 A 16.1222-5 D
4.1.5 Wartungsintervall alle 1000 Betriebsstunden 10-2 A 16.1222-6 D
4.1.6 Wartungsintervall alle 2000 Betriebsstunden 10-2 A 16.1222-7 D
4.1.7 Ölwechsel 10-2 A 16.1222-8 D
4.1.8 Ölfilter 10-2 A 16.1222-9 D
4.1.9 Schmieranweisung 10-2 A 16.1222-9 D
4.1.10 Schmierstellen 10-2 A 16.1222-10 D
4.1.11 Motor 10-2 A 16.1222-11 D
4.1.12 Schleifringübertrager 10-2 A 16.1222-12 D
4.2 Durchzuführende Prüfungen
4.2.1 Ölstand prüfen 10-2 A 16.1222-13 D
Originalbetriebsanleitung
6DO]JLWWHU0DVFKLQHQEDX$* 7HOHIRQ (PDLO 9RUVWDQG 6LW]GHU*HVHOOVFKDIW6DO]JLWWHU%DG
:LQGPKOHQEHUJVWUDH SHLQHU#VPDJGH 6HEDVWLDQ+%UDQGHV9RUVLW]HQGHU 5HJLVWHUJHULFKW
6DO]JLWWHU*HUPDQ\ 7HOHID[ ,QWHUQHW -UJHQ%LDOHN $PWVJHULFKW%UDXQVFKZHLJ
ZZZVPDJGH 9RUVLW]HQGHUGHV$XIVLFKWVUDWHV 5HJLVWHUQXPPHU
ZZZSHLQHUGH 8OULFK'HFNHU +5%
Maschinenkarte / Technische Daten
Eigengewicht: 3.600 kg
Tragfähigkeit SWL: 144.000 kg
erf. Krantragfähigkeit: 147.600 kg
Mechanische Daten
-1
Drehzahl / Achse: 5,4 / 6,8 min
Drehmoment / Achse: 4850 Nm
Elektrische Daten
Betriebsart: S3 Schutzart: IP 56 1)
Motor-Typ: 112M-4 Isolierklasse: F
Aussetzbetrieb: 40% ED max. Schalthäufigkeit: 120 /h
Motorleistung: 3,5 / 4,2 kW Schaltplan-Nr.: 2307.9132
Spannung: 400 V Steckvorrichtung: ODU-37 pol.
Frequenz: 50 / 60 Hz Steuerspannung: 230 V AC
Stromart: Drehstrom Anzahl d. Schleifringe: 31pol.x36A+PE+2 CAN
Nennstrom (Vollast): 7,9 A ± 10 % BUS
Stromaufnahme (Leerlauf):
Hydraulische Daten
max. Betriebsdruck Drehrichtung rechts [± 10 bar] 2) Drehrichtung links [± 10 bar]
2)
Messstelle MA 200
Messstelle MB 200
Zubehör
– Kreuzstück mit Doppelhaken Nr. 32
1)
Schutzart nur mit montierter und geschlossener Haube
2)
mit Blickrichtung von oben auf Haube / Schleifringübertrager
Abmessungen
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1.0 Sicherheit
1.2 Zielgruppe
Zielgruppe dieser Betriebsanleitung ist technisches Fachpersonal.
Die Maschine darf nur von technischem Fachpersonal bedient, gewartet und / oder
instandgesetzt werden die in das sachgemäße Arbeiten eingewiesen sind.
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1.4.1 Warnhinweise
Warnhinweise in dieser Betriebsanleitung weisen auf besondere Gefahren hin und
nennen Maßnahmen zum Vermeiden der Gefahr.
Warnhinweise gibt es in vier Stufen:
Signalwort Bedeutung
GEFAHR Unmittelbar bevorstehende Gefahr
Tod oder schwere Verletzung tritt ein
WARNUNG Möglicherweise bevorstehende Gefahr
Tod oder schwere Verletzung kann eintreten
VORSICHT Möglicherweise bevorstehende Gefahr
(Personenschaden) Leichte Verletzung kann eintreten
VORSICHT Möglicherweise bevorstehende Gefahr
(Sachschaden) Sachschaden kann eintreten
1.4.2 Sicherheitszeichen
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3
3(,1(5*UHLIHU
%(75,(%6$1/(,781*
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Das PEINER Motor-Schwenkwerk hat folgenden Aufbau:
Das Schwenkwerk besteht aus einer Traverse (1), in der das Hydraulikaggregat (22),
der Hydraulikmotor (3) und die Nabe (4) angeordnet sind. Die Nabe dient zur Aufnahme
der Achse (5). Die Lastkräfte werden über eine auf der Achse aufgeschraubten Mutter
(6) von einem in der Nabe eingebauten Axial-Rillenkugellager (7) aufgenommen. Auf der
Achse kann je nach Bedarf ein mehrpoliger Schleifringkörper (8) befestigt werden. Durch
die Achse wird vom Schleifringkörper eine Leitung (9) mit entsprechender Aderzahl dem
angehängten Lastaufnahmemittel zugeführt.
Das Hydraulikaggregat (22) ist als kpl. Einheit senkrecht in der Traverse eingebaut. Das
Hydraulikaggregat besteht aus Motor (2) und Pumpe (20).
Durch Lösen der Befestigungsschrauben kann das kpl. Hydraulikaggregat aus dem
Schwenkwerk herausgenommen werden. Der Hydrauliksteuerblock (17) ist an der
Traversenseitenwand befestigt. Das Magnetventil (18) sitzt auf einem Klotz und ist direkt
am Hydraulikmotor (3) angeschlossen.
Das an der Achse befestigte Kreuzstück mit dem Doppelhaken gewährleistet eine
weitestgehend zentrische Krafteinleitung in die Hohlachse und schützt sie somit vor zu
großer Biegebelastung. Eine Leitungszugentlastung verhindert eine mechanische
Belastung der Elektro-Steckvorrichtung.
12.07.2010
3
3(,1(5*UHLIHU
%(75,(%6$1/(,781*
6&+:(1.:(5.
Sortier-Nr. Blatt-Nr.
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1 Traverse 18 Magnetventil
2 Motor 20 Pumpe
3 Hydraulikmotor 21 Ritzel
5 Achse 22 Hydraulikaggregat
6 Mutter 23 Filter
7 Axial-Zylinderrollenlager 27 Doppelhaken
8 Schleifringübertrager 29 Verschlußschraube
9 Leitung (Belüftungsschraube)
12 Kreuzstück 32 Steckvorrichtung
17 Hydrauliksteuerblock 33 Stromversorgungskabel
27.01.2010
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3.0 Betriebsanleitung
X Das Schwenkwerk darf nur von darin unterwiesenen Personen betrieben werden.
X Die Beförderung von Personen auf der Last oder dem Schwenkwerk ist verboten!
X Sicherstellen, dass beim Betrieb alle Schläuche, Leitungen, Rohre und Verschraubun-
gen intakt und dicht sind.
X Das Schwenkwerk, der Doppelhaken und die Anschlagmittel dürfen niemals über ihre
Tragfähigkeit hinaus belastet werden!
X Der Doppelhaken darf nicht unmittelbar in die Last eingehängt werden. Ausgenommen
ist das Einhängen in besonders hierfür eingerichtete Einhängevorrichtungen.
X Verwenden Sie niemals eine Anschlagmittel, die schadhaft oder deren Kennzeichnung
nicht mehr vorhanden ist!
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X Bei allen Kranbewegungen hat der Kranführer vor allem die Last oder bei Leerfahrt das
Lastaufnahmemittel zu beobachten. Ist das nicht möglich, darf er den Kran nur auf
Zeichen eines Einweisers führen.
X Bei Funktionsstörungen ist das Schwenkwerk sofort still zusetzen und gegen wieder-
einschalten zu sichern. Störungen umgehend beseitigen lassen!
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3.2 Inbetriebnahme
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Montage:
1. Schläuche, Verbindungselemente und Dichtungen der Hydraulik auf Dichtheit
prüfen.
2. Aufhängung des Schwenkwerks mit dem Tragmittel verbinden; Tragfähigkeit des
Hebezeuges beachten.
3. Schwenkwerk mit der Steckvorrichtung des Stromversorgungs-Kabels verbinden.
4. Zugentlastung anbringen; das Stromversorgungs-Kabel darf keinerlei Zug auf die
Steckvorrichtung ausüben. (Befestigungspunkte siehe Bild 4.1.5 Schmierstellen)
Die Zugentlastung so anbringen, dass das Stromversorgungs-Kabel nirgends
scheuert.
5. Sicherstellen, dass sich niemand im Gefahrenbereich des Schwenkwerks aufhält.
Das Schwenkwerk soweit anheben, dass der Doppelhaken frei hängt.
6. Ölstand prüfen und bei Bedarf nachfüllen (siehe 4.2.1)
Ölempfehlung siehe Bl.-Nr. 11-1
7. Drehrichtung des Schwenkwerks überprüfen. Bei falscher Drehrichtung zwei
Außenleiter vertauschen. Bei nicht montierter Steckvorrichtung diese nach Schalt-
plan anklemmen.
8. Prüfen ob die Sicherungen an allen Bolzen und Schäkel vorhanden und fest sind.
9. Vor der Erst-Inbetriebnahme ist die ordnungsgemäße Montage und die sichere
Funktion des Schwenkwerkes von einer hierzu befähigten Personen zu prüfen
f Wenn die Temperatur der Hydraulikflüssigkeit unter der Anlauftemperatur liegt (siehe
Blatt-Nr. 8-5 Tabelle 3.2.1 Öltemperaturen) dann muss die Hydraulikflüssigkeit mit
einer Heizung bis zur Inbetriebnahmetemperatur vorwärmt werden (ob eine Heizung
im Schwenkwerk vorhanden ist siehe 2.4 Teilebenennungsplan und Ersatzteilliste:
Schaltplan). Wenn keine Heizung vorhanden ist: die Hydraulikflüssigkeit wechseln;
falls erforderlich vorgewärmte Hydraulikflüssigkeit verwenden.
Bei Temperaturen zwischen der Anlauftemperatur und der Inbetriebnahmetemperatur
(siehe Blatt-Nr. 8-5 Tabelle 3.2.1 Öltemperaturen) die Hydraulikflüssigkeit mit einer
Heizung bis zur Inbetriebnahmetemperatur vorwärmen oder
• wenn vorhanden, Kugelhähne KH2 und KH3 schließen (siehe Blatt-Nr. 10-1)
oder wenn vorhanden das Schwenkwerk gegen den Anschlag fahren (siehe
Nummer 36 Kapitel 2.4 Teilebenennungsplan)
• Das Schwenkwerk für eine Minute einschalten damit die Pumpe das Öl über das
Druckbegrenzungsventil in den Tank pumpt.
• Danach zwei Minuten pausieren.
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• Den Vorgang so lange wiederholen bis sich das Öl auf die Inbetriebnahme-
temperatur erwärmt hat.
• wenn vorhanden, Kugelhähne KH2 und KH3 wieder öffnen (siehe Blatt-Nr. 10-1)
Tabelle 3.2.1 Öltemperaturen
Hydraulikflüssigkeit Anlauftemperatur Inbetriebnahme- maximale obere
temperatur Einsatztemperatur
Shell Tellus Arctic 32 -30 °C -20 °C +70 °C
NATO-Kode: H 540 -25 °C -15 °C +85 °C
HVLP 32 -15 °C -5 °C +70 °C
nach DIN 51524/3 HV
HLP 46 -5 °C +5 °C +80 °C
nach DIN51524/2
HLP 68 +5 °C +12 °C +85 °C
nach DIN51524/2
3
3(,1(5*UHLIHU
%(75,(%6$1/(,781*
6&+:(1.:(5.
Sortier-Nr. Blatt-Nr.
$'
%HWULHE
+LQZHLVHIUGHQ%HWULHE
$&+781* Anschlagen des Schwenkwerkes gegen Gegenstände vermeiden, um
Beschädigungen zu verhindern.
Hinweise für den sicheren Betrieb siehe 3.1 Blatt-Nr. 8-1
Funktionsbeschreibung siehe Blatt-Nr. 4-1 bis 4-3
f Es ist zu beachten, dass sich das mögliche Lastgewicht des Krans um das Gewicht
des Schwenkwerks reduziert.
f Den Doppelhaken immer über dem Schwerpunkt positionieren.
f Immer die besonderen Gebrauchshinweise für jedes Anschlagmittel beachten.
f Die Aufhängeglieder von Anschlagmitteln sind so groß zu wählen, dass sie sich frei
im Doppelhaken bewegen können.
f Hebebänder oder Rundschlingen niemals lose über den Doppelhaken laufen
lassen. Die Last könnte kippen!
f Schief hängende Lasten wieder ablassen und neu befestigen.
f Die Funktion der Hakensicherung des Doppelhakens regelmäßig überprüfen.
$XHUEHWULHEQDKPH
f Das Absetzen des Schwenkwerkes sollte auf einer geeigneten Unterlage
(Holzbalken) erfolgen, da sonst das Schwenkwerk beschädigt werden kann.
f Beim Absetzen ist darauf zu achten, daß die nach unten hängende Leitung nicht
abgeknickt oder gequetscht wird.
f Die Steckvorrichtung ist mit Schutzkappen zu versehen.
f Bei längerer Außerbetriebnahme ist darauf zu achten, daß das Schwenkwerk in
Abständen von ca. 3 Monaten mehrere Male betätigt wird, um eine Korrosions-
bildung bzw. ein Verharzen des Hydrauliköles in den Steuerelementen zu
verhindern.
f Wird das Schwenkwerk langfristig außer Betrieb genommen, sind grundsätzlich alle
Schmierstellen mit Fett zu versorgen.
:LHGHULQEHWULHEQDKPH
f alle Punkte von 3.2 und 3.3 beachten
f auf eventuelle Beschädigungen prüfen
f Schmierstellen mit Fett gemäß 4.4 Ölempfehlung versorgen (Schmieranweisung
siehe 4.1.4; Schmierstellen siehe 4.1.5; vom Hersteller verwendete Fettsorte siehe
Maschinenkarte ).
7UDQVSRUW
f Das Transportieren des Schwenkwerkes muß auf einer geeigneten Unterlage
erfolgen, da es sonst beschädigt werden kann.
f Das Schwenkwerk ist gegen Kippen zu sichern.
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4.0 Instandhaltung
Bild 4.01
Bild 4.02
Beschreibung:
8 Belüftungsschraube
9 Ölstandsauge
10 Schmierstelle Achse
11 Ölfilter
12 Ölablaßschraube
14 Hydraulikschlauch
15 Tankdeckelbefestigung
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Arbeiten an der Hydraulikanlage und an der Elektrik dürfen nur von hierfür
qualifiziertem Fachpersonal nach den gültigen Schaltplänen durchgeführt werden.
Das Personal muss über die auftretenden Gefährdungen und die sich hieraus
ergebenden Schutzmaßnahmen unterwiesen sein.
GEFAHR
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wöchentlich b)
c)
nach 500 h
alle 1000 h
alle 2000 h
nach 50 h
täglich
a)
1 Schmierstellen G (Bolzen) schmieren (und M) X X X X X X
2 Schmierstellen H (Verzahnung) schmieren X X
3 Schmierstellen K (Achse) schmieren X X
4 Schmierstellen L (Lager) und S (Schäkel und X X X
Ketten) schmieren
5 Schläuche, Verbindungselemente und Dichtungen X X X X X
der Hydraulik auf Dichtheit prüfen
6 Steckvorrichtung und Zugentlastung auf X X X X X
einwandfreien Sitz prüfen (siehe Kapitel 3.2.2)
7 Hydraulikölstand prüfen X X X X X X
d)
8 Hydrauliköl wechseln X X
9 Verschmutzung des Filterelements prüfen; X X
10 Filterelement vom Rücklauffilter wechseln X Xd)
11 Hydraulik-Schlauchleitungen auf ordnungsgemäße X X
Montage und auf arbeitssicheren Zustand zu prüfen
12 Alle Schraubverbindungen auf festen Sitz prüfen X X X
13 Doppelhaken auf Abnutzung und Risse prüfen X X
14 Schwenkwerk auf Risse und Bruchanzeigen im X X
Werkstoff und an Schweißfugen prüfen
15 Bauteilen und Einrichtungen auf Beschädigung, X X
Verschleiß oder sonstige Veränderungen prüfen
16 Vollständigkeit und Funktion von Sicherheitsein- X X X
richtungen (z.B. Bolzensicherungen) prüfen
17 Wartungsarbeiten am Schleifringübertrager Xc)
a)
bei Containerhandling wöchentlich, spätestens nach 100 Betriebsstunden, bei
anderen Lasten monatlich, spätestens nach 300 Betriebsstunden, abschmieren
b)
spätestens nach jeweils 100 Betriebsstunden
c)
spätestens nach einem Jahr; siehe Wartungsanweisung in der Ersatzteilliste
d)
Eine Verlängerung der Nutzungszeit des Hydrauliköls ist möglich, wenn die
Überprüfung des Hydrauliköls durch ein Labor, dies zulässt.
*) Die Zahlen in dieser Spalte entsprechen den Positionen in den Kapiteln mit den
einzelnen Wartungsintervallen.
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4.1.7 Ölwechsel
Der erste Ölwechsel ist nach ca. 500 Betriebsstunden vorzunehmen. Weitere Ölwechsel
nach jeweils 1000 Betriebsstunden - spätestens nach 1 Jahr.
Außergewöhnliche Betriebszustände können eine unzulässig hohe Verschmutzung oder
eine Alterung des Öles verursachen. In solchen Fällen wird empfohlen, bereits vor dem
fälligen Ölwechsel eine Ölanalyse im Labor des Ölherstellers durchführen zu lassen.
− Ölarten, siehe Tabelle Ölempfehlung Blatt-Nr. 11-1. Eingefüllte Ölsorte siehe
Maschinenkarte.
Zum Schutz der Hydraulikkomponenten muss das Öl mindestens die Reinheitsklasse
20/18/15 nach ISO 4406 haben (entspricht in etwa der Klasse 9 nach NAS 1638).
Neues Öl hat in der Regel eine schlechtere Reinheitsklasse, es ist deshalb erforderlich
das neue Öl zu filtern. Dies kann erfolgen in dem das Öl durch den Filter nachgefüllt
wird oder durch die Verwendung von speziellen Befüllaggregaten, die das Öl so filtern
dass die geforderte Reinheitsklasse erreicht wird.
Hinweis: Beim Ölwechsel auf größte Sauberkeit achten. Verschmutzungen können
zu Fehlfunktionen und zu Schäden an der Hydraulik führen. Die Teile der
Hydraulik (Tank, Pumpe, Schläuche usw.) nie länger als nötig offen lassen.
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4.1.8 Ölfilter
Bei Neuanlagen ist der Filtereinsatz nach etwa 50 Betriebsstunden auszuwechseln -
ansonsten nach jedem Ölwechsel. Ferner ist der Ölfilter nach Reparaturarbeiten an der
Hydraulik zu kontrollieren und ggf. der Filtereinsatz zu wechseln.
4.1.9 Schmieranweisung
Um einen einwandfreien Betrieb des Schwenkwerkes zu gewährleisten Schmierstellen,
regelmäßig abschmieren (siehe 4.1.10).
f Schmierstellen G bei Containerhandling wöchentlich, spätestens nach 100 Betriebs-
stunden, abschmieren
f Schmierstellen G bei anderen Lasten monatlich, spätestens nach 300 Betriebs-
stunden, abschmieren.
f Schmierstelle H, K und L vierteljährlich, spätestens nach 1000 Betriebsstunden,
abschmieren.
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4.1.10 Schmierstellen
Beschreibung:
Schmierstelle H (Verzahnung)
Schmierstelle K (Achse)
Schmierstelle L (Antriebslager)
Schmierstelle G (Bolzen)
Schmierstelle S (Kettenglied,
Schäkel)
Ausstattungsvariante:
„Aufhängung mit Bolzen“
Schmierstelle M (Bolzen)
1 Befestigungspunkte für
Zugentlastung
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4.1.11 Elektromotor
Vorsicht Verbrennungsgefahr!
An der Oberfläche des Elektromotors können hohe Temperaturen von über 80°C
auftreren.
WARNUNG f Vor Beginn der Wartungsarbeiten den Motor abkühlen lassen.
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4.1.12 Schleifringübertrager
GEFAHR
Wartungsintervalle: 1x jährlich
f Vor Beginn der Wartungsarbeiten die elektrische Versorgung des Schwenkwerks
abschalten und und gegen Wiedereinschalten sichern.
A c h t u n g ! Alle Arbeiten am Schleifringübertrager nur im elektrisch spannungs-
losen Zustand durchführen!
f Haube des Schwenkwerks öffnen beziehungsweise entfernen.
f Abgefallenen Abrieb durch Absaugen entfernen.
V o r s i c h t ! Die Schleifbügel können dabei leicht verbogen werden.
Wenn das Absaugen nicht möglich ist: Entfernen des Staubes durch Ausblasen mit
trockener, ölfreier, sauberer Luft.
f Die Kontaktstellen von Schleifring und Drahtschleifbügel hauchdünn Einsprühen mit
dem vorgeschriebenen Kontaktöl: CRAMOLIN Schutz (ITW Chemische Produkte
GmbH)
V o r s i c h t ! Den Kohlebürstenhalter und seinen Schleifring n i c h t einsprühen!
f Verschleiß der Schleifbügel prüfen
f Verschleiß der Kohlenbürsten prüfen. Teile vom Kohlebürstenhalter dürfen keine
Isolierringe oder Schleifringe berühren.
f Nach dem Reinigen die Haube wieder montieren.
Darauf achten, dass keine Leitung gequetscht, die Isolierung abgeschabt oder sonst
wie beschädigt wird.
Beschreibung:
1 Drahtschleifbügel
2 Kohlebürste
3 Kohlebürstenhalter
4 Schleifring
5 Isolierring
Bild 4.1.12
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4.2.3 Abnutzung
Die Prüfung auf Verformung, z. B. am Hakenmaul und Hakenschaft, ist nach Bedarf,
jedoch mindestens einmal im Jahr durchzuführen. Bei einer größeren Aufweitung der
Maulweite a2 max nach Tabelle 4-1 ist der Doppelhaken zu ersetzen.
Der Doppelhaken ist ebenfalls zu ersetzen, wenn die Verformung 10 %, bezogen auf
das Ausgangsmaß Y1 oder Y2, überschreitet (die Ausgangsmaße sind auf dem
Doppelhaken angegeben siehe auch Bild Doppelhaken Blatt-Nr. 10-2).
Wurden Verformungen festgestellt, so muss eine Prüfung auf Oberflächenrisse nach
einem hierfür geeigneten Verfahren durchgeführt werden oder das entsprechende Teil
ist zu ersetzen. Wenn diese Prüfung im Abnutzungs- und Verformungsbereich am
eingebauten Doppelhaken nicht durchgeführt werden kann, muss er ausgebaut werden.
Dies betrifft auch den Hals und die Augen des Doppelhakens.
Vor dem Prüfen sind die Oberflächen in einen Zustand zu versetzen, der das
einwandfreie Erkennen von Oberflächenrissen ermöglicht. Beschädigungen und
Oberflächenrisse dürfen kerbfrei beseitigt werden, soweit Funktion, zulässige
Maßabweichungen und zulässige Abnutzung es erlauben. Teile mit unzulässigen
Oberflächenrissen sind zu ersetzen.
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Ausgangsmaße von
Y1 und Y2 siehe
Angaben auf dem
Doppelhaken
Doppelhaken
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Bild 4.2.4
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Reparaturen dürfen nur vom Hersteller oder bei kleineren Kerben ( siehe Punkt c) )
von einem Sachkundigenc c durchgeführt werden.
c Sachkundige sind Personen, die auf Grund ihrer fachlichen Ausbildung und
Erfahrung ausreichende Kenntnisse auf dem Gebiet der Lastaufnahme-
einrichtungen beim Verladen von Schüttgütern haben und mit den einschlägigen
staatlichen Arbeitsschutzvorschriften, Unfallverhütungsvorschriften, Regeln für
Sicherheit und Gesundheit bei der Arbeit, Richtlinien und allgemein anerkannten
Regeln der Technik (z.B. VDE-Bestimmungen, DIN-Blättern) sowie dieser
Betriebsanleitung soweit vertraut sind, dass sie den arbeitssicheren Zustand von
Lastaufnahmeeinrichtungen, Schäkeln und Ketten beurteilen können.
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Weitere Prüfungen:
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4.3 Instandsetzung
4.3.1 Allgemeines
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Das Schwenkwerk so absetzen, dass sich der Doppelhaken und die beweglichen Teile
der Schwenkwerksaufhängung nicht unbeabsichtigt bewegen.
Nach jeder Demontage bzw. Reparatur ist eine Überprüfung des auf dem Typenschild
bzw. der Maschinenkarte angegebenen max. Druckes erforderlich. Geeignete
Prüfmanometer sind zu verwenden.
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Bild 4.3.2
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Bild 4.3.3
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Bild 4.3.4
Beschreibung
1 Traverse 9 Schleifringkörper
3 Schleifringübertrager 10 Bürstenhalter
6 Zylinderschraube 11 Axial-Zylinderrollenlager
7 Achse
Service Manager:
Hr. Kevin Wenke +49 -5341 / 302 - 493 kevin.wenke@smag.de
Service Administration:
Fr. Schwarz +49 -5341 / 302 - 673 elke.schwarz@smag.de
Service Techniker:
Hr. Müller +49 -5341 / 302 - 672 marcus.müller@smag.de
Hr. Olbrich +49 -5341 / 302 - 491 olaf.olbrich@smag.de
Hr. Schmerschneider +49 -5341 / 302 - 492 bernd.schmerschneider@smag.de
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Bild 4.3.5
Beschreibung
8 Hydraulikmotor 12 Flansch
9 Sechskantschraube (70 Nm Anziehmoment) 13 Schmierstoffleitung
10 Zylinderschrauben (47 Nm Anziehmoment) 14 Ritzel
11 Zylinderschrauben (250 Nm Anziehmoment) 16 Ritzelhalter
17 Schutzblech
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Winter Sommer
ISO-Viskositätsklasse VG 32 VG 46 VG 68
Norm HVLP 32 HLP 46 HLP 68
nach DIN 51524/3 HV nach DIN51524/2 nach DIN51524/2
Anlauftemperatur *) -15°C -5°C +5°C
Inbetriebnahme- -5°C +5°C +12°C
temperatur
maximale obere +70°C +80°C +85°C
Einsatztemperatur
Umgebungstemperatur < -5°C bis -20°C -5°C bis +30°C > +30°C
ARAL Vitam HF 32 Vitam GF 46 Vitam GF 68
AVIA AVIA FLUID HVI 32 AVIA FLUID RSL46 AVIA FLUID RSL68
BP ENERGOL ENERGOL ENERGOL
SHF-HV 32 HLP-HM 46 HLP-HM 68
CASTROL HYSPIN AWH-M 32 HYSPIN AWS 46 HYSPIN AWS 68
ESSO UNIVIS J 32 NUTO H 46 NUTO H 68
FUCHS RENOLIN MR 32 MC RENOLIN MR 15 RENOLIN MR 20
FUCHS LUBRITECH RENOLIN B 32 HVI RENOLIN RENOLIN
B15VG46 B20VG68
MOBIL Univis N 32 DTE 25 DTE 26
SHELL Tellus T 32 Tellus 46 Tellus 68
Tellus S2 V 32 Tellus S2 M 46 Tellus S2 M 68
TOTAL Equivis ZS 32 Azolla ZS 46 Azolla ZS 68
*) Temperatur ab der die Hydraulikpumpe eingeschaltet werden darf, um das Öl mit dem
Druckbegrenzungsventil auf die Inbetriebnahmetemperatur vorzuwärmen.
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Der Einsatz anderer Hydrauliköle darf nur nach Freigabe durch die SMAG erfolgen.
Das Mischen von verschiedenen Hydraulikflüssigkeiten ist nur nach Rücksprache mit
dem jeweiligen Hersteller und nach entsprechender Freigabe erlaubt.
Der Einsatz von biologisch abbaubarem Hydrauliköl darf nur nach Freigabe durch die
SMAG erfolgen. Das Mischen von Mineral- und biologisch abbaubarem Hydrauliköl ist
grundsätzlich nicht zulässig!
Für den Betrieb bei -50°C bis +40°C ist ein Hydrauliköl vom Typ HVLP nach
DIN 51524-3 NATO-Kode: H 540 zu verwenden. Bei Temperaturen unter -25°C muss
das Hydrauliköl vorgewärmt werden.
Winter Winter
Norm HVLP
nach DIN 51524/3 HV
NATO-Kode: H 540
Anlauftemperatur *) -25°C -30°C
Inbetriebnahme- -15°C -20°C
temperatur
maximale obere +85°C +70°C
Einsatztemperatur
Umgebungstemperatur < - 50°C bis +40°C < - 50°C bis +40°C
ARAL Vitam H 540
AVIA AVILUB HYDRAULIKFL H 540
SHELL Hydraulikflüssigkeit H-540 Shell Tellus Arctic
H&R ChemPharm GmbH SRS Wiolan H-540
*) Temperatur ab der die Hydraulikpumpe eingeschaltet werden darf, um das Öl mit dem
Druckbegrenzungsventil auf die Inbetriebnahmetemperatur vorzuwärmen.
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4.5 Schmierstoffempfehlung
Vom Hersteller verwendete Fettsorten: siehe Maschinenkarte!
Isolierklasse und Baugröße des Elektromotors: siehe Maschinenkarte
Castrol Firetemp XT 2
- 25°C bis + 180°C
*) Temperatureinsatzbereich
24.09.2010
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BETRIEBSANLEITUNG
ÖLEMPFEHLUNG
Sortier-Nr. Blatt-Nr.
A 16.0721-4 D 11-4
AVIA LITHOPLEX 3 EP
- 20°C bis + 150°C
BREMER & Rivolta S.K.D. 4002 Rivolta S.K.D. 4002
LEGUIL GMBH -50°C bis +210°C *) -50°C bis +210°C *)
BP Energrease LS 3
- 25°C bis + 130°C
Fuchs RENOLIT GP3 RENOLIT DURAPLEX EP 2
-30°C bis +120°C -30°C bis +160°C
KLÜBER Staburags
LUBRICATION NBU 8 EP
- 20°C bis + 140°C
*) Temperatureinsatzbereich
Bei der Umstellung auf ein Schmierfett mit anderer Seifenbasis oder anderem Verdicker
ist das zuvor verwendete Schmierfett möglichst weitgehend zu entfernen. Nach der
Umstellung sind die Nachschmierfristen zu verkürzen, um eine möglichst schnelle
Entfernung des alten Schmierfettes zu erreichen. Eine Vermischung von Schmierfetten
führt zu einer Verschlechterung der Schmiereigenschaften und somit zu einer
Verringerung der Lebensdauer der Bauteile.
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BETRIEBSANLEITUNG
ÖLEMPFEHLUNG
Sortier-Nr. Blatt-Nr.
A 16.0721-5 D 11-5
AVIA AVIACAL 2 LD
-30 bis +120°C
BP Energrease Mp-MG 2
-30°C bis +175°C
*) Temperatureinsatzbereich
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BETRIEBSANLEITUNG
ÖLEMPFEHLUNG
Sortier-Nr. Blatt-Nr.
A 16.0721-6 D 11-6
*) Temperatureinsatzbereich
Vom Hersteller verwendete Fettsorte siehe Maschinenkarte!
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BETRIEBSANLEITUNG
ÖLEMPFEHLUNG
Sortier-Nr. Blatt-Nr.
A 16.0721-7 D 11-7
CRAMOLIN Schutz
Hersteller: ITW CHEMISCHE PRODUKTE GMBH & Co KG
Mühlacker Strasse 149 D-75417 Mühlacker
Telefon: +49 (0) 7041-9634-0 Telefax: +49 (0) 7041-9634-29
Internet: www.itwcp.de E-Mail: info@itwcp.de
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0138-1 E 1-1
C o n t e n t s
Page-no. Class-no.
Data Sheet / Technical Data
1.0 Safety
1.1 About this Document 2-1 A 16.0200-1 E
1.2 Audience 2-1 A 16.0200-1 E
1.3 Intended Use 2-1 A 16.0200-1 E
1.4 Fundamental Safety Notes 2-2 A 16.0200-2 E
1.4.1 Warning Notes 2-2 A 16.0200-2 E
1.4.2 Safety Symbols 2-2 A 16.0200-2 E
1.4.3 Organizational Measures 2-3 A 16.0200-3 E
1.4.4 Personnel Selection and Qualification 2-4 A 16.0200-4 E
1.4.5 Measures to be Performed by the Operating 2-4 A 16.0200-4 E
Company
1.4.6 Measures to be Performed by the Operator 2-5 A 16.0200-5 E
1.4.7 Measures for the Maintenance, Servicing and Repair 2/5-6 A 16.0200/5-6 E
1.4.8 Safety Notes for the Electrical System 2/6-7 A 16.0200/6-7 E
1.4.9 Safety Notes for the Hydraulic System 2-7 A 16.0200-7 E
1.4.10 Handling of Oil, Grease and Other Chemical 2-7 A 16.0200-7 E
Substances
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0138-2 E 1-2
C o n t e n t s
Page-no. Class-no.
4.0 Maintenance and repair 10-1 A 16.1222-1 E
4.1 Maintenance 10-2 A 16.1222-2 E
4.1.1 Maintenance Overview 10-2 A 16.1222-3 E
4.1.2 Maintenance interval after the first 50 operating hours 10-2 A 16.1222-4 E
4.1.3 Maintenance interval after the first 500 operating 10-2 A 16.1222-4 E
hours
4.1.4 Maintenance interval weekly 10-2 A 16.1222-5 E
4.1.5 Maintenance interval every 1000 operating hours 10-2 A 16.1222-6 E
4.1.6 Maintenance interval every 2000 operating hours 10-2 A 16.1222-7 E
4.1.7 Oil change 10-2 A 16.1222/8-9 E
4.1.8 Oil filter 10-2 A 16.1222-9 E
4.1.9 Lubricating instructions 10-2 A 16.1222-9 E
4.1.10 Lubrication points 10-2 A 16.1222-10 E
4.1.11 Motor 10-2 A 16.1222-11 E
4.1.12 Slip-ring transmitter 10-2 A 16.1222-12 E
4.2 Required checks
4.2.1 Check oil level 10-2 A 16.1222-13 E
Deadweight: 3.600 kg
Crane lifting capacity SWL: 144.000 kg
Required crane lifting capacity: 147.600 kg
Mechanical Data
-1
Rotational speed / axle: 5,4 / 6,8 min
Torque / axle: 4850 Nm
Electric Data
Mode of operation: S3 System of protection: IP 56 1)
Motor type: 112M-4 Insulation class: F
Intermittent service: 40% duty cycle max. duty classification: 120 /h
Motor power: 3,5 / 4,2 kW Circuit diagram no.: 2307.9132
Voltage: 400 V Plug-in connector: ODU-37 pol.
Frequency: 50 / 60 Hz Control voltage: 230 V AC
Current: threephase No. of slip rings: 31pol.x36A+PE+2 CAN
Rated current (full load): 7,9 A ± 10 % BUS
Current consumption:
Hydraulic Data
max. service pressure Rotational sense right [± 10 bar] 2) Rotational sense left [± 10 bar] 2)
Measuring point MA 200
Measuring point MB 200
Zubehör
– Crosspiece with double hook no. 32
1)
System of protection ensured only with mounted and closed hood
2)
top view onto hood / slip ring transmitter
Dimensions
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0200-1 E 2-1
1.0 Safety
1.2 Audience
The audience of this operating manual is the technical personnel.
The machine must only be used, maintained and/or repaired by technically skilled
personnel that is used to carry out such work.
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0200-2 E 2-2
Warning notes in this operating manual indicate particular dangers and mention
measures for the avoidance of the danger.
There are four levels of warning notes:
Signal word Meaning
DANGER Immediate potential danger
Death or severe injury occurs
WARNING Possible potential danger
Death or severe injury can occur
CAUTION Possible potential danger
(personal injury) Minor injury can occur
CAUTION Possible potential danger
(damage to property) Damage to property can occur
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0200-3 E 2-3
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OPERATING INSTRUCTIONS
SLEWING UNIT
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A 16.0200-4 E 2-4
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0200-5 E 2-5
The regulations applicable to the place of operation must be adhered to. The operation
of the slewing unit is in any case subject to the local safety regulations and instructions
for the prevention of accidents.
Before putting the slewing unit into operation make sure that nobody might be
endangered by operation of the slewing unit! Slewing unit components might
automatically restart when the slewing unit is restarted!
The crane operator must at all times be able to see the working area and the load!
Ensure adequate lighting in conditions of poor sight and darkness.
Do nor stand or work under suspended loads!
Avoid any safety-compromising working!
Examine the slewing unit at least once per shift to make sure it is exempt from damages
or defects! Notify the responsible post/person of any occurred abnormality (including
abnormal operating behaviour)! Immediately shut down and secure the slewing unit if
necessary! Remedy any failure immediately!
Observe the adjustment, maintenance and inspection tasks and schedules, including
details concerning the replacement of parts and equipment prescribed in the operating
manual! These tasks may only be performed by specialized personnel.
Inform the operations personnel before commencing maintenance and servicing work!
Designate a supervisory person.
The shutdown instructions according to the operating instructions must be adhered to
during any work referring to assembly/disassembly, putting into operation, operation,
maintenance and repair.
Carry out repair work on the hydraulic and electric system in a clean and dust-free
environment.
If necessary, secure the work area!
Before carrying out any maintenance or repair work completely shut down the slewing
unit and protect it against any unauthorized restart:
- Unplug electric plug-in connector.
Remove protective equipment only after the machine has been shut down!
Carefully fasten and secure spare parts and modules being replaced to the lifting gear
so that they do not endanger anyone. Use only suitable and technically perfect lifting
gear and load carrying equipment with adequate carrying capacity!
Do not stand or work under suspended loads!
If necessary, use security-conform ladders and work platforms for installation and
servicing work! Do not use machine parts as steps! Wear fall-prevention gear for work
performed at height.
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0200-6 E 2-6
Because contact with hot parts and the discharge of oil during maintenance and
servicing work cannot be excluded, always wear protective glasses and protective
gloves.
Clean electric components in voltage-free state only. Unplug electric plug-in connector
for this purpose. This regulation also applies to non-touch cleaning (air-blasting).
Do not bypass pressure-operated switches, pressure-operated valves, safety valves and
other sensors.
The pressure-operated switches, pressure-operated valves, safety valves and other
sensors may only be adjusted with the written approval of the manufacturer.
Safety valves may only be replaced with the same valves.
Replace immediately any damaged hydraulic hoses, pipes, cables and valves.
Replace hydraulic hoses at indicated or reasonable intervals, even if no safety-relevant
defects can be detected (see check of hydraulic hose lines, page 10-2).
Observe the prescribed tightening torques and check regularly.
For maintenance and repair work, always tighten loosened screwed joints as specified in
the guidelines.
Before cleaning the slewing unit with water or by means of a vapour stream (high-
pressure cleaner) or with other detergents cover or obturate all openings in which no
water/vapour/detergent may penetrate for safety or functional reasons. Electromotors,
switch cabinets, stop switches, ball bearings, gears and chains are especially
vulnerable.
Regularly check all electrical cables and hydraulic oil lines for damage and abrasion.
Also inspect hydraulic oil lines for leaks.
Before resuming operation after completing maintenance or repair work, check whether
all safety equipment has been reattached to the machine and is operational! Check all
functions of the slewing unit and the working pressure!
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0200-7 E 2-7
the work area with a red-white safety chain and a warning notice. Use only insulated
tools!
After the associated electrical installation or repair, test the installed protective measures
(e.g., earthing resistance).
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The slewing unit consists of a traverse (1), which incorporates the hydraulic unit (22), the
hydraulic motor (3) and the hub (4). The hub holds the axle (5). Via a nut (6) that is
mounted on the axle, the loads are absorbed by an axial deep groove thrust ball bearing
(7) that is screwed into the hub. Depending on the requirement, a multi-pole slipring body
(8) may be fixed on the hollow axle. Through this axle, a cable (9) with a corresponding
number of leads, is led from the slipring body to the suspended load-lifting member.
The hydraulic unit (22) has been mounted vertically into the traverse, as a complete unit.
It consists of motor (2) and pump (20).
By loosening the fastening screws, the complete hydraulic unit can be taken out of the
slewing unit. The hydraulic control block (17) is mounted on the side wall of the traverse.
The solenoid valve (18) sits on a block and is connected directly to the hydraulic motor
(3).
By means of the assembly opening in the hood, all important maintenance jobs can be
carried out on the hydraulic unit (e. g. re-fill the hydraulic oil).
The components hydraulic unit, hydraulic motor and slipring body are protected against
mechanical damages by means of a hood.
The cross piece with the double hook that is fixed to the hollow axle guarantees that most
of the forces are led centrically into the hollow axle and thus protects it against excessive
bending stress. A cable tension relief prevents mechanical stressing of the electric plug-
in connector.
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1036 E 7-1
Legend:
1 traverse 18 solenoid valve
2 motor 20 pump
3 hydraulic motor 21 pinion
5 axle 22 hydraulic unit
7 ball bearing slewing gear 23 oil filter
8 slipring transmitter 27 double hook
9 cable 29 screw plug (ventilation screw)
12 gimbal suspension 32 plug-in connector
17 control block 33 power supply cable
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0619-1 E 8-1
X Follow the regulations in the relevant accident prevention specifications for "Load
suspension devices".
X Only operate the slewing unit in its original condition or in a condition released by the
manufacturer.
X Make sure that during operation of the grab all hoses, lines, pipes and fittings are in
good order and tight.
X It is not permitted to ever load the slewing unit, the double hook, and the sling gear
more than their load-bearing capacity!
X Grommets, becket, gimbals, and other suspended elements must be positioned in the
base of the hook and be able to move freely on the double hook.
X The double hook’s safety hood must be fully functioning to prevent accidental
unhinging.
X It is not permitted to hang the double hook directly in the load. The exception here is
hanging the double hook in suspension equipment especially designed for this
purpose.
X Never use a damaged sling gear or a sling gear where the identification mark is no
longer present!
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OPERATING INSTRUCTIONS
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Class-no. Page-no.
A 16.0619-2 E 8-2
X The crane operator must particularly observe the load or the empty run of the load-
carrying equipment during all crane movements. If this is not possible, the crane
operator is only allowed to operate the crane when following a signalperson’s signals.
X Avoid any jerky starting, lifting, stopping or lowering of the slewing unit.
X Immediately inform the responsible supervising person of any slewing unit failure or
any lifting accessory failure as well as of any watched circumstance that might give rise
to expectations of a failure (e. g. noises, elevated temperatures, unusual behaviour of
the slewing unit, etc.).
X Only operate the slewing unit, the hydraulic fluid and the lubricants within the
admissible temperature range (see Technical Data or Recommended Oil).
X In case of any failures stop the slewing unit operation immediately and prevent it from
being restarted. Failures must immediately be remedied!
X Dismantle protective equipment when and only when the slewing unit is at standstill.
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OPERATING INSTRUCTIONS
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Class-no. Page-no.
A 16.0619-3 E 8-3
The assembly and initial start-up may only be carried out by qualified personnel.
Personal protective equipment must be worn during all work. It includes:
• Protective clothes
• Protective helmet
• Safety shoes with toe caps and puncture-resistant base
• Protective goggles
• Protective gloves
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0619-4 E 8-4
Assembly:
1. Check hosepipes, connecting elements and gaskets of the hydraulic system for
leaks.
2. Connect the suspension of the slewing unit with the carrying device and observe the
SWL of the lifting appliance.
3. Connect the slewing unit with the plug-in connector of the power supply cable.
4. Fit the cable tension relief. Take care that the rubber-sheathed power supply cable
does not stress the plug-in connector (for fastening points, see Fig. 4.1.5
Schmierstellen). Attach the tension relief in such a way as to avoid any chafing of
the power supply cable.
5. Make sure that nobody remains in the danger area of the slewing unit. Lift the
slewing unit until the double hook hangs freely.
6. Check the oil level and refill as needed (see chapter 4.2.1)
For oil recommendations, see sheet no. 11-1
7. Check the sense of rotation of the slewing unit. If the sense of rotation is wrong,
swap the two external cables. If the plug-in connector is not assembled, connect
them according to the wiring diagram.
8. Check that the locking devices on all pins and shackles are present and secured.
9. Before the initial commissioning, the proper assembly and the correct working of the
slewing unit must be inspected by a person qualified to do so.
f If the temperature of the hydraulic fluid is below the start-up temperature (see page
no. 8-5 Table: 3.2.1 Oil temperature), then the hydraulic fluid must be preheated by
means of a heating up to the temperature that is necessary to put the system into
operation (Please refer to chapter 2.4 Nomenclature and Hydraulic Diagram in the
Spare parts list to see if the slewing unit is equipped with a heating). If no heating is
available, change hydraulic fluid and use preheated hydraulic fluid if necessary.
If the temperature is between the start up temperature and the temperature that is
necessary to put the system into operation, (see page no. 8-5 Table: 3.2.1 Oil
temperature), use a heating to preheat the hydraulic fluid up to the temperature that
is necessary to put the system into operation or
• Close the ball cocks KH2 and KH3 (see page no. 10-1), if any,
or move the slewing unit until the stop, if any, is reached (see number 36 chapter
2.4 Legend)
• Turn on the slewing unit and keep it turned on for one minute to ensure the pump
pumps oil via the pressure relief valve into the tank.
• Then pause for two minutes.
• Repeat this procedure until the oil is warmed-up to the temperature that is
necessary to put the system into operation.
• Open ball cocks KH2 and KH3, if any (see page no. 10-1).
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Class-no. Page-no.
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f After about 50 operating hours, change the oil filter set (see sheet no. 10-1) and
check that screws and nuts are tightly secured; for tightening torques, see the spare
parts list..
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Class-no. Page-no.
A 16.1218 E 9-1
3.3 Operation
3.4 Shut-down
f The slewing unit must be put down on a suitable support (wooden beam) since
otherwise the turner can be damaged.
f During putting down it is to be seen to it that the hanging cable is neither broken nor
pinched.
f The plug-in connector is to be provided with protective caps.
f In addition, for longer periods out of service, the slewing unit should be exercised
every 3 month to prevent corrosion and gumming of the hydraulic oil in the control
elements.
f In case the slewing unit is intended to be put out of operation for a longer period of
time, grease must be applied to all lubricating points.
3.5 Reoperation
f Observe all the specifications of point 3.2 and 3.3
f Check the device for possible damages
f Supply the lubricating points with grease in accordance with 4.4 Oil
Recommendation (for lubricating instructions, see 4.1.4, for lubricating points, see
4.1.5; for the greases used by the manufacturer please refer to data sheet).
3.6 Transportation
f The slewing unit must be transported on a suitable support since otherwise
damages can occur.
f The slewing unit is to be secured against overturning.
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-1 E 10-1
Figure 4.01
Figure 4.02
Legend:
8 ventilation screw
9 oil level glass
10 lubricating point K: axle
11 oil filter
12 oil drain plug
14 hosepipes
15 tank cap mounting
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-2 E 10-2
4.1 Maintenance
Insufficient and improper maintenance might result in operating troubles and thus high
repair costs and downtimes. This is why regular maintenance is imperative.
Risk of injury due to maintenance work that has been carried out
improperly!
Improper working might cause considerable personal and material damages.
WARNING f Maintenance and repair of the slewing unit must only be carried out by
authorized, well-trained and instructed specialized personnel. This personnel
must be specifically instructed in the imminent dangers. the personnel must be
allowed to reject any instructions of third parties that might breach the safety
instructions.
f The operating staff must be informed about any maintenance work carried out
before starting the maintenance work.
f Responsibilities of the staff for assembly/disassembly, putting into operation,
operation, maintenance and repair must be clearly defined and adhered to!
f Make sure that only such personnel works on the slewing unit who is assigned
to do so!
f Before starting the maintenance work disconnect the power supply of the
slewing unit and protect it against accidental restart. To do this, it is also
possible to unplug the electric plug-in connector.
f The product-specific safety instructions must be complied with when handling
oils and greases.
Only qualified technical personnel may carry out any work on the hydraulic system
and the electrical system in accordance with the valid circuit diagrams.
Personnel must be instructed regarding the possible hazards and the protective
measures that need to be taken.
DANGER
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c)
every 1000 h
every 2000 h
after 500 h
after 50 h
weekly b)
daily
a)
1 Grease lubricating points G (pin) (and M) X X X X X X
2 Grease lubricating points H (toothing) X X
3 Grease lubricating points K (axle) X X
4 Grease lubricating points L (bearing) and S X X X
(shackles and chains)
5 Check hoses, connecting elements and gaskets of X X X X X
the hydraulics for tightness
6 Check the plug-in connector and the tension relief X X X X X
for firm seating (see chapter 3.2.2)
7 Check the hydraulic oil level X X X X X X
d)
8 Change the hydraulic oil X X
9 Check the filter element for clogging X X
10 Change the filter element of the return filter X Xd)
11 Check the hydraulic hoses for proper assembly and X X
operational safety
12 Check all screw connections for firm seating X X X
13 Check the double hook for wear and cracks X X
14 Check the slewing unit for cracks and signs of X X
breakage in the material and at welding joints
15 Check the parts and fittings for damage, wear or X X
other changes
16 Check the integrity and function of safety devices X X X
(e.g. pin locking devices)
17 Maintenance work on the slip-ring transmitter Xc)
a)
for container handling: grease weekly, after 100 operating hours at the latest; for
other loads: grease monthly, after 300 operating hours at the latest
b)
after every 100 operating hours at the latest
c)
after one year at the latest; see maintenance instructions in the spare parts list
d)
An extension of the useful life of the hydraulic oil is possible if a laboratory testing of
the hydraulic oil will allow it.
*) The values in the column correspond to the items in the sections with the individual
maintenance intervals.
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Class-no. Page-no.
A 16.1220-4 E 10-2
*) The values in the column correspond to the items in the maintenance overview (see
4.1.1 Maintenance Overview).
*) The values in the column correspond to the items in the maintenance overview (see
4.1.1 Maintenance Overview).
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-5 E 10-2
*) The values in the column correspond to the items in the maintenance overview (see
4.1.1 Maintenance Overview).
a)
for container handling: grease weekly, after 100 operating hours at the latest; for
other loads: grease monthly, after 300 operating hours at the latest
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-6 E 10-2
*) The values in the column correspond to the items in the maintenance overview (see
4.1.1 Maintenance Overview).
a)
for container handling: grease weekly, after 100 operating hours at the latest; for
other loads: grease monthly, after 300 operating hours at the latest
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OPERATING INSTRUCTIONS
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Class-no. Page-no.
A 16.1220-7 E 10-2
*) The values in the column correspond to the items in the maintenance overview (see
4.1.1 Maintenance Overview).
a)
for container handling: grease weekly, after 100 operating hours at the latest; for
other loads: grease monthly, after 300 operating hours at the latest
d)
An extension of the useful life of the hydraulic oil is possible if a laboratory testing of
the hydraulic oil will allow it.
c)
after one year at the latest; see maintenance instructions in the spare parts list
Clean and grease the bearings of the electric motor every 15000 operating hours (see
4.1.11 )
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
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N O T I C E ! Pay attention to utmost cleanliness during the oil change. Any pollution
might cause malfunctions and damages of the hydraulic system. Make
sure that parts of the hydraulic system such as tank, pump, hoses, etc.
never are open longer than necessary.
X Proceeding: (Components see figure 4.0 and figure 4.1.10)
1. Set down the slewing unit
2. Put a suitable collection basin under the oil drain plug (5)
3. Unscrew and clean drain plug (5) (figure 4.1.10)
4. Unscrew ventilation screw (8) (figure 4.0) to ventilate the tank
5. Drain oil out of tank (the unit should have its operational temperature)
6. Clean tank:
• Clean the area around the tank cap.
• Depressurize the hoses (10) (see figure 4.0). For this purpose connect a
MINIMESS hose to the test point (MA) in such a way to ensure the oil flows
into a basin at the other end of the MINIMESS hose. Repeat this procedure at
test point (MB) and (MT).
• Unscrew hoses (10) (see figure 4.0) from the tank cap.
• Unscrew the tank cap from the traverse (15) and take the hydraulic unit
including tank cap out of the traverse.
• Clean the tank by means of a plain plastic scraper. Don´t use cleaning wool,
cloths or cleaning paper since they might leave fibers. Clean the tank by
rinsing it by means of a suitable detergent, e. g. benzene.
Note: If metal particles are found in the tank, this might be a sign of pump
wear.
• Check the threaded holes of the tank cap mounting (15). Clean and/or recut
thread if necessary.
• Pay attention to utmost cleanliness during assembly of the hydraulic unit and
hoses.
19.07.2010
P
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-9 E 10-2
Note: Do not mix synthetic lubricants with each other, neither with mineral lubricants!
19.07.2010
P
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-10 E 10-2
Legend:
lubrication point H (toothing)
lubrication point K (axle)
lubrication point L (drive end
bearing)
lubrication point G (pin)
lubrication point S (shackles and
chains)
Design version:
„suspension with pin“
lubrication point M (pin)
Figure 4.1.10
Note: Regular lubrication of the chain, suspension links and shackles can ensure a
significantly longer permissible service life compared to unlubricated parts. It
is recommended to lubricate all chain links and shackles before the initial
start-up. During lubrication, make sure that you lubricate the contact surfaces
to prevent premature wear. Suitable lubricants are those used for lubrication
of wire ropes or toothing (see Chapter 4.4)
19.07.2010
P
PEINER Greifer
OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-11 E 10-2
Maintenance intervals: every 15,000 operating hours, after 3 years at the latest
f Before the start of the maintenance work, the power supply of the slewing unit must
be disconnected and secured against restart.
f Clean the bearings and fill them to the half with grease, according to Chapter 4.5
“Lubricant recommendation“.
19.07.2010
P
PEINER Greifer
OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-12 E 10-2
DANGER
Legend:
1 carbon-brush
2 carbon-brush holder
3 slip-ring way
4 insulating ring
Figure 4.1.12
19.07.2010
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-13 E 10-2
4.2.3 Wear
Depending on the conditions of use and the circumstances of operation, the double
hook must be assessed by a competent person as required. This must occur at least
once a year. A competent person is someone who has sufficient knowledge of load-
carrying equipment due to their specialist training and experience. They must be familiar
with the corresponding state work safety rules, accident prevention rules, and general
recognised rules of engineering to an extent that they can evaluate the work safety
conditions for slewing units and crane hooks.
The permissible wearing is listed in Table 4-1. Calliper gauge (sliding calliper) precision
is sufficient when measuring.
Grooves of wear may be reground to remove grooves within the amount of wearing
permissible. Parts that are impermissibly worn or damaged must be replaced.
Welding on double hooks and bolts, e.g., to repair signs of wear, is not permitted.
P
PEINER Greifer
OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-14 E 10-2
See specifications on
the double hook for
initial dimensions from
Y1 and Y2
P
PEINER Greifer
OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-15 E 10-2
The hydraulic hose lines must be checked as required, but at least once a year, in case
of multishift operation every six months. After any maintenance and repair work the
hydraulic hose lines must be checked to make sure they are assembled properly and in
an operational safety state.
The hose lines must be replaced if one of the following criteria has been detected:
- Damages of the external layer event to the wire braid reenforcement (e. g. chafe
marks, cuts, cracks)
- Brittleness of the external layer (formation of cracks in the hose material)
- Deformations that do not correspond to the natural form of the hose or of the hose
line, in unpressurized as well as in pressurized condition or when bended, e. g.
separation of layers, bubbling
- Leakages
- Damage or deformation of the hose fitting (prejudiced sealing function)
- Detaching of the hose out of the fitting
- Corrosion of hose fitting impairing the function and rigidity
- Specified period of storage and/or use of the hose or of the hose line is exceeded.
f Hydraulic hoses must not be stored longer than 2 years.
f Hydraulic hoses must not be used longer than 6 years (including
maximum storage period of 2 years).
P
PEINER Greifer
OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-16 E 10-2
Figure 4.2.4
The repairs may only be carried out by the manufacturer or, for minor dents (see Point
c) ), by a specialist c.
Note: Regular lubrication of the chain, suspension links and shackles can ensure a
significantly longer permissible service life compared to unlubricated parts. It is
recommended to lubricate all chain links and shackles before the initial start-up.
During lubrication, make sure that you lubricate the contact surfaces to prevent
premature wear. Suitable lubricants are those used for lubrication of wire ropes
or toothing (see Chapter 4.4)
19.07.2010
P
PEINER Greifer
OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.1220-17 E 10-2
Miscellaneous checks
P
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0722-1 E 10-3
4.3 Repairs
4.3.1 General
For major repairs please consult the after-sales service of Salzgitter Maschinenbau AG.
Wear the following personal when carrying out any maintenance or repair work:
- Protective helmet
- Protective goggles
- Protective clothes
- Protective gloves
- Safety shoes with toe caps and puncture-resistant base
Shift the slewing unit in such a way that the double hook and the movable parts do not
move accidentally.
After each disassembly or repair the maximum pressure indicated on the nameplate
must be checked. Use appropriate test manometers for this purpose.
27.09.2010
P
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0722-2 E 10-3
As a basic principle, supply all the lubricating points with grease in accordance with 4.4
Oil Recommendation before any restart (for lubricating instructions see 4.1.9, for
lubricating points see 4.1.10).
P
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0722-3 E 10-3
Figure 4.3.2
1. Disconnect power supply to the slewing unit and secure it against restart. If one or
more plug-in connectors are available, remove them.
2. Dismantle the hood.
3. Depressurise the hydraulics.
4. Unscrew the mounting (13) and put it down carefully on the slewing unit.
5. Dismantle the hydraulics, where required, and protect it from dirt.
6. Protect the open hydraulic pipes on the slewing unit from dirt.
7. Unscrew the screws (8) and (10) and lift the hydraulic motor (7) from the slewing
unit.
8. Assemble the new hydraulic motor in reverse order.
9. Fill the hydraulic motor with hydraulic oil through the drain connection (5) !
27.09.2010
P
PEINER Greifer
OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0722-4 E 10-3
Figure 4.3.3
1. Disconnect power supply to the slewing unit and secure it against restart. If one or
more plug-in connectors are available, remove them.
2. Dismantle the hood.
3. Depressurise the hydraulics
4. Dismantle the hydraulics, where required, and protect it from dirt.
5. Unscrew the screws (3) and lift the hydraulic unit (4) from the slewing unit.
6. Unscrew the distributor parts (7) and protect them from dirt.
7. Unscrew the pump (8).
8. Remove the plastic plug (9) on the underside of the new pump !
9. Assemble the new pump in reverse order.
27.09.2010
P
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0722-5 E 10-3
Figure 4.3.4
Legend:
1 traverse 9 slip-ring body
3 slip-ring transmitter 10 brush holder
6 socket head cap screw 11 axial cylindrical roller bearing
7 axle
Before repair work and before replacement of the axle bearing, please consult
the after-sales service of Salzgitter Maschinenbau AG. Only specialist service
centres who have experience of handling with axial cylindrical roller bearings are
allowed to carry out this work.
Manager Service:
Mr. Kevin Wenke +49 -5341 / 302 - 493 kevin.wenke@smag.de
Service Administration:
Mrs. Schwarz +49 -5341 / 302 - 673 elke.schwarz@smag.de
Service Technicians:
Mr. Müller +49 -5341 / 302 - 672 marcus.müller@smag.de
Mr. Olbrich +49 -5341 / 302 - 491 olaf.olbrich@smag.de
Mr. Schmerschneider +49 -5341 / 302 - 492 bernd.schmerschneider@smag.de
27.09.2010
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PEINER Greifer
OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0722-6 E 10-3
Figure 4.3.5
Legend:
8 hydraulic motor 12 flange
9 hexagon screw (tightening 13 lubricant duct
torque 70 Nm) 14 pinion
10 socket head cap screws 16 pinion holder
(tightening torque 47 Nm) 17 cover
11 socket head cap screws
(tightening torque 250 Nm)
1. Disconnect power supply to the slewing unit and secure it against restart. If one or
more plug-in connectors are available, remove them.
2. Dismantle the hood.
3. Depressurise the hydraulics.
4. Unscrew the cover (17).
5. Unscrew the screw (9)
6. Unscrew the screw (11)
7. Pull out the pinion (14) and dismantle the pinion holder (16). If the pinion cannot
be pulled out easily, proceed as described below. Use an extractor tool to
dismantle the pinion.
8. Assemble the new pinion in reverse order. For tightening torque of the screws,
see the spare parts list.
27.09.2010
P
PEINER Greifer
OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0722-7 E 10-3
P
PEINER Greifer
OPERATING INSTRUCTIONS
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-1 E 11-1
Winter Summer
ISO viscosity VG 32 VG 46 VG 68
P
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OPERATING INSTRUCTIONS
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-2 E 11-2
A hydraulic oil of type HVLP according to DIN 51524-3 NATO code: H 540 should be
used for operation at -50°C to +40°C. In case of temperatures below -25°C, the
hydraulic oil must be pre-heated.
Winter Winter
Standard HVLP
acc. to DIN 51524/3 HV
NATO-code: H 540
Start up temperature *) -25°C -30°C
Temperature that is -15°C -20°C
necessary to put the
system into operation
Max. upper working +85°C +70°C
temperature
Ambient temperature < - 50°C bis +40°C < - 50°C bis +40°C
ARAL Vitam H 540
AVIA AVILUB HYDRAULIKFL H 540
SHELL Hydraulikflüssigkeit H-540 Shell Tellus Arctic
H&R ChemPharm GmbH SRS Wiolan H-540
*) Temperature from which the hydraulic pump may be started in order to preheat the
oil by means of the pressure relief valve up to the temperature that is necessary to
put the system into operation.
28.09.2010
P
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OPERATING INSTRUCTIONS
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-3 E 11-3
Castrol Firetemp XT 2
- 25°C to + 180°C
P
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OPERATING INSTRUCTIONS
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-4 E 11-4
AVIA LITHOPLEX 3 EP
- 20°C bis + 150°C
BREMER & Rivolta S.K.D. 4002 Rivolta S.K.D. 4002
LEGUIL GMBH -50°C bis +210°C *) -50°C bis +210°C *)
BP Energrease LS 3
- 25°C bis + 130°C
Fuchs RENOLIT GP3 RENOLIT DURAPLEX EP 2
-30°C bis +120°C -30°C bis +160°C
KLÜBER Staburags
LUBRICATION NBU 8 EP
- 20°C bis + 140°C
If you change over to a grease based on another soap type or another thickening agent,
the grease that had been used so far should be completely removed if possible. After
changeover the regreasing periods should be reduced in order to ensure the old grease
is removed as quickly as possible. If greases are mixed, this will impair the lubricating
properties and thus reduce the service life of the parts.
28.09.2010
P
PEINER Greifer
OPERATING INSTRUCTIONS
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-5 E 11-5
AVIA AVIACAL 2 LD
-30 to +120°C
BP Energrease Mp-MG 2
-30°C to +175°C
P
PEINER Greifer
OPERATING INSTRUCTIONS
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-6 E 11-6
P
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OPERATING INSTRUCTIONS
OIL RECOMMENDATION
Class-no. Page-no.
A 16.0721-7 E 11-7
Slip-ring transmitter: the contact oil is solely intended for very light spraying of
wire contact bows and their slip ring.
CRAMOLIN Protection
Manufacturer: ITW CHEMISCHE PRODUKTE GMBH & Co KG
Mühlacker Strasse 149 D-75417 Mühlacker
Phone: +49 (0) 7041-9634-0 Fax: +49 (0) 7041-9634-29
Website: www.itwcp.de E-mail: info@itwcp.de
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OPERATING INSTRUCTIONS
SLEWING UNIT
Class-no. Page-no.
A 16.0757 E 12-1
5.2 Slewing unit does - turning time and number - pressure relief valve is
not render enough of rotations are maladjusted (see 4.2.2)
out-put (axle turns) considerably slower - pump is worn
- torque is too low - either dirt in the pressure relief
valve or the spring is too old -
pressure adjustment is required
- oil level in the tank is too low
In case the pump sucks air, this
mostly leads to a destruction of the
pump.
- connection between pump and
control block is loose or damaged
- slide piston in the control block is
jammed; this might be caused by
foreign matter in the oil or a
broken spring
- tubes are not tight
- solenoid valve is defect (jammed)
- flow regulator
28.04.2011 -1/2-
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Inhaltsverzeichnis
Contents
Bei Ersatzteilbestellung ist außer der Bestellnummer das Erzeugnis, die Werks-Nr. und Kommissions-Nr.
anzugeben.
For spare part orders, the product, serial-no. and commission-no. must be given in addition to the
requisition-no.
Salzgitter Maschinenbau AG Phone: E-mail: Board of management: Domicile of company: Salzgitter Bad
Windmühlenbergstraße 20-22 +49 53 41 / 302 647 peiner@smag.de Sebastian H. Brandes (Chairman), Registration court:
38259 Salzgitter / Germany Fax: Internet: Jürgen Bialek Amtsgericht Braunschweig
+49 53 41 / 302 424 www.smag.de Chairman of the Supervisory Board: Registration number:
www.peiner.de Ulrich Decker HRB 201 389
08.10.2010
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Motor-Schwenkwerk SW 144 DISK B 23080453
Motor Slewing Unit SW 144 DISK Gruppe-Nr.
Group-no. 1.0
1/1
10.12.2010 (12023)
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Motor-Schwenkwerk SW 144 DISK Order-no. 23080453
Motor Slewing Unit SW 144 DISK Gruppe-Nr.
Group-no. 1.0
Pos. Bestell - Nr. Menge Benennung
Item Order - no. Quantity Description
02 23084814 1 Traverse
traverse
04 23083822 1 Achse
axle
09 23082111 2 Blinddeckel
blind cover
1/2
B 23080453
10.12.2010 (12023)
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Motor-Schwenkwerk SW 144 DISK Order-no. 23080453
Motor Slewing Unit SW 144 DISK Gruppe-Nr.
Group-no. 1.0
Pos. Bestell - Nr. Menge Benennung
Item Order - no. Quantity Description
21 23082496 1 Stopfen
plug
22 23004907 1 Dichtung
gasket
34 23083438 2 Dichtung
gasket
35 23084510 1 Anschlussplatte
connecting plate
37 23083469 1 Deckel
cover
2/2
B 23080453
08.10.2010 (12023)
P
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Ersatzteilliste
Spare parts list
Grundgerät B 23080455
basic unit Gruppe-Nr.
Group-no. 3.0
1/1
10.12.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
*UXQGJHUlW Order-no.
EDVLFXQLW Gruppe-Nr.
Group-no.
3RV %HVWHOO1U 0HQJH %HQHQQXQJ
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05 23084565 1 Stirnrad
spur gear
06 23082059 1 Flansch
flange
07 23082586 1 Halterung
mounting
10 23082027 1 Keil
fitting key
11 23083067 1 Mutter
nut
B 23080455
10.12.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
*UXQGJHUlW Order-no.
EDVLFXQLW Gruppe-Nr.
Group-no.
3RV %HVWHOO1U 0HQJH %HQHQQXQJ
,WHP 2UGHUQR 4XDQWLW\ 'HVFULSWLRQ
17
20 23083069 1 Ring
ring
26 23082600 1 Ring
ring
B 23080455
10.12.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
*UXQGJHUlW Order-no.
EDVLFXQLW Gruppe-Nr.
Group-no.
3RV %HVWHOO1U 0HQJH %HQHQQXQJ
,WHP 2UGHUQR 4XDQWLW\ 'HVFULSWLRQ
32 23082601 1 Schauglas
side class
33 08022741 2 Verschluß-Shr. R¾
screw plug
B 23080455
10.12.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
*UXQGJHUlW Order-no.
EDVLFXQLW Gruppe-Nr.
Group-no.
3RV %HVWHOO1U 0HQJH %HQHQQXQJ
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46
56 08031074 2 Blockkugelhahn
ball cock
B 23080455
10.12.2010
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
*UXQGJHUlW Order-no.
EDVLFXQLW Gruppe-Nr.
Group-no.
3RV %HVWHOO1U 0HQJH %HQHQQXQJ
,WHP 2UGHUQR 4XDQWLW\ 'HVFULSWLRQ
58 23084832 1 Schmierverlängerung
lubricating extension
59 23084833 1 Schmierverlängerung
lubricating extension
B 23080455
10.11.2006
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
+DXEH %
KRRG Gruppe-Nr.
Group-no.
23.01.2009 (10686)
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Haube 31pol. Order-no. 23082943
hood Gruppe-Nr.
Group-no. 5.0
Pos. Bestell - Nr. Menge Benennung
Item Order - no. Quantity Description
01
15
1/1
B 23082943
05.11.2007
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
6FKHOOHIU(OHNWUR/HLWXQJ %
FODPSIRUFDEOH Gruppe-Nr.
Group-no.
23.01.2009
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Schelle für Elektro-Leitung Order-no. 23084214
clamp for cable Gruppe-Nr.
Group-no. 5.6
Pos. Bestell - Nr. Menge Benennung
Item Order - no. Quantity Description
03
04 23084229 1 Deckplatte
cover plate
06 23084228 2 Scheibe
disc
1/1
B 23084214
09.02.2009
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
%JHONSO %
IUDPHFSO Gruppe-Nr.
Group-no.
3
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%HVWHOO1U
%JHONSO 2UGHUQR
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16.07.2009
3
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K\GUDXOLFXQLW Gruppe-Nr.
Group-no.
08.10.2010
3
3(,1(5*UHLIHU
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6SDUHSDUWVOLVW
Bestell-Nr.
+\GUDXOLNDJJUHJDW Order-no.
K\GUDXOLFXQLW Gruppe-Nr.
Group-no.
3RV %HVWHOO1U 0HQJH %HQHQQXQJ
,WHP 2UGHUQR 4XDQWLW\ 'HVFULSWLRQ
02 23005109 2 Verteilerstück
distributor part
03
04 23081601 1 Kupplung
coupling
10
15
B 23081599
08.10.2010
3
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(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
+\GUDXOLNDJJUHJDW Order-no.
K\GUDXOLFXQLW Gruppe-Nr.
Group-no.
3RV %HVWHOO1U 0HQJH %HQHQQXQJ
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16 23004916 1 Dichtung
gasket
18
B 23081599
04.06.2009
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
/LVWHGHVSLqFHVGHUHFKDQJH
5FNVFKODJYHQWLONSO %
FODSHWDQWLUHWRXUFRPSO Gruppe-Nr.
o
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3
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11.11.2008
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Rücklauffilter D 043-88 25 μm B 00020900
return filter Gruppe-Nr.
Group-no. 11.0
1/1
29.04.2009
3
3(,1(5*UHLIHU
(UVDW]WHLOOLVWH
6SDUHSDUWVOLVW
Bestell-Nr.
5FNODXIILOWHU'P Order-no.
UHWXUQILOWHU Gruppe-Nr.
Group-no.
3RV %HVWHOO1U 0HQJH %HQHQQXQJ
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02 N 031.0562 1 Flachdichtung
gasket
03 D 023.0704 1 Flachdichtung
gasket
05 00021735 1 Exapor-Filterelement
filter element Exapor
B 00020900
11.11.2008
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Doppelhaken mit Aufhängung B 23082811
double hook with suspension Gruppe-Nr.
Group-no. 25.4
1/1
3
3(,1(5*UHLIHU
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05.08.2009 (10735)
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Hydraulikmotor mit Anbaublock B 23084827
hydraulic motor with valve plate Gruppe-Nr.
Group-no. 37.0
1/1
29.07.2009 (11237)
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Hydraulikmotor mit Anbaublock Order-no. 23084827
hydraulic motor with valve plate Gruppe-Nr.
Group-no. 37.0
Pos. Bestell - Nr. Menge Benennung
Item Order - no. Quantity Description
02 23005095 1 Ventilblock NG 6
valve block
1/1
B 23084827
11.06.2010
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Hydraulikmotor HCC - M300 B 00041083
hydraulic motor HCC - M300 Gruppe-Nr.
Group-no. 37.4
1/1
11.06.2010
P
PEINER Greifer
Ersatzteilliste
Spare parts list
Bestell-Nr.
Hydraulikmotor HCC - M300 Order-no. 00041083
hydraulic motor HCC - M300 Gruppe-Nr.
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01 23084566 1 Ritzel
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Schleifringübertrager 31x36A + PE, 150 A B 00040328
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anzugeben.
For spare part orders, the product, serial-no. and commission-no. must be given in addition to the
requisition-no.
Salzgitter Maschinenbau AG Phone: E-mail: Board of management: Domicile of company: Salzgitter Bad
Windmühlenbergstraße 20-22 +49 53 41 / 302 647 peiner@smag.de Sebastian H. Brandes (Chairman), Registration court:
38259 Salzgitter / Germany Fax: Internet: Jürgen Bialek Amtsgericht Braunschweig
+49 53 41 / 302 424 www.smag.de Chairman of the Supervisory Board: Registration number:
www.peiner.de Ulrich Decker HRB 201 389
24.11.2008
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Geräteteil UW-SEE B 23079944
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141082 / 001
Operations manual
for
BROMMA TELESCOPIC SPREADER
TYPE: EH170U
General assembly drawing No: 1012972
Serial number:
SWL: 41 tonne
Twinlift capacity: 2 x 25 tonne
Customer: Liebherr
End User:
Date of shipping:11
_____________________________________________________________________________________
BROMMA CONQUIP AB 00 01 ENG
rev.
Warning!
This Operations manual is intended as a guide to the use and maintenance of
Bromma spreaders.
DO NOT exeed the Safe Working Load (SWL) of the spreader bar. The
Safe Working Load is found on the nameplate that is permanently affixed
to the side frame of the spreader.
__________________________________________________________________________________
BROMMA CONQUIP AB 00 02 ENG
rev.
7DEOHRIFRQWHQWV
1 x INTRODUCTION
2 x SPREADER DATA SHEET
5 x SAFETY PRECAUTIONS
6 x START-UP PROCEDURES
7 x MAINTENANCE PROCEDURES
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8 x SPARE PARTS AND SERVICE
6SDUHSDUWVOLVWE\PDMRUJURXSV
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9 x HYDRAULIC CIRCUIT DIAGRAMS
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_________________________________________________________________________________
BROMMA CONQUIP 00 03 ENG
rev.01
BrommaGroupManual
0-1-may02rev.00 BrommaConquip
1 Introduction
Maintenance.
Repairs.
Trouble-shooting.
Service.
Spare parts.
0-1-may02rev.00 BrommaConquip
2 x Spreader - Datasheet
Type EH170U
Art.No 1012972
Container Range 20’- 40’
Capacity
Lifting capacity (evenly loaded) 41 tonne
Lifting capacity (10% gravity point off set) 41 tonne
Twinlift capacity 2 x 25 tonne
Twinlift capacity (10% gravity point off set) 2 x 20,5 tonne
Lifting lug capacity (gable end) 4 x 10 tonne
Lifting lug capacity (main beam) 4 x 10 tonne
Operating Movements
Telescoping 20’ to 40’ or 40’ to 20’ 30 s
Twistlock rotation locking or unlocking 90o 1,5 s
Electrical Equipment
Power voltage 400 V AC
Frequency 50 Hz
Control voltage 230 V AC
Control valve 24 V DC
Total power consumption 2x2,2 k + 1x3kW + 3+5,5 =15,9kW
Electrical protection IP 5
Hydraulic Equipment
Pump running Pressure 100 bar
Pump flow 3 x 15 l/min
Tank capacity 3 x 50 l
Normal running temperature (above ambient) 50˚C
Filter type 10 μm
Filter
Pressure line 10 μm
Corrosion protection
All surfaces are grit blasted SA 2.5
Interzinc 72 EPA 069/073 (Interzink 72 EPA 069/073) 0 μm
Intervinux Serie VL (Intervinux Serie VL) [50 μm
Intervinux Serie VS (Intervinux Serie VS) 0 μm
Min. coating thickness, total 200 μm
______________________________________________________________________________________________________
BROMMA CONQUIP AB 02 01ENG
rev..1
BrommaGroupManual
0-1-may02rev.00 BrommaConquip
3 Technical description
Functional description
Bromma telescopic spreader EH5 (EH12 & EH170) are fabricated as all
welded, high quality steel, construction. Two pairs of telescopic beams slide in
the centre main frame construction. The telescopic beams are joined together
at the ends by end beams, which house the twistlocks, flipper arms and
hydraulic valves.
The spreader has an inbuilt under clearance of 185 mm. This enables
hatchcovers and containers with protrusions up to 185 mm to be handled. If
larger clearances are required then overweight extension legs need to be fitted.
The spreader is optionally fitted with one set of lifting lugs. Mostly, they are
placed at each corner of the gable end. In case the spreader is provided with
this device, it can be used for handling of badly damaged containers or non-
containerised cargo.
TELESCOPIC SYSTEM
The telescoping system is driven by means of an electric motor and reduction
gearbox connected to an endless chain. This chain is titted with stacks of spring
washers that work as chock absorbers where the chain attaches to the tension
rods.. These tension rods are connected to the end beam. The springs allow for
changes in the length of the spreader up to plus or minus 7 mm . The springs
do not only act as shock absorbers; they also provide a floating possibility for
the twistlocks to handle distorted containers. This "floating" action also
eliminates the need for corner guide rollers.
________________________________________________________________________________________________________
1 of 3 BROMMA CONQUIP AB 03 09 ENG.
rev. x
This brake not only controls the accuracy in stopping the expansion and
retraction but also prevents changes from occurring in the spreader length
during use.
TOWER
The main frame of the spreader is connected to the crane through a sliding
tower assembly. This enables the centre of gravity lifting point to be moved a
maximum of 1,2 meters toward each end of the spreader. This means that
unevenly loaded containers can be picked up horizontally, which is specially
important when loading or unloading in the guides in the ship´s cells. After
unlocking an unevenly loaded container, the sliding tower assembly
automatically returns to the central position
FLIPPERS
Flat gather guides, commonly called flippers, are fitted to each end beam of the
spreader. They are of strong construction and are driven by a powerful
hydraulic motor, which enables easy and fast location of the spreader onto the
containers. The flipper gather is 155 mm and has a gathering torque of
1200 Nm. The flipper arms are always under pressure and each arm has a
shock relief valve, which opens at a pre-set pressure of 45 bar above the
normal working pressure. As soon as the shock load ends the flipper returns to
the vertical position.
Each flipper is controlled by its own solenoid valve and shock relief valve. The
flippers work in pairs along the length of the spreader, individually at the gable
ends, or all together.
The speed of the flipper is approximately 180 in 6 seconds and is
controlled by an orifice plug in the pipe connection to the motor.
TWISTLOCK
Four twistlocks for single container spreader are located in the corners of the
spreader to engage and lift the container. A hydraulic cylinder rotates the
twistlock and two sensors indicate the position of the twistlock, Locked or
Unlocked.
A landing pin safety system is provided to assure that the spreader is properly
landed on the container before rotating the twistlocks.
A spring loaded landing pin near each twistlock is pushed up into the twistlock
housing when the spreader is landed on the container. When the spreader is
properly landed on a container, the landing pin will activate a proximity switch.
Only when all the corners of the spreader are landed, can the twistlocks be
turned. At the same time, the blockading key is moved high enough so the
blockading stop on the twistlock lever arm passes underneath it. If the
spreader is not properly landed the proximity switch will not be activated and
________________________________________________________________________________________________________
2 of 3 BROMMA CONQUIP AB 03 09 ENG.
rev. x
the blockading key will get in the way of the blocking stop. This will stop the
twistlocks from turning.
SIGNAL LIGHT
Near each end of the spreader mainframe there is a set of three signals light,
one green, one red, one white, which can be clearly seen from the crane cabin.
The green and red lights indicate if corresponding twistlocks are unlocked or
locked respectively. The white light indicates when the spreader is properly
"landed", and the twistlocks are correctly engaged in the container corner
castings.
In twinlift spreaders (EH170U), when using the twinlift function, the left side
signal lamps are valid for the left side container and the right side lamps are for
the right side container.
HYDRAULIC UNITS
The hydraulic units are protected inside each end beam. The unit consists of a
built-in tank, variable displacement piston pump, motor valves and filter. The
filter cap is fitted with a pressure relief valve plus or minus 0,14 bar to allow
expansion and contraction of air inside the tank.
The hydraulic components used are designed to work at over 200 bar but
normal working pressure is 100 bar. The hydraulic valves are solenoid
operated and can be tested by hand operating.
The EH170U has a third hydraulic unit placed in the main beam. This unit
provides the four cylinders for center twistlock housings up-down and the four
cylinders for lock-unlock in the central twistlocks with power.
________________________________________________________________________________________________________
3 of 3 BROMMA CONQUIP AB 03 09 ENG.
rev. x
Design calculations
The spreader structure is designed according to DIN15018 and to the
following loading group which represents a container handling crane.
HOISTING GROUP H2
LOADING GROUP B4
LIFTING CASES
The following lifting cases are considered:
1. The spreader should only be hoisted/lowered when all four twistlocks are
fully locked/unlocked.
4. During hoisting the four blockading pins move to the "down" position.
This prevents electrically the twistlocks from moving.
NOTE ! When carrying out maintenance on the twistlocks, the blockading pin clamps can
be fitted to each corner, to by pass the electric and mechanical blockading when running
the twistlock.
__________________________________________________________________________________
BROMMA CONQUIP AB 03 03 ENG
rev.
In-plant testing
STRUCTURAL
Each spreader is fully proof tested in the factory to a minimum of 50%
overload prior to delivery. The proof test loading report enclosed illustrates the
loads applied to the spreader.
All lifting lugs are also proof tested in the factory.
The testing is witnessed and certified by a third part inspection official.
All spreader twistlocks are individually proof tested, stamped and certified to a
loading of 37 tonne.
FUNCTIONAL
Each spreader is run in the factory prior to delivery being controlled by a
specially designed simulator.
__________________________________________________________________________________
BROMMA CONQUIP AB 03 04 ENG
rev. x
4 Testing records and certificates
______________________________________________________________________________________________________
BROMMA CONQUIP AB 04 01 ENG
rev.
BrommaGroupManual
0-1-may02rev.00 BrommaConquip
5 Safety precautions
Warnings
The manual contains vital information for the safety of personnel and the
correct use of the spreader.
Bromma Group will not accept any liability for the use of the spreader for
any purposes outside what is described in the manual.
DO NOT exeed the Safe Working Load (SWL) of the spreader bar. The Safe
Working Load is shown on the nameplate that is permanently affixed to the
side frame of the spreader.
Safety precautions
2. The spreader must only be used for the purpose for which it is
designed.
6. Stay clear of all moving parts, such as guide arms (flippers), moving
beams, telescopic chains, etc. A safe distance is 5 meters.
12. Care must be taken when performing any maintenance inside the
spreader frame. It must be carried out under extreme caution and by
personnel familiar with risks related to spreader function and
movements. Serious injury by crushing can occur
13. Contact Bromma Conquip AB before doing any repair work on the
spreader apart from replacing normal wear parts.
14. DO NOT walk or stand beneath the spreader bar during operation.
15. DO NOT attempt to lift a container that is not level (+/- 5°).
19. DO NOT stand between a container and any construction that many
prevent your movement to safety. A definite hazard exists that could
cause serious injury or death by being crushed between the container
and an obstruction (such as a building or another container).
20. Mobile work platforms which are used in repair and service work on the
spreader must be equipped with safety rails and kick plates.
22. The tower must be moved back to the centre of the spreader before it
leaves the container. There must be a good clearance between the
Spreader and the container before slewing the crane boom.
23. When welding might be needed on the spreader with SCS2 assembled,
make sure that it is properly grounded or dismantle the plug connection
and earth cable.
_____________________________________________________________
BROMMA CONQUIP AB 05 02d ENG.
rev.
BrommaGroupManual
0-1-may02rev.00 BrommaConquip
6 Start - Up procedure
ASSEMBLY OF TOWER (drg no 34476)
2 Suspend the tower from a suitable forklift or crane (tower weight 1,4 t)
using
the main lifting pin (pos 1).
3 Remove the protective material from the robalon pads on tower (pos 2).
Remove the drive sprocket cover (pos 6).
Remove the (2) lifting lugs from main frame of the spreader at the
assembly end
(pos 3).
NOTE: Take care that flipper does not fall down and cause injury!
7 Remove lamp assembly by taking out the quick release fastening from
the four pins and lay the lamp assembly in the main frame.
8 Release the gravity point chain, by removing the two screws and the
locking device from adjuster.
9 You are now able to slide the tower into the main frame close to the
centre.
Note the direction of assembly. Arrows are painted on the tower and
frame.
10 Now replace the lamp assembly, rubber covers and lifting lugs. If the
flipper is rise at this time, care should be taken as it is liable to fall, now
that the motor is empty.
______________________________________________________________________________________________________
1 BROMMA CONQUIP AB 06 02 ENG
rev.
11 Remove the drive sprocket cover (pos 6).
It is now possible to install the chain, complete with the anchor block
fitted.
The chain goes, under the first sprocket, over the centre one and under
the third.
To assist with the chain installation, pull the brake release lever, towards
the back of the motor. It is then possible to turn the motor, using the
handle supplied.
12 Replace the chain back into it's fixing point and tighten the adjusting
screws, until the chain is tight (allow a sag of about 30 mm and place the
tower in middle position) and replace the locking device. Grease the chain.
14 Pass the main plug up through the tower and fix conduit pipes with screws
supplied.
16 Connect the tower motor. The connections are marked u1 and w1 to give
correct position.
19 Check all bolts are tight and the spreader is clear of all discarded material
and tools. Take care that nothing had fallen into the chain.
______________________________________________________________________________________________________
2 BROMMA CONQUIP AB 06 02 ENG
rev.
TOWER FUNCTIONS AND TESTING
The tower function is to level/unlevel loaded containers. Any other use of the
tower is an abuse of the equipment and could result in serious damage.
When the spreader is locked onto a container, it is possible to move the tower
in any direction. The tower will stay where it is placed. The return to the middle
position is done by the crane driver. When he has driven the tower to yellow or
blue, it goes always to the middle position.
To test the newly assembled unit, place the blockading pin clamps onto the
spreader and lock the twistlocks. With the spreader on the ground, commence
to travel the tower towards one end of the spreader. Now hold a piece of
metal, i.e. spanner or screwdriver, in front of the stop switch, for the end that
the tower is travelling. The tower should now stop.
Try the other direction. If both of the limits work, travel the tower to both ends
of the spreader, to confirm the limits work on the detection bar. When at each
end, unlock the twistlocks and release a clamp, to confirm the tower returns to
it's centre position. If any of these functions fail, please seek advice.
WARNING!
Use the tower only to level loads, or serious damage may occur!
Never use the hand crank on the motor with power connected, or serious
injury may occur!
______________________________________________________________________________________________________
3 BROMMA CONQUIP AB 06 02 ENG
rev.
Start - Up the spreader
1. Before any connection to container crane, place the main frame of the
spreader on trestles or similar about 0,7 m height and in such a way that the
flipper arms can be lowered.
3. Connect the main current and control supply to the spreader. Connect the 24
pin plug to the service panel.
4. Start the electric motor of the hydraulic units by turning the ”pump on” switch on
service panel.
5. For testing of the twistlocks all 4 blockading pins should be in ”up” position. This
is achieved by using a blockading pin clamp. In the ”down” position the
blockading pins electrically and mechanically block all twistlock rotation.
6. Test all functions of the spreader using the push buttons and switches on the
service panel.
a) When ”pump on” switch is on, both electric motors should be running in
gable ends.
b) Operate the push buttons to put the spreader in the different length positions.
As an additional length, check that the twistlock centre length is marked on
the plate positioned on side of the main beam.
c) Check that the flippers works in pairs along the length of the spreader,
individually at the gable ends, or all together by pressing the appropriate
buttons.
d) Check that when clamps are fitted to the blockading pins and all pins are up,
this will be indicated by the white lights on the spreader.
e) Check that the twistlocks lock/unlock and that the light indicators on the top
of the spreader main frame indicate red when locked and green when
unlocked.
7. Check that the pump operating pressure is 100 bar.
______________________________________________________________________________________________________
4 BROMMA CONQUIP AB 06 02 ENG
rev.
8. Check each end hydraulic assembly to ensure there are no oil leaks.
9. Note that the solenoid valves operating flippers and twistlocks can be
manually operated if required.This is achieved by pushing the end of the
solenoid with a small screwdriver. As power is generally always on the
solenoid, the plug connection has to be disconnected first.
10. Service and lubrication should be carried out in accordance with the
lubrication manual.
______________________________________________________________________________________________________
5 BROMMA CONQUIP AB 06 02 ENG
rev.
7 Maintenance procedures
Maintenance Instructions
IMPORTANT!
When the spreader is disconnected from the crane the heating function
(if fitted) must always be connected and energised.
Pos. 1
TWISTLOCK (drg no 22808)
All twistlock are to be greased through the greasecups 4 per spreader.
Pos. 2
TWISTLOCK CYLINDER & BEARING HOUSING IN TOWER (drg no 22808)
Piston rod ends are to be greased. 8 per spreader. Bearing housing in tower.
2 per spreader.
Pos. 3
HYDRAULIC UNIT (drg no 22809)
Oil is to be changed after first 50 hours, then after every 1000 hours.
Pos. 4
OIL FILTER (drg no 22809)
Filter is to be changed after first 50 hours, then after every 1000 hours of
operation or when the indicator is red.
Pos. 5
LIFTING SHAFTS (drg no 22808)
(If the spreader/headblock is equipped with lifting shafts).
ACTION! To be greased.
Pos. 6
GLIDE PLATE (drg no 22810)
The robalon glide plates are to be replaced when the thickness is down to
17 mm.
ACTION! To be checked.
Pos. 8
TELESCOPIC GEARBOX (drg no 22808 & 22809)
Oil level is to be checked through dismantled oil level plug. Bearings at the
gearbox and the pedestal are to be greased through greasecups.
Pos. 9
ALL ROLLER CHAINS AND TENSION WHEEL (drg no 22808)
Roller chains and tension wheel are to be checked from abrasion and
greased.
Pos. 10
SIGNAL LAMPS (drg no 22810)
Vibration proof glow lamp.
ACTION! To be checked.
Pos. 11
TELESCOPIC BEAMS (drg no 22808)
To be greased as follows:
2. In fully expanded position, with a brush on the sliding area under the
telescopic beams ca 100g/ at interval min.1000 hour. The amount of
grease and service interval depends on spreader use and environmental
circumstances which vary from place to place.
Pos. 12
ELECTRICAL MOTORS (Only for EH5)
Adjust brakes as per attached instructions.
Item Quant Title Material / Article No. Dwg No. Art. No. Remarks
1 1 TWISTLOCK PIN 1000431 1000431
2 1 GUIDE BLOCK 1000430 1000430
3 1 SPHERICAL WASHER 41683 53968
4 1 TWISTLOCK ARM, ASSY. 43653 43653 TYPE 1
5 1 TWISTLOCK KEY 1000434 1000434
6 1 NUT 1000432 1000432 (M39x4-6H)
7 1 SCREW A4 1000600 M6S 8x75, Art. No. was 70165
8 2 SPACER RING 41731 54049
9 1 HYDRAULIC CYLINDER 74147 (CA 32/20-100/65)
10 1 BLOCKADING PIN 37704 37704 FZB
11 1 SPRING 70429 SF-TF 4.5x22x90 SS 1774-04
12 1 NUT LOCK-KING A4 77891 M12, Art. No was 75055
13 2 WASHER NORD-LOCK A4 701440 M12, Art. No. was 75295
14 2 LOCK PIN 74044 R.R 3.0
15 2 GREASE FITTING 71328 R 1/8"
16 6 SWITCH ATTACH. STD. 74970 (SENSOR D=30)
17 3 SCREW A4 1000596 M6S 8x50, Art. No. was 75226
18 1 SWITCH PAD h=10 1001482 1001482
19 4 SCREW A4 1000585 M6S 6x55, Art. No. was 75694
20 2 SCREW A4 1000587 M6S 6x65, Art. No. was 700686
21 1 BLOCKADING PIECE 43654 43654 FZB
22 4 NUT A4 76460 LOC-KING M8, Art. No. was 75090
23 6 WASHER A4 77798 BRB 8.4x16x1.6, Art. No. was 75328
24 3 BOLTING PLATE 48916 48916 FZB
25 6 WASHER NORD-LOCK A4 701433 M6, Art. No. was 75268
26 3 COVER PLATE DEP4 79850 FZB
27 1 SENSOR PLATE ASSY. LEFT 1002453 1002453 FZB
Page 1 of 1
Article No: 1002946 TWISTLOCK ASSEMBLY date
Drawing No: 1002946 ISO, STD, RIGHT sign: PWH 2005-02-18
Serial No: - BGS rev: b / SC 2007-01-23
Customer: -
Standard: -
Item Quant Title Material / Article No. Dwg No. Art. No. Remarks
1 1 TWISTLOCK PIN 1000431 1000431
2 1 GUIDE BLOCK 1000430 1000430
3 1 SPHERICAL WASHER 41683 53968
4 1 TWISTLOCK ARM, ASSY. 43653 57059 TYPE 2
5 1 TWISTLOCK KEY 1000434 1000434
6 1 NUT 1000432 1000432 (M39x4-6H)
7 1 SCREW A4 1000600 M6S 8x75, Art. No. was 70165
8 2 SPACER RING 41731 54049
9 1 HYDRAULIC CYLINDER 74147 (CA 32/20-100/65)
10 1 BLOCKADING PIN 37704 37704 FZB
11 1 SPRING 70429 SF-TF 4.5x22x90 SS 1774-04
12 1 NUT LOCK-KING A4 77891 M12, Art. No was 75055
13 2 WASHER NORD-LOCK A4 701440 M12, Art. No. was 75295
14 2 LOCK PIN 74044 R.R 3.0
15 2 GREASE FITTING 71328 R 1/8"
16 6 SWITCH ATTACH. STD. 74970 (SENSOR D=30)
17 3 SCREW A4 1000596 M6S 8x50, Art. No. was 75226
18 1 SWITCH PAD h=10 1001482 1001482
19 4 SCREW A4 1000585 M6S 6x55, Art. No. was 75694
20 2 SCREW A4 1000587 M6S 6x65, Art. No. was 700686
21 1 BLOCKADING PIECE 43654 43654 FZB
22 4 NUT A4 76460 LOC-KING M8, Art. No. was 75090
23 6 WASHER A4 77798 BRB 8.4x16x1.6, Art. No. was 75328
24 3 BOLTING PLATE 48916 48916 FZB
25 6 WASHER NORD-LOCK A4 701433 M6, Art. No. was 75268
26 3 COVER PLATE DEP4 79850 FZB
27 1 SENSOR PLATE ASSY. RIGHT 1002454 1002454 FZB
A A
A-A
1:5
H:\DWG\A3\A38\38073A.dwg
1 of 2
PERIODIC MAINTENANCE PROCEDURE
RUNNING-IN OF A NEW SPREADER
2. Check that all hydraulic tank mountings are tight. Twistlock pin
4. Carefully inspect all hoses, hose clips and hose connections. Defective
hydraulic hoses and connections may cause personal injury when jets of
liquid escape under high pressure.
If the work requires that the electrical supply remains connected then staff on
or in the vicinity of the spreader must be informed that it could move.
NOTE. See the twistlock drawing and/or the separate adjustment instructions
for the adjustment of the twistlock end stop switches after reassembly.
--------------------------
2
If the spreader is equipped with twistlock counter
3
If there is no hour counter or twistlockcounter
4
If the spreader is equipped with twistlock counter
5
If there is no hour counter or twistlock counter
6
Only for floating twistlocks
When ordering a new hydraulic pump always state the direction of rotation as
marked on the old pump housing.
NOTE. Every time the pump is emptied, new oil must be added until it starts
to run out of the drain hose.
These are cross over relief valves which relieves excess hydraulic pressure
caused by external forces on the flipper arms or the telescopic system. The
rising hydraulic pressure acts against the spring to open the flow path to the
other port.
All leakage’s through these valves at the normal operating pressure of the
pump (lower setting than the pump's operating pressure) cause a substantial
increase in the temperature of the hydraulic oil. Leaks of this type are often
indicated by a hissing sound coming from the relief valve.
4. Remove the chain pin connected to the shock absorber by pulling out the
cotter pin.
6. Install a new chain or insert a joining link and reinstall the chain and the
adjusting nut.
8. Connect the power supply and make a fine adjustment as per the
instructions in 'Setting the spreader length'.
3. Operate the telescopic drive by manually pressing the valves until the
Robalon plate mounting bolts are accessible through the aperture in the
lower flange of the main beam. Replace the plates.
1. Start by removing all the Robalon plates from the ends of telescopic
beams. Leave the plates on the main frame in place.
2. Disconnect the power cables and the hydraulic hoses from the end units.
Seal all hydraulic hoses correctly.
3. Remove the stud from the drawbar connection in the end beam.
4. Take the weight off the end unit using a fork lift truck and extend the unit to
the 40 foot position.
6. Extract the beams from the main frame and inspect them as required.
6. Reassemble the beams and the end units in the reverse order to that in
the instructions above.
NOTE. When replacing the flipper arm motor ensure that the outlet plug is
correctly positioned.
c) Drift out the shaft. Once the shaft has been removed the bearing will be
pushed out by the middle key.
e) Install the parts in the reverse order to dismantle except for that both
bearings have to be drifted into position using a pipe of a suitable bore.
Sensors:
a) Adjust the centre to centre distance Sensor
between twistlocks for each position
by moving the sensors.
Adjusting Key
1. Remove the M6 screw from the top of the twistlock.
2. To lower the twistlock, loosen the twistlock nut
slightly. To raise the twistlock, tighten the nut.
The distance between the top of twistlock head and the Twistlock pin
bottom of guide block 1 -2 mm
3. Recheck the float of the twistlock.
4. Reinstall the M6 screw.
Twistlock
8 of 10 BROMMA CONQUIP AB
head
07 02 ENG
rev. x
Removing the Twistlock Cylinder
1. Make sure the power supply is disconnected
and the oil pressure is relieved from the
system. Split pin
2. Remove the hoses from the cylinder.
3. To avoid oil leakage, thread a plastic bag Spacer
over the end of the hoses and secure
ring
them with straps.
4. Pull out the split pins. Remove the spacer
rings and the cylinder.
Removing Sensors
1. Unscrew the cable connection from
the sensor.
2. Loosen the two screws on the switch
attachment. Signal
3. Remove the sensor. cable
Sensor connection
Installing Sensors
1. Perform the steps above in the reverse
order, using blue Loctite to the cable
connection.
2. The distance between sensor face and
flag is approximately 5-6 mm. Check
the sensor by grabbing the twistlock
head and moving it around in different
positions. If the signal is lost, adjust the
sensor closer to its flag. Make sure the
flag does not come in contact with
the sensor.
Tower Crank
motor
75 Nm
Torque
wrench
•
•
•
•
1
Bromma Manual
331Nm
331Nm
End beam
68Nm 6.5 Nm
40Nm
331Nm
40Nm
331Nm
Twistlock Twistlock
EH5 / EH170 EH5U / EH170U
100 Nm
95 Nm
91Nm
91 Nm
after 200
test cycles
5
4
3
2
22
21
e
10 20
c 19
b
a 18
17
16
15
14
11 12 13
2
8 Inspection and maintenance of brake BMG 4 and 8
1. Isolate the moto r and brake from the supply, safeguarding them against
un inten tional power -up.
2. Remove the following:
– If fitted, forced- cooling fan for
motor and brake maintenance.
– F lange co ver or fa n guard (21 ).
3. Pu sh the rubber sealing co llar (5) aside.
– R elease the clip to do this, if necessary .
– E xtract the abr aded ma tter.
4. Measure the brake disc (7 ):
If the brak e d isc is:
– ≤ 9 mm on b rake motors up to size 100 .(BMG4)
– ≤ 10 mm on bra ke motor s up to size 1 12.(BMG8)
Fit a new brake disc (→ Section "Ch anging brake disc on BMG 4 and 8
3
Inspection and maintenance of brake BMG 4 and 8 8
1. Iso late the moto r and brake from the supply,, safeguarding them against
un inten tional power -up.
2. Remove the following:
– If fitted, forced coolin g fan
BMG 4 and 8 2
Importan t: This flo ating clerance "s" is necessary so that the pressure plate
can move up as the brake lining wears. Otherwise, reliable braking is not
gu ara nteed.
9. Fit the r ubber sea ling colla r ba ck in place and re-install th e dismantled pa rts.
Note: • T he locka ble man ual brake r elea s e ( type HF) is a lready r elea s ed if a re sistan ce is
encountered whe n ope rating the gr ub scre w.
• T he se lf-reengaging manual b rake re lea s e (type HR) ca n be operated with normal
hand pressu re.
Imp ortant: In brake motors with self-reengaging manual brake release, the
manual brake release lever must be removed after startup/maintenance. A bracket
is provided for storing it on the outside of the motor.
4
8 Inspection and maintenance of brake BMG 4 and 8
Changing Springs
1. Isolate the moto r and brake from the supply, safeguarding them against
un inten tional po wer -up.
2. Remove the following:
– If fitted, fo rced -cooling fan ,
For motor and brake ma intenance .
– F lange cover or fa n guard (21 ), ci rclip (2 0) and fan (19).
3. Remove the ru bber sea ling colla r (5) an d the ma nual brake release:
– s etting nuts (18 ), conical coil sp rings (1 7), studs ( 16) , release le ver ( 15) , dowel
pin (1 4).
4. Unscrew he x nuts ( 10e ), pull o ff the co il body ( 12) .
– B y app rox. 50 mm (watch the bra ke ca ble!) .
5. Cha nge brake springs (11).
– P os ition the bra ke sp rings symme trically.
6. Re- install th e br ake components..
– E xcept fo r the r ubber sea ling colla r, fan an d fan gu ard,
set the wor king air ga p (→ ”Ins pecting brake BMG 4 and 8 setting the
working air gap ” , points 5 th rough 8)
7. With manual brake release: Use setting nuts to s et floating c learance "s" between
the co nical coil springs (pressed fla t) an d the setting nuts ( → following illustration.)
BMG 4 and 8 2
Importan t: This floating clearance "s" is necessary so that the pressure plate
can move up as the brake lining wears. Otherwise, reliable braking is not
gu aranteed.
8. Fit the rubber sealing colla r ba ck in place and re-install th e dismantled pa rts.
Note Fit new settingnuts (18) an d hexag on nuts ( 10e ) if the re moval pr oced ure is r epeated!
5
kVA n
9 f Work done, working air gap, braking torques of brake BMG 4 - 8
i
P Hz
9.3 Work done, working air gap, braking torques of brake BMG 4-8
Workin g air gap
Work do ne Br aking torque se ttings
[mm]
Brak e Fo r until
Br aking Type an d n o. of Order n umber o f
type motor size main tenance
[10 6 J] min. 1) ma x. torque springs spr ings
[N m] Nor mal Red Norma l Red
0.25 0.6
75 6 -
112M
BMG 8 600 0.3 1.2 184 845 3 135 570 8
132S
1)
Please note when checking the air gap:
Parallelism tolerances on the brake disk may give rice to deviation of ±0.1 after
a test run.
6
A ddres s lis t
C o n t a c t y o u r B R O M M A l o c a l r e p r e s e n t a t i v e o r S E W A ddres s es below.
G ermany
Headquarters B ruc hs al S E W-E UR ODR IV E G mbH & C o Tel. (0 72 51) 75-0
P roduc tion E rnst-B lickle-S traß e 42 F ax (0 72 51) 75-19 70
S ales D-76646 B ruchs al http://www.S E W-E UR ODR IV E .de
S ervic e P.O. B ox s ew@ s ew-eurodrive.de
P os tfach 3023 · D-76642 B ruchsal
P roduc tion G raben S E W-E UR ODR IV E G mbH & C o Tel. (0 72 51) 75-0
E rnst-B lickle-S traß e 1 F ax (0 72 51) 75-29 70
D-76676 G raben-Neudorf Telex 7 822 276
P.O. B ox
P os tfach 1220 · D-76671 G raben-Neudorf
A s s embly G arbs en S E W-E UR ODR IV E G mbH & C o Tel. (0 51 37) 87 98-30
S ervic e (near Hannover) Alte R icklinger S traß e 40-42 F ax (0 51 37) 87 98-55
D-30823 G arbs en s cm-garbs en@ s ew-eurodrive.de
P.O. B ox
P os tfach 110453 · D-30804 G arbs en
K irc hheim S E W-E UR ODR IV E G mbH & C o Tel. (0 89) 90 95 52-10
(near München) Domagks traß e 5 F ax (0 89) 90 95 52-50
D-85551 K irchheim s cm-kirchheim@ s ew-eurodrive.de
L angenfeld S E W-E UR ODR IV E G mbH & C o Tel. (0 21 73) 85 07-30
(near Düs s eldorf) S iemens s traß e 1 F ax (0 21 73) 85 07-55
D-40764 Langenfeld s cm-langenfeld@ s ew-eurodrive.de
Meerane S E W-E UR ODR IV E G mbH & C o Tel. (0 37 64) 76 06-0
(near Zwickau) Dänkritzer Weg 1 F ax (0 37 64) 76 06-30
D-08393 Meerane s cm-meerane@ s ew-eurodrive.de
Additional address es for s ervice in G ermany provided on reques t!
F ranc e
P roduc tion Haguenau S E W-US OC OME S AS Tel. 03 88 73 67 00
S ales 48-54, route de S oufflenheim F ax 03 88 73 66 00
S ervic e B . P. 185 http://www.us ocome.com
F -67506 Haguenau C edex s ew@ us ocome.com
A s s embly B ordeaux S E W-US OC OME S AS Tel. 05 57 26 39 00
S ales P arc d’a ctivité s de Magellan F ax 05 57 26 39 09
S ervic e 62, avenue de Magellan - B . P. 182
F -33607 P es s ac C edex
Lyon S E W-US OC OME S AS Tel. 04 72 15 37 00
P arc d’A f faires R oos evelt F ax 04 72 15 37 15
R ue J acques Tati
F -69120 Vaulx en Velin
P aris S E W-US OC OME S AS Tel. 01 64 42 40 80
Zone indus trielle F ax 01 64 42 40 88
2, rue Denis P apin
F -77390 Verneuil I’E t ang
Additional address es for s ervice in F rance provided on reques t!
A rgentina
A s s embly B uenos A ires S E W E UR ODR IV E AR G E NT INA S .A. Tel. (3327) 45 72 84
S ales C entro Indus trial G arin, Lote 35 F ax (3327) 45 72 21
S ervic e R uta P anamericana K m 37,5 s ewar@ s ew-eurodrive.com.ar
1619 G arin
A us tralia
A s s embly Melbourne S E W-E UR ODR IV E P T Y. LT D. Tel. (03) 99 33 10 00
S ales 27 B everage Drive F ax (03) 99 33 10 03
S ervic e Tullamarine, Victoria 3043
S ydney S E W-E UR ODR IV E P T Y. LT D. Tel. (02) 97 25 99 00
9, S leigh P lace, Wetherill P ark F ax (02) 97 25 99 05
New S outh Wales , 2164
A us tria
A s s embly Wien S E W-E UR ODR IV E G es .m.b.H. Tel. (01) 6 17 55 00-0
S ales R ichard-S traus s -S tras s e 24 F ax (01) 6 17 55 00-30
S ervic e A-1230 Wien s ew@ s ew-eurodrive.at
7
Address list
Belgium
Assembly Brüssel CARON-VECTOR S.A. Tel. (010) 23 13 11
Sales Avenue Eiffel 5 Fax (010) 2313 36
Service B-1300 Wavre http://www.caron-vector.be
info@caron-vector.be
Brazil
Production Sao Paulo SEW DO BRASIL Tel. (011) 64 60-64 33
Sales Motores-Redutores Ltda. Fax (011) 64 80 33 28
Service Rodovia Presidente Dutra, km 208 sew@sew.com.br
CEP 07210-000 - Guarulhos - SP
Additional addresses for service in Brazil provided on request!
Bulgaria
Sales Sofia BEVER-DRIVE GMBH Tel. (92) 9 53 25 65
Bogdanovetz Str.1 Fax (92) 9 54 93 45
BG-1606 Sofia bever@mbox.infotel.bg
Canada
Assembly Toronto SEW-EURODRIVE CO. OF CANADA LTD. Tel. (905) 7 91-15 53
Sales 210 Walker Drive Fax (905) 7 91-29 99
Service Bramalea, Ontario L6T3W1 www.sew-eurodrive.ca
Vancouver SEW-EURODRIVE CO. OF CANADA LTD. Tel. (604) 9 46-55 35
7188 Honeyman Street Fax (604) 946-2513
Delta. B.C. V4G 1 E2
Montreal SEW-EURODRIVE CO. OF CANADA LTD. Tel. (514) 3 67-11 24
2555 Rue Leger Street Fax (514) 3 67-36 77
LaSalle, Quebec H8N 2V9
Additional addresses for service in Canada provided on request!
Chile
Assembly Santiago de SEW-EURODRIVE CHILE Tel. (02) 6 23 82 03+6 23 81 63
Sales Chile Motores-Reductores LTDA. Fax (02) 6 23 81 79
Service Panamericana Norte No 9261
Casilla 23 - Correo Quilicura
RCH-Santiago de Chile
China
Production Tianjin SEW-EURODRIVE (Tianjin) Co., Ltd. Tel. (022) 25 32 26 12
Assembly No. 46, 7th Avenue, TEDA Fax (022) 25 32 26 11
Sales Tianjin 300457
Service
Colombia
Assembly Bogotá SEW-EURODRIVE COLOMBIA LTDA. Tel. (0571) 5 47 50 50
Sales Calle 22 No. 132-60 Fax (0571) 5 47 50 44
Service Bodega 6, Manzana B sewcol@andinet.com
Santafé de Bogotá
Croatia
Sales Zagreb KOMPEKS d. o. o. Tel. +385 14 61 31 58
Service PIT Erdödy 4 II Fax +385 14 61 31 58
HR 10 000 Zagreb
Czech Republic
Sales Praha SEW-EURODRIVE S.R.O. Tel. 02/20 12 12 34 + 20 12 12 36
Business Centrum Praha Fax 02/20 12 12 37
Luná 591 sew@sew-eurodrive.cz
16000 Praha 6
Denmark
Assembly Kopenhagen SEW-EURODRIVEA/S Tel. 4395 8500
Sales Geminivej 28-30, P.O. Box 100 Fax 4395 8509
Service DK-2670 Greve http://www.sew-eurodrive.dk
sew@sew-eurodrive.dk
Estonia
Sales Tallin ALAS-KUUL AS Tel. 6 59 32 30
Paldiski mnt.125 Fax 6 59 32 31
EE 0006 Tallin
8
Address list
inland
Assembly ahti SEW-EURODRIVE O Tel. (3) 589 300
Sales Vesim entie 4 Fax (3) 780 6211
Service FIN-15860 Hollola 2
reat Britain
Assembly ormanton SEW-EURODRIVE Ltd. Tel. 19 24 89 38 55
Sales Beckbridge Industrial Estate Fax 19 24 89 37 02
Service P.O. Box No.1
GB-Normanton, West- orkshire WF6 1QR
reece
Sales Athen Christ. Boznos Son S.A. Tel. 14 22 51 34
Service 12, Mavromichali Street Fax 14 22 51 59
P.O. Box 80136, GR-18545 Piraeus Boznos@otenet.gr
ong Kong
Assembly ong Kong SEW-EURODRIVE LTD. Tel. 2-7 96 04 77 + 79 60 46 54
Sales Unit No. 801-806, 8th Floor Fax 2-7 95-91 29
Service Hong Leong Industrial Complex sew@sewhk.com
No. 4, Wang Kwong Road
Kowloon, Hong Kong
ungary
Sales Budapest SEW-EURODRIVE Kft. Tel. +36 1 437 06 58
Service H-1037 Budapest Fax +36 1 437 06 50
Kunigunda u. 18
ndia
Assembly Baroda SEW-EURODRIVE India Pvt. Ltd. Tel. 0 265-83 10 86
Sales Plot No. 4, Gidc Fax 0 265-83 10 87
Service Por Ramangamdi Baroda - 391 243 sew.baroda@gecsl.com
Gujarat
reland
Sales Dublin Alperton Engineering Ltd. Tel. (01) 8 30 62 77
Service 48 Moyle Road Fax (01) 8 30 64 58
Dublin Industrial Estate
Glasnevin, Dublin 11
taly
Assembly Milano SEW-EURODRIVE di R. Blickle Co.s.a.s. Tel. (02) 96 98 01
Sales Via Bernini,14 Fax (02) 96 79 97 81
Service I-20020 Solaro (Milano)
apan
Assembly Toyoda cho SEW-EURODRIVE APAN CO., LTD Tel. (0 53 83) 7 3811-13
Sales 250-1, Shimoman-no, Fax (0 53 83) 7 3814
Service Toyoda-cho, Iwata gun
Shizuoka prefecture, P.O. Box 438-0818
Korea
Assembly Ansan City SEW-EURODRIVE KOREA CO., LTD. Tel. (031) 4 92-80 51
Sales B 601-4, Banweol Industrial Estate Fax (031) 4 92-80 56
Service Unit 1048-4, Shingil-Dong master@sew-korea.co.kr
Ansan 425-120
u embourg
Assembly Brüssel CARON-VECTOR S.A. Tel. (010) 23 13 11
Sales Avenue Eiffel 5 Fax (010) 2313 36
Service B-1300 Wavre http://www.caron-vector.be
info@caron-vector.be
Macedonia
Sales Skopje SGS-Skopje / Macedonia Tel. (0991) 38 43 90
Teodosij Sinactaski Fax (0991) 38 43 90
6691000 Skopje / Macedonia
Malaysia
Assembly ohore SEW-EURODRIVE SDN BHD Tel. (07) 3 54 57 07 + 3 54 94 09
Sales No. 95, alan Seroja 39, Taman ohor aya Fax (07) 3 5414 04
Service 81000 ohor Bahru, ohor
West Malaysia
9
Address list
etherlands
Assembly Rotterdam VECTOR Aandrijftechniek B.V. Tel. +31 10 44 63 700
Sales Industrieweg 175 Fax +31 10 41 55 552
Service NL-3044 AS Rotterdam http://www.vector.nu
Postbus 10085 info@vector.nu
NL-3004 AB Rotterdam
e Zealand
Assembly Auckland SEW-EURODRIVE NEW ZEALAND LTD. Tel. 0064-9-2 74 56 27
Sales P.O. Box 58-428 Fax 0064-9-2 74 01 65
Service 82 Greenmount drive sales@sew-eurodrive.co.za
East Tamaki Auckland
Christchurch SEW-EURODRIVE NEW ZEALAND LTD. Tel. 0064-3-3 84 62 51
10 Settlers Crescent, Ferrymead Fax 0064-3-3 85 64 55
Christchurch sales@sew-eurodrive.co.nz
or ay
Assembly Moss SEW-EURODRIVE A/S Tel. (69) 2410 20
Sales Solgaard skog 71 Fax (69) 2410 40
Service N-1599 Moss sew@sew-eurodrive.no
Peru
Assembly ima SEW DEL PERU MOTORES REDUCTORES Tel. (511) 349-52 80
Sales S.A.C. Fax (511) 349-30 02
Service Los Calderos 120-124 sewperu@terra.com.pe
Urbanizacion Industrial Vulcano, ATE, Lima
Poland
Sales odz SEW-EURODRIVE Polska Sp.z.o.o. Tel. (042) 6 16 22 00
ul. Pojezierska 63 Fax (042) 6 16 22 10
91-338 Lodz sew@sew-eurodrive.pl
Portugal
Assembly Coimbra SEW-EURODRIVE, LDA. Tel. (0231) 20 96 70
Sales Apartado 15 Fax (0231) 20 36 85
Service P-3050-901 Mealhada infosew@sew-eurodrive.pt
Romania
Sales Bucuresti Sialco Trading SRL Tel. (01) 2 30 13 28
Service str. Madrid nr.4 Fax (01) 2 30 71 70
71222 Bucuresti sialco@mediasat.ro
Russia
Sales St Petersburg ZAO SEW-EURODRIVE Tel. (812) 3 26 09 41 + 5 35 04 30
P.O. Box 193 Fax (812) 5 35 22 87
193015 St. Petersburg sew@sew-eurodrive.ru
Singapore
Assembly SEW-EURODRIVE PTE. LTD. Tel. 8 62 17 01-705
Sales No 9, Tuas Drive 2 Fax 8 61 28 27
Service urong Industrial Estate Telex 38 659
Singapore 638644
Slovenia
Sales Celje Pakman - Pogonska Tehnika d.o.o. Tel. 00386 3 490 83 20
Service UI. IV. divizije 14 Fax 00386 3 490 83 21
SLO 3000 Celje pakman@siol.net
10
Address list
South Africa
Assembly ohannesburg SEW-EURODRIVE (PROPRIETAR ) LIMITED Tel. + 27 11 248 70 00
Sales Eurodrive House Fax +27 11 494 23 11
Service Cnr. Adcock Ingram and Aerodrome Roads ljansen@sew.co.za
Aeroton Ext. 2
ohannesburg 2013
P.O.Box 90004
Bertsham 2013
Capeto n SEW-EURODRIVE (PROPRIETAR ) LIMITED Tel. +27 21 552 98 20
Rainbow Park Fax +27 21 552 98 30
Cnr. Racecourse Omuramba Road Telex 576 062
Montague Gardens
Cape Town
P.O.Box 36556
Chempet 7442
Cape Town
Durban SEW-EURODRIVE (PROPRIETAR ) LIMITED Tel. +27 31 700 34 51
2 Monaceo Place Fax +27 31 700 38 47
Pinetown
Durban
P.O. Box 10433, Ashwood 3605
Spain
Assembly Bilbao SEW-EURODRIVE ESPA A, S.L. Tel. 9 44 31 84 70
Sales Parque Tecnol gico, Edificio, 302 Fax 9 44 31 84 71
Service E-48170 Zamudio (Vizcaya) sew.spain@sew-eurodrive.es
S eden
Assembly nk ping SEW-EURODRIVE AB Tel. (036) 34 42 00
Sales Gnejsv gen 6-8 Fax (036) 34 42 80
Service S-55303 önköping www.sew-eurodrive.se
Box 3100 S-55003 önköping
S itzerland
Assembly Basel Alfred lmhof A.G. Tel. (061) 4 17 17 17
Sales urastrasse 10 Fax (061) 4 17 17 00
Service CH-4142 M nchenstein bei Basel http://www.imhof-sew.ch
info@imhof-sew.ch
Thailand
Assembly Chon Buri SEW-EURODRIVE (Thailand) Ltd. Tel. 0066-38 21 40 22
Sales Bangpakong Industrial Park 2 Fax 0066-38 21 45 31
Service 700/456, Moo.7, Tambol Donhuaroh sewthailand@sew-eurodrive.co.th
Muang District
Chon Buri 20000
Turkey
Assembly stanbul SEW-EURODRIVE Tel. (0216) 4 41 91 63 + 4 41 91 64 + 3
Sales Hareket Sistemleri San. ve Tic. Ltd. Sti 83 80 14 + 3 83 80 15
Service Bagdat Cad. Koruma Cikmazi No. 3 Fax (0216) 3 05 58 67
TR-81540 Maltepe ISTANBUL seweurodrive@superonline.com.tr
SA
Production reenville SEW-EURODRIVE INC. Tel. (864) 4 39 75 37
Assembly 1295 Old Spartanburg Highway Fax Sales (864) 439-78 30
Sales P.O. Box 518 Fax Manuf. (864) 4 39-99 48
Service Lyman, S.C. 29365 Fax Ass. (864) 4 39-05 66
Telex 805 550
Assembly San rancisco SEW-EURODRIVE INC. Tel. (510) 4 87-35 60
Sales 30599 San Antonio St. Fax (510) 4 87-63 81
Service Hayward, California 94544-7101
Philadelphia PA SEW-EURODRIVE INC. Tel. (856) 4 67-22 77
Pureland Ind. Complex Fax (856) 8 45-31 79
200 High Hill Road, P.O. Box 481
Bridgeport, New ersey 08014
Dayton SEW-EURODRIVE INC. Tel. (9 37) 3 35-00 36
2001 West Main Street Fax (9 37) 4 40-37 99
Troy, Ohio 45373
Dallas SEW-EURODRIVE INC. Tel. (214) 3 30-48 24
3950 Platinum Way Fax (214) 3 30-47 24
Dallas, Texas 75237
11
Address list
SA
Additional addresses for service in the USA provided on request!
Venezuela
Assembly Valencia SEW-EURODRIVE Venezuela S.A. Tel. +58 (241) 8 32 98 04
Sales Av. Norte Sur No. 3, Galpon 84-319 Fax +58 (241) 8 38 62 75
Service Zona Industrial Municipal Norte sewventas@cantr.net
Valencia sewfinanzas@cantr.net
12
BrommaGroupManual
0-1-may02rev.00 BrommaConquip
8 Spare parts and service
Page - 1
THIS DRAWING IS COPYRIGHT AND IS THE PROPERTY
12 13 1 2 6 10
CONSENT OF THE OWNER.
5 9 4 3 14 7
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
DESIGNED TREATMENT SS-ISO 2768
Illtek 021029 EH5
PLOT DATE
SCALE REVISION
Spreader EH5 01
ARTICLE No
E DRAWING NUMBER
General assy
A Partek Company
SP-52000
THIS DRAWING IS COPYRIGHT AND IS THE PROPERTY
48
3 33 47 4 32
CONSENT OF THE OWNER.
1 49
35
36
37 50
16 20
26 34 17 10 21 14
7
39
43
38
8
39
9
2
24
15
29
11 23
5 43
6 44
38
22 43 44 20 38
28 43
41
18
38
12 43
31 46
25 39
40 38 36 43 42
30 19
38
43
39
45 27
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
TREATMENT SS-ISO 2768
DESIGNED Illtek 021029 EH5
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Tower DRAWING NUMBER
A Partek Company
SP-52001
EH5 Tower New standard
DRAWING SP-52001
PART NO DESCRIPTION QTY POS REMARKS
24161 TOWER 1 1
14 11 35 10 33 34 39 36 43 4
CONSENT OF THE OWNER.
20
12
19 25
18
29 8
45 24
23
22
40 9
32 13
21
1 12 6
26
13
7 12
44 15
5
2 41
3
31 42
38
48 27
47
17 37 28 30 46 16
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
TREATMENT SS-ISO 2768
DESIGNED Illtek 021002 EH5 ll
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Tower gear box assy DRAWING NUMBER
A Partek Company
SP-52002
EH5 Tower Gearbox Assy
DRAWING SP-52002
PART NO DESCRIPTION QTY POS REMARKS
58549 GEARBOX R97 ELM.BRAKE 360-404V 1 1 Part no for gearbox is 72157 and for only El motor is 58538
48188 DISTANS 4 13
71549 DISTANCE 4 19
44769 WASHER 1 44
13
7
15 14
CONSENT OF THE OWNER.
16
32
25
8 26
36
37
22
24
18 33
5 21
23 35
31
20 10 2
4 19 34
12 11
3
29
17
6 28
30
27
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
TREATMENT SS-ISO 2768
DESIGNED Illtek 020903 EH5
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Frame DRAWING NUMBER
A Partek Company
SP-52003
EH5 Frame
DRAWING SP-52003
PART NO DESCRIPTION QTY POS REMARKS
16997 FRAME 1 1
401278 GLIDE PLATE FRAME 2 3 Included in Glide plate assy See drawing SP-52004
47805 PLATE 1 10
38865 COVER 1 12
401281 SHIM 2 17
49853 SLEEV 2 26
401280 20´BUFFER 1 28
401276 BUFFER 1 36
17
19 25 16
15
18
2
10
11 9
13
20
12 3
24
15
14
10
22
21
23 1
6
5
7
8
4
6
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
TREATMENT SS-ISO 2768
DESIGNED Illtek 021002 EH5 ll
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Telescopic Beam DRAWING NUMBER
A Partek Company
SP-52004
EH5 Telescopic Beam
DRAWING SP-52004
PART NO DESCRIPTION QTY POS REMARKS
38861 GLIDE PLATE ASSY 2 0 Include pos. 4,5,6,7,8 and pos 3 on drawing SP-52003
24142 TELESCOPIC BEAM ASSY 1 1 Assy with 2 Beams and 1 Gable end
62595 FLIPPER ARM 1 2 Please note! Rubber buffer not included, see item 11
24168 FLIPPER ARM 1 3 Please note! Rubber buffer not included, see item 11
24167 FLIPPER ARM 1 9 Please note! Rubber buffer not included, see item 11
15
CONSENT OF THE OWNER.
2 3 38 53 54 55 231
47 10 13 12 16 17 59 19 58 40 41 23 65 37
4
34
57 49
35
33 32
56 42
43 7
24
45 61 18 14 51 14 25 28 22
11 39
44
31
62 60 20 28 29 30
46
8 9 74 63
27
26
36
71
68
72
67 73
52
64
69
69 70 66 65 70
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
TREATMENT SS-ISO 2768
DESIGNED Illtek 020926 EH5
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E DRAWING NUMBER
Hydraulic Assy End beam
A Partek Company
SP-52005
EH5 Hydraulic Assy
DRAWING SP-52005
PART NO DESCRIPTION QTY POS REMARKS
76196 HYDRAULIC MOTOR INCL.CHOCKVALV 300CC 3 9 SEE DRAWING SP-52009 FOR MORE DETAILS
71320 HYDRAULIC PUMP PVQ10 1 18 WHEN YOU ORDER SEAL KIT FOR THIS PUMP PLEASE STATE K4264
73096 VALVE DG4V-3-2C-MU-H7-60 4 23 WHEN YOU ORDER SEAL KIT PLEASE STATE PART NO K4222 AND SOLENOID 70422
401400 FLATBAR 1 65
401399 FLAP 1 66
8 6 5 2 7 18
26
25
1 7 4 5 7 3 9 10 13 15 16
12
11
23
22
19 20 14
24 17
21
28
27
30 29
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
TREATMENT SS-ISO 2768
DESIGNED Illtek 020910 EH5
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Telescopic Gearbox Assy DRAWING NUMBER
A Partek Company
SP-52006
EH5 Telescopic Gearbox Assy
DRAWING SP-52006
PART NO DESCRIPTION QTY POS REMARKS
53596 SHAFT 1 1
53603 DISTANCE 1 2
53604 DISTANCE 1 3
53605 DISTANCE 1 4
53595 COVER 1 8
53594 COVER 1 9
401287 PLATE 1 20
6
7
9
13
10
CONSENT OF THE OWNER.
3 4
S*
5
2
1
8
10
10
11 12
6
9
7
10 13
15
4
S*
5
2
1
8
10
10 12
11
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
TREATMENT SS-ISO 2768
DESIGNED Illtek 020926 EH5 ll
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Sensor Assy DRAWING NUMBER
A Partek Company
SP-52008
Single Sensor Assy Part no 38084 SP-52008
Pos Part no Description Qty Remarks
0 38084 SENSOR SINGEL ASSY 0 Include pos.2,3,4,5,6,7,8,9,10,11,12,13
2 400267 PLATE 1
2 400267 PLATE 2
9
19
16
3
17
1
13
15
20 12
21 7
5
10 6
22
8
2
19
18 11 6 4
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
TREATMENT SS-ISO 2768
DESIGNED Illtek 021029 EH5 ll
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Gearbox DRAWING NUMBER
A Partek Company
SP-52009
EH5 Flipper Gearbox Assy Part no 53275
DRAWING SP-52009
PART NO DESCRIPTION QTY POS REMARKS
60629 GEAR BOX ASSY TYPE 2 1 0 Include pos.1-8,11-12,15,17-20 ( Pos.3 Mirrow inverted)
56230 GEAR BOX ASSY TYPE 2 1 0 Include pos.1-8,11-12,15-18 ( Pos.3 Mirrow inverted)
2
CONSENT OF THE OWNER.
35
9 36 52
33 53
34 47
39
46
42
43
45 14
44
48
41
7 54
40
3 28
37 29
38 27
25 8
30
31
32
26
13
1 48
49
50 5
51
10 11 15 16
4
23 18 22 17 20 21 24 19
12
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
TREATMENT SS-ISO 2768
DESIGNED Illtek 020911 EH5
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Telescopic Drive DRAWING NUMBER
A Partek Company
SP-52012
EH5 Telescopic Drive
DRAWING SP-52012
PART NO DESCRIPTION QTY POS REMARKS
16441 TELESCOPIC DRIVE ATT. ASSY 1 2 See Telescopic assy Drawing SP-52006
1
A
A-A ( 1 : 2 )
9 6 2 4 3
7 10 5 8
A
THIS DRAWING IS COPYRIGHT AND IS THE PROPERTY OF BROMMA CONQUIP AB. THE DESIGN AN OR CONSTRUCTIONS CONTAINED THEREIN MAY NOT BE
COPIED OR REPRODUCED WITHOUT THE WRITTEN CONSENT OF THE OWNER.
C/C 430x150
1018972
ty ame Rev Type Title Title
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&RQQHFWRUVDQG7HUPLQDOV (OHFWULFDOFRPSRQHQW *ODQGQXW06NLQGLFKW
REV DESCRIPTION ECO-No. DATE BY
RUBBER COVER ADDED
a Value 2008-09-30 PON
AND MOUNTING PARTS
b matrix update Value 2008-10-13 PON
MOUNTING PARTS FOR
c Value 2009-02-04 PON
RUBBER COVER CHANGED
A
1
A-A
6
B
2
A
a c 3
B (2:1)
7 8 9 2
CABINET X100 A2 c
DRAWING NUMBER
A A
Cabinet X100
B B
Terminal fuses
C C
Marking 1,2,......7.
21 23 22 6 7 9
13
30
12
27
8 26
17 11
19
18 28
20
3
14
16
4
15
24
10 5
2 25
32 31 35 34 33 1 29
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
TREATMENT SS-ISO 2768
DESIGNED Illtek 031013 EH170 U
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Twinlift boxes DRAWING NUMBER
A Partek Company
SP-52014
17652 Twin Housing Assy
SP-DRAWING NO: 52014
SP-POS PART NO DESCRIPTION QTY REMARKS NOTE
12 402534 SPACER 2
14 29 28 23 24 26 2
CONSENT OF THE OWNER.
1
12
17 27 25
21 29
11
S*
13
20
15
30
6
19
25
26 18 8
24
23 10 16
22
5
31
S*
9 7
SIGN DATE GENERAL ASSY SERIAL No SPREADER TYPE SURFACE TOLERANCE GENERAL
TREATMENT SS-ISO 2768
DESIGNED Illtek 031027 EH170 U
PLOT DATE
SCALE REVISION
Exploded View
ARTICLE No
E
Retractable Twistlock Assembly DRAWING NUMBER
A Partek Company
SP-52015
62907 Twin Twistlock Assy Right
SP-DRAWING NO: 52015
SP-POS PART NO DESCRIPTION QTY REMARKS NOTE
BGS Accessories
8.15 LED signal lamps
Application
Bromma telescopic spreaders can be equipped with LED
signal lamps to inform the crane driver and other personnel if
the sprader has landed, (white or yellow), is unlocked (green)
or has locked (red) on a container. For twinlift spreaders a
fourth lamp is used to indicate twinboxes down (blue). For
mobile harbour crane spreaders the fourth lamp indicates
- Low power consumption tower in mid position (yellow).
Available models
LED Colors voltage Art. No. Rec. cable
Green, red, yellow 24 VDC 1001399
Technical specifications
Model 24VDC 110/230VAC
Dimensions
Light
aspects A (mm) B (mm)
1 160 130
2 305 275
3 450 420
4 595 565
Spare parts
SP-POS PART NO. DESCRIPTION QTY REMARKS
1 75102 Screw M6S 8x30 4 FZB 8.8
2 75328 Washer BRB 8,4x16x1,5 8 FZB HB2
3 75090 Nut M8 LOC-KING 4 FZB
4 see page 1
5 1001415 Attachment stright 2 per LED
6 1002903 Attachment tilted 300 2 per LED
70396 Cable 10m for 24VDC
Warnings
CAUTION: LED light units are sources of bright light. Do
not stare directly into the beam from close distances and
observe all the warnings and guidelines in the instruction
manual. Bromma LED indicator panels are classified as
Class 2M LED devices according to the standard
IEC60825-1:1993+A1:1997+A2:2001.
Item Quant Title Material / Article No. Dwg No. Art. No. Remarks
1 4 SCREW M6S 8x30 FZB 8.8 75102
2 8 WASHER BRB 8,4x16x1,5 FZB HB2 75328
3 4 NUT M8 LOC-KING FZB 75090
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
x +RZWRRUGHUVSDUHSDUWVDQGRUVHUYLFH
All ordering of Bromma spare parts must be done by the Bromma e-commerce
website. To order the requested spare parts some important information must be
available.
The serial no. of the spreader. See Data Sheet chapt. 3or the dataplate mounted on
main frame of the current spreader.
The requested Art no. and the quantity needed. See Spare part list.
Registered User
To be able to log in at the Bromma e-commerce site you must be a registered user.
To become a registered user you have to fill in the Application Form on the Bromma
website. After a few days you will receive an User ID and a password by e-mail.
When you are a regitered user fill in your User ID and password at the fields on the
Bromma e-commerce website (www.bromma.com) to log in. Then follow the
instructions on the screen.
Search Function
If you do not find the parts requested on the e-commerce site or if you have any other
problems finding valid part numbers you can use the search function on the website
or call your local Bromma dealer. The phone number is published on the website
at www.bromma.com
FOR SERVICE AND SPARE PARTS PLEASE CONTACT YOUR LOCAL
DEALER
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Page 1 of 1
0-1-may02rev.00 BrommaConquip
0 1 2 3 4 5 6 7 8 9
A A
BROMMA
MALAXGATAN 7
SE-164 2 KISTA
SWEDEN
Email: SALES@BROMMA.COM
Tel: +46 (0)8 620 09 00
B B
Customer : CABINET X1
Plant designation : A1
C C
Drawing Number : 1002177
Revision : l
E E
Created on the : 08/07/2010
The latest revition : 08/07/2010 By : chanka Number of pages : 24
Manufacturing site :
A NOTE: A
Wire for 380-400VAC
shall bee 2,5mm²
with black colour.
1 1
B 1 3 5 1 3 5 -F1 -P1 h B
2A 2 2
-QM8 I> I> I> -QM1 I> I> I>
2 4 6 2 4 6
1 3 5
-Q1
2 4 6
1 3 5
-K1
/5.01 1 3 5 1 3 5 1 3 5 1 3 5
2 4 6 -K8 -K9 -K2 -K3
/7.04 2 4 6 /7.05 2 4 6 /7.01 2 4 6 /7.02 2 4 6
C C
-XP23 PE 20 21 22 7 8 9 -X2 :1 :2 :3
D D
/4.00 / -Phase L1
/4.00 / -Phase L2
/4.00 / -Phase L3
E E
NOTE:
A Wire for 380-400VAC A
shall bee 2,5mm²
with black colour.
/3.01 / -Phase L2
/3.01 / -Phase L1
B 14 12 24 22 B
-KA1 -KA1
/5.07 /5.07
11 21
1 3 5
1 3 5
-K6
/7.03 2 4 6
-QM10 I> I> I>
2 4 6
L
C -EH1 C
1 3 5 1 3 5
N
-QM6 -QM7 1 3 5
I> I> I> I> I> I> -K10
/7.06 2 4 6
2 4 6 2 4 6
-XP23 1 2 3 4 5 6 10 11 12
D D
E E
A A
NOTE:
All 24vdc supply should be ring Connected
-X2 :107 :105 :108 :106
13
-Q1
/3.01 14
B B
1 3
-F2 -X2 :N
10A 2 4
:N -N.VAC / /10.00
.01
21 :L
-SS1 -L.VAC / /8.00
22
-X2 :L
GND
L N
C C
BN YL/GL BU
90-255VAC -G1 A1
---- -KA1
A2 A2
24VDC
-K1
A1
RD RD BK BK
-24VDC SCS² / /12.00
+ + - -
-24VDC / /6.00
D -0VDC / /7.00 D
11
-SS1
.01 12
NOTE:
-X1 Wire for 24VDC
:2 7 8
.01
shall bee 2,5mm²
:1 with blue colour.
-X1 :3 -K1 :+ :+ :+ :+ :+ :+ :+ :- :- :- :- :- :- :-
-XP21 1 2 3 4 5 6 7 8 9 10
14
11/4.07
E 1 2 /3.01 12 E
24
3 4 /3.01 21/4.07
22
5 6 /3.01
7 8
Spreader -KA1
. 24VDC . + 24VDC 0 VDC . .
stop Cabinet heater
O O O O O O O O
A I 1 I 2 I 3 I 4 I 5 I 6 I 7 I 8 A
PIN NO: 21
PIN NO: 44
+B1-XPX1 :44 :31 :41 :43 :42 :21 :3 :2 :11 :1
C C
-XP23 13 14 15 16 17 18 19
D D
E E
O O O O O O O O
A I 9 I 10 I 11 I 12 I 13 I 14 I 15 I 16 A
PIN NO: 21
PIN NO: 44
+B1-XPX1 :8 :26 :16 :6 :7 :35 :4 :5 :25 :15
C C
A1 A1 A1 A1 A1 A1
-K2 -K3 -K6 -K8 -K9 -K10
A2 A2 A2 A2 A2 A2
D D
/5.08 / -0VDC
-0VDC / /8.00
K2 K3 K6 K8 K9 K10
Not Not
Gravity point Gravity point Hydralic pump Retract Extend Hydraulic pump
connected connected
to left to right left/right gable telescope telescope twin
MACHINE TYPE: SHEET
- EH170U 7
This drawing is copyright, and is SERIAL NO.
Electrical cabinet X1 CANopen CONT.
- the property of BROMMA CONQUIP AB. - 8
F The design and/or constructions CHECKED BY: Circuit diagram TOTAL SH.
F
- 24
contained therein, may not be copied
or reproduced, whitout the written DRAWN BY: PLANT (=) : PLOTTED: DRAWING NO. REV.
- STOCKHOLM SWEDEN LAT A1 08/07/2010 14:33
consent of the owner.
DRAWING DATE: UNIT (+) : FILENAME: 1002177 l
ITEM SUBJECT OF CHANGE SIGN. DATE 06/29/2004 X1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
O O O O O O O O
A I 17 I 18 I 19 I 20 I 21 I 22 I 23 I 24 A
PIN NO: 9
PIN NO: 50
+B1-XPX1 :9 :10 :20 :30 :40 :50 :46 :47 :49 :48
B B
C C
-X2 :133
D D
1
-P2
2
E E
Twin legs down Not Not Not Container Not Not Not
signal connected connected connected counter connected connected connected
O O O O O O O O
A I 25 I 26 I 27 I 28 I 29 I 30 I 31 I 32 A
PIN NO: 43
PIN NO: 11
+B1-XPX3 :11 :21 :31 :41 :42 :43 :24 :35 :44 :45
/8.09 / -L.VAC
B B
C C
D D
E E
Locked Unlocked Spreader landed G.p. in centre G.p. at left G.p. at right H.I.S TTDS ok
signal signal signal signal signal signal signal (option) signal (option)
A A
B B
C C
D D
-B1
E I I I I I I I I
E
O 33 O 34 O 35 O 36 O 37 O 38 O 39 O 40
PIN NO: 1
PIN NO: 15
A A
B B
C C
/8.09 / -24VDC
D D
/10.08 / -N.VAC
+B1-XPX3 :36 :49 :48 :47 :46 :8 :7 :10 :9 :40 :50 :30 :20
-B1
E I I I I I I I I
E
O 41 O 42 O 43 O 44 O 45 O 46 O 47 O 48
PIN NO: 8
PIN NO: 36
PIN NO: 10
PIN NO: 40
PIN NO: 20
COMMON GROUP 11
A A
B B
-X2 :129 :130
C C
-XP22 2 3
/11.09 / -0VDC
D D
WH
WH;BN
BN;GN
GN
RED
-KEY1
BLUE
BLACK
GREEN
6 16 26 36
+B1-XPX2 :42 :43 :44 :45 :10 :9 :19 :29 :39 :49 :30 :40 :50 :20 :48 :6 :16 :26 :36
-B1
E E
SD
SC
ID0
ID1
ID3
ID4
ID5
VCC
GND
GND
GND
GND
+24V
+24V
B-Can L
B-Can H
Can-GND
Can-open L
Can-open H
A
Internal layout X1 cabinet EH170U A
B
B1 B
290mm
X1
/4.01 /4.03 /3.04 /3.07
/7.04 /7.01 /8.05
/7.03
740mm
30x90x115mm
-K6 -K8 -K2
-QM6 -QM7 -QM8 -P2
-QM1
D D
30x90x490mm
G1
-F1 2A /3.09 -EH1
/5.01 /4.05
/5.02 /5.07 /7.06
30x90x380mm
10A
Power supply -F2
/3.09
-KA1 -K10
-K1 -QM10
-P1 X2
E E
15mm 60x90x520mm
40mm
733mm
MACHINE TYPE: SHEET
- EH170U 13
This drawing is copyright, and is SERIAL NO.
Electrical cabinet X1 CANopen CONT.
- the property of BROMMA CONQUIP AB. - 14
F The design and/or constructions CHECKED BY: Cabinet layout TOTAL SH.
F
- 24
contained therein, may not be copied
or reproduced, whitout the written DRAWN BY: PLANT (=) : PLOTTED: DRAWING NO. REV.
- STOCKHOLM SWEDEN krpulha A1 08/07/2010 14:33
consent of the owner.
DRAWING DATE: UNIT (+) : FILENAME: 1002177 l
ITEM SUBJECT OF CHANGE SIGN. DATE 11/02/2001 X1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
A A
B 1 B
101-134
106 105 108
L1-L3
Even number on top
L
N
1-3
2-3
+ -
C C
D D
Blue
X1 X2 Link by Jumper.
Based on main elec. drawing
E (106-105) for Liebherr E
EEPROM-gland assembly
XP22 XP21 XP23
from the inside and out
(Female) (Female) (Female)
B B
Contact No.1
Contact No.1
Guide Pin
Guide Pin
C C
M25 Plug
D D
Use Locktite 243 when assamble the chassi plug in to the cabinet
A A
B B
C C
D D
PE-rail 12/3
Assembly the earth braid
between this two pin bults
200 mm
E E
A A
B B
CE-label
BROMMA
P.O Box 1133
SE- 164 22 KISTA
SWEDEN
Control Cabinet
Circuit
diagram no. 10XXXXX
Rated voltage A Hz IP
400-460 XX 50/60 55
Spreader no.
C Year of manufacturing
C
89/336/EEC
73/23/EEC
Art.No. 1002455
D D
E E
A A
CE-label
B B
BROMMA
P.O Box 1133
SE- 164 22 KISTA
SWEDEN
Control Cabinet
C C
Circuit
diagram no. 1002177
Rated voltage A Hz IP
400-460 30 50/60 55
Spreader no.
D D
Year of manufacturing
89/336/EEC
73/23/EEC
Art.No. 1002455
E E
A A
B B
C C
Q1
D D
SB1
SS1
E E
A A
SPREADER AUT.RETURN TEXT TEXT
STOP OFF ON
B B
C C
D D
E E
-B1 1 Digital output -XPX1:31 HL1 Unlocked left -B1 25 Digital output -XPX3:21 Locked signal
-B1 2 Digital output -XPX1:41 HL2 Locked left -B1 26 Digital output -XPX3:31 Unlocked signal
-B1 3 Digital output -XPX1:43 HL3 Landed left -B1 27 Digital output -XPX3:41 Spreader landed signal
-B1 4 Digital output -XPX1:42 HL4,8 Tower in centre left/right -B1 28 Digital output -XPX3:42 G.p. in centre signal
-B1 5 Digital output -XPX1:3 HL5 Unlocked right -B1 29 Digital output -XPX3:24 G.p. at left signal
-B1 6 Digital output -XPX1:2 HL6 Locked right -B1 30 Digital output -XPX3:35 G.p. at right signal
-B1 7 Digital output -XPX1:11 HL7 Landed right -B1 31 Digital output -XPX3:44 H.I.S signal
-B1 8 Digital output -XPX1:1 Not connected -B1 32 Digital output -XPX3:45 TTDS ok signal
-B1 9 Digital output -XPX1:26 K2 Gravity point to left -B1 33 Digital input -XPX3:5 Telescope retract CMD
-B1 10 Digital output -XPX1:16 K3 Gravity point to right -B1 34 Digital input -XPX3:4 Not connected
-B1 11 Digital output -XPX1:6 K6 Hydralic pump left/right gable -B1 35 Digital input -XPX3:3 Telescope expand CMD
-B1 12 Digital output -XPX1:7 K8 Retract telescope -B1 36 Digital input -XPX3:2 Flippers all up CMD
-B1 13 Digital output -XPX1:4 K9 Extend telescope -B1 37 Digital input -XPX3:6 Flipper waterside down CMD
-B1 14 Digital output -XPX1:5 K10 Hydraulic pump twin -B1 38 Digital input -XPX3:16 Flipper right down CMD
-B1 15 Digital output -XPX1:25 Not connected -B1 39 Digital input -XPX3:25 Flipper left down CMD
-B1 16 Digital output -XPX1:15 Not connected -B1 40 Digital input -XPX3:26 Flipper landside down CMD
-B1 17 Digital output -XPX1:10 Twin legs down signal -B1 41 Digital input -XPX3:49 Twl lock CMD
-B1 18 Digital output -XPX1:20 Not connected -B1 42 Digital input -XPX3:48 Twl unlock CMD
-B1 19 Digital output -XPX1:30 Not connected -B1 43 Digital input -XPX3:47 G.p. move to left CMD
-B1 20 Digital output -XPX1:40 Not connected -B1 44 Digital input -XPX3:46 G.p. move to right CMD
-B1 21 Digital output -XPX1:46 Container counter -B1 45 Digital input -XPX3:7 Twin legs up CMD
-B1 22 Digital output -XPX1:47 Not connected -B1 46 Digital input -XPX3:9 Twin legs down CMD
-B1 23 Digital output -XPX1:49 Not connected -B1 47 Digital input -XPX3:50 Spreader stop
-B1 24 Digital output -XPX1:48 Not connected -B1 48 Digital input -XPX3:20 G.p. auto return
-B1
X1 -B1 1 =A1+X1/9.00 700498 SCS I/O MARKING BROMMA BROMMA 700498 See document
X1 -B1 1 =A1+X1/9.00 39952 Attachment for SCS² in cabinet NPP/ Bromma 39952 39952 EH5-170-U
X1 -B1 1 =A1+X1/9.00 700020 SCS² SOFTWARE LICENS ENEA ENEA OSE SYSTEMS AB
X1 -B1 9 =A1+X1/9.00 1001750 OUTPUT MODULE 0-240VAC DELCON/AXIOM OEM-AUTOMATIC GLO5TR GLO5TR Sek:0-240VAC 3A
X1 -B1 80 =A1+X1/9.00 700080 SCS² DUMMY PIN AD-CONTACT AD-CONTAKT AB 0413-204-2005 0413-204-2005
X1 -B1 14 =A1+X1/9.00 78603 OUTPUT MODULE DC OPTO22 ELECTRONA-SIEVERT AB G40DC5 G4 ODC 5 24VDC 4A
X1 -B1 1 =A1+X1/9.00 700086 SCS² PLUG K2 AD-CONTACT AD-CONTAKT AB DRC 26-50-S08 DRC 26-50-S08
X1 -B1 1 =A1+X1/9.00 700087 SCS² PLUG K3 AD-CONTACT AD-CONTAKT AB DRC 26-50-S09 DRC 26-50-S09
X1 -B1 1 =A1+X1/9.00 38905 IDENTIFICATION KEY FOR SCS² CC-SYSTEM CC-SYSTEM SEE DRAWING 38905
X1 -B1 3 =A1+X1/9.00 1002003 SCS² CONNECTOR COVER BMAL BMAL 1002003 Rubber boot for deutsch connectors
X1 -B1 80 =A1+X1/9.00 700079 SCS² SOCKET PIN AD-CONTACT AD-CONTAKT AB 0462-201-2031 AU 0462-201-2031 AU
X1 -B1 1 =A1+X1/9.00 700085 SCS² PLUG K1 AD-CONTACT AD-CONTAKT AB DRC 26-50-S07 DRC 26-50-S07
X1 -B1 3 =A1+X1/9.00 78601 INPUT MODULE DC OPTO22 ELECTRONA-SIEVERT AB G4IDC5 G4 IDC 5 24 VDC
X1 -EH1 1 =A1+X1/4.07 1001690 HEATER CABINET STEGO OEM AUTOMATIC HG140 14001.0-01 30W 110-250V AC/DC
X1 -F1 1 =A1+X1/3.09 1001828 MCB 1-POL 2A SIEMENS SIEMENS 5SY6 102-7 C-CHARACTER
X1 -F2 1 =A1+X1/5.02 1001829 MCB 2-POL 10A SIEMENS SIEMENS 5SY6 210-7 C-CHARACTER
X1 -G1 1 =A1+X1/5.02 1001859 POWER SUPPLY 90-255VAC/ 24VDC PrimePower OEM-Automatic 0036515 0036515 30A / 0-400HZ
X1 -K1 1 =A1+X1/5.01 1001826 CONTACTOR SIEMENS SIEMENS 3RT13 25-1BB40 3RT13 25-1BB40 24VDC 22kW 4-pol SIZE 0
X1 -K2 1 =A1+X1/7.01 1001827 PHASEREVERSER SIEMENS SIEMENS 3RA13 25-8XB30-1BB4 3RA13 25-8XB30-1BB4 24VDC 7,5kW 17A
X1 -K6 1 =A1+X1/7.03 1000763 CONTACTOR SIEMENS SIEMENS 3RT1025-1BB40 32 667 91 24VDC 7.5KW 17A SIZE 0
X1 -K8 1 =A1+X1/7.04 1001827 PHASEREVERSER SIEMENS SIEMENS 3RA13 25-8XB30-1BB4 3RA13 25-8XB30-1BB4 24VDC 7,5kW 17A
X1 -K10 1 =A1+X1/7.06 1000763 CONTACTOR SIEMENS SIEMENS 3RT1025-1BB40 32 667 91 24VDC 7.5KW 17A SIZE 0
X1 -KA1 1 =A1+X1/5.07 78980 RELAY SOCKET 2-SWITCHING RELECO OEM-AUTOMATIC AB 40 165 54 S7M
X1 -KA1 1 =A1+X1/5.07 78986 AUXILIARY CONTACTOR RELECO OEM C7 A20 D24D C7 A20 D24D 24VDC 2-SWITCHING
X1 -KEY1 1 =A1+X1/12.03 38905 IDENTIFICATION KEY FOR SCS² CC-SYSTEM CC-SYSTEM SEE DRAWING 38905
X1 -P1 1 =A1+X1/3.09 70873 TIMECOUNTER 380 VAC BAUSER METRIC AB 632A.2 380VAC 24-0015-78
X1 -P2 1 =A1+X1/8.05 76140 PULSECOUNTER 190.07 24V DC BAUSER METRIC AB 632 A.2 24VDC 24-2032-25DC
X1 -Q1 1 =A1+X1/3.01 700869 LOCK HANDLE GREY 66X66mm BACO OEM 0174601 0174601
X1 -Q1 1 =A1+X1/3.01 700871 AUXILIARY BLOCK BACO OEM-AUTOMATIC AB 0172179 172179 NO+NC 400V 10A SIGNALCONTACT
X1 -Q1 1 =A1+X1/3.01 700868 MAIN CIRCUIT BREAKER BACO OEM 0172200 0172200 50A
X1 -QM1 1 =A1+X1/3.07 78993 THERMAL-MAGNETIC CIRCUIT BREAK SIEMENS SIEMENS 3RV10 21 - 4BA10 3RV1021-4BA10 7.5KW 14-20A
X1 -QM6 1 =A1+X1/4.01 79042 THERMAL-MAGNETIC CIRCUIT BREAK SIEMENS SIEMENS 3RV10 11-1GA10 3RV1011-1GA10 2.2kW 4.5-6.3 A
X1 -QM7 1 =A1+X1/4.03 79042 THERMAL-MAGNETIC CIRCUIT BREAK SIEMENS SIEMENS 3RV10 11-1GA10 3RV1011-1GA10 2.2kW 4.5-6.3 A
X1 -QM8 1 =A1+X1/3.04 79043 THERMAL-MAGNETIC CIRCUIT BREAK SIEMENS SIEMENS 3RV10 11-1HA10 3RV1011-1HA10 3,0kW 5,5-8A
X1 -QM10 1 =A1+X1/4.05 79043 THERMAL-MAGNETIC CIRCUIT BREAK SIEMENS SIEMENS 3RV10 11-1HA10 3RV1011-1HA10 3,0kW 5,5-8A
X1 -SB1 1 =A1+X1/11.08 1019818 FRAME BACO OEM LWG3 (Suitable with LIB5 - 1019819)
X1 -SB1 1 =A1+X1/11.08 1019811 AUXILIARY BLOCK BACO OEM-AUTOMATIC AB 230 E10 230E 10 switch body with 1NO block
X1 -SB1 1 =A1+X1/11.08 1019832 SWITCH HEAD BACO OEM L21KA03 L21KA03 Only operating head 2 pos, 45º
X1 -SB1 1 =A1+X1/11.08 1019819 WHITE SIGNPLATE (+GRAVERING) BACO OEM-IDEALGRAVYR AB LIB5 GRAVERING ENL BILAGA (Suitable with LWG3 - 1019818)
X1 -SS1 1 =A1+X1/5.01 1019819 WHITE SIGNPLATE (+GRAVERING) BACO OEM-IDEALGRAVYR AB LIB5 GRAVERING ENL BILAGA (Suitable with LWG3 - 1019818)
X1 -SS1 1 =A1+X1/5.01 1019818 FRAME BACO OEM LWG3 (Suitable with LIB5 - 1019819)
X1 -SS1 1 =A1+X1/5.01 1019809 AUXILIARY BLOCK BACO OEM-AUTOMATIC AB 333E 02 333E 02 switch boddy with 2NC block
X1 -SS1 1 =A1+X1/5.01 1019810 PUSH BUTTON BLACK BACO OEM-AUTOMATIC AB L22 EC03 L22 EC03 FOR SPREADER STOP Ø29mm
X1 -XP21 1 700854 SURFACE MOUNTED HOUSING HTS TYCO ELECTRONICS HIP-K.10/24.AG 2-1102647-5 SCREW LOCK
X1 -XP21 10 700862 CRIMP CONTACT FEMALE HTS TYCO ELECTRONICS 4-1105101-1 2,5mm2 AWG14
X1 -XP21 1 1002018 PROTECTION COVER HTS ABB ABB 5DLN296350-A 5DLN296350-A SIZE4
X1 -XP21 1 700858 INSERT FEMALE 10POLE HTS TYCO ELECTRONICS HE.10.BU.C 2-1103637-3 CRIMP
X1 -XP22 1 1001921 SURFACE MOUNTED HOUSING HTS TYCO ELECTRONICS HIP.3/4.AG 1-1102603-5 SCREW LOCK
X1 -XP22 2 1001926 CRIMP CONTACT FEMALE HTS TYCO ELECTRONICS 1-1105051-1 0,14-0,37mm²
X1 -XP22 1 1001923 INSERT FEMALE 7+POLE HTS TYCO ELECTRONICS HN.D.7.Bu.C 2-1103103-3 CRIMP
X1 -XP22 1 1002520 PROTECTION COVER HTS ABB ABB 5DLN296350-C 5DLN296350-C SIZE1
X1 -XP23 1 700854 SURFACE MOUNTED HOUSING HTS TYCO ELECTRONICS HIP-K.10/24.AG 2-1102647-5 SCREW LOCK
X1 -XP23 1 1002018 PROTECTION COVER HTS ABB ABB 5DLN296350-A 5DLN296350-A SIZE4
X1 -XP23 1 700856 INSERT FEMALE 42POLE HTS TYCO ELECTRONICS HN.2D.42.BU.C 2-1103206-3 CRIMP
X1 -XP23 24 1001927 CRIMP CONTACT FEMALE HTS TYCO ELECTRONICS 4-1105051-1 1,5mm²
X1 :1 1 =A1+X1/5.02 79367 FUSE ATTACHMENT WAGO HELLERMANN TYTON AB 282-696 282-696 Blade fuse terminal
X1 :1 1 =A1+X1/5.02 79371 FUSE 30A LITTELFUSE ELFA AB 33-051-82 Blade fuse 30A
SCS²
1 REV 3
Index
Node Hardware ............................................................................................................... 4
DIGITAL I/O ................................................................................................................................................ 4
General............................................................................................................................ 4
The X2 connector............................................................................................................ 5
Node ID....................................................................................................................... 5
Main Supply................................................................................................................ 6
CAN ............................................................................................................................ 6
The X1 and X3 connectors (I/O-connectors).................................................................. 7
I/O Groups .................................................................................................................. 7
Common junction........................................................................................................ 8
Internal jumper bars .................................................................................................... 8
Connecting a switch.................................................................................................... 9
Connecting a valve...................................................................................................... 9
I/O Modules .............................................................................................................. 10
APPLICATION .......................................................................................................................................... 10
ABE (Application Builder Environment) ................................................................................... 10
System view .............................................................................................................. 10
Pin configuration....................................................................................................... 11
Component view ....................................................................................................... 11
Load view.................................................................................................................. 14
ANYBUS ..................................................................................................................................................... 15
General.......................................................................................................................... 15
Connecting the B1 node............................................................................................ 15
Connecting the A1 node............................................................................................ 16
The Anybus card (in this case for Profibus) ............................................................. 16
APPLICATION WITH A ANYBUS INTERFACE ................................................................................ 18
ABE............................................................................................................................... 18
ANYBUS GATEWAY................................................................................................................................ 20
General.......................................................................................................................... 20
BCAN - Status LEDs ................................................................................................ 21
Power connector........................................................................................................ 21
BCAN connector....................................................................................................... 21
Node address key switches ....................................................................................... 21
Serial port connector ................................................................................................. 21
APS .............................................................................................................................................................. 22
Absolute encoder on the telescope................................................................................ 22
General...................................................................................................................... 22
The RS485 component.............................................................................................. 22
From bits to millimetres (scale) ................................................................................ 23
2 REV 3
Teach......................................................................................................................... 23
EXTERNAL EE-PROM ............................................................................................................................ 24
General...................................................................................................................... 24
Hardware................................................................................................................... 24
Software .................................................................................................................... 25
Activate the EE-prom ............................................................................................... 26
3 REV 3
Node Hardware
Below is a picture of a SCS2 node.
Digital I/O
General
Here follows an example of how to build up a Can bus system with two nodes one with
one input and the other with one output.
Switch
Input
Slave (A1)
B1 Master
Output
Valve
4 REV 3
The X2 connector
The three connectors X1,X2&X3 have different connection keys to avoid the possibility
of connecting them in the wrong place. It is important to choose the correct one.This is
easy to check, on the connecting side of the connector just below the mounting screw
there is a number 7, 8 or 9.
connection
The X2 key
should be
marked “8”
Node ID
All nodes in a system must have a unique identity. This is read from the Id pins
9,19,29,39,49 on the X2 connector, where pins being connected to the ground pin (10)
correspond to ”zeroes” and pins left unconnected are correspond to ”ones”. A master
node (B1) has pins 10,9,19,29,49 connected together. (Commonly used as a spreader
Node)
A slave node on the crane A1 has pins 10,19,29,39,49 connected together.
Start with making “ID” jumpers.
5 REV 3
Main Supply
24Volt AC or DC powers the node internally. The signals are doubled in the connector
due to the current limit of single pins. DC voltage can be applied in either direction. The
potential is measured between the A section and the B section.
Name Pin number in
connector
24INA X2/42 Potential 1
24INA X2/43
24INB X2/45 Potential 2
24INB X2/44
CAN
The CAN net connection is placed in the X2 connector.
All nodes in the system have to be connected equal (bus topology) to CAN High and
CAN Low to be able to establish communication.
Name Pin number in
connector
CAN High X2/30
CAN Low X2/40
Here is a schematic with the X2 connectors of two nodes, one A1 and one B1 with node id,
CAN bus and power supply connected.
+
24V Supply
-
Low
CAN Bus High
ID
9 10 19 29 30 40 42 43 44 45 49 10 19 29 30 39 40 42 43 44 45 49
B1 X2 A1 X2
Pin no.
CAN-bus
24V SUPPLY
6 REV 3
The X1 and X3 connectors (I/O-connectors)
Just like the X2 connector the X1 and X3 connectors are keyed to avoid connecting them
in the wrong place. The X1 can be identified by the number “7” on the front of the
connector, and the X3 connector by the number “9”.
connection
key
I/O Groups
There are 48 digital I/O on a node. Each I/O can be configured as either an input or an
output via the software. The I/O 1 to 44 are joined in groups of 4 resulting in 11 groups.
I/O 45 to 48 are single I/O’s. Each group has a “Common” junction. This makes it
possible to have different voltages in each group.
7 REV 3
Common junction
This point is to be connected to live or neutral depending on if the group is used for
inputs or outputs, Inputs need neutral and outputs need live as showed below. Inputs can
be viewed upon as relay coils and outputs as switching contacts.
SC S SC S
9 10 11 12 9 10
SC S 11 12
8 26 16 6 7 8 26 16 6 7
I/O M oduls
In the picture is one I/O group used as inputs on the left, and on the right the same group
is used as outputs.
8 REV 3
Connecting a switch
Here is one example of how to use the internal jumpers while connecting the switch into A1.
One of the jumper groups is fed with live and supplies the switch, the other jumper group is
connected to neutral and supplies the I/O group.
L/24V Supply
Internal jumper groups
N/0V Supply
Switch
Cablage
6 7 8 12 13 1 4 16 17 18 19 22 23 24 26 27 X1 Connector
11 12
One Input group
10 9
SCS Internal
Connecting a valve
Here is one example of how to use the internal jumpers while connecting the valve into B1.
One of the jumper groups is connected to Neutral and supplies the valves secondary side, the
other jumper group is connected to live and supplies the I/O group.
L/24V Supply
Internal jumper groups
N/0V Supply
Valve
Cablage
6 7 8 12 13 1 4 16 17 18 19 22 23 24 26 27 X1 Connector
9 REV 3
I/O Modules
To be able to adapt the I/Os to the system voltage each I/O channel have a solid-state
interface relay (OPTO 22). This makes it possible to choose input or output and a voltage
range of 12-230 VAC/DC. Each module has a led indicating active state. On the output
modules there is a 3 Amp fuse. These modules are located inside the SCS² cover. The
cover has a lens for each channel, so the I/O status can be seen from the outside.
LED
FUSE
Application
ABE (Application Builder Environment)
System view
When ABE is started a new application is automatically started, and the default view is
the system view. The system view enables the user to select a node configuration in the
software, the application compares the hardware with the software configurations and
these have to be equal to work. You may also set system properties in this view. Some
properties will be updated automatically when a project is saved.
System properties
Menu tabs
10 REV 3
Pin configuration
Next menu tab is “pin configuration”, all present nodes are visible as tabs in this view. (1)
Make sure tab A1 is activated in the view. Give Port id# 9 the following name ”switch”.
(2) Comment field is optional. (3)
Activate tab B1 in the view (1) and do the same for Port id# 9 with following name
”VALVE”. (2)
Note: The red color of the fields indicates that the ports are not yet connected or that any
of the letters are unaccepted. Space between words is not accepted instead use “_”.
A red field makes it impossible to compile the application.
Component view
Next menu tab is the “component view”
The component view is where components are deployed and connected. A palette
displaying all components is available in the view.
The palette can be made visible
by pressing “components” if it is
not already visible.
Available
component
pallet
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Select the OD timer (On Delay timer) component from the available component pallet
(1). It’s located in the Digital tab (2).
Place the component on Page 1 in the view with the left mouse button. Then press the
right button to get the arrow back.
Do the same thing on the right red dot and choose the output in this case “VALVE”
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Put the arrow on the component and right click, and select “properties”.
Put the delay time to two seconds (in mille seconds). The instance name is an internal
component address and should not be changed. When ready press “OK”.
Instance name
Delay time
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Load view
The last view is the “Load view”. From this view it is possible to download and up load
applications to and from a connected SCS² system. Press the “Download” button and a
dialogue box will appear, choose the desired “spr” file and press the “Open” button.
Download
Choose file
and press
open
Then the system distributes the file over the CAN-bus to the rest of the nodes (if
necessary).
When the download is ready
this dialogue box appears.
Current transfer
completed (%)
Total transfer
completed (%)
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Anybus
General
Here follows an example of how to build up the same system as before with two nodes,
but the B1 node has one output and one input and on the A1 node is the input replaced
with an Anybus
interface
Outside net
Slave (A1)
with anybus
SCS2
CAN network (BCAN)
B1 Master
Input Output
Switch Valve
44 31 41 43 42 8 26 16 6 7
I/O M oduls
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Connecting the A1 node
Connect power supply, can bus and an ID jumper as A1 in the X2 connector.
An “Anybus card” is also to be mounted and connected inside the hood where the digital
I/Os are located.
There is a D-sub connector on the card for connecting to outside net (1), and a selector
for termination resistance (2) and two selectors used for setting hard ware identification
of the unit in the outside net (3).
Item 3. HW address
1 2 3
1 2 *10 *1
4 3
The four LEDs are used for showing the state of the communication from the
Anybus-card and the outside net.
1:not used
2:(green) on-line on the Fieldbus
3:(red) off-line on the Fieldbus
4:(red) indicate faults on the Fieldbus side as follows:
Flashing 1hz-Error in configuration: IN and/or OUT length set during initialization
of the module is not equal to the length set during configuration of the network.
Flashing 2hz-Error in user parameter data: the length/contents of the user parameter
data set during initialization of the module is not equal to the length/contents set
during configuration of the network.
Flashing 4hz-Error in initialisation of the Profibus communication ASIC.
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The Anybus card
is to be mounted
inside the hood on
the right upper
corner of the node
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Application with a Anybus interface
ABE
Open the application used in the digital chapter. Get in to the ”pin configuration” view
and remove the switch from A1, add a new “switch” to B1 in Port id# 1
Then get in to the “component view” and set the cursor on the OD timers input connector
(on the left) and press Disconnect, the connection point turns red if a connection is
acquired for the component to function.
Connect the switch to the “split”, the “input bit” and the “split” to the “or” and the “or” to
the “OD timer”. Yore connection should now be as below.
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Right click on in/output bits and choose properties. In the properties menu it is possible to
configure following.
“Note” is a free text field. Use this field for notes about the Anybus port.
“Bit number” is the bit number of the chosen byte in Anybus interface. (0-7)
“Byte number” is the start byte in the Anybus interface. (0-63)
“Node” is where the any bus card is located (in this case A1)
Note: The size of the data areas is decided of the highest byte in the application, in both
directions separately. The two sizes have to be equal on both sides of the Anybus card
(outside master/any bus) to be able to establish contact. If the outside areas is bigger than
in the application is it possible to put an empty byte to make the areas match.
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Anybus gateway
General
Compared to a conventional SCS² node the Anybus gateway does not have any digital or
analogue I/O’s, no internal battery backing up the event log (locally
The anybus gateway is used in cases where a physical I/O is not needed; one example is
when the SCS² system is connected as a slave unit (via a anybus card in the crane node)
on the crane PLC.
Status LEDs
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BCAN - Status LEDs
There are three green LEDs for Power, BCAN and Anybus indicating operating status
and one red LED indicating error status.
Power LED is lit when power is applied and system starts to execute.
BCAN LED is lit when the BCAN communication interface is operating normally and
flashing when the communication interface is not working as intended.
Anybus LED is flashing when the Anybus interface is not configured and lit when
configured and operating normally. (Between the node and the anybus card)
Error LED is unlit when system is running normally and lit when an error has occurred.
Power connector
The power connector is a Phoenix Contact 2- NAME DESCRIPTION PIN NUMBER
pin header (MC1,5/2-G-3,81).
VCC 10 to 28 V DC 1
24Volt DC powers the node internally.
GND Ground 2
BCAN connector
The BCAN connector is a Phoenix Contact 3-
NAME DESCRIPTION PIN NUMBER
pin header (MC1,5/3-G-3,81). All nodes in
the system have to be connected equal (bus CAN H CAN high 1
topology) to CAN High and CAN Low to be CAN L CAN low 2
able to establish communication.
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APS
Absolute encoder on the telescope
General
The absolute encoder should be connected to the RS485 port. (Channel A at X2/38 and
channel B at X2/37) In the ABE component pallet under the “analogue” tab, the RS485
port component is located. It is also possible to rescale the information from the sensor to
be able to work or monitor the actual measurements (in for instance mm), the tool for this
is the “scale” component. The “scale” component is also located under the “analogue”
tab.
Teach is used Add the RS485 port component
for storing from the analogue tab
positions
The scale component
makes it possible to
translate the sensor
value to the
mechanical distance
When using the SSI protocol some more information is needed. (See sensor/manufacture
for data)
Code type: determines how the sensor value (bit pattern) shall be read when converting
to a decimal value (made internally in the component). Gray or Binary.
Input resolution: how many steps (bits) per revolution.
Max revolutions: how many revolutions that are supported by the sensor.
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From bits to millimetres (scale)
Retract the spreader to the mechanical end stop, measure the distance between the single
twistlocks, note the value down, read the sensor value with the ABE online and make a
note of this. Expand the spreader to the mechanical end stop and repeat the same
procedure.
Note: It is very important that the sensor doesn’t wraparound (when counting up, after
the highest value it starts at zero again), the retracted value should be low and the
expanded value should be larger.
Then verify the scale, put the spreader in some different positions measure and compare
with the scaled value.
Teach
To be able to store positions the APS component is equipped with a storing function
called “TEACH”. By giving the teach command and expand or retract command it is
possible to move the spreader in a lesser speed (defied by the parameter “PWM value for
teach” in APS properties) to the required length, for position “20ft”, hold the teach
command and give the go to position “20ft” command. The value is now stored in the
spreader memory (NV RAM). Repeat this procedure on all the required positions.
The connection point for teach
Note: If the scale is made correctly it is possible to verify the spreader length by
activating the teach command, when the teach function is active the sensor value input on
the APS is displayed on the B1 display. Beware of if a "position direct command" is
given at the same time that position is destroyed.
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External EE-prom
General
In the external EE-prom it is possible to store information as spreader ID, twistlock
counters, running time etc. this makes it possible to replace the node(s) in the system
without loosing this information.
Hardware
The EE-prom is to be connected in to the node as following.
Name Pin number in Cable
connector
10V supply X2/36 Red
Serial data X2/16 Blue
Serial clock X2/26 Green
Signal ground X2/6 Black
The EE-prom is located in a gland. The gland should be mounted solid near by the SCS²
node within the cable range.
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Software
A “spreader properties” component needs to be added in the application, that make the
system try to find the “EE-prom” at boot.
The “spreader properties” component (1) is located in the “misc…” tab (2) in the
“available component” menu.
4
3
2 1
The “spreader properties” contains twistlock counters and a time counter etc. To make
the counters work some info is needed, connect the available signals corresponding to the
connection points on the left of the component (3).
The information is possible to send out as analogue words true the bus to the outside net
(if present), the connection points for these values is located on the right of the
component (4).
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Activate the EE-prom
The EE-prom is activated after the “Serial number” value is set.
The BMS have to be connected to the node that the EE-prom is connected to.
Left click on the “Serial number” key in the BMS “spreader info” tab.
In the “current key” dialogue box down in the left corner there should now be seen “serial
number”.
Put the spreader serial number in the value bar and press the “set” button to store and
activate the EE-prom. It now displays the different values.
The information from the EE-prom is possible to upload with the BMS from the
“spreader info” tag. Connect the BMS to the system and press the “get all” button.
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User Manual
Version 1.0
Table of contents
1 INTRODUCTION .............................................................................................................5
2 INSTALLING ABE...........................................................................................................5
2.1 HW requirements .................................................................................................................................................... 5
2.3 Disclaimer................................................................................................................................................................. 5
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7 LOAD VIEW...................................................................................................................16
7.1 General ................................................................................................................................................................... 16
8 COMPONENTS .............................................................................................................17
8.1 Controllers.............................................................................................................................................................. 17
8.1.1 TLC4 – Twistlock Controller 4 ....................................................................................................................... 17
8.1.2 TLC8 – Twistlock Controller 8 ....................................................................................................................... 20
8.1.3 FAC – Flipper Arm Controller ........................................................................................................................ 24
8.1.4 DPS – Discrete Positioning System................................................................................................................. 26
8.1.5 Tower – Head block ........................................................................................................................................ 29
8.1.6 APS – Automatic Positioning System ............................................................................................................. 32
8.1.7 MPS – Memory position system...................................................................................................................... 36
8.1.8 Twin Telescope................................................................................................................................................ 40
8.1.9 TwinUpDown .................................................................................................................................................. 42
8.1.10 PID................................................................................................................................................................... 46
8.1.11 AutoTuner........................................................................................................................................................ 50
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8.8 Analogue................................................................................................................................................................. 78
8.8.1 RS485 port....................................................................................................................................................... 78
8.8.2 IN0 > IN1 ........................................................................................................................................................ 78
8.8.3 IN0 * IN1......................................................................................................................................................... 79
8.8.4 IN0 / IN1.......................................................................................................................................................... 79
8.8.5 IN0 – IN1......................................................................................................................................................... 79
8.8.6 IN0 + IN1 ........................................................................................................................................................ 80
8.8.7 Scale ................................................................................................................................................................ 80
8.8.8 AnalogueLatch ................................................................................................................................................ 81
8.8.9 Filter ................................................................................................................................................................ 81
8.8.10 AuxAnalogue................................................................................................................................................... 82
9 TUTORIAL.....................................................................................................................83
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1 Introduction
ABE – Application Builder Environment has been developed to create and manage spreader programs specifically for the
Bromma Conquip SCS2 system used on Spreaders. This tool gives the programmer/user the possibility of configuring and
programming the logic of the SCS2 via a graphical interface.
In principal ABE generates a binary file describing the interconnection between the graphical objects the user has tied
together. This file, when downloaded onto the target system, connects the precompiled objects within the target system
together according to the functionality described by the user. Hence all logical objects, components, reside within the
target system and the program file generated by ABE determines their interconnection.
The objects, from no on referred to as components, within ABE contain a varying amount of logic ranging from basic
Boolean instruction sets to Spreader specific blocks of functionality which can be altered in behaviour via parameter
settings. The components containing specified Spreader functions are developed to ensure that years of Spreader
experience is re-used and also contain the interlocking for generating fault and event messages to the onboard NVRAM
(log).
This programming tool is intended for use by staff with adequate knowledge of both the system and the functionality of
the Spreader/Crane in which it shall be used only. Any alterations or new programs causing failure in functionality due to
logical faults in the program are the responsibility of the person/company carrying out this work.
2 Installing ABE
2.1 HW requirements
The minimum requirements to run this application on your PC are:
x an Intel compatible PC running Windows 95 / 98 / NT 4.0 / 2000.
x at least one serial communication port available (COM1 or COM2).
x at least 2Mb of free disk space.
2.2 Installation
x Close any other applications running under windows.
x Insert the CD into your station.
x Run the file Setup.exe.
x Follow the instructions on the screen.
2.3 Disclaimer
Copyright Bromma Conquip AB. All rights reserved.
Products and company names mentioned herein may be trademarks or trade names of their respective owners.
Bromma Conquip AB operates on a policy of continuous improvement. Therefore we reserve the right to make changes
and improvements to any of the products described in this manual without prior notice.
Bromma Conquip AB is not responsible for any loss of data, income or any consequential damage howsoever caused.
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3 User interface
ABE-application is divided into four main functions.
This chapter describes the four main functions of the program.
Remark:
Allowed characters when giving names to Item identifiers, Comments, Components and Tags are:
[a, b, c..., z], [A, B, C..., Z], [0, 1, 2,..., 9] and “_” (underscore). No other characters must be used.
3.4.1 File
Two types of files are available.
Type *.spr is a compiled file ready to download onto the SCS2.
Type *.spi is an intermediate file. Use Save or Save As... if you are not able to generate downloadable program file but
want to continue your work later on. The file extension will then be *.spi.
3.4.1.1 New
Creates a new program file for editing.
3.4.1.2 Open
Opens a program file for editing/viewing.
3.4.1.4 Save
Saves the current project. The file extension will be *.spi.
3.4.1.5 Compile
Generates and prompts you to save a downloadable program file used in the SCS2. The file extension will be *.spr.
3.4.1.6 Print
Prints the Component view.
3.4.1.7 Exit
Exits the application.
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3.4.2 Edit
3.4.2.1 Cut
Selected components will be cut and saved to the clipboard.
3.4.2.2 Copy
Selected components will be copied to the clipboard.
3.4.2.3 Paste
Content of clipboard will be pasted into selected page in the Component view. If connections match existing ports theses
will also be pasted into the page.
3.4.2.4 Find
Finds a text string in component comments, component identifiers or an actual component.
3.4.3 Settings
3.4.4 Tools
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3.4.5 Help
3.4.5.1 About
Short information about ABE such as version, current number of components etc.
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4 System view
4.1 General
The system view provides a way of enabling and disabling (connecting/disconnecting) nodes and setting system
properties such as version number, author, comments and date of modification. The nodes are named A1-A4 for the nodes
intended to be fitted to the crane and B1-B8 for the nodes intended to be fitted to the Spreader. Each node name
corresponds to a unique address key setting.
The system view allows the user to set up the node configuration by checking the desired nodes. A fixed set of
checkboxes are available that represent the used nodes in the system. The enabled nodes then have to be present in that
system. An exception is if the “EXISTS” function is used. This function can then replace a node on the bus with an input
on the master node.
The B1-node is selected by default, since every system has to contain exactly one Master node, B1. Four crane nodes and
seven spreader nodes are available for selection.
Checkboxes for enabling Twistlock redundancy as well as “Spreader stop” have to be checked here as well if these
functions are used.
4.2 Functionality
The system view enables the user to select a node configuration. By filling in the checkboxes you determine the lay-out
(topology) of the system. You also determine on which nodes (B1 & B2) you are to have the twistlock redundancy and
Spreader stop enabled. Each node configuration gives the respective node a unique ID represented by the address key.
You may also set system properties in this view. Some properties will be updated automatically when a project is saved.
The properties are:
4.2.1 Author
This is the author of the spreader program. Contains text of max 80 characters.
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4.2.8 Customer
This property is to contain the name of the customer who will use the Spreader program. Contains text of max 80
characters.
4.2.9 Comments
This is a text field intended for general comments regarding the Spreader program. Contains text of max 80 characters.
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5.1 General
The pin configuration view is presented as a tabular view of the system, where each tab represents a node. An I/O list
corresponding tags will be available for all enabled nodes in the system. The top tabs indicate which node is displayed.
A tag is composed of its Item identifier and its Comment. The used I/O not yet connected is marked red.
The Port id# field contains a port id, the numerical ID of the I/O number of the SCS2. The Connection field is either IN,
OUT or NC (Not connected) and if it’s a digital, analogue, PWM or Encoder signals. These fields cannot be edited.
Remark:
Allowed characters when giving names to Item identifiers, Comments, Components and Tags are:
[a, b, c..., z], [A, B, C..., Z], [0, 1, 2,..., 9] and “_” (underscore). No other characters must be used.
5.2 Functionality
This view allows you to change the tag for all port numbers on all nodes in the system. Within this view you give each
individual I/O its’ nick name, Item Identifier, to make the program more comprehensible, you also assign any comments
to the I/O. The connection type (IN/OUT) will be updated automatically as the Spreader program is altered in the
component view; i.e. the direction of the I/O point is decided when the I/O is connected. Note that ABE will only permit
I/O configuration that is supported by the current SCS2 HW, hence the digital I/O direction can only differ outside of
groups of four apart from the last four I/O points in the list (45-48) which can configured individually.
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6 Component view
6.1 General
The component view is where components are deployed and connected. A palette displaying all components is available
in the view. To add a component, select the component from the Palette and place it on your work space with the mouse.
Remark:
Allowed characters when giving names to Item identifiers, Comments, Components and Tags are:
[a, b, c..., z], [A, B, C..., Z], [0, 1, 2,..., 9] and “_” (underscore). No other characters must be used.
Components may be dragged within a page to change the layout. Each page can be resized vertically.
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Select COM1 or COM2 under selection depending on what serial port is connected to the SCS2.
Automatic update will be performed at an interval specified by Update interval, if Auto is checked
The online monitoring starts by telling the SCS2 to add all visible components and their connections. This takes more or
less time depending on the number of present components and connections in visible Page(s). A progress bar appears
above the buttons, when adding the components, to show you current status.
Stop online monitoring by pressing the Stop online monitoring button (same button as Start online monitoring button).
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7 Load view
7.1 General
The load view provides functionality to download and upload Spreader programs. The connection to the system is
selected in the connection box; the possible choices are, Com1 and Com2. Current status of the transfer is displayed in the
three progress bars.
7.2 Functionality
When the download button is pressed the user is prompted to point out the file to download to the system. It has to be a
compiled downloadable program file (*.spr-file). The current status of a download process from the PC to the system is
shown in the top progress bar. The distribution transfer between nodes is shown in the two progress bars at the bottom of
the page. The upload button allows the user to retrieve a program file from a connected system and save it to a file.
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8 Components
Terminology:
In this section the follow terms are used:
False = 0 = logical low level
True = 1 = logical high level
8.1 Controllers
States:
DISABLED:
When enable goes false or Spreader Stop is activated this state is reached.
All outputs are set false.
STARTUP:
This state is reached every time the system is starting up or when DISABLED state is left.
A decision is made if lock or unlock sequence should be initiated (i.e. a transition to those states).
LOCK_ALL:
Lock all Twistlocks.
UNLOCK_ALL:
Unlock all Twistlocks.
IDLE:
When a lock or unlock command has resulted in a complete sequence this state is reached. Lock/unlock outputs are not
changed from previous state.
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LOCK_ALL
[ SpreaderStop = 0, Enable = 1 ]
[ All unlocked ]
[ All unlocked ]
DISABLED
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8.1.1.4 Parameters
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“Unlock after landed” = when an unlock command is given after landed on all corners (and delay has elapsed if any)
“Lock after landed” = when a lock command is given after landed on all corners (and delay has elapsed if any)
States:
DISABLED:
When enable goes false or Spreader Stop is activated this state is reached.
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STARTUP:
This state is reached every time the system is starting up or when DISABLED state is left.
A decision is made if lock or unlock sequence should be initiated (i.e. a transition to those states).
LOCK_ALL:
Lock single and twin Twistlocks.
LOCK_SINGLE:
Lock single Twistlocks.
UNLOCK_ALL:
Unlock single and twin Twistlocks.
UNLOCK_SINGLE:
Unlock single Twistlocks.
IDLE:
When a lock or unlock command has resulted in a complete sequence this state is reached. Lock/unlock outputs are not
changed from previous state.
[ T in is do n ]
[ T in is up ]
[ All locked ]
[ All locked ]
enable = 1
[ All unlocked ]
DISABLED [ All unlocked ]
[ T in is do n ]
T in is up
UNLOCK_SIN LE
UNLOCK_ALL
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8.1.2.4 Parameters
This component generates the following messages stored in the fault and event log onboard the SCS2. The message log
can be turned on/off in the parameter settings view via the check box Enable logging.
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States:
DISABLED:
When enable goes false or Spreader Stop is activated this state is reached.
All outputs are set false.
STARTUP:
This state is reached every time the system is starting up or when DISABLED state is left.
A decision is made if lock or unlock sequence should be initiated (i.e. a transition to those states).
IDLE:
This state is reached emedeately after UP or DOWN states have been reached.
UP:
All Flippers are sent up.
DOWN:
All Flippers are sent down.
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[ UpCom m and ]
START_UP IDLE
[ Do nCom m and ]
DISABLED DO N
8.1.3.4 Parameters
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States:
DISABLED:
When enable goes false or Spreader Stop is activated this state is reached.
All outputs are set false.
STARTUP:
Unconditional transition is made to IDLE state.
IDLE:
Waiting for command input.
EXPAND:
Expanding to next stop. Next stop is either next closest stop or a stop decided according to which Return to position X
command is given. A transition is made to IDLE state when next stop is reached.
RETRACT:
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Retracting to next stop. Next stop is either next closest stop or a stop decided according to which Return to position X
command is given. A transition is made to IDLE state when next stop is reached.
CONSTANT REPEAT:
When stopped at a position a new constant command is required to go to another position. Depressed keys or similar must
be released before a new command will be excepted.
Example:
1. Expand command is given.
2. Next stop is reached.
3. The telescope stops.
4. Expand command is released.
5. New expand command is given.
6. The telescope continues.
DELAY:
A delay is made for a time defined by Stop delay time (parameter). This delay is only performed if Delay is set in
Operation mode (parameter) else ignored.
“currentCommand” = is always EXPAND or RETRACT. The command inputs Retract / Expand command or Return to
position X. These command inputs are internally converted to EXPAND or RETRACT depending on current position
and desired position.
[ desiredStop = currentStop,
Operation m ode = Cons tant repeat ]
RETRACT
[ desiredStop = currentStop,
Operation m ode = Delay ]
START_UP DISABLED
[ SpreaderStop = 0,
Enable = 1 ]
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States:
DISABLED:
When enable goes false or Spreader Stop is activated this state is reached.
All outputs are set false.
STARTUP:
Unconditional transition is made to IDLE state.
IDLE:
Waiting for command input.
FEED_LEFT:
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FEED_RIGHT:
Feeds the Tower to the right.
CENTER:
Centres the tower. The Tower is centred when both At left sensor and At right sensor is true.
DELAY:
A delay is performed for a time defined by Direction change time (parameter).
or all s tates
rans ition is m ade to DIS D s tate i
SpreaderStop = or na le =
D_ D_ I
[ eed ri t]
[ eed le t ]
S _ ID
[ SpreaderStop = , na le = ]
[ Center ]
[ Delay per orm ed ]
DIS D
C N D
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8.1.5.4 Parameters
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States:
DISABLED:
When enable goes false or Spreader Stop is activated this state is reached.
All outputs are set false.
STARTUP:
Unconditional transition is made to IDLE state.
IDLE:
Waiting for command input.
Expand command or Go position command (depending on current position) makes a transition to EXPAND state.
Retract command or Go position command (depending on current position) makes a transition to RETRACT state.
EXPAND:
Expands telescope.
PWM expand output is set to maximum (High speed) if not in Low speed window or in Stop window.
PWM expand output is set to minimum (Low speed) if in Low speed window.
PWM expand output is set to zero if in Stop window.
Digital expand output is set to false if in Stop window else true.
RETRACT:
Retracts telescope.
PWM retract output is set to maximum (High speed) if not in Low speed window or in Stop window.
PWM retract output is set to minimum (Low speed) if in Low speed window.
PWM retract output is set to zero if in Stop window.
Digital retract output is set to false if in Stop window else true.
DELAY:
Performs a delay (Stop delay time) at each stop if Delay is selected in Operation mode (parameter)
Expand and retract outputs are set to false in this state.
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CONSTANT_REPEAT:
A new Expand or Retract command must be given to leave this state if Constant repeat is selected in Operation mode
(parameter).
Expand and retract outputs are set to false in this state.
or all s tates
rans ition is m ade to DIS D s tate i
SpreaderStop = or na le =
ND [ Operation m ode = Delay ] D
[ desired os ition
current os ition ]
S ID
[ no utton is pres s ed ]
[ SpreaderStop = , na le = ]
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8.1.6.5 Parameters
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the possibility of storing the current position in a volatile memory of the SCS2 and then returning to this position via a
command until the power is cycled or a new position is stored.
States:
DISABLED:
When enable goes false or Spreader Stop is activated this state is reached.
All outputs are set false.
STARTUP:
Unconditional transition is made to IDLE state.
IDLE:
Waiting for command input.
Expand command, Returned to logged position command (depending on current position) and Go to predefined position
(depending on current position) makes a transition to EXPAND state.
Retract command, Returned to logged position command (depending on current position) and Go to predefined position
(depending on current position) makes a transition to RETRACT state.
EXPAND:
Expands the Twin boxes until position is within range Stop window from desired stop.
RETRACT:
Retracts the Twin boxes until position is within range Stop window from desired stop.
or all s tates
rans ition is m ade to DIS D s tate i
SpreaderStop = or na le =
S ID
DIS D
ND
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8.1.7.4 Parameters
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States:
DISABLED:
When enable goes false or Spreader Stop is activated this state is reached.
All outputs are set false.
STARTUP:
Unconditional transition is made to IDLE state.
IDLE:
Waiting for command input.
Expand command makes a transition to EXPAND state if In 45ft sensor is false.
Retract command makes a transition to RETRACT state if one not In zero left sensor is true and if not In zero right
sensor is false.
EXPAND:
Expands the Twin boxes as long as Expand command is given and In 45ft is false.
RETRACT:
Retracts the Twin boxes as long as Retract command is given and both In zero left and In zero right sensors are false.
or all s tates
rans ition is m ade to DIS D s tate i
SpreaderStop = or na le =
ND
[ pand, in os ]
[ pand O in os ]
S ID
[ etract O in ero os e t, in
[ SpreaderStop, na le ] ero os i t ]
[ etract, in ero os e t,
in ero os i t ]
DIS D C
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8.1.8.4 Parameters
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8.1.9 TwinUpDown
The TwinUpDown component is designed to be used on the twin telescopic Spreaders. The component performs the twin
up and twin down sequences automatically upon the commands twin up and twin down. The sequence for twin down
consists of the twin units separating until the Left attach & right attach permits have been made. Thereafter the hooks
situated on the tension rod are lowered and finally the twin boxes are lowered. The sequence for twin up consists of the
hooks on the tension rod being raised followed by the twin boxes being raised. The twin consoles are now retracted until
the zero position switches are made, the retract output is active for a short off-delay after that to ensure that both units are
fully retracted. When a complete up sequence has been performed a pulse is given on the output “ Twin up ready pulse ”,
which in turn can be used for instance to run the Spreader back to the correct single 40ft position.
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IN_ IN_DO N
[ all in p oo e t [ all in p oo [ t inDo n e ues tM ]
Disconnected oo i t e tDis connected
Disconnected ] IS _ O S
oo i tDis connected ]
CONN C
[ all in p ] [ all in p ]
[ oo e tConnected oo
[ all in p i tConnected ]
oo e tDis connected
IS _ OO S oo i t
Disconnected ]
[ oo e tDis connected
oo i tDis connected ] O S_DO N
[ t inIn ero os e t
t inIn ero os i t ] INC _IN
[ las t in pStateM = O
_D _INC t inIn ero [ any in p ] [ any in p ]
os e t t inIn ero os
i t ener is eInc InM ]
O D_DO N
O D_
O _D _INC
[ t inIn ero os e t t inIn
ero os i t delayM is im eout ]
rans ition to ID s tate i rans ition to ID s tate i
t inDo nCom m and t in pCom m and
[ t in pCom m and ]
ID
[ any in p oo
e tConnected oo [ t in p e ues tM ] [ any in p oo
i tConnected ] e tConnected oo
i tConnected ]
or all s tates
[ SpreaderStop = , na le = ] DIS D
rans ition is m ade to DIS D s tate i
SpreaderStop = or na le =
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8.1.9.4 Parameters
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8.1.10 PID
8.1.10.1 Overview
The PID components are used to control fast processes, e.g. positioning, syncronisation and control of hydraulic cylinders
with special requirements.
Each PID component controls a single cylinder, but usually they ared used in pair and then 2 PID components are needed.
The PID component have the following features:
Position control
Velocity control
Syncronisation of two cylinders
Acceleration limitation
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8.1.10.6 Implementation
Each node are equipped with two PID components that can be used.
Each PID can control a single cylinder. All parameters for each cylinder are located in the corresponding PID. To identify
the two PIDs each component has a parameter called Regulator index which has to be set to 0 and 1 respectively.
When using sync mode both PID components cooperate and the sync parameters are taken from PID0.
For more detailed information about the implementation, it is reffered to a special document describing the PID
component and AutoTuner component.
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8.1.10.9 Parameters
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8.1.11 AutoTuner
This component is intended as a help when setting up the PID component. It will automatically move the cylinder(s) and
measuring it’s characteristics when component is enabled. If one intentions are to synchronize two cylinders with PID
components, it’s possible to adapt the two cylinders with the use of this component. This is done by enabling the check
box Prepare for sync parameter.
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The AutoTuner will store it’s measured parameters in the onboard NVRAM. These parameters can then be uploaded and
monitored/transferred to the matching PID component. It is important that the Record name is identical to the PID that is
supposed to use the auto tuned parameters.
For more detailed information about the implementation, it is reffered to a special document describing the PID
component and AutoTuner component.
8.1.11.3 Parameters
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8.2 AnyBus
8.2.1 Introduction
Apart from the parallel I/O of the nodes, each node can be equipped with an AnyBus card used for external buses. This
card is fitted into the node on the connector at the right side of the board when the cover is off. By using the Anybus the
crane can utilise the SCS2 as an integrated slave on the PLC network or an Anybus card can be used as a Master bus for
an internal I/O bus on the Spreader. The principal behind the Anybus is that the interface card translates a number of
different bus protocols to a standardised format on the address and data bus of the node. To change between different
buses one can then simply change the type of interface card. For details regarding configuration of a specific bus, please
view the user manual for that specific card and the electrical documentation for your specific project.
The size of the data exchange area between the SCS2 and the Anybus card is configurable up to 64 bytes in and 64 bytes
out. The configuration is done via HMS standard files. This interface must be configured in the same way for both the
Master and the SCS2 slave for the bus to work correctly. For each project a document has to be sent to the customer
describing the used parts of the interface. When referring to in/out we view it from the SCS2 side, hence input for the
SCS2 is an output from the master in the crane.
OUT IN
Byte 0-63 Byte 0-63
Project Project
specific specific
outputs inputs
Output Segment
In the output segment it is possible to use a number of bytes for diagnostic information in the form codes. The diagnostics
are handled by the Anybus System component. The code sent will be equivalent with the code displayed in the onboard
display, hence there will be three levels of this code INFO, WARNING, ERROR. Apart from the code and the byte for
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indicating the type of code a counter will be incremented each time a code is sent. The counter is a 16bit value and
therefore will begin from 0 if the counter overflows. The value of this counter will be sent each time that a new diagnostic
message is transmitted. The start position of the diagnostic areas is configurable.
The remaining bytes for output will be assigned the interface with the crane and will vary on each project. The
assignments here are discrete outputs from the Spreader and current values (pressure etc.) from devices on the Spreader.
These assignments are documented in the electrical documentation of the project.
Input Segment
The entire range of the input area is configurable per project. The assignments here are discrete inputs to the Spreader and
set point values for the Spreader. These assignments shall be documented in the electrical documentation of the project.
8.2.2.2 Parameters
Parameter Unit Description
Node Node id The node identity of the node where
the Anybus interface is located.
Log active Option Indicates if the log should be
exported to the Anybus interface or
not.
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8.2.3.2 Parameters
8.2.4.2 Parameters
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8.2.5.2 Parameters
8.2.6.2 Parameters
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8.2.8.2 Parameters
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8.3 CANopen
8.3.1 Introduction
CANopen is a field bus protocol based on CAN and provides a flexible and powerful open industrial communication
solution.
Apart from the parallel I/O of the nodes the SCS2 master node can control up to 15 CANopen slaves. The SCS2 master
node act’s as a CANopen master, this includes network management, SDO services and PDO handling.
The SCS2 master node processes the CANopen slave data i.e reads inputs and controls outputs.
All configuration of the CANopen functionality is made in the CANopen IO configuration view described in section
5.2.4. Note that the components described in the following section is not visible in the component palette.
8.3.2.2 Parameters
8.3.3.2 Parameters
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8.3.4.2 Parameters
8.3.5.2 Parameters
8.3.6.1 Parameters
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8.4 Guards
8.4.1.2 Parameters
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8.4.3.3 Parameters
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8.4.4.2 Parameters
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8.5 Gates
This section contains the simple Boolean instruction set.
8.5.1 AND
This function block performs the function of the logical AND with the number of inputs specified in the parameter
settings.
Basic function
IN 0 IN n OUT
0 0 0
0 1 0
1 0 0
1 1 1
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8.5.1.3 Parameters
8.5.2 NAND
This function block performs the function of the logical NAND with the number of inputs specified in the parameter
settings.
Basic function
IN 0 IN n OUT
0 0 1
0 1 1
1 0 1
1 1 0
8.5.2.3 Parameters
8.5.3 NOR
This function block performs the function of the logical NOR with the number of inputs specified in the parameter
settings.
Basic function
IN 0 IN n OUT
0 0 1
0 1 0
1 0 0
1 1 0
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8.5.3.3 Parameters
8.5.4 OR
This function block performs the function of the logical OR with the number of inputs specified in the parameter settings.
Basic function
IN 0 IN n OUT
0 0 0
0 1 1
1 0 1
1 1 1
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8.5.4.3 Parameters
8.5.5 NOT
This function block performs the function of the logical NOT with the number of inputs specified in the parameter
settings.
Basic function
IN OUT
0 1
1 0
8.5.6 XOR
This function block performs the function of the logical XOR (exclusive or) with the number of inputs specified in the
parameter settings.
Basic function
IN 0 IN n OUT
0 0 0
0 1 1
1 0 1
1 1 0
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8.5.7 SR Latch
This function block performs the function of the logical SR latch with the number of inputs specified in the parameter
settings. The output will go high at a high signal on the Set input and will go low again at a high signal on the Reset input.
If both inputs are on simultaneously this latch will reset (output goes low).
8.5.8 RS Latch
This function block performs the function of the logical RS latch with the number of inputs specified in the parameter
settings. The output will go high at a high signal on the Set input and will go low again at a high signal on the Reset input.
If both inputs are on simultaneously this latch will set (output goes high).
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8.5.9.3 Parameters
8.6 Digital
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8.6.1.3 Parameters
8.6.2.3 Parameters
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8.6.3.3 Parameters
8.6.4 Split
The split component is used to generate two or more signals available for connection from one signal line. I.e. it can in
many cases replace the use of intermediate variables, since the signal value of the input and the outputs are always the
same.
8.6.4.3 Parameters
8.6.5 Pulse
The Pulse component is used to generate a pulse. The duration of the pulse is set by a parameter. The pulse can be trigged
on either positive or negative flank. The pulse is restarted if an new active flank is detected during the pulse.
An output indicating time left until pulse is unlit is also available.
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8.6.5.3 Parameters
8.7 Miscellaneous
8.7.1 Constant
The Constant component is used to store a Boolean or Analogue value as a constant variable to use within the logic. Note
that any other value than zero is considered as a logical one when using this component for digital purposes.
8.7.1.2 Parameters
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8.7.3.3 Parameters
8.7.4 Memory
The Memory component is used when one wishes to write or read an analogue value from or to the NVRAM.
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8.7.5.3 Parameters
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8.7.6.3 Parameters
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8.8 Analogue
The Analogue components are used to work with analogue values.
8.8.1.2 Parameters
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8.8.6.3 Parameters
8.8.7 Scale
The Scale components scales a analogue value according to the formula,
OUT = ((scaledMax – scaledMin)/(INMax-INMin))*(IN - INMin) + scaledMin,
which performs a linear scaling with an offset according to OUT = k*IN + m.
8.8.7.3 Parameters
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8.8.8 AnalogueLatch
The Analogue latch is a component that stores a value internally when triggered by a digital input. The value stored in an
internal variable can be read at the output of the component. As long as the digital trigger input is active the input value is
directly transferred to the output value and as soon as the digital input goes low the output value remains constant at the
current value until a new digital command is given.
8.8.9 Filter
The Filter component is used to filter analogue signals from noise.
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8.8.9.3 Parameters
8.8.10 AuxAnalogue
This component implements two more analogue inputs.
8.8.10.2 Parameters
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9 Tutorial
This tutorial will guide you through the process of designing a Spreader program using ABE.
Steps covered in this tutorial.
Creating a new project
System view
Pin configuration
Component view
Load view
Fill in the Value fields in the parameter listing. Note that some of the fields are not editable.
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Make sure tab B2 is activated in the view and do the same for Port id# 1 to 4.
Note: The red colour of the fields indicates that the ports are not yet connected.
If available components pallet is not visible. Activate it by clicking at the Components button shown in picture below.
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Note: Connections with red colour indicate that they are not yet connected. Connections with white colour indicate that
they are optional to connect.
Double click on the component to open Properties for the FAC component. Change the property Number of Flippers to 2.
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The new appearance for the component should look like this:
By placing the pointer over the component or one of its connections a hint (tool tip) will appear. The hint tells you about
the properties for the component or its connection.
Click with your right mouse button over a connection on the component. A pop up menu will appear. Move the cursor as
shown in the picture below and click on your left mouse button over Flipper_Down.
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Continue with the remaining connections until you have all connections connected.
If you want to disconnect a connection you click over the connection with your right mouse button and choose disconnect
when it appears.
When your system is complete there should not be any red coloured connections in the Component view or Item
identifiers in the Pin configuration view.
Your Component view should look like Figure 12 when all your connections are made.
Now you are ready to generate downloadable Spreader program file. Select Compile from the File menu.
If the following message box appears your system is not configured properly. Look for red coloured connections or item
identifiers. If port is configured to be used but isn’t you must delete it.
Save the output file (when compiling the spreader program) with the name “tutorial.spr”.
When you have generated your downloadable program file it can be found at the location where it was saved. You must
not edit this file.
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1. Select COM1 or COM2 under selection depending on what serial port is connected to the SCS2.
Answer Yes to the second dialog to open the uploaded spreader program in the editor. (If you press No, you have to
manually open the uploaded spreader program.)
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1. Make sure you have the same spreader program in ABE and SCS2. If you are not sure about this, you can always
download your current spreader program or upload the spreader program from the SCS2 (see Step 5).
2. Select COM1 or COM2 under selection depending on what serial port is connected to the SCS2.
If Auto is checked, automatic update will be performed at an interval specified by Update interval.
The online monitoring starts by telling the SCS2 to add all visible components and their connections. This takes more or
less time depending on the number of present components and connections in visible Page(s). A progress bar appears
above the buttons, when adding the components, to show you current status.
Once the online monitoring is started, the design window is locked for editing. If you want to monitor another part of
your design (not visible at the moment); you have to stop the online monitoring and then scroll to that part and start the
monitoring again.
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o tutorial
This tutorial will guide you through the process of configuring a Spreader program containing CANopen functionality.
The tutorial covers the following steps:
Add a CANopen slave
Add an input
Connecting input to Spreader logic
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The CANopen I/O configuration view now looks like the picture below.
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User Manual
BMS - Light
Version 1.0
Ta l o o t t
1 Introduction ................................................................................................................................................................... 3
2 Installing BMS – Light .................................................................................................................................................. 3
2.1 HW requirements................................................................................................................................................... 3
2.2 Installation ............................................................................................................................................................. 3
2.3 Disclaimer.............................................................................................................................................................. 3
3 User interface................................................................................................................................................................. 4
3.1 Menu (top toolbar) options: ................................................................................................................................... 4
3.2 Status bars in main window................................................................................................................................... 5
4 Download view.............................................................................................................................................................. 6
5 Get log view .................................................................................................................................................................. 7
5.1 Filtering constraints ............................................................................................................................................... 8
6 I/O status view............................................................................................................................................................... 9
7 Misc. view ................................................................................................................................................................... 10
Anybus view........................................................................................................................................................................ 11
8 Spreader info view....................................................................................................................................................... 12
9 CANopen IO view ....................................................................................................................................................... 13
10 Upload view............................................................................................................................................................. 14
11 Advanced................................................................................................................................................................. 15
11.1 CAN Tester.......................................................................................................................................................... 15
11.2 Boot Loader ......................................................................................................................................................... 17
11.3 Asserts ................................................................................................................................................................. 18
11.4 POM Loader ........................................................................................................................................................ 19
11.5 Bluetooth ............................................................................................................................................................. 19
11.6 CANopen services ............................................................................................................................................... 20
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tro u tio
The BMS is a software tool used for monitoring and handling the Bromma system SCS2. This manual assumes the user
has good knowledge of the SCS2 system as well as Windows environments.
talli i t
HW requirements
x An Intel compatible PC running Windows 95 / 98 / NT 4.0 / 2000.
x At least one serial communication port available (COM1 or COM2).
x At least 1Mb of free disk space.
Installation
x Close any other applications running under Windows.
x Insert the first disc into your disc station (if installing from disc)
x Run the file BMSSetup.exe from the BMS folder on your provided disk.
x Follow the instructions on the screen.
Disclaimer
Copyright Bromma Conquip AB. All rights reserved.
Products and company names mentioned herein may be trademarks or trade names of their respective owners.
Bromma Conquip AB operates on a policy of continuous improvement. Therefore we reserve the right to make changes
and improvements to any of the products described in this manual without prior notice.
Bromma Conquip AB is not responsible for any loss of data, income or any consequential damage howsoever caused.
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File:
Exit --- Terminates the application.
View:
Activates selected tab [Download, Get log, I/O status, Misc., Anybus, Spreader info, Upload]
Tools:
Connect serial cable: activates selected communication port [COM1, COM2].
Connect modem: activates modem connected to selected communication port [COM1, COM2].
The dialog below is used for making the connection. Once a connection has been made the dialog window disappears.
The BMS commands are working via the modem if the modem has connected successfully.
Modem connection
Connect to node: connects BMS to selected node [B1, B2,..., B8, A1, A2, A3, A4]. This connection is made over RS232
link through the CAN bus. Normally select Local node.
Advanced options: Intended for Bromma R&D personnel.
Help:
About: shows the version of the BMS.
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Main window
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This tab is used to download the entire system program to the system. Note. It takes a considerable amount of time to
update the system program and therefore make sure that the system can be down for this amount of time.
1. Transfer status from BMS to the connected node [4]. PC downloading to the connected node.
2. Transfer status from connected node [4] to node [5]. Distribution of the program via the bus lines to the other nodes
on the bus.
3. Total transfer status. Status of complete system to be downloaded.
4. Connected node (to PC).
5. Receiving node when distributing between nodes.
6. Select file to download. Press here to select the file to be downloaded. When file is selected download process starts.
7. Cancels current transfer to connected node. The operation just cancels the feedback of transfer status if distribution
between nodes has started (i.e. the operation will not effect the transfer in this case).
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Download view
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This used to retrieve the onboard error and event log.
1. Gets next set of logged messages (max 128 messages each time its’ pressed)
2. Get all messages in log.
3. If checked, auto mode is on. Auto mode triggers the Next button [1] at an interval of X seconds defined by [4].
4. Interval for reading via auto mode in seconds.
5. Enable filtering. The filtered table is shown if checked. Filtering can be used to only view certain parts of the log.
6. Opens the Filtering constraint dialog. Select the type of filtering here.
7. Clears the log table on the PC. The log in the SCS2 remains unaffected.
8. Saves the entire log table in a comma separated text file. Can be opened in for instance in Wordpad, Excel etc.
9. Cancels current operation.
10. Load button. Loads and displays a saved log file.
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Filtering constraints
Select the type of filtering for the log view in this view.
Checked Categories, Nodes, Sub codes and Codes will appear in the filtered table.
Ex: APS_TEACH_COMMAND (of category Info) is checked but not Info under Category. The message will therefor not
appear in the filtered table.
1. Message categories
2. Nodes that have reported messages.
3. Message codes for entire table
Filtering constraints
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This view is used to read (and force) the I/O status of the SCS2.
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This view is used to get and set general information of the SCS2.
1. Updates the Date and Time fields from the PC when pressed.
2. Set the time and date on SCS2 according to Date and Time fields.
3. Get current date and time from the SCS2. Displayed in Date and Time fields.
4. Get address key information from the node [5].
5. Destination of question.
6. Serial cable connection.
7. Cancels current operation.
8. Get version information. Software version and protocol version for Boot and System program. The Boot program
version is Boot SW version and the System program version is System SW version. Don’t care about the COM
versions.
9. Reboots the system.
Ex. Serial cable [6] is connected via COM1 to B1 and Destination [5] is set to Local node (or B1, which would be the
same). B1 is configured to have E-stop and Redundancy block activated. This will give us the answer:
Key: 5
E-Stop: YES
Redundancy: YES
Module name: B1
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The Anybus view shows the status of the I/O transferred over the fieldbus interface of the Anybus card.
1. Input data to SCS2 via Anybus interface. The index field shows which byte is being viewed and the value field the
value of that byte in binary format.
2. Output data from SCS2 via Anybus interface. The index field shows which byte is being viewed and the value field
the value of that byte in binary format.
3. Reads all Input data [1] and Output data [2] from Anybus interface.
4. Cancels current operation.
5. Set DeviceNet master in Run mode. This operation can only be done when using a DeviceNet master.
6. Set DeviceNet master in Idle mode. This operation can only be done when using a DeviceNet master.
7. Select node where to Read [3] data from.
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Anybus view
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This view is used to administrate the external EEPROM that is mounted on some spreaders.
Key = generic name of memory area of EEPROM.
1. Shows the selected key in the Spreader info field [6]. This field can not be edited.
2. Shows the current value of corresponding Key [1].
3. Sets the Value [2] for selected Key [1].
4. Deletes the value for selected Key [1]. The Key [1] can not be deleted, just the value.
5. Updates the entire Spreader info [6] view on the PC.
6. Table of all Keys stored in external EEPROM.
7. Cancels current operation.
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The CANopen view shows the status of the I/O transferred over the CANopen interface.
From this view its also possible to select individual or groups of I/O and override it/them.
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CANopen IO view
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This view is for Bromma R&D personnel only. It is used to upload memory blocks from the SCS2.
Upload view
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These six sub views are mainly intended for Bromma’s R&D personnel only.
CAN Tester
This view holds the functionally of the CAN Tester. To be able to use the CAN Tester the master node has to be keyed as
Test. See the SCS2 manual for information.
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Boot Loader
The Boot Loader view is used to download new boot program to connected node.
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Asserts
The asserts view holds the functionality of reading asserts from the SCS2 . It is used for detecting unexpected system
events.
Asserts view
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POM Loader
The POM Loader view is used for downloading new power monitoring programs to the SCS2 .
Bluetooth
From this dialog it’s possible to configure and manage Bluetooth settings.
Note that the configuration possibilities only works with Bromma Conquip’s own Serial port adapter.
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CANopen services
From this view it’s possible to perform read and write actions to CANopen slave nodes OD (Object Dictionary).
The read and write actions uses the SDO (Service Data Objects) concept of CANopen. For a more detailed description of
CANopen and it’s functionality it’s referred to more specific documentation.
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CANopen services view
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Spreader Control System
2:nd generation
2
SCS
Document: Project: Project No
a ual
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1 GENERAL ...................................................................................................................................................................3
1.1 OVERVIEW ...............................................................................................................................................................3
1.2 REFERENCES ............................................................................................................................................................3
1.3 DICTIONARY AND ABBREVIATIONS ..........................................................................................................................3
1.4 DOCUMENT LAYOUT ................................................................................................................................................3
2 INTRODUCTION .......................................................................................................................................................4
2.1 GENERAL .................................................................................................................................................................4
2.2 THE NODES ..............................................................................................................................................................5
3 SOFTWARE ................................................................................................................................................................6
3.1 BOOT PROGRAM .......................................................................................................................................................6
3.2 SYSTEM PROGRAM ...................................................................................................................................................6
3.3 SPREADER PROGRAM ...............................................................................................................................................6
4 HARDWARE OVERVIEW........................................................................................................................................7
4.1 I/O LED’S ................................................................................................................................................................7
4.2 DISPLAY ...................................................................................................................................................................7
4.2.1 Event categories.............................................................................................................................................8
4.2.2 Message format..............................................................................................................................................8
4.2.3 Priority of displayed messages ......................................................................................................................9
4.3 GROUND CONNECTION .............................................................................................................................................9
4.4 THE X1 AND X3 CONNECTORS .................................................................................................................................9
4.4.1 X1 I/O connector..........................................................................................................................................10
4.4.2 X3 I/O connector..........................................................................................................................................11
4.5 THE X2 CONNECTOR ..............................................................................................................................................13
4.5.1 Main Supply .................................................................................................................................................13
4.5.2 CAN .............................................................................................................................................................13
4.5.3 Address Key .................................................................................................................................................14
4.5.4 Analogue Inputs ...........................................................................................................................................15
4.5.5 PWM Outputs...............................................................................................................................................15
4.5.6 External Spreader Memory..........................................................................................................................15
4.5.7 RS 485 and SSI.............................................................................................................................................16
4.5.8 Additional Jumper Group ............................................................................................................................16
4.6 THE X4 CONNECTOR .............................................................................................................................................17
4.6.1 AnyBus .........................................................................................................................................................18
4.6.2 Two auxiliary Analogue Inputs ....................................................................................................................18
4.7 THE X5 CONNECTOR .............................................................................................................................................19
4.7.1 RS-232..........................................................................................................................................................19
4.8 THE REDUNDANCY FUNCTION ............................................................................................................................... 19
4.9 FIELD BUS CONNECTIONS.......................................................................................................................................20
4.9.1 Mapping of I/O ............................................................................................................................................20
4.10 SPREADER STOP ................................................................................................................................................21
4.11 FAULT FINDING TABLE ......................................................................................................................................22
5 SOFTWARE TOOLS................................................................................................................................................23
5.1 OVERVIEW .............................................................................................................................................................23
5.2 ABE.......................................................................................................................................................................23
5.3 BMS ......................................................................................................................................................................23
6 MISCELLANEOUS ..................................................................................................................................................24
a ual © ro a o ui
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Document: Project: Project No
Manual SCS2
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1 General
1.1 Overview
This document serves as a user manual and shall be used by the surveillance and maintenance operators of the Bromma
SCS2. Software as well as hardware routines and descriptions are covered in this document.
1.2 References
Location where to find the latest revision of this document: http://www.bromma.com/backyard/
2 ntrodu tion
The core of the Bromma Smart Spreader is the Spreader Communications System (SCS2). In 1991 when Bromma decided
to develop a new and highly advanced communications system a close look at the available bus systems revealed a
number of shortcomings, such as temperature range, EMC (Electro Magnetic Compatibility) protection and mechanical
roughness.
Bromma therefore decided to design a bus system that met the demands made on an electronic system for a tough
Spreader application. We decided to develop a modular programmable controller, with a heavy-duty field bus interface
that complies with European and international standards for control equipment in this area. The SCS2 solution is a single
control product that can be used as I/O, as a PLC, and as distributed control for up to 528 I/O points. SCS2 nodes are
simple to install. You can connect up to 11 devices using just a single pair of wires. With its modular and scaleable
architecture, intuitive features and unparalleled ease of use, it will help save crane builders and end users time and money.
A bus system able to handle 528 I/O ports (programmable input or output).
Up to four analogue inputs with 12 bit resolution.
Four PWM outputs for proportional solenoids.
One general purpose RS485 channel OR SSI channel.
Communication with the help of a standard spreader cable — no screening, no twisted pair.
A system that withstands the repeated shocks and vibrations suffered by spreaders.
A system able to operate in tropical heat and arctic cold.
Choice of different field bus interfaces (ProfiBus, Interbus-S, Device Net….)
Optional duty cycle input
2.1 General
As a universal I/O, SCS2 gives you the freedom to connect to a wide variety of host controllers, including PLC's, DCS
and PC-based control systems by way of DeviceNet, Profibus-DP. SCS2 can be networked as a slave to Profibus-DP or
you can choose a DeviceNet master module for easy third-party integration. Designed by Bromma engineers for reliable
performance in the particularly challenging environment of container handling the system corporate four basic elements:
Crane Node1 A device directly interfacing with the crane’s control systems, computer and
monitoring screens, providing an optional serial bus interface for
programming or diagnostic communications, as well as an interface to the
spreader node.
Crane-Spreader Communications Link A two-wire conventional cable CAN communications between the crane
control system and the spreader.
Spreader Node A device that interfaces directly with the spreader’s sensors, supports discrete
signals, and acts as the Master node.
Sensors and Switches Conventional sensors, switches, and actuators on the spreader.
The system is divided into several hardware units called nodes. The nodes are located on the spreader and in the crane.
The nodes are connected to each other via a CAN network, see figure 1. The number of nodes required is based on the
1
For details regarding separate dedicated crane fieldbus gateway, see separate manual
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number of I/O needed. The nodes are all equals, both in software as well as in hardware. This reduces spare parts and
enables easy-to-change procedures.
The only difference is their identity, id. Depending on their location the nodes have different ids. They are numbered
from 0 to 11 where:
0 is the master called B1
1-7 are slave nodes located on the spreader called B2-B8
8-11 are slave nodes located in the crane called A1-A4.
Crane
I/O
Slave A1 ... Slave A4
2
CAN network (BCAN) SCS
Spreader
Figure 1. The figure shows SCS2 connected to the spreader and the crane via I/O. The nodes are also connected internally
via a CAN network.
The SCS2 is built up of several nodes co-operating in the system. Each node has a specific role, either slave or master.
There must be only one master node in the system and the rest are slaves.
The master node makes all the calculations and decisions. The slave nodes act as remote I/O to the master, but can also
have distributed functions such as regulators.
3 So tware
The SCS2 software consists of three types of programs; Boot Program, System Program and Spreader Program.
4 ardware er iew
2
Below is a picture of a SCS node. The different parts are explained in the following chapter.
4.2 Display
The display shows three pages of information where each page has a maximum of 8 characters. Each page is shown for 1
second. The pages show the following:
Node ID and System program version. Format: <Node ID><Version>.
Elapsed time running since power on. Format: DDD HHMM where DDD is the number of days, HH the number of hours
and MM the number of minutes.
Message page. The message page shows numeric information only, which has to be translated into comprehensive plain
text manually. The meaning of this page is explained in the rest of this section.
There are also four red LED’s in the bottom of the display window indicating the supply voltage level. Four different
levels are indicated and the ideal voltage is when all LED’s are lit.
It is not recommended to run the system below the OK level though it still seems to work fine. Attached devices may
malfunction at lower voltages thus making the system unreliable. The green LED is the “power on” indicator.
Warning W W60 Warning shows information about the system status that is of high
importance. The system keeps on running. Warning messages will
begin with a W.
Information
LTTTSSSS
L = Level type
TTT = Message type
SSSS Su type
ample:
102 rror in initialisin t e ardware
1 1 arnin indi atin t at a twistlo is indi atin lo ed and unlo ed e su ode indi ates t at it is orner 1
5 n ormation t at t e system as started
Level type
The level type can be one of the following: I = Information, W = Warning, E = Error
Message type
The message type represents the cause of the message. Examples of message types are System started, Wrong system
version and I/O error.
All these types are described in appendix A.
Sub type
The sub type is used to specify more detailed information about the message type. The sub types have different meanings
for all message types. For example does sub type 14 together with message type 47 mean I/O error on digital port 14
instead of just I/O error.
These sub types are described in appendix A.
Note that warnings are cleared from the display after at least 10 messages of informational type have passed and the
warning message is older than 15 minutes. Error messages are cleared by resetting the system.
2
Redundancy remark.
I/O signals 21 – 24 are affected by the redundancy safety functionality. See chapter 4.8
To make linking of common supplies easier the X1 connector also has groups if pins linked together to be used basically
as jumper bars with the same potential. The following pins are linked together internally for the purpose of feeding
switches/valves with common potential.
To make linking of common supplies easier the X3 connector also has groups if pins linked together to be used basically
as jumper bars with the same potential. The following pins are linked together internally for the purpose of feeding
switches/valves with common potential.
4.5.2 CAN
The two CAN nets are placed in the X2 connector. The first net use Bromma CAN (BCAN) voltage levels and the second
net use standard CAN voltage levels. The standard CAN net has to be terminated with external resistors.
3
CAN channel is std CAN for CAN-Open installations
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Configuration
Since all nodes are the same in reference to the software as well as hardware you have to configure them to carry different
roles. Setting the address key configures the role of the node. The address key has two other functions as well, enabling
Spreader stop and enabling redundancy block. These functions are described in chapters 4.10 and 4.8.
Key input Node Spreader Redundancy block and Pins to be linked together in Node number identifier
stop
name override of landing X2 connector when viewing Display and
pins Log
00000 Test 10,9,19,29,39,49
00001 A1 No No 10,19,29,39,49 8
00010 A2 No No 10,9,29,39,49 9
00011 A3 No No 10,29,39,49 10
00100 A4 No No 10,9,19,39,49 11
00101 B1 Yes Yes 10,19,39,49 0
00110 B1 Yes No 10,9,39,49 0
00111 B1 No Yes 10,39,49 0
01000 B1 No No 10,9,19,29,49 0
01001 B2 Yes Yes 10,19,29,49 1
01010 B2 Yes No 10,9,29,49 1
01011 B2 No Yes 10,29,49 1
01100 B2 No No 10,9,19,49 1
01101 B3 No No 10,19,49 2
01110 B4 No No 10,9,49 3
01111 B5 No No 10,49 4
10000 B6 No No 10,9,19,29,39 5
10001 B7 No No 10,19,29,39 6
10010 B8 No No 10,9,29,39 7
10011- Not
11110 Used
11111 Test None
Example
Here are three examples of how to set the address key:
A node with id B1 without redundancy block or emergency stop has the address key 01000.
A node with id B2 with both redundancy block and emergency stop has the address key 01001.
A node with id A2 (cannot have redundancy block or emergency stop enabled) has the address key 00010.
Analogue in 2 X2/17
10Vref 2 X2/27
Signal ground 2 X2/7
Field bus operation is selected by connecting the field bus connector on the Anybus card with pin header CN103. The RS
232 serial port is selected by connecting CN100 and CN103. The two additional analogue inputs are selected by
connecting CN105 and CN103. Finally the duty cycle input is selected by connecting CN104 with CN103.
4.6.1 AnyBus
The AnyBus connector is used to interface any of the fieldbus types used apart from BCAN.
4.7.1 RS-232
The RS-232 connector, called BMS port, is located to the right of the node and is used only for this purpose.
C D
B
A E
The commands either from a remote node on the network or the local node itself.
The CPU and the system software as well as the application specific software (Spreader program).
The redundancy block of hardware static logic. The block has two functions, to make sure the twistlocks are energised
correctly at boot and to prevent the software from changing between lock and unlock when not landed during operation.
At boot the redundancy block checks the sensor status and determines if the twistlock valves are to be energised and in
what direction. After a correct landing and a transition between lock/unlock the redundancy block goes passive only
preventing the software to change between lock and unlock unless the Spreader is properly landed. In this state the
redundancy can be viewed as two relay contacts, where only one contact is closed at a time permitting the twistlock
outputs. The only way of overriding the logic of the redundancy block is to energise a specific I/O (landed override) on
that particular node.
The outputs to the lock/unlock valves
The sensor signals from landed, locked and unlocked.
To enable the redundancy the address key on B1 or B2 is used, this then automatically means you have to use input 48 as
Landed override to be able to override the hardware logic. The landed override signal sets the spreader in landed mode
and thereby temporarily disables the redundancy block.
The size of the data exchange area between the SCS2 and the Anybus card is configurable up to 64 bytes in and 64 bytes
out. The configuration is done via HMS standard files. This interface must be configured in the same way for both the
Master and the SCS 2 slave for the bus to work correctly. For each project a document has to be sent to the customer
describing the used parts of the interface. When referring to in/out we view it from the SCS2 side, hence input for the
SCS2 is an output from the master in the crane.
OUT IN
Byte 0-63 Byte 0-63
Project Project
specific specific
outputs inputs
Output Segment
In the output segment it possible to use a number of bytes for diagnostic information in the form codes. The code sent
will be equivalent with the code displayed in the onboard display; hence there will be three levels of this code INFO,
WARNING, ERROR. Apart from the code and the byte for indicating the type of code a counter will be incremented
each time a code is sent. The counter is a 16bit value and therefore will begin from 0 if the counter overflows. The value
of this counter will be sent each time that a new diagnostic message is transmitted.
The remaining bytes for output will be assigned the interface with the crane and will vary on each project. The
assignments here are discrete outputs from the Spreader and current values (pressure etc.) from devices on the Spreader.
These assignments shall be are documented in the electrical documentation of the project.
Input Segment
The entire range of the input area is configurable per project. The assignments here are discrete inputs to the Spreader and
set point values for the Spreader. These assignments shall be documented in the electrical documentation of the project.
This is performed by enabling Spreader stop using the address key on B1 or B2 and connecting the signal from the
spreader stop button to digital port 47 on the corresponding node (B1 or B2).
The spreader stop configuration must correspond to the spreader stop setting in the spreader program. This means that if
and only if the spreader stop on a node is enabled, digital port 47 must be connected to the Spreader Stop component in
the spreader program.
RS-232
BMS system can not communicate Probe TxD and RxD lines with Data lines should show square waves
with the node. oscilloscope while trying to between –10V to +10V relative to
communicate. GND pin.
CAN
The node can not communicate with Probe bus lines with oscilloscope.
the other nodes. CAN high should show square waves
pointing downwards and CAN low
should be showing square waves
pointing upwards.
Digital Ports
Input signal fault Check if LED indicator on I/O module The LED should be lit when current
responds to sensor signal. flows through the module.
Check the Common connection for
correct supply.
Output signal fault Check if LED indicator on I/O module The LED should be lit when the circuit
responds to command. is closed.
Check the load for proper connection The load should be connected between
and grounding. the modules out pin and ground.
Check for broken fuse on the I/O
module.
Check the Common connection for The supply voltage depends on the
correct supply. type of load. 220V,110V,24V or other.
Node ID
The node stops at start-up with Node Measure the voltage of all ID pins. 5V This can indicate that the node has
Id displayed. represent ones and 0V represents wrong id strapped telling the node to
zeroes. The measures should indicate participate in the system with wrong
the expected id. role.
Analogue Inports
Analogue input signal appears to be Check the reference voltage relative to There should be exactly 10V
faulty. the GND. difference between them.
Check if the node chassis is properly This is very important in an AC driven
grounded to the spreader. system.
PWM Outports
PWM output appears to be faulty. Check the load for errors.
Try another load.
5 So tware tools
5.1 Overview
There are some related tools to the SCS2, which support it in different ways. A brief description of these tools is given
below.
5.2 ABE
ABE (Application Builder Environment) is a tool for developing and configuring the spreader program, which controls
the logic of the spreader. ABE generates a load file. For more detailed see the separate manual.
5.3 BMS
BMS ultra light (Bromma Monitoring System ultra light) is a tool for monitoring events and reading status of I/O in the
SCS2. BMS can also be used to download new programs to the SCS2. For more detailed see the separate manual.
Mis ellaneous
6.2 Dimensions
24 spare 16 .
25 spare 17 .
26 spare 18 .
27 spare 19 .
28 WARNING No data in program/system . System cannot start Contact Bromma
memory
29 spare 20 .
30 WARNING Checksum of memory corrupt .
31 ERROR HW fault on memory . System is brought into Contact Bromma
failsafe mode. if problem
persists
32 spare 21 .
33 spare 22 .
34 ERROR System init. Display. This error The error codes during the system boot phase that have caused the
code accumalates and displays system to go into failsafe mode
the errors ocurred during the
system boot, since no reporting
is done until the system has
started.
35 ERROR System failed in reading . System is brought into reload and
spreader program from memory failsafe mode. restart
36 ERROR No spreader program residing in . System is brought into download
memory failsafe mode. program
37 ERROR System failed to run spreader . System is brought into reload proram
program failsafe mode.
38 ERROR Spreader program object . System is brought into Check spreader
instances failed failsafe mode. program. If
problems persist
contact Bromma
39 ERROR Spreader program object . System is brought into Check spreader
instances failed failsafe mode. program. If
problems persist
contact Bromma
40 ERROR Spreader program object . System is brought into Check spreader
instances failed failsafe mode. program. If
problems persist
contact Bromma
41 ERROR Spreader program object . System is brought into Check spreader.
instances failed failsafe mode. If problems
persist contact
Bromma
42 ERROR Spreader program object . System is brought into Check spreader
instances failed failsafe mode. program. If
problems persist
contact Bromma
52 ERROR System initialising error when The node ID which has System is brought into restart
configuring nodes I/O generated the error failsafe mode.
53 ERROR Duplicate answers on I/O The node ID which has System is brought into restart
configuration from the same generated the error failsafe mode.
node when initialising system
54 spare 27
55 ERROR Duplicate answers on I/O The node ID which has System is brought into restart
configuration from the same generated the error failsafe mode.
node when initialising system
61 WARNING TWL - One twistlock indicating ID no. of the twistlock Message stored in log and check for
both locked and unlocked which generated the displayed on Spreader damaged sensors
warning and sensor
adjustment or
mechanical
reasons
62 WARNING TWL - timeout locking. Locked ID no. of the twistlock Message stored in log and check sensor,
signal has not been received which generated the displayed on Spreader valves and/or
after output to valve warning wiring or
mechanical
reasons
63 WARNING TWL - Locked sensor lost ID no. of the twistlock Message stored in log and check for
during operation. Sensor lost which generated the displayed on Spreader damaged sensors
without command/output when warning and sensor
twistlocks are all locked adjustment or
mechanical
reasons
64 WARNING TWL - timeout unlocking. ID no. of the twistlock Message stored in log and check sensor,
Unlocked signal has not been which generated the displayed on Spreader valves and/or
received after output to valve warning wiring or
mechanical
reasons
65 WARNING TWL - Unocked sensor lost ID no. of the twistlock Message stored in log and check for
during operation. Sensor lost which generated the displayed on Spreader damaged sensors
without command/output when warning and sensor
twistlocks are all unlocked adjustment or
mechanical
reasons
66 WARNING TWL - all landed sensors not ID no. of the twistlock Message stored in log and check for
received after first landed and which generated the displayed on Spreader damaged sensors
timeout. warning and sensor
adjustment or
mechanical
reasons
67 WARNING TWL - landed sensor not ID no. of the twistlock Message stored in log and check for
released when the other sensors which generated the displayed on Spreader damaged sensors
not active and a timer has timed warning and sensor
out adjustment or
mechanical
reasons
68 WARNING TELESCOPE - prox. type. No . Stops the telescope and check for
valid sensor found within displays/stores message damaged sensors
timeout limit after output has and sensor
been activated adjustment or
mechanical
reasons
69 WARNING TELESCOPE - prox. type. ID no. of the sensor Stops the telescope and check for
Wrong sensor in telescoping missing which displays/stores message damaged sensors
sequence reached generated the warning and sensor
adjustment or
mechanical
reasons
70 WARNING TELESCOPE - prox. type. The ID no. of the lost Message stored in log and displayed on
position sensor is lost without an sensor Spreader
output.
71 WARNING TELESCOPE - prox. type. Two ID no.s. of the sensors Message stored in log and check for
different position sensors displayed on Spreader damaged sensors
indicating simultaneously and sensor
adjustment or
mechanical
reasons
72 ERROR Duplicate answers from one The node ID which has System is brought into restart (check
node during boot verification generated the error failsafe mode. address keying)
73 ERROR Wrong boot version in a node The node ID which has System is brought into contact Bromma
generated the error failsafe mode.
74 ERROR No answer when master The node ID which has System is brought into restart
requesting boot version. generated the error failsafe mode.
75 spare 28
76 spare 29
77 spare 30
78 spare 31 .
79 spare 32 .
80 ERROR Wrong node answered request The node ID which has System is brought into restart
from master to check if pc was generated the error failsafe mode.
connected
81 ERROR No answer after master request The node ID which has System is brought into restart, check
to check PC port (RS232) generated the error failsafe mode. connections
82 ERROR Unable to download program . System is brought into retry
failsafe mode.
83 ERROR Unable to download program . System is brought into Check spreader
(checksum failure) failsafe mode. program. If
problems persist
contact Bromma
84 WARNING Onboard realtime clock time .
couldn't be read
85 WARNING Onboard realtime clock time .
couldn't be set
86 INFO minimum system CPU cycle time in ms Message stored in log and displayed on
time. Periodically reported every Spreader
half hour. The counter is reset
after reporting.
87 INFO maximum system CPU cycle time in ms Message stored in log and displayed on
time. Periodically reported every Spreader
half hour. The counter is reset
after reporting.
88 INFO average system CPU cycle time. time in ms Message stored in log and displayed on
Periodically reported every half Spreader
hour. The counter is reset after
reporting.
89 spare 33 .
90 INFO The number of control loops The number of the Message stored in log and displayed on
exceeding 100ms for th last half counter Spreader
hour. The counter is reset after
reporting
91 spare 34 .
92 spare 35 .
93 spare 36 .
94 ERROR No operative system in Node . Systems fails to start contact Bromma
95 ERROR Duplicate answer on The node ID which has System is brought into check adress key
determining Spreader stop set up generated the error failsafe mode.
96 ERROR No answer on Master request for . System is brought into check adress key
"Spreader stop" configuration failsafe mode.
97 INFO Spreader stop has been 0= activated Message stored in log and displayed on
activated/deactivated 1=deactivated Spreader
98 spare 37 .
99 spare 38 .
100 ERROR Spreader program fault . System is brought into
recompile and
failsafe mode. reload spreader
program
101 WARNING CAN message buffer is full The first message type Message stored in log and displayed on
in the buffer Spreader
106 spare 41 .
107 WARNING 10V reference voltage too low Actual voltage *10 Message stored in log and check supplies
displayed on Spreader
108 WARNING 12V internal supply too low Actual voltage *10 Message stored in log and check supplies
displayed on Spreader
109 ERROR Battery voltage too low Actual voltage *10 Message stored in log and check battery
displayed on Spreader
110 ERROR The System failed to lock th I/O . System is brought into restart
on a node during system init. failsafe mode.
111 spare 42
112 spare 43 .
113 spare 44 .
114 INFO System is shutting down .
115 INFO System shutdown has been .
completed
116 spare 45 .
117 spare 46 .
118 INFO Landed override has been .
activated
119 INFO Landed override has been .
deactivated
120 spare 47 .
121 spare 48 .
122 spare 49 .
123 spare 50 .
124 spare 51 .
125 spare 52 .
126 spare 53 .
127 spare 54 .
128 spare 55 .
129 ERROR Spreader program fault or load . System is brought into check and
file has been korrupted failsafe mode. recompile
spreader
program.
Reload. /contact
Bromma
130 ERROR Spreader program fault or load . System is brought into check and
file has been korrupted failsafe mode. recompile
spreader
program.
Reload. /contact
Bromma
131 ERROR Spreader program fault or load . System is brought into check and
file has been korrupted failsafe mode. recompile
spreader
program.
Reload. /contact
Bromma
132 spare 56 .
133 spare 57 .
134 spare 58 .
135 spare 59 .
136 ERROR Spreader program fault or load . System is brought into check and
file has been korrupted failsafe mode. recompile
spreader
program.
Reload. /contact
Bromma
137 spare 60 .
138 spare 61 .
139 spare 62 .
140 WARNING Unknown CAN message The ID type of the Message stored in log and displayed on
received message Spreader
141 INFO CAN messages missed. The count of the Message stored in log and displayed on
Cyclically reported. missed messages Spreader
142 ERROR Two nodes within the system The ID which is System is brought into check and
have the same ID/adress duplicate failsafe mode. correct the
adress key
143 WARNING 10V reference voltage is too Voltage * 10 Message stored in log and check supplies
high displayed on Spreader
144 WARNING 12V internal voltage is too high Voltage * 10 Message stored in log and check supplies
displayed on Spreader
145 WARNING Battery voltage is too high Voltage * 10 Message stored in log and check supplies
displayed on Spreader
146 WARNING User defined Warning. The . Message stored in log and Check specific
user/programmer defines what displayed on Spreader project.
this fault should indicate within
the application program.
147 WARNING User defined Warning. The . Message stored in log and Check specific
user/programmer defines what displayed on Spreader project.
this fault should indicate within
the application program.
148 WARNING User defined Warning. The . Message stored in log and Check specific
user/programmer defines what displayed on Spreader project.
this fault should indicate within
the application program.
149 WARNING User defined Warning. The . Message stored in log and Check specific
user/programmer defines what displayed on Spreader project.
this fault should indicate within
the application program.
150 WARNING User defined Warning. The . Message stored in log and Check specific
user/programmer defines what displayed on Spreader project.
this fault should indicate within
the application program.
151 WARNING User defined Warning. The . Message stored in log and Check specific
user/programmer defines what displayed on Spreader project.
this fault should indicate within
the application program.
152 WARNING User defined Warning. The . Message stored in log and Check specific
user/programmer defines what displayed on Spreader project.
this fault should indicate within
the application program.
153 WARNING User defined Warning. The . Message stored in log and Check specific
user/programmer defines what displayed on Spreader project.
this fault should indicate within
the application program.
154 WARNING User defined Warning. The . Message stored in log and Check specific
user/programmer defines what displayed on Spreader project.
this fault should indicate within
the spreader program.
155 WARNING User defined Warning. The . Message stored in log and Check specific
user/programmer defines what displayed on Spreader project.
this fault should indicate within
the spreader program.
156 spare 63 .
157 spare 64 .
158 spare 65 .
159 spare 66 .
160 spare 67 .
161 WARNING CAN error . Message stored in log and displayed on
Spreader
163 WARNING Power monitor P1 = sensor . Message stored in log and check supplies
supply voltage. Warning 1 = displayed on Spreader
Voltage < 21V
164 ERROR Power monitor P1 = sensor . System is taken down check supplies
supply voltage. ERROR = into idle mode. Ie if the
Voltage below permissive system voltage comes up
voltage of system. again it wakes otherwise
is prepared to shut down
165 WARNING Power monitor P2 = internal . Message stored in log and check supplies
supply voltage. Warning 1 = displayed on Spreader
Voltage < 21V
166 ERROR Power monitor P2 = internal . System is taken down check supplies
logic supply voltage. ERROR = into idle mode. Ie if the
Voltage below permissive system voltage comes up
voltage of system. again it wakes otherwise
is prepared to shut down
167 WARNING Power monitor P3 = PWM . Message stored in log and check supplies
supply voltage. Warning 1 = displayed on Spreader
Voltage < 21V
168 ERROR Power monitor P3 = PWM . System is taken down check supplies
supply voltage. ERROR = into idle mode. Ie if the
Voltage below permissive system voltage comes up
voltage of system. again it wakes otherwise
is prepared to shut down
169 WARNING System failed to read/write to a ID of port: Message stored in log and check supplies
I/O port Digital=0+port_no, displayed on Spreader
Analogue=100+port_n
o, PWM=200+port_no,
encoder=300+port_no.
170 spare 68 .
171 spare 69 .
172 spare 70 .
173 spare 71 .
174 ERROR No answer when on general . Message stored in log and displayed on
information request between Spreader
nodes.
175 INFO TWL - twistlock lock command . Message stored in log and displayed on
received Spreader
176 INFO TWL - twistlock unlock . Message stored in log and displayed on
command received Spreader
177 INFO TWL - twistlock has been . Message stored in log and displayed on
locked Spreader
178 INFO TWL - twistlock has been . Message stored in log and displayed on
unlocked Spreader
179 INFO TELESCOPE - prox. type. . Message stored in log and displayed on
Expand command received Spreader
180 INFO TELESCOPE - prox. type. . Message stored in log and displayed on
Retract command received Spreader
181 INFO TELESCOPE - prox. type. The ID of the position Message stored in log and displayed on
Command to go to a speceific requested Spreader
position has been received
182 INFO TELESCOPE - prox. type. The The ID of the position Message stored in log and displayed on
desired position has been requested Spreader
reached
183 WARNING TELESCOPE - automatic type. 0 = Desired position The telescopic motion is check sensor,
The telescope hasn't reached its' not reached within time stopped until a new pressure,mechan
position within time limit limit. command is given. ics. If necessary
1 = telescope has not Message stored in log and calibrate system.
moved more than 1 cm displayed on Spreader
during 3 seconds.
184 INFO TELESCOPE - automatic type. . Message stored in log and displayed on
expand command received Spreader
185 INFO TELESCOPE - automatic type. . Message stored in log and displayed on
Retract command received Spreader
186 INFO TELESCOPE - automatic type. The ID of the position Message stored in log and displayed on
Command to go to a specific requested Spreader
position received
187 INFO TELESCOPE - automatic type. The ID of the position Message stored in log and displayed on
The desired position reached requested Spreader
188 INFO The year has been set current value (year) Message stored in log and displayed on
Spreader
189 INFO The month has been set current value (month) Message stored in log and displayed on
Spreader
190 INFO The day/date has been set current value (date) Message stored in log and displayed on
Spreader
191 INFO The time of day (hour) has been current value (hour) Message stored in log and displayed on
set Spreader
192 WARNING Nocontact with the master for The ID of the node Message stored in log and check
10s which doesn't have displayed on Spreader connections
contact
195 INFO Download request active . Message stored in log and displayed on
(system boot functionality) Spreader
196 INFO Information request received . Message stored in log and displayed on
(system boot functionality) Spreader
197 INFO set time request received . Message stored in log and displayed on
(system boot functionality) Spreader
198 INFO Boot version request received. . Message stored in log and displayed on
(system boot functionality) Spreader
199 spare 72 .
200 INFO Download flag request received. . Message stored in log and displayed on
(system boot functionality) Spreader
201 spare 73 .
202 spare 74 .
203 spare 75 .
204 spare 76 .
205 INFO Check flash memory request . Message stored in log and displayed on
received. (system boot Spreader
functionality)
206 INFO Restart node request received. . Message stored in log and displayed on
(system boot functionality) Spreader
207 INFO System start init. (system boot . Message stored in log and displayed on
functionality) Spreader
208 INFO System look for downloadflag. . Message stored in log and displayed on
(system boot functionality) Spreader
209 INFO Send datablock request. (system . Message stored in log and displayed on
boot functionality) Spreader
210 INFO Received datablock. (system . Message stored in log and displayed on
boot functionality) Spreader
213 spare 77 .
214 spare 78 .
215 ERROR No answer when waiting for . System is brought into failsafe mode.
present nodes response
216 INFO Inforamtion on present nodes . Message stored in log and displayed on
has been received Spreader
230 ERROR Failed to set up spreader destination of error System is brought into Check spreader
program correctly failsafe mode. program. If
problems persist
contact Bromma
231 ERROR Spreader program download . System is brought into Check spreader
error failsafe mode. program. If
problems persist
contact Bromma
232 ERROR Spreader program download . System is brought into Check spreader
error failsafe mode. program. If
problems persist
contact Bromma
233 INFO Power monitor P1 = sensor . Message stored in log and displayed on
supply voltage. OK Spreader
234 INFO Power monitor P2 = internal . Message stored in log and displayed on
supply voltage. OK Spreader
235 INFO Power monitor P3 = PWM . Message stored in log and displayed on
supply voltage. OK Spreader
236 INFO Reboot (restart) request sent . Message stored in log and displayed on
from master to slaves. Happens Spreader
when slaves are powered on
before master at system start
237 INFO System has been taken down to . Message stored in log and displayed on
idle mode. Ie waiting to wake Spreader
up.
238 Spare 81 .
239 INFO System failed to cancel . Message stored in log and displayed on
shutdown process Spreader
240 INFO No answer when attempting to . Message stored in log and displayed on
cancel shutdown process Spreader
241 INFO System received timeout when . Message stored in log and displayed on
attempting to cancel shutdown Spreader
process
242 INFO System shutdown aborted . Message stored in log and displayed on
Spreader
243 spare 82 .
244 INFO TWL - The spreader has been . Message stored in log and displayed on
landed Spreader
245 INFO TWL - The Spreader has been . Message stored in log and displayed on
totally lifted (not landed) Spreader
246 INFO FLIPPER - flipper up command . Message stored in log and displayed on
received Spreader
247 INFO FLIPPER - flipper down . Message stored in log and displayed on
command received Spreader
248 WARNING Power monitor P1 = sensor . AI can start to flicker. Message stored in
supply voltage. Warning 2 = log and displayed on Spreader
Voltage < 17V
249 WARNING Power monitor P2 = internal . AI can start to flicker. Message stored in
supply voltage. Warning 2 = log and displayed on Spreader
Voltage <17V
250 WARNING Power monitor P3 = PWM . AI can start to flicker. Message stored in
supply voltage. Warning 2 = log and displayed on Spreader
Voltage < 17V
251 ERROR System failed to initialise fielbus . System is brought into failsafe mode.
interface
252 ERROR Duplicate answers when setting . System is brought into failsafe mode.
up fieldbus interface
253 ERROR No answer when configuring . System is brought into failsafe mode.
fieldbus interface
254 WARNING System failed in locking .
fieldbus interface
255 WARNING TWIN195 - twinboxes have ID of the twin box Message stored in log and check
failed to get to their upper failing displayed on Spreader solenoids/mecha
position within time limit nics/sensors
256 WARNING TWIN195 - left hook has failed . Message stored in log and check
to reach its' upper position displayed on Spreader solenoids/mecha
within time limit nics/sensors
257 WARNING TWIN195 - right hook has failed . Message stored in log and check
to reach its' upper position displayed on Spreader solenoids/mecha
within time limit nics/sensors
258 WARNING TWIN195 - twin boxes left . Twin down sequence check
timed out when expanding to stopped. Have to return solenoids/mecha
their attach position. Failed to Spreaer to twin up nics/sensors
reach switch within time limit position. Message stored
in log and displayed on
Spreader
259 WARNING TWIN195 - twin boxes right . Twin down sequence check
timed out when expanding to stopped. Have to return solenoids/mecha
their attach position. Failed to Spreaer to twin up nics/sensors
reach switch within time limit position. Message stored
in log and displayed on
Spreader
260 WARNING TWIN195 - left hook has failed . Message stored in log and check
to reach its' lower position displayed on Spreader solenoids/mecha
(connect) within time limit nics/sensors
261 WARNING TWIN195 - right hook has failed . Message stored in log and check
to reach its' lower position displayed on Spreader solenoids/mecha
(connect) within time limit nics/sensors
262 WARNING TWIN195 - twinboxes have ID of the twin box Message stored in log and check
failed to get to their lower failing displayed on Spreader solenoids/mecha
position within time limit nics/sensors
263 WARNING TWIN195 - twin up sensor lost ID of the twin box Message stored in log and check
unexpectedly. (not due to failing displayed on Spreader solenoids/mecha
output) nics/sensors
264 WARNING TWIN195 - twin up sensor ID of the twin box Message stored in log and check
received when twinboxes are failing displayed on Spreader solenoids/mecha
down nics/sensors
265 WARNING TWIN195 - left hook down . Message stored in log and check
sensor lost unexpectedly. displayed on Spreader solenoids/mecha
nics/sensors
266 WARNING TWIN195 - right hook down . Message stored in log and check
sensor lost unexpectedly. displayed on Spreader solenoids/mecha
nics/sensors
267 WARNING TWIN195 - left hook up sensor . Message stored in log and check
lost unexpectedly. displayed on Spreader solenoids/mecha
nics/sensors
268 WARNING TWIN195 - right hook up sensor . Message stored in log and check
lost unexpectedly. displayed on Spreader solenoids/mecha
nics/sensors
269 ERROR System failed to init. RS485 Node ID System is brought into restart / contact
failsafe mode. Bromma
270 ERROR Duplicate answers in system Node ID System is brought into restart / contact
when setting up RS485 failsafe mode. Bromma
271 ERROR System timed out when trying to . System is brought into restart / contact
configure RS485 failsafe mode. Bromma
272 INFO TELESCOPE - automatic type. . Message stored in log and displayed on
Teach in command received Spreader
280 spare 83 .
281 INFO TWINMPS - teaching a pre- The ID of the position Message stored in log and displayed on
defined position teached Spreader
282 INFO TWINMPS - command to go to The ID of the position Message stored in log and displayed on
a pre-defined position has been requested Spreader
received
284 INFO TWINMPS - A command to The ID of the position Message stored in log and displayed on
return to a log position has been requested Spreader
received
286 INFO TWIN195 - twin up command . Message stored in log and displayed on
has been received Spreader
287 INFO TWIN195 - twin down . Message stored in log and displayed on
command has been received Spreader
288 INFO TWIN195 - twin boxes have . Message stored in log and displayed on
reached their upper position Spreader
289 INFO TWIN195 - twin boxes have . Message stored in log and displayed on
reached their lower position Spreader
290 INFO TTDS - override request . Message stored in log and displayed on
received Spreader
291 INFO TTDS - override request ended . Message stored in log and displayed on
Spreader
292 WARNING Buffer full transferring serial . Message stored in log and displayed on
port info over CAN bus Spreader
293 WARNING No answer when transferring . Message stored in log and displayed on
serial port info over Can bus Spreader
295 spare 84 .
296 spare 85 .
297 spare 86 .
298 ERROR Failed reading spreader System is brought into Check spreader
program. failsafe mode. program. If
problems persist
contact Bromma
299 spare 87
300 spare 88
301 WARNING RS485 not functioning as Depending on type of Message stored in log and displayed on
intended sensor/device Spreader
302 WARNING AnyBus not functioning as Depending on type of Message stored in log and displayed on
intended sensor/device Spreader
306 INFO Spreader properties Number of containers Message stored in log and
353 INFO Present nodes shown in sub code bitwise OR for all included nodes. 12bit Value
357 INFO AnyBus Input data area size size of data area (bytes)
358 INFO AnyBus output data area size size of data area (bytes)
359 ERROR Hardware initialisation failed psu_mon.=1, temp_sens.=2, realtime_clock=3
(system prog.)
372 INFO The Spreader info has been set. The index of the field
which is set.
373 INFO The Spreader info has been set. The value of the field
which is set. The
logged value is in the
range 0-9999. This
range limit has nothing
374 INFO The time of day (minute) has Current value (minute) Message stored in log and displayed on
been set Spreader
378 WARNING Codeloading via anybus failed. node ID that failed to Message stored in log and displayed on
(start sequence) handle start sequence. Spreader
379 WARNING Codeloading via anybus failed. node ID that failed to Message stored in log and displayed on
(download sequence) download. Spreader
380 WARNING Codeloading via anybus failed. node ID that failed to Message stored in log and displayed on
(finish sequence) handle finish sequence. Spreader
381 WARNING Disabeling outputs failed. node ID that failed to Message stored in log and displayed on
disable outputs. Spreader
382 WARNING No answer when attempting to Message stored in log and displayed on
disable outputs. Spreader
383 WARNING Enabeling outputs faild. node ID that failed to Message stored in log and displayed on
enabeling outputs. Spreader
384 WARNING No answer when attempting to Message stored in log and displayed on
enabeling outputs. Spreader
385 INFO AutoTuner stored in NVRAM Regulator index. Message stored in log and displayed on
Spreader
386 INFO Tandem - Teaching a pre- The ID of the position Message stored in log and displayed on
defined position teached Spreader
387 INFO Tandem - A command to store a Message stored in log and displayed on
new value for a log position has Spreader
been received
388 INFO Tandem - command to go to a The ID of the position Message stored in log and displayed on
pre-defined position has been requested Spreader
received
389 INFO Tandem - A command to return The ID of the position Message stored in log and displayed on
to a log position has been requested Spreader
received
390 WARNING Tandem - Cylinder position has The ID of the cylinder Message stored in log and displayed on
changed more than allowed. Spreader
391 INFO Tandem – Both landside and Message stored in log and displayed on
waterside spreaders enabled Spreader
392 INFO Tandem – Landside spreader Message stored in log and displayed on
enabled Spreader
393 INFO Tandem – Waterside spreader Message stored in log and displayed on
enabled Spreader
395 INFO TandemPush – Inner position Message stored in log and displayed on
reached. Spreader
396 INFO TELESCOPE – Impact detected Message stored in log and displayed on
Spreader
398 WARNING TELESCOPE – Sensor value is Message stored in log and displayed on
out of range Spreader
399 INFO TELESCOPE – Bumped out of Message stored in log and displayed on
signal window Spreader
400 INFO TWL – TTDS active Message stored in log and displayed on
Spreader
401 WARNING TWL – Lock attempt with Message stored in log and displayed on
TTDS active Spreader
402 INFO Digital I/O configured on an Node id on where I/O Message stored in log and displayed on
AnybusGateway configured Spreader
403 INFO Analogue I/O configured on an Node id on where I/O Message stored in log and displayed on
AnybusGateway configured Spreader
404 INFO PWM configured on an Node id on where I/O Message stored in log and displayed on
AnybusGateway configured Spreader
405 INFO ASC – Antisway sytem active Message stored in log and displayed on
Spreader
406 INFO ASC – Antisway sytem ready Message stored in log and displayed on
Spreader
407 INFO ASC – Antisway sytem failed Message stored in log and displayed on
Spreaderi
408 spare 88
412 WARNING Auto Tuner – Finished but failed Parameter No. Some parameters could not be calculated.
to calculate some parameters Check sensors etc.
416 INFO CANopen – Node removed from Node number Message stored in log and displayed on
heartbeat list Spreader
417 INFO CANopen – New node added to Node number Message stored in log and displayed on
heart beat list Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
418 INFO CANopen – Boot message Node number Message stored in log and displayed on
received from node Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
419 INFO CANopen – Node stopped Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
420 INFO CANopen – Node in operational Node number Message stored in log and displayed on
state Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
421 INFO CANopen – Node in Node number Message stored in log and displayed on
preoperational state Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
422 WARNING CANopen – Heartbeat failed on Node number Message stored in log and displayed on
node Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
423 ERROR CANopen – To many slaves in Message stored in log and displayed on
use Spreader. Check spreader program.
424 ERROR CANopen – Failed to configure Message stored in log and displayed on
SDO Spreader. Check spreader program.
425 WARNING CANopen – Failed to send SDO Node number Message stored in log and displayed on
Spreader. Check spreader program.
426 WARNING CANopen – Bus off occured Message stored in log and displayed on
Spreader.
427 ERROR CANopen – Failed to change the Message stored in log and displayed on
bitrate on CAN interface Spreader.
428 Spare 89
429 Spare 90
430 Spare 91
431 WARNING CANopen – Emergency object Contents of byte Message stored in log and displayed on
additional byte 1 Spreader. See more specific literature
regarding CANopen [DS 301, DS 401] and
slave user manual
432 WARNING CANopen – Emergency object Contents of byte Message stored in log and displayed on
additional byte 2 Spreader. See more specific literature
regarding CANopen [DS 301, DS 401] and
slave user manual
433 WARNING CANopen – Emergency object Contents of byte Message stored in log and displayed on
additional byte 3 Spreader. See more specific literature
regarding CANopen [DS 301, DS 401] and
slave user manual
434 WARNING CANopen – Emergency object Contents of byte Message stored in log and displayed on
additional byte 4 Spreader. See more specific literature
regarding CANopen [DS 301, DS 401] and
slave user manual
435 WARNING CANopen – Emergency object Contents of byte Message stored in log and displayed on
additional byte 5 Spreader. See more specific literature
regarding CANopen [DS 301, DS 401] and
slave user manual
436 INFO CANopen – Slave OK Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401] and
slave user manual
437 WARNING CANopen – Generic error Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401] and
slave user manual
438 WARNING CANopen – Current Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
439 WARNING CANopen – Current, device Node number Message stored in log and displayed on
input side Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
440 WARNING CANopen – Current, inside Node number Message stored in log and displayed on
device Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
441 WARNING CANopen – Current, device Node number Message stored in log and displayed on
output side Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
442 WARNING CANopen - Voltage Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
443 WARNING CANopen – Mains voltage Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
444 WARNING CANopen - Voltage inside Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
445 WARNING CANopen – Voltage output Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
446 WARNING CANopen - Temperature Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
447 WARNING CANopen – Temperature Node number Message stored in log and displayed on
ambient Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
448 WARNING CANopen – Temperature device Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
449 WARNING CANopen – Hardware device Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
450 WARNING CANopen – Software device Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
451 WARNING CANopen – Software inside Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
452 WARNING CANopen – software user Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
453 WARNING CANopen – Data set Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
454 WARNING CANopen – Additional module Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
455 WARNING CANopen - Monitoring Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
456 WARNING CANopen – CAN overrun Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
457 WARNING CANopen – CAN error passive Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
458 WARNING CANopen – Lifeguard or Node number Message stored in log and displayed on
heartbeat Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
459 WARNING CANopen – Recover from bus Node number Message stored in log and displayed on
off Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
460 WARNING CANopen - Transmit COB id Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
461 WARNING CANopen – General Node number Message stored in log and displayed on
communication Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
462 WARNING CANopen – General protocol Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
463 WARNING CANopen – PDO not processed Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
464 WARNING CANopen – PDO length Node number Message stored in log and displayed on
exceeded Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
465 WARNING CANopen – External error Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
466 WARNING CANopen – Additional Node number Message stored in log and displayed on
functions Spreader. See more specific literature
regarding CANopen [DS 301, DS 401]
467 WARNING CANopen – Device specific Node number Message stored in log and displayed on
Spreader. See more specific literature
regarding CANopen [DS 301, DS 401] and
slave user manual
468 WARNING CANopen – Node missing Node number Check CAN connections and spreader
program.
469 INFO CANopen – Node id changed Changed to node Message stored in log and displayed on
number Spreader.
470 WARNING CANopen – Node id chage Node number Message stored in log and displayed on
failed Spreader.
e 10 05-03-08
Document: Project: Project No
2
Manual SCS Any us Gateway
Prepared by: Date: Version: Page:
Andy Lewis 2005-03-08 10:41 11 2(13)
1 General ......................................................................................................................................................................... 3
1.1 OVERVIEW ............................................................................................................................................................... 3
1.2 DICTIONARY AND ABBREVIATIONS .......................................................................................................................... 3
1.3 DOCUMENT LAYOUT ................................................................................................................................................ 3
2 Introduction ................................................................................................................................................................. 4
2.1 GENERAL ................................................................................................................................................................. 4
2.2 THE NODES .............................................................................................................................................................. 5
3 Software........................................................................................................................................................................ 5
3.1 BOOT PROGRAM ...................................................................................................................................................... 5
3.2 SYSTEM PROGRAM ................................................................................................................................................... 5
3.3 SPREADER PROGRAM ............................................................................................................................................... 6
4 Hardware Overview .................................................................................................................................................... 6
4.1 BCAN - STATUS LEDS ........................................................................................................................................... 6
4.2 THE ANY BUS CARD ................................................................................................................................................. 6
4.3 POWER CONNECTOR ................................................................................................................................................. 6
4.4 BCAN CONNECTOR ................................................................................................................................................. 7
4.5 NODE ADDRESS KEY SWITCHES ................................................................................................................................ 7
4.6 SERIAL PORT CONNECTOR ........................................................................................................................................ 7
4.7 GROUND CONNECTION ............................................................................................................................................. 7
4.8 FIELD BUS CONNECTIONS. ....................................................................................................................................... 8
4.8.1 Mapping of I/O .............................................................................................................................................. 8
4.9 FAULT FINDING TABLE........................................................................................................................................... 10
5 Software tools............................................................................................................................................................. 10
5.1 OVERVIEW ............................................................................................................................................................. 10
5.2 ABE....................................................................................................................................................................... 10
5.3 BMS ...................................................................................................................................................................... 10
6 Miscellaneous ............................................................................................................................................................. 11
6.1 DATA SHEET........................................................................................................................................................... 11
6.2 DIMENSIONS .......................................................................................................................................................... 12
7 Appendix A (Error messages)................................................................................................................................... 13
1 General
1.1 Overview
This document serves as a user manual and shall be used by the those installing and using the Bromma SCS2 Anybus
Gateway. Software as well as hardware routines and descriptions are covered in this document.
2 ntrodu tion
The core of the Bromma Smart Spreader is the Spreader Communications System (SCS2). In 1991 when Bromma decided
to develop a new and highly advanced communications system a close look at the available bus systems revealed a
number of shortcomings, such as temperature range, EMC (Electro Magnetic Compatibility) protection and mechanical
roughness.
Bromma therefore decided to design a bus system that met the demands made on an electronic system for a tough
Spreader application. We decided to develop a modular programmable controller, with a heavy-duty field bus interface
that complies with European and international standards for control equipment in this area. The SCS2 solution is a single
control product that can be used as I/O, as a PLC, and as distributed control for up to 528 I/O points. SCS2 nodes are
simple to install. You can connect up to 11 devices using just a single pair of wires. With its modular and scaleable
architecture, intuitive features and unparalleled ease of use, it will help save crane builders and end users time and money.
2.1 General
As a universal I/O, SCS2 gives you the freedom to connect to a wide variety of host controllers, including PLC's, DCS
and PC-based control systems by way of DeviceNet, Profibus-DP. SCS2 can be networked as a slave to Profibus-DP or
you can choose a DeviceNet master module for easy third-party integration. Designed by Bromma engineers for reliable
performance in the particularly challenging environment of container handling the system corporate four basic elements:
Crane Node A device directly interfacing with the crane’s control systems, computer and
monitoring screens, providing an optional serial bus interface for
programming or diagnostic communications, as well as an interface to the
spreader node.
Crane-Spreader Communications Link A two-wire conventional cable CAN communications between the crane
control system and the spreader.
Spreader Node A device that interfaces directly with the spreader’s sensorsand actuators.
One of the Spreader nodes normally acts as Master.
Sensors and Switches Conventional sensors, switches, and actuators on the spreader.
The system is divided into several hardware blocks called nodes. The nodes are located on the spreader and in the crane.
The nodes are connected to each other via a CAN network, see figure 1. The number of nodes required is based on the
number of I/O needed.
The only difference is their identity, id. Depending on their location the nodes have different ids. They are numbered
from 0 to 11 where:
Crane PLC
Crane field bus
Anybus Gateway A1
Spreader
Figure 1. The figure shows SCS2 connected to the spreader and the crane via I/O. The nodes are also connected internally
via a CAN network.
The SCS2 is built up of several nodes co-operating in the system. Each node has a specific role, either slave or master.
There must be only one master node in the system and the rest are slaves.
The master node makes all the calculations and decisions. The slave nodes act as remote I/O to the master.
3 So tware
The SCS2 software consists of three types of programs; Boot Program, System Program and Spreader Program.
4 ardware er iew
Figure2 is a SCS2 Anybus Gateway node equiped with a Profibus slave card. The different parts are explained in the
following chapter. This view shows a Profibus card, this can naturally be exchanged for any other available fieldbus.
AnyBus
(Profibus) card
Status LEDs
status LEDS
Figure 2. The SCS2 Anybus Gateway node equiped with a Profibus slave card.
The size of the data exchange area between the SCS2 and the Anybus card is configurable up to 64 bytes in and 64 bytes
out. The configuration is done via HMS standard files. This interface must be configured in the same way for both the
Master and the SCS 2 slave for the bus to work correctly. For each project a document has to be sent to the customer
describing the used parts of the interface. When referring to in/out we view it from the SCS2 side, hence input for the
SCS2 is an output from the master in the crane. Hence the crane PLC and the AnyBus card must have corresponding
addresses and the nymber of bytes configured for input/output data have to be the same on both sides of the
communication link i.e. the crane PLC and the SCS2.
OUT IN
Byte 0-63 Byte 0-63
Project Project
specific specific
outputs inputs
Output Segment
In the output segment it possible to use a number of bytes for diagnostic information in the form codes. The code sent
will be equivalent with the code displayed in the onboard display, hence there will be three levels of this code INFO,
WARNING, ERROR. Apart from the code and the byte for indicating the type of code a counter will be incremented
each time a code is sent. The counter is a 16bit value and therefore will begin from 0 if the counter overflows. The value
of this counter will be sent each time that a new diagnostic message is transmitted.
The remaining bytes for output will be assigned the interface with the crane and will vary on each project. The
assignments here are discrete outputs from the Spreader and current values (pressure etc.) from devices on the Spreader.
These assignments shall be are documented in the electrical documentation of the project.
Input Segment
The entire range of the input area is configurable per project. The assignments here are discrete inputs to the Spreader and
set point values for the Spreader. These assignments shall be documented in the electrical documentation of the project.
Power Supply
The node won’t start. The power LED Measure the main supply. The voltage The power LED should be on.
is off. should exceed 10V DC and be less
than 30V DC.
RS-232
BMS system can not communicate Probe TxD and RxD lines with Data lines should show square waves
with the node. oscilloscope while trying to between –10V to +10V relative to
communicate. Ensure that connection GND pin.
cables aren’t damaged.
CAN
The node can not communicate with Probe bus lines with oscilloscope. Check that CAN high and CAN low
the other nodes. CAN high should show square waves are not mixed up.
pointing downwards and CAN low
should be showing square waves
pointing upwards.
Node ID
The unit stops at start-up. Check selected node ID. This can indicate that the node has
wrong id strapped telling the node to
participate in the system with wrong
role.
5 So tware tools
5.1 Overview
There are some related tools to the SCS2, which support it in different ways. A brief description of these tools is given
below.
5.2 ABE
ABE (Application Builder Environment) is a tool for developing and configuring the spreader program, which controls
the logic of the spreader. ABE generates a load file. For more detailed see the separate manual.
5.3 BMS
BMS ultra light (Bromma Monitoring System ultra light) is a tool for monitoring events and reading status of I/O in the
SCS2. BMS can also be used to download new programs to the SCS2. For more detailed see the separate manual.
Mis ellaneous
6.2 Dimensions
Figure 3. The SCS2 Anybus Gateway node equiped with a Profibus slave card. All dimensions are in mm.
WEIGHT
1 lb = 0,4536 kg
1 kg = 2,2046 lb
1 ton = 1 t = 2000 lb = 907 kg = 0,893 Lt= 0,907 tonne
1 Lt = 2240 lb = 1016 kg = 1,016 tonne = 1,120 ton
1 tonne = 1 mT = 2204 lb = 1000 kg = 0,9842 Lt = 1,103 ton
VOLUME
1l = 0,21997 UKgal = 0,26417 USgal
PRESSURE
1 bar = 10 N/cm2 = 1,02 Kp/cm2 = 14,503 lbf/in2
POWER
1 Hp = 0,746 kW
1 kW = 1,341 Hp
TORQUE
1 Kpm = 9,81 Nm = 7,233 lbf
FORCE
1 Kgf = 1 kp = 9,81 N = 2,2046 lbf
TEMPERATURE
dgr C = 5 •(dgr F-32)
9
A = ampere l = litre
o
C = degrees centigrade lb = pound
c/s = cycles per second lbf= pound force
o
F = degrees Fahrenheit m = meter
ft = foot min= minute
gal = gallon n = newton
Hp = horse power s = second
Hz = hertz t = tonne
in = inch v = volt
kg = kilogramme w = watt
Kgf = kilopond force m = micron