PAT America DS 350, Service Manual

Page 1: ...ww patamerica com PAT America Inc LOAD MOMENT INDICATOR DS 350 MODULAR GRAPHIC for Lattice Boom Cranes SERVICE MANUAL P N 031 300 190 118 REV 12 18 2000 ...

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Page 3: ...ot be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing performance or use of this manual This document contains proprietary information which is protected by copyright All rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of PAT MANUAL ...

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Page 5: ...SOLE 21 13DRAWINGS 23 13 1 ELECTRICAL WIRING DRAWING 1 PART 1 23 13 2 CENTRAL UNIT BREAKDOWN PARTS LIST DRAWING 2 25 13 3 CONSOLE DS350 1334 PARTS LIST DRAWING 3 27 13 4 CENTRAL UNIT MAIN BOARD LAYOUT DRAWING 4 28 13 5 CENTRAL UNIT ANALOG INPUT MODULE DRAWING 5 29 13 6 CONSOLE CONNECTION BOARD DRAWING 6 30 13 7 FORCE TRANSDUCER DRAWING 7 31 13 8 AREA DEFINITION SWITCH DRAWING 8 31 13 9 BOOM JUNCTI...

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Page 7: ... of approaching overload conditions and of over hoist conditions that could cause damage to equipment and personnel The device is not and shall not be a substitute for good operator judgment experience and use of accepted safe crane operating procedures The responsibility for the safe crane operation shall remain with the crane operator who shall ensure that all warnings and instructions supplied ...

Page 8: ... data is the reference information used to calculate the operating conditions The boom angle is measured by the angle sensor mounted in the boom base The cable reel cable serves as an electrical conductor for the anti two block switches and force transducer signals The load on the boom is measured by force transducer mounted on top of the boom close to the tip The interactive user guidance conside...

Page 9: ...e detailed flowcharts shown in Sections 5 through 12 The drawings and procedures that are referenced in these sections can be found in Section 13 and 14 What s Wrong Lever Lockout Activated Go to Section 6 No display Anti Two Block Problem Load Reading Problem Bad Data Transfer Interference Between Central Unit and Console Area Definition Indication Problem Go to Section 7 Go to Section 8 Go to Se...

Page 10: ...r angle specified in the load chart E04 Operating mode not existing or non permitted slewing zone A non existing operating mode has been selected Set the correct operating mode for the crane configuration in question The selected operating mode is not available in the data EPROM or blocked Check programming of the data EPROM The boom is in a non permitted slewing zone Slew the crane into a permitt...

Page 11: ...ows Sensor Pins Terminal X1 Lower Limit Upper Limit Main Force Transducer 36 E14 E24 Angle Sensor Main Boom 29 E15 E25 Each channel is constantly being monitored to be within 4 mA 1 1V resp and 20 mA 5 5V resp If it exceeds these limits the following errors are triggered Error Code Error Cause Elimination E14 Fallen below the lower limit value in the main force channel Cable between the central un...

Page 12: ...ve Replace system program PROM PROM No 0 E38 System program and data EPROM do not match The system program in the LMI does not match to the programming in the data EPROM Replace the system program PROM or the data EPROM PROM No 1 E41 Error in the internal write read memory RAM of the computer component 80C537 Computer component 80C537 defective CPU module defective Processor board defective Replac...

Page 13: ...acc to memory type Replace crane data EPROM E56 Error in the data EEPROM Memory module wrongly bridged Crane data EEPROM defective Bridge memory module acc to memory type Replace crane data EEPROM E57 Error in serial crane data EEPROM Serial crane data EEPROM does not contain valid data Memory module defective Write data on the serial crane data EEPROM by means of test program or on line function ...

Page 14: ...f the console electronics might be damaged Therefore replaces the console electronics Transmitter receiver module is defective Exchange console electronics or LMI main board resp E92 Error in the data transmission from console to central unit Loose connection in the line between console electronics and central unit Transmitter receiver module is defective Check the connection between console elect...

Page 15: ...ror in the internal RAM of the console The CPU of the console is defective The console main board is defective Replace the CPU of the console Replace the console main board E97 Error in the external RAM of the console The external RAM of the console is defective The console main board is defective Replace the external RAM of the console Replace the console main board EAB Short circuit in the A2B s...

Page 16: ... to Sect 14 Procedure 2 Main board replacement The LMI by pass warning light and or anti two block warning light is lit on the console LED s H8 H9 and H10 are lit on the main terminal board Refer to Drawing 4 in Section 13 The fault is located in LMI cables wiring fuses or console Read error code displayed on console and go to Section 5 Start Use the console key switch and the LMI by pass button o...

Page 17: ...This is an input voltage from the crane Refer to Drawing 1 Check fuses in central unit Replace fuses Measure voltage on the main board between X1 3 12 24V and X1 4 ground This is an output voltage to the console Refer to Drawing 1 NEXT PAGE START NO Check crane power supply for faulty wiring in crane electric NO YES YES NO Replace the main board in central unit Refer to Drawing 2 and Replacement P...

Page 18: ...ve Replace the console Refer to Drawing 1 and 3 Check connections of the cable between console and central unit Replace cable if necessary Refer to Drawing 1 in Section 13 END Correct PREVIOUS PAGE NO Measure voltage in the console between X1 1 12 24V and X1 2 ground Refer to Drawing 1 3 6 YES ...

Page 19: ... see whether or not crane is in two block condition Correct Lower hook down into safe position Plug appropriate bypass plug or system cable connectors into socket Refer to Drawing 1 and 2 Next Page Correct NO NO YES YES Check anti two block weight and or flags whether installed correctly Refer to Operator s Manual Pre Operational Inspection and Calibration Install A2B weight or flag if not correct...

Page 20: ...sensor cables not connected greater than 6 short then EAB error is given to the system The signal is returned to the CU unmodified for example a jumper wire connected between X1 31 and X1 32 in CU If the signal is within 3 to 6 volts or the A2B circuit is by passed LED H9 on the main board will be lit Refer to Drawing 3 Measure voltage on the main board terminal strip between X1 31 9V 0 5 and X1 3...

Page 21: ...measure the resistance between terminals 5 and 6 the junction box must be connected as follows a switch or by pass plug connected to the two 2 pin receptacles Switch closed 4 7KOhms weight or flag installed Switch open 1 Megaohm weight or flag removed Refer to Drawing 1 and 9 Check wire connections in boom nose box Replace junction box Refer to Drawing 1 Correct No Yes Check cable reel for damaged...

Page 22: ...ages or movement of mounting bracket Refer to Drawing 1 and Adjustment Procedure 3 START PROBLEM Angle displayed incorrect Crane is not in out of load chart condition Fuse blown or main board defective Replace main board Refer to Drawing 2 and Replacement Procedure 4 NEXT PAGE Correct mount Correct NO NO YES YES Measure the crain power supply voltage in the central unit between terminals X1 1 12 2...

Page 23: ...age and amperage measurements Three conductor wires are X1 26 A Ub X1 29 B signal 4 20mA X1 28 C GND PREVIOUS PAGE Replace angle sensor Refer to Adjustment Procedure 3 Somewhere between angle sensor and central unit the signal is lost Check wiring and replace Check analog input board voltage between X1 4 on analog input board and MP0 GND 0 5V to 4 5V is correct If otherwise main or analog board de...

Page 24: ...to Drawing 2 in Section 12 and Replacement Procedure 3 in Section 13 NO YES Measure signals for main force transducer in the central unit measure voltage between X1 36 and X1 25 or amperage at X1 36 voltage should be between 1 1 5 5 volt or amperage between 4 20mA Zero force on load cell equals 1 1V or 4mA Refer to Drawing 1 Correct Fault in cable assemblies cable reel boom tip junction box and or...

Page 25: ...D Check linerider for any visual damages and check continuity in force transducer cable assembly A to A B to C C to B note the wiring of the connector junction box 5 socket to 14 pin A to D B to C and C to A cable reel and cable assembly 14 pass connectors B to B C to C and D to D Refer to Drawing 1 NO Check power supply to force transducer by unplugging the cable assembly from the force transduce...

Page 26: ...d be between 24 volts and the DI3 LED should be on Refer to Drawing 1 4 and 8 Measure the proximity sensor supply voltage in the central unit between terminals X1 33 24v and X1 35 ground Refer to Drawing 1 Main board defective Replace main board Refer to Drawing 4 in Section 12 and Replacement Procedure 3 in Section 13 NO Correct Correct Measure the proximity sensor supply voltage at cable assembl...

Page 27: ...e on the main board Refer to Procedure 1 Place EPROM in correct socket Refer to Procedure 1 Make sure external and internal power supplies are correct Refer to No Display Section NEXT PAGE Correct Correct START NO YES NO Turn off system power Check the continuity of the receive RXD and transfer TXD wires Check continuity between central unit main board X1 5 and console X1 3 central unit main board...

Page 28: ...ake correct shield connection Refer to connection and wiring diagrams Drawings 1 Ensure that cable shields are connected correctly Check continuity in shielded cable assemblies Refer to connection and wiring diagrams Drawings 1 Install ground line single cable minimum of AWG14 2 0mm between terminal MP1 and central unit box mounting bracket Refer to Drawing 2 and 4 Check if additional ground link ...

Page 29: ...Drawings PAT Rev 12 18 00 CSH 190118_ DOC 23 13 DRAWINGS 13 1 Electrical Wiring Drawing 1 Part 1 ...

Page 30: ...Service Manual DS 350 Modular PAT Rev 12 18 00 CSH 190118_ DOC 24 Electrical Wiring Drawing 1 Part 2 ...

Page 31: ...al Unit Breakdown Parts List Drawing 2 The central unit is located in the cabin behind the operator s seat shown with the lid removed The electronics consist of the mainboard with the following modules Mainboard CPU Module w Data Module Analog Input Module ...

Page 32: ...7 1 CPU MODULE 04 024 351 300 016 1 EPROM MODULE 05A 000 304 140 112 1 RELAY 12V 05B 000 304 140 241 1 RELAY 24V 06 031 300 050 170 1 FUSE 4amp auto F1 07 031 300 050 171 1 FUSE 10amp auto F2 08 024 350 100 661 1 KEYSWITCH 09 031 300 101 131 1 SPARE KEY 10 024 000 100 095 2 MEMBRANE ELEMENT BREATHER 11 24 350 050 292A 1 CENTRAL UNIT COVER 12 024 350 100 135 1 SCREW SET FOR COVER 13 024 350 110 067...

Page 33: ...SOLE PARTS LIST PART NO 031 300 060 170 NO PART NO QTY DESCRIPTION 01 050 150 300 050 1 BOARD 02 050 150 300 051 1 TERMINAL BOARD 03 050 150 300 052 1 BOARD PUSHBUTTON SET KEYBOARDS 04 003 051 905 235 1 SWITCH KEY 05 050 350 110 139 1 KEY SPARE 06 050 350 300 076 1 BOARD TERMINAL INTERFACE FOR LIGHTBAR ...

Page 34: ...wing 4 BOARD P N 024 352 300 001 MP1 KGND MP4 5V MP8 9V MP9 6V MP23 VBAT MP24 BATT MP25 UBS console sensors DI s MP26 GND LED S H08 LOAD H09 A2B H10 LOCKOUT on when K10 is lit H11 POWER H12 TxD FUSES F1 4A F2 10A DI 1 not used D1 2 rigging mode UB on DI 3 not used DI 4 not used DI 5 not used DI 6 not used ...

Page 35: ...1 18 CH07 9V 4 X1 19 CH08 VREFA 2 2 500V X1 20 UKLEMM app VREFA limits ADC input to 5 0V MP1 AGND MP8 5V MP1 7 Input channels 1 7 0 5V 4mA 2 5V 20mA MP14 13V REF02 MP16 HESIN input voltage MP17 app 5 4V clamp for inputs The analog input module converts the sensor signals on channels 1 7 to signals that will be processed at the CPU and software The incoming signal measured at the measuring points M...

Page 36: ...Service Manual DS 350 Modular PAT Rev 12 18 00 CSH 190118_ DOC 30 13 6 Console Connection Board Drawing 6 ...

Page 37: ...3 7 Force Transducer Drawing 7 There are no spare parts associated with the force transducer 13 8 Area Definition Switch Drawing 8 A BROWN 10 30VDC B BLACK NO UB LED ON C WHITE NC UB LED OFF D BLUE GND LED ON WHEN STEEL IS PASSED IN FRONT OF SWITCH ...

Page 38: ...Service Manual DS 350 Modular PAT Rev 12 18 00 CSH 190118_ DOC 32 13 9 Boom Junction Box Drawing 9 You can use the terminal strip to easily measure voltages in one central point ...

Page 39: ...gs PAT Rev 12 18 00 CSH 190118_ DOC 33 13 10 Cable Reel Drawing 10 All boom tip signals go from the central unit through this cable reel to the boom tip sensors and switches Refer to drawing 3 for schematics ...

Page 40: ... CSH 190118_ DOC 34 14 PROCEDURES 14 1 Procedure 1 EPROM Location and Installation Ensure the notch is in the correct direction The DATA EPROM fills the bottom of the socket as shown by the arrows Place EPROM s in the correct EPROM socket as shown ...

Page 41: ...rminal wires from the main board 7 Remove the 14 large Philips screws holding the main board in place 8 Take notice of the orientation of the main board in the central unit Remove main board and place in the packing material that the replacement main board came in 9 Carefully insert the new main board in place Refer to Drawing 4 for location 10 Insert the 14 Philips mounting screws be sure to atta...

Page 42: ...tual angle make sure you use a high precision inclinometer to determine actual boom angle right at the angle sensor Due to boom deflection etc an angle measured at another part of the boom can differ from the indicated angle To adjust the angle sensor carefully loosen screws that hold it to the boom adjust the sensor very carefully and re tighten the screws Double check your indicated angle When y...

Page 43: ... is possible to find out the source of water ingress by going through the following steps and ruling out one possibility after the other until the cause is identified 1 Spray Cleaning The enclosures used for the PAT DS 350 system are water protected to IP 65 This means protection against the environment such as rain However through the use of spray cleaner at short distances it is possible to forc...

Page 44: ...n relief water may still enter the box through the inside of the cable In this case you have to find out why and where water enters the cable Look for damages to the cable itself and inspect the opposite side of the cable In example if the cable comes from a connector that is full of water the water will run through the inside of the cable and fill up the central unit too 14 4 2Condensation In a c...

Page 45: ...ntral unit and measure the current with the ammeter in series The measurement should be between 4 20mA 14 5 2Measuring voltage The voltmeter is used to measure voltage between pins X1 29 angle signal and X1 28 GND on the main board 024 352 300 001 The resistors are there to show that at 4mA the voltage is 1 1V because current multiplied with resistance equals voltage therefore 4mA x 275 ohms total...