Troublesshooting manual 3b6.pdf

3B6 LOAD MOMENT INDICATOR (LMI) FOR MRT TELESCOPIC HANDLERS TROUBLESHOOTING MANUAL Su stabilizzatori 360° 0 0 1000 1001 4 4,5 5 5,5 6 6,5 7 7,5 8 8,5 9 9,5 10 10,5 11 11,5 12 12,5 13 13,5 14 14,5 15 15,5

1 5,7 110

2 6,7 100

3 7,9 100

4 9,1 100

5 10,3 100

6 11,5 100

7 12,8 100

8 14 100

9 15,2 100

10 16,6 100

5 5 4,5 4,2 4

5 5 4,5 4,2 4 4 3,2 3 2,8

5 5 4,5 4,2 4 4 3,2 3 2,8 2,4 2,4 2,1 2

4,5 4,5 4,5 4,2 4 4 3,2 3 2,8 2,4 2,4 2,1 2 1,65

4 4 4 3,7 3,5 3,2 3 2,8 2,8 2,4 2,4 2,1 2 1,65 1,6 1,4 1,35 1,2 1,15

3,2 3,2 3,2 3 3 2,8 2,8 2,4 2,2 2,2 2,2 2,1 2 1,65 1,6 1,4 1,35 1,2 1,15 1 0,95

3 3 3 3 2,8 2,8 2,4 2,2 2,2 2,1 1,9 1,9 1,8 1,65 1,6 1,4 1,35 1,2 1,15 1 0,95 0,85 0,8 0,8

2,8 2,8 2,8 2,8 2,8 2,55 2,4 2,2 2,1 2 1,9 1,8 1,65 1,6 1,5 1,4 1,35 1,2 1,15 1 0,95 0,85 0,8 0,8

2,8 2,8 2,8 2,8 2,65 2,5 2,3 2,15 2,05 1,9 1,8 1,7 1,6 1,5 1,45 1,4 1,35 1,2 1,15 1 0,95 0,85 0,8 0,8

2,4 2,4 2,4 2,4 2,3 2,3 2,2 2,1 1,95 1,8 1,7 1,6 1,55 1,45 1,45 1,4 1,35 1,2 1,15 1 0,95 0,85 0,8 0,8

11

29

22-01-02 Up-grade

0 1 2 3 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

Complies to the MACHINES DIRECTIVE Standards: EN60204 – 1 , EN954 , EN12077 - 2 EMC according to the “ Heavy Industrial Environment” category: EN50081 - 2 , EN50082 - 2

INDEX

1 ACCESS PROCEDURES TO µMACXxx

PAGE 2,3,4

DESCRIPTION

LMI COMPONENTS POSITIONING ON THE MACHINE MAIN CONTROL UNIT CODE: UMMST01-2/XX MAIN CONTROL UNIT GENERAL CHARACTERISTICS MAIN CONTROL UNIT CONNECTIONS AND SIGNALS BOOM LENGTH AND ANGLE SENSOR CODE : CIT-1PICW1/xx BOOM LENGTH AND ANGLE SENSOR - DIMENSIONS AND WIRING BOOM LENGTH AND ANGLE SENSOR - EXPLODED VIEW PRESSURE TRANSDUCER CODE : Y11 4740-350 PRESSURE TRANSDUCER TECHNICAL SPECIFICATIONS CONTROL PANEL CODE : IDR1-3/xx CONTROL PANEL DIMENSIONS, CHARACTERISTICS, CABLE

5 6 7 8 9 10 11 12 13 14 15

DETECTION

TROUBLESHOOTING ALARM CODES AND ACTIONS TO TAKE AUTO DIAGNOSTIC- Geometric data and load data AUTO DIAGNOSTIC- Hydraulic pressures data AUTO DIAGNOSTIC- Sensors digital signals AUTO DIAGNOSTIC- Status of digital Inputs AUTO DIAGNOSTIC- Status of digital Outputs ALARM CODE 1 : MEMORY DATA NOT RELIABLE ALARM CODE 2 : ANGLE READING < MINIMUM VALUE ALARM CODE 3 : ANGLE READING > MAXIMUM VALUE ALARM CODE 4 : EXTENSION READING < MINIMUM VALUE ALARM CODE 5 : EXTENSION READING > MAXIMUM VALUE CABLE REEL POWER SUPPLY VERIFYING ANGLE POTENTIOMETER VERIFYING BOOM LENGTH POTENTIOMETER VERIFYING ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE ALARM CODE 9 : MAIN CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUE ALARM CODE10 : MAIN CYLINDER (ROD SIDE ) < MINIMUM VALUE ALARM CODE11 : MAIN CYLINDER (ROD SIDE ) > MAXIMUM VALUE ALARM CODE18 : COMPENSATION CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE ALARM CODE19 : COMPENSATION CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUE ALARM CODE20 : COMPENSATION CYLINDER (ROD SIDE ) < MINIMUM VALUE ALARM CODE21 : COMPENSATION CYLINDER (ROD SIDE ) > MAXIMUM VALUE

16 17,18,19 20 21 22 23 24 25 26 26 27 27 28 29 30 31 32 33 34 35 36 37 38

ACTION

EPROM and EEPROM REPLACEMENT POTENTIOMETERS ALIGNMENT ANGLE AND EXTENSION SENSORS CALIBRATION - 1ST PASSWORD INTRODUCTION ANGLE AND EXTENSION SENSORS CALIBRATION - LMI SELF-CALIBRATION DATA DOWNLOADING ON E2PROM -“SAVE” FUNCTION LANGUAGE/MEASURE SYSTEM SELECTION AND 2ND PASSWORD INTRODUCTION DATA DOWNLOAD FROM LAP-TOP TO LMI DATA DOWNLOAD FROM LMI TO PC AND FROM PC TO FLOPPY DISK SYSTEM LAY-OUT AND CONNECTIONS EXTERNAL WIRING RECOMMENDED SPARE PARTS LIST

39 40 41 42 43 43 44 45 46 47 48

2

ACCESS PROCEDURES TO µMACXxx LOAD MONITORING SYSTEM (LMI) This system has been conceived and developed to offer different levels of functionality of access to internal data, according to the actions to be done; the following description explains these several levels. Starting from the basic level (Operator) some access levels are available, identified by three different PASSWORDS; the first one given to the Technical Service Department and possibly authorized Dealers (for troubleshooting and sensors replacement), and the second one given to the MANITOU Technical Service Department only (for refined calibration), and the third one exclusively to Authorised programming personnel (for Load Table and Machine Parameters programming), due to the danger of wrong handling. 1°LEVEL: OPERATOR: Without needing a PASSWORD (also see OPERATOR MANUAL) all the working information of the machine is available through system monitoring displayed by the display panel; starting from basic working data: lifted load, max admitted load, outreach, working conditions, and tilting percentage. By pressing the ENTER key it is possible to show other machine working data: boom angle and length. By pressing ENTER again it will be possible to show the hydraulic pressure values at their 4 measuring points, (two on the main cylinder, and two on the compensation cylinder); Further pushing of the ENTER key gives more information about transducers signals digital converted values, and about ON/OFF Inputs and Outputs. The aim is to give to the Operator the possibility of reviewing these readings, allowing him to communicate them to the Technical Assistance Department, giving relevant data, possibly avoiding a direct Service on site. The Operator can also find some information to solve easy faults in his OPERATOR MANUAL.

3

2° LEVEL: (1st PASSWORD) SENSORS REPLACEMENTS : TECHNICAL ASSISTANCE DEPT. AND AUTHORIZED DEALERS The second level corresponds to the information contained in this TROUBLE SHOOTING MANUAL, where all details referred to system components are included (Main Unit, Transducers, Display Panel), troubleshooting codes introduction, and the useful information to remove the problems without specific tools (except a voltmeter). For this level a 1st PASSWORD is given, allowing entry into all diagnostic functions and transducer calibration (Angle and Length) in case of their replacement, without needing any PC or programming tool. As far as Pressure Transducers are concerned, please note that they do not need any calibration, as they are totally interchangeable.

5

LMI COMPONENTS POSITIONING ON THE MACHINE

Angle/length transducers on left side of the boom

Display: into the cabin

Main unit: into the cabin

SYSTEM LAY-OUT AND CONNECTIONS at page 46

4 Pressure Transducers on lifting and compensation cylinders

6

MAIN CONTROL UNIT

CODE: UMMST01-2/XX

UMMST01-2 Main Control Unit is equipped with memories for Data and program storage not erasable EPROM type or erasable EEPROM type for calibration parameters storage. INPUT/OUTPUT

circuits

are

self-protected

against overloads and short circuits. Power supply internal circuits are designed to operate at low voltage and are provided with all protection for harsh environments. UMMST01-2 Main Control Unit is provided with all EMC necessary components.

7

MAIN CONTROL UNIT GENERAL CHARACTERISTICS
POWER SUPPLY • From vehicle battery • Current consumption, without loads


INPUT / OUTPUT • 8 Digital Inputs • 4+1 Digital Outputs • 6 (+2) Analog Inputs • Watch Dog Dynamic Output : not used • Voltage working range : 10-28 VCC • Output Current : 2A • Analog Inputs Voltage : 0- 5V • 2 Serial Links RS232 (panel and PC), CAN BUS (option) • Clock and Buffer Battery (option) • Epoxy Resin Coating • 8 Kb E2prom for Data Recording (32Kb Option)

MECHANICAL CHARACTERISTICS
MECHANICAL DIMENSIONS • Case Dimension • Fixing holes


:10-28 V : 0,35A

VIBRATIONS • Continuous • Shock

: 253 x 217 x 91 mm : 226 x196 mm : 5g’s from 20 to 400Hz Over 3 AXIS : 10g’s


ENVIROMENTAL • Salt spray resistance over 48 Hours


TEMPERATURE • Working range • Storage range

:-30 -+70°C :-45 - +85°C

8

MAIN CONTROL UNIT

NOTE:

CONNECTIONS and SIGNALS EPROM : LOAD TABLES AND PARAMETERS

EEPROM: CALIBRATION DATA

CODE DIODE PIN DI0 D35 17 DI1 D39 18 DI2 D43 19 DI3 D47 20

FUNCTION OUTRIGGERS FRONT 1/2 OUTRIGGERS BASKET

DO0 DO2

SHUT-DOWN WARNING

D68 D77

25 27

D2 = RED LED When lit means that +15V Voltage is active

PC (LAPTOP) CONNECTIONS

D1 = RED LED When lit means that +5V Voltage is active

Note : D1 and D2 must be lit when the system is ON EXTERNAL WIRING See page 47 SHUT-DOWN

D35, D39, D43, D47, D51, D55, D59, D63 =RED LED’s They show the INPUT status ON = ACTIVE INPUT

WARNING

D68, D71, D74, D77 = RED LED’s

They show the OUTPUT status ON = ACTIVE OUTPUT

9

BOOM LENGTH AND ANGLE SENSOR

CODE : CIT-1PICW1/xx

The boom and angle sensor is formed by a cable reel with pulley on which a cable is wound; the other end is attached to the boom head (or to the first telescopic element in case of proportional extension). When extending the boom, the cable unwinds (max. 12 mt.) measuring the extension length signal through a 10-turns servo potentiometer. While using the machine, it is always necessary to carefully survey the unwinding cable along the boom, as it can be accidentally broken if it is snagged or struck by external forces. The replacement of this element has to be done by Qualified Personnel only. The angle sensor (inside the cable reel) detects the absolute angle of the boom referred to the vertical gravity reference thanks to a 1-turn servopotentiometer activated by a pendulum. Analog signals from above potentiometers are used by the LMI to compute the boom geometrical data.

10

BOOM LENGTH AND ANGLE SENSOR OVERALL DIMENSION

WIRING DIAGRAM

11

BOOM LENGTH AND ANGLE SENSOR EXPLODED VIEW Description 7-2 2

7

7-1

5-1

5 3 8-1

6 6-1

8 12

9

10

1 4

11

1 Case 2 Base 3 Circuit board 4 Step 5 Pinion 5-1 Shaft 6 Clutch 6-1 10-turns Potentiometer 7 1-turn Potentiometer 7-1 Pendulum 7-2 Bearing support 8 Pulley 8-1 Cap 9 Strain relief 10 Breather 11 Spring 12 Cable

12

PRESSURE TRANSDUCER

CODE : Y11 4740-350

The 4 Pressure transducers detect the pressure into the boom lifting and compensation cylinders; typically 2 sensors are required for measuring the differential pressure inside cylinders : they must be installed on the two cylinder chambers to allow differential pressure. By these values, weight computing is achieved by the Main Control Unit. These sensing devices detect the pressure by means of a sensor, which transforms the measured pressure into a direct voltage proportional to the pressure itself. An on-board amplifier is included in the transducer itself. Any replacement of these elements is very easy because they are complete compatibility and must be done by Qualified Personnel. MECHANICAL DIMENSIONS

13

PRESSURE TRANSDUCER PIN CONNECTIONS PIN 1 2 3

TECHNICAL SPECIFICATIONS

3 Wires +VB (15V) Output signal 0,5 .. 5,5 V GND

INPUT DATA • • • •

Measuring ranges 350 bar Overload ranges 800 bar Max pressure 2000 bar Parts in contact with oil

OUTPUT DATA • Output Signal • Temperature compensation • Accuracy • Hysteresis • Repeatability ENVIRONMENTAL CONDITIONS • Nominal temperature range • Operating temperature range • Storage temperature range • Fluid temperature range OTHER DATA • Supply voltage • Current consumption • Life expectancy • Weight

Stainless steel ; Viton seal

0,5 ... 5,5V Max ≤0,15%/10K Typ.≤0,08%/10K Max ≤0,3%FS Typ.≤0,1%FS Max ≤0,1%FS Typ.≤0,05%FS ≤0,05%FS -25 ...+85°C -40 ...+85°C -40 ... +100°C -40 ... +100°C

12 ...30V ca.15mA 106 load cycle 145g.

14

CONTROL PANEL

CODE : IDR1-3/xx

Operating Mode Identification Symbols ( External automatic selections) Equipment Identification symbols (Manually selected from the control panel) Green/Amber/Red Lights showing working conditions( Safety/ Alarm/Shut down) Two rows alpha-numeric LCD display showing working data




2.2 4.0

Symbols and letters related to the display indications

6.1

11

4 Set-up keys (key “-” and “+” are not used in normal working condition)

Icon representing the machine and letters related to geometric data.

15

CONTROL PANEL : DIMENSIONS, CHARACTERISTICS, CABLE

TECHNICAL CHARACTERISTICS • Power supply • Temperature working range • Microcontroller structure

8 - 24 V. -20°+ 70°. 16 bit.

• Load typical accuracy

3,5%.

• Outreach computing accuracy

1%.

• Link to Main Control Unit

RS-232/C

CONNECTING CABLE TO MAIN CONTROL UNIT

1 Pin plugs 2 Cable 4x0,5 sch 3 Thermo shrink sheath

4 6 pins male connector 5 Crimping pins

16

TROUBLESHOOTING The first step to check a fault is to identify the problem which occurred with the machine Operator. Thanks to the auto-diagnostic procedures, which are able to recognise transducer failures, cable breaking and internal electronic faults,alarm codes are automatically shown on the display to the Operator, allowing him a certain capability of repairing, and also to better inform the Technical Assistance even remotely. When an alarm occurs, the LMI puts itself in a safe condition (shut down) blocking the dangerous movements and, at the same time, the display shows the alarm corresponding message on the display upper row. Depending on the message, the fault can be identified. Alarm: 2.2 4.0

6.1

18 11

Alarm codes are listed in the following pages. The list also includes some hints to help solve the problems and return to normal working conditions.

17

ALARM CODES AND ACTIONS TO TAKE Alarm code 1 PAGE 25 and 39,44

Description

Memory data not reliable

• Switch the system off and on. If the alarm persists: •Verify that E2prom chip is fitted properly in its socket. • Re-enter data and save it again • Replace the E2PROM chip and recalibrate the machine

Angle sensor reading lower than the minimum value

•Verify that the wiring and the connectors are not in short circuit. If the alarm persists: • Verify the angle sensor integrity.

2 PAGE 26 and 28,29, 40,41

3 PAGE 26 and 28,29, 40,41

4

What to do

Angle sensor reading higher than the maximum value

•Verify that the cable or the connector wiring is not open If the alarm persists: • Verify the angle sensor integrity.

PAGE 27 and 28,30, 40,41

Reading of the boom length sensor lower than the minimum value

•Verify that the wiring and the connectors are not in short circuit If the alarm persists: •Verify the length transducer integrity

5

Reading of the boom length sensor higher than the maximum value

• Verify that the cable or the connector wiring is not broken If the alarm persists: • Verify the length transducer integrity

PAGE 27 and28,30, 40,41

6

Length sensor 1 value lower than the calibration value

7

Length sensor 2 value lower than the calibration value

18

Alarm codes

Description

What to do

8 PAGE 31

Reading pressure of the main cylinder (bottom side) lower than the minimum.

• Verify that the cable or the connectors wiring is not in short circuit If the alarm persists: • Verify the pressure transducer integrity

9 PAGE 32

Reading pressure of the main cylinder (bottom side) higher than the maximum.

• Verify that the cable or the connector wiring is not open If the alarm persists: • Verify the pressure transducer integrity

10 PAGE 33

Reading pressure of the main cylinder (rod side) lower than the minimum.

•Verify that the wiring and the connectors is not in short circuit If the alarm persists: • Verify the pressure transducer integrity

11 PAGE 34

Reading pressure of the main cylinder (rod side) higher than the maximum.

• Verify that the cable or the connector wiring is not open If the alarm persists: • Verify the pressure transducer integrity

12

N/A

13

N/A

14

N/A

15

N/A

16

Output hasn’t been verify

17

N/A

19

Alarm codes

Description

18 PAGE 35

Reading pressure of the compensation cylinder (bottom side) lower than the minimum.

•Verify that the cable or the connector wiring is not in short circuit If the alarm persists, please, contact MANITOU Technical Assistance : • Verify the pressure transducer integrity.

19 PAGE 36

Reading pressure of the compensation cylinder (bottom side) higher than the maximum.

• Verify that the cable or the connector wiring is not open If the alarm persists, please, contact MANITOU Technical Assistance : •. Verify the pressure transducer integrity.

20 PAGE 37

Reading pressure of the compensation cylinder (rod side) lower than the minimum.

• Verify that the cable or the connector wiring is not in short circuit If the alarm persists, please, contact MANITOU Technical Assistance : •. Verify the pressure transducer integrity.

21 PAGE 38

Reading pressure of the compensation cylinder (rod side) higher than the maximum.

•. Verify that the cable or the connector wiring is not open If the alarm persists, please, contact MANITOU Technical Assistance : •. Verify the pressure transducer integrity.

12

N/A

13

N/A

14

N/A

15

N/A

What to do

19

Alarm codes

What to do

Description

26

N/A

27

N/A

28

N/A

29

N/A

30

“Stabiliser out” fault

Check related inputs (all related inputs must have the same status) Check wiring Check sensors

31

“Stabiliser touch down” fault

Check related inputs (all related inputs must have the same status) Check wiring Check sensors

32

Angle fault

Check related inputs Check wiring Check sensors

Telescope fault

Check related inputs Check wiring Check sensors

33

19

Alarm codes

Description

34

Angle sensor 2 reads lower than minimum value.

• Check for short-circuit in the wiring or in wiring connector plugs • If the alarm persists, consult Authorised MANITOU Assistance to: check for angle sensor default

35

Angle sensor 2 reads higher than maximum value.

• Check for short-circuit in the wiring or in wiring connector plugs • If the alarm persists, consult Authorised MANITOU Assistance to: check for angle sensor default

36

Elongation sensor 2 reads lower than minimum value.

• Check for short-circuit in the wiring or in wiring connector plugs • If the alarm persists, consult Authorised MANITOU Assistance to: check for elongation sensor default

37

Elongation sensor 2 reads higher than maximum value.

• Check for short-circuit in the wiring or in wiring connector plugs • If the alarm persists, consult Authorised MANITOU Assistance to: check for elongation sensor default

What to do

20

AUTO DIAGNOSTIC- System internal working conditions monitoring Geometric data and load data These readings show on some pages the internal status of the system which is very useful when a fault occurs. Starting from the main working data page press twice the ENTER button: The display will show the first control page, giving geometric data and main cylinder differential pressure summary.

P100 A 60

W 5.0 L20.3

M 5.0 R15.1

This page is displayed for 30 seconds; after which, it returns to the normal working condition page. The displayed parameters are as follows: • P : Main cylinder differential pressure in Bar; • W : Lifted load weight in Tonnes (Pounds/1000 if Imperial Measurement System is used); • M : Maximum admitted load in present position in Tonnes (Pounds/1000 if Imperial Measurement System is used) • A : Actual angle in Degrees: • L : Actual boom length in Meters (in Feet if Imperial Measurement System is used ); • R : Radius from turret rotation centre in Meters (in Feet if Imperial Measurement System is used)

21

AUTO DIAGNOSTIC- System internal working conditions monitoring Hydraulic pressures data By pressing the ENTER button again the display will show the second page showing: individual hydraulic pressures summary :

P100 p 0

L: 50 l: 0

H: 40 h: 0

This page is displayed for 30 seconds; after which , it returns to the normal working condition page. The displayed parameters are as follows: Upper row: • P : Main cylinder differential pressure in Bar; • L : Main cylinder bottom side pressure in Bar; • H : Main cylinder rod side pressure in Bar; Lower row: • p : Compensation cylinder differential pressure in Bar; • l : Compensation cylinder bottom side pressure in Bar; • h :Compensation cylinder rod side pressure in Bar; Remark: hydraulic displayed pressures might have correct values and coherent to the use of the machine. The effectiveness of these values can be evaluated only on the base of the Technical Engineer experience and to his knowledge of the actual corresponding pressures into the cylinders

22

AUTO DIAGNOSTIC- System internal working conditions monitoring Sensors Digital Signals By pressing once again the ENTER button the display will show the third page giving pressure transducers and length/angle sensors digital signals corresponding to the actual measurements.

1111 4444

2222 5555

3333 6666

This page is displayed for 30 seconds; after which, it returns to the normal working condition page. The displayed parameters are as follows: • 1111 : Main cylinder bottom side pressure value in Bits; between 0 and 1023 (*) • 2222 : Main cylinder rod side pressure value in Bits; between 0 and 1023 (*) • 3333 : Angle value in Bits; between 0 and 1023 (*) • 4444 : Boom Length value in Bits; between 0 and 1023 (*) • 5555 : Compensation cylinder bottom side pressure value in Bits; between 0 and 1023 (*) • 6666 : Compensation cylinder rod side pressure value in Bits; between 0 and 1023 (*) REMARK: These numerical readings follow the analog signals variations of the sensors. Minimum and maximum limits exist and they have not to be exceeded, otherwise the relevant signal is taken wrong by the system: THE MINIMUM VALUE IS 10, THE MAXIMUM VALUE IS 1010. (*) = Due to 10bits A/D Converter

23

AUTO DIAGNOSTIC - System internal working conditions monitoring Status of Digital Inputs By pressing the ENTER button again, the display will show the fourth page giving Inputs given by the micro-switches (Operating Mode OM ) status summary.

I 0 1 2 3 4567890123 * * - - ----------

This page is displayed for 30 seconds; after which, it returns to the normal working condition page. The displayed parameters are as follows: Digital Inputs (I) The upper row indicates the Input number, while the lower row indicates its status. The symbol “*” means active Input, the symbol “-” means non active Input . • 0 : Outriggers : “*” When they are on the ground and completely extended • 1 : Turret rotation : “*” When in front position. • 2 : ½ Outriggers : “*” When they are on the ground but half extended. • 3 : Basket : “*” When a basket is not fitted • 4…N : N/A NOTE : The combination of the Inputs status automatically selects the proper Operating Mode (OM ) and the corresponding load Table, depending on the machine model. REMARK: This page has the aim to check the proper Inputs status from outside (micro-switches) in the specific Machine positions. See also Page 8 : LED’S ON MAIN BOARD

24

AUTO DIAGNOSTIC - System internal working conditions monitoring Status of Digital Outputs to outside By pressing the ENTER button again, the display will show the fifth page giving Outputs of the system status summary ( automatic signals ).

O 0 1 2 3 4567890123 * * - - ----------

This page is displayed for 30 seconds; after which ,it returns to the normal working condition page. The displayed parameters are as follows: Digital Outputs (O) The upper row indicates the Output number, while the lower row indicates its status. The symbol “*” means active Output, the symbol “-” means non active Output . 0 : Shut-off

: “*” When the machine is working in safe or alarm conditions. “-” When the machine gets in to a shut-down condition( 100%)

• 1 : N/A • 2 : External alarm : “*” In Shut-down and alarm conditions, external buzzer is activated (>90%) NOTE : The aim of this page is to check the correct Outputs status to the external system components when an ALARM or SHUT-DOWN occurs. See also Page 8 : LED’S ON MAIN BOARD

25

ALARM CODE 1 : MEMORY DATA NOT RELIABLE CAUSE: All the calibration data is stored in the EEPROM 24C65 . Through the “Check-sum” equation, software continuously checks the comparison with the original memorised value. When detecting a difference, the display will show the following message: ALARM 1 = memory data not reliable. ACTION TO TAKE: 1) Switch the system off and on. 2) Verify that the EEPROM chip is fitted properly in its socket (see also page 39-EPROM and EEPROM REPLACEMENT). 3) Re-enter data and save again, switch off and on again. (To load data from the PC, please refer to the “SAVING DATA TO A PC” section-pages 44-45). 4) If the problem persists, replace the PC board making sure that software/parameters installed correspond to the machine characteristics.

EEPROM

26

ALARM CODE 2 : ANGLE TRANSDUCER READING LOWER THAN THE MINIMUM VALUE CAUSE: The signal from the angle transducer to the main PC board is lower than the minimum programmed value. This can be produced by a short-circuit in the electrical wiring, between the Main Unit and Sensor or the sensor itself is faulty. NOTE: The Main Unit Processor identifies below and above the signal range a minimum zone and a maximum zone in order to check the sensor. ACTION TO TAKE: Verify the cable reel PC board has the correct power supply ( refer to “CABLE REEL POWER SUPPLY VERIFYING” section - page 28 ). Verify angle potentiometer (refer to “ANGLE POTENTIOMETER VERIFYING” section - page 29).

ALARM CODE 3 : ANGLE TRANSDUCER READING HIGHER THAN THE MAXIMUM VALUE CAUSE: The signal from the angle transducer to the main PC board is higher than the maximum programmed value. This can be produced by a break in the electrical wiring, between the Main Unit and Sensor or the sensor itself is faulty. NOTE: The Main Unit Processor identifies below and above the signal range a minimum zone and a maximum zone in order to check the sensor. ACTION TO TAKE: Verify the cable reel PC board as the correct power supply ( refer to “CABLE REEL POWER SUPPLY VERIFYING” section - page 28 ). Verify angle potentiometer (refer to “ANGLE POTENTIOMETER VERIFYING” section - page 29).

27

ALARM CODE 4 : BOOM LENGTH TRANSDUCER READING LOWER THAN THE MINIMUM VALUE CAUSE: The signal from the boom length transducer to the main PC board is lower than the minimum programmed value. This can be produced by a short-circuit in the electrical wiring, between the Main Unit and Sensor or the sensor itself is faulty. NOTE: The Main Unit Processor identifies below and above the signal range a minimum zone and a maximum zone in order to check the sensor. ACTION TO TAKE: Verify the cable reel PC board has the correct power supply ( refer to “CABLE REEL POWER SUPPLY VERIFYING” section - page 28 ). Verify length potentiometer (refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 30)

ALARM CODE 5 : BOOM LENGTH TRANSDUCER READING HIGHER THAN THE MAXIMUM VALUE CAUSE: The signal from the boom length transducer to the main PC board is higher than the maximum programmed value. This can be produced by a short-circuit in the electrical wiring, between the Main Unit and Sensor or the sensor itself is faulty. NOTE: The Main Unit Processor identifies below and above the signal range a minimum zone and a maximum zone in order to check the sensor. ACTION TO TAKE: Verify the cable reel PC board has the correct power supply ( refer to “CABLE REEL POWER SUPPLY VERIFYING” section - page 28 ). Verify length potentiometer (refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 30)

28

CABLE REEL POWER SUPPLY VERIFYING Verify 5Volts between 1(+) and 2(GND) on cable reel board

TRUE

Verify the Potentiometers (**)

FALSE

Verify on the Main PC board 5Volts between 7(+) and 8(GND)

TRUE

FALSE

Cable break down. Check the cable-reel cable

Disconnect wires 7 and 8 from the Main pc board and Check for 5Vdc

TRUE

Probably the cable is in short circuit. Check cable

FALSE

Main pc board Is faulty. Replace it with a new one (*)

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39 (**) REFER TO pages 29 and 30

+ GND

29

ANGLE POTENTIOMETER VERIFYING Put the machine boom at 0° (horizontal). Verify between 2(GND ) e 3 (+ ) +2,5Vcc +/- 5%

FALSE

TRUE

Angle potentiometer broken (**)

Raise the boom slowly.

Verify with a voltmeter that the signal increases in a linear and continous way. . The variation is continous and linear

Losses of Signal

Angle potentiometer broken (**)

Verify on the Main PC board the potentiometer signal on 8(GND) and 9(ADC2) GND ADC2

The signal is not correct

Problems on the Connection Cable.Probably short circuited. Check the cable

The signal is correct

The Main PC board is faulty. Proceed with the replacement (*)

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39 (**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 40

30

BOOM LENGTH POTENTIOMETER VERIFYING The machine boom must be completely retracted. Verify between 2(GND ) and 5 (+ ) a voltage of roughly +250mV

TRUE

Voltage higher or at 5V

Extend the Boom

Boom Length potentiometer broken (**)

FALSE

Boom Length Potentiometer broken (**)

Verify with a voltmeter that the signal increases in a linear and continous way.

The variation is continous and linear

Losses of Signal

Boom Length potentiometer broken (**)

Verify on the Main PC board the potentiometer signal on 8(GND) and 12(ADC3) GND

The signal is not correct

Problems on the Connection Cable.Probably short circuited. Check the cable

The signal is correct

The Main PC board is faulty. Proceed with the replacement (*)

ADC3

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39 (**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 40

31

ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE) READING LOWER THAN THE MINIMUM VALUE NOTE: The Main Unit Processor identifies below and above the signal range a minimum zone and a maximum zone in order to check the sensor.

Verify on the Main pc board that between 1(+) e 2(GND) there is a voltage of +15Vdc

FALSE

TRUE

Disconnect wires on 1(+) and 2(GND) and Verify a voltage of +15Vdc

FALSE

The Main PC board is faulty.Proceed with the replacement(*)

TRUE

Problems on the Connection Cable.Probably short circuited. Check the cable

Broken Pressure Transducer.Proceed With the Replacement

+ GND

Measure on the Main PC board the voltage on 2(GND) and 3(ADC0)

Value 0,5Vdc

Broken Pressure Transducer.Proceed With the Replacement

The Main PC board is faulty.Proceed with the replacement(*)

32

ALARM CODE 9 : MAIN CYLINDER (BOTTOM SIDE) READING HIGHER THAN THE MAXIMUM VALUE NOTE: The Main Unit Processor identifies below and above the signal range a minimum zone and a maximum zone in order to check the sensor.

Verify on the Main PC board that between 1(+) e 2(GND) there is a voltage of +15Vdc

FALSE

TRUE

Disconnect wires on 1(+) and 2(GND) and Verify a voltage of +15Vdc

FALSE

The Main PC board is faulty.Proceed with the replacement (*)

TRUE

Problems on the Connection Cable.Probably short circuited. Check the cable

Broken Pressure Transducer.Proceed With the Replacement

+ GND

Measure on the Main PC board the voltage on 2(GND) and 3(ADC0)

Value >5Vdc

Broken Pressure Transducer.Proceed With the Replacement

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39

Value 5Vdc

Broken Pressure Transducer.Proceed With the Replacement

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39

Value 5Vdc

Broken Pressure Transducer.Proceed With the Replacement

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39

Value 5Vdc

Broken Pressure Transducer.Proceed With the Replacement

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39

Value