DS 85 Operators MTX
DS 85 Operators MTX
DS 85 Operators MTX
com
HIRSCHMANN
OPERATOR’S MANUAL
P/N 031-300-190-165 REV C 02/29/2008
Operator's Manual DS 85
NOTICE
Hirschmann makes no warranty of any kind with regard to this material, including, but not limited
to, the implied warranties of merchantability and/or its fitness for a particular purpose.
Hirschmann will not be liable for errors contained in this manual or for incidental or
consequential damages in connection with the furnishing, performance, or use of this manual.
This document contains proprietary information, which is protected by copyright, and all rights
are reserved.
Hirschmann reserves proprietary rights to all drawings, photos and the data contained therein.
The drawings, photos and data are confidential and cannot be used or reproduced without the
written consent of Hirschmann. The drawings and/or photos are subject to technical
modification without prior notice.
MANUAL REVISIONS
TABLE OF CONTENTS
2 WARNINGS ........................................................................................................................... 1
10 TROUBLESHOOTING ..................................................................................................... 25
10.1 GENERAL .......................................................................................................................... 25
10.2 SERVICE SCREEN ............................................................................................................... 25
10.3 MALFUNCTION TABLE ........................................................................................................ 26
10.4 OPERATING ERRORS ......................................................................................................... 26
1 GENERAL INFORMATION
The PAT Load Moment Indicator1 (LMI) has been designed to provide the crane operator with
the essential information required to operate the machine within its design parameters.
Using different sensing devices, the Load Moment Indicator monitors various crane functions
and provides the operator with a continuous reading of the crane’s capacity. The readings
continuously change as the crane moves through the motions needed to make the lift.
The LMI provides the operator with information regarding the length and angle of the boom,
working radius, rated load and the total calculated weight being lifted by the crane.
If non permitted conditions are approached, the Load Moment Indicator will warn the operator
by sounding an audible alarm, lighting a warning light and locking out those functions that may
aggravate the crane’s condition.
2 WARNINGS
The LMI is an operational aid that warns a crane operator 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 are fully understood and observed.
Prior to operating the crane, the operator must carefully and thoroughly read and understand
the information in this manual to ensure that he knows the operation and limitations of indicator
and crane.
Proper functioning depends upon proper daily inspection and observance of the operating
instructions set forth in this manual. Refer to Section 6. Pre-Operation Inspection and
Calibration Verification of this handbook.
The LMI can only work correctly, if all adjustments have been properly set. For correct
adjustment, the operator has to answer thoroughly and correctly all questions asked
during the setup procedure in accordance with the real rigging state of the crane. To
prevent material damage and serious or even fatal accidents, the correct adjustment
of the LMI has to be ensured before starting the crane operation.
1
LOAD MOMENT: generally the product of a force and its moment arm; specifically, the product of the load and the load-radius. Used in the
determination of the lifting capacity of a crane
3 SYSTEM DESCRIPTION
The PAT Load Moment Indicator consists of a central micro processor unit/operating console,
length/angle sensor, pressure transducers, and anti-two block switches.
The system operates on the principle of reference/real comparison. The real value, resulting
from the pressure measurement is compared with the reference data, stored in the central
processor memory and evaluated in the micro processor. When limits are reached, an overload
warning signal is generated at the operator’s console. At the same time, the aggravating crane
movements, such as hoist up, telescope out and boom down, will be stopped.
The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity
and dimensions are stored in memory in the central processor unit. This data is the reference
information used to calculate the operating conditions.
The of operating modes are selected by the operating mode key on the console by scrolling
through the text messages defining the boom truck configuration.
The crane load is measured by pressure transducers attached to the piston and rod side of the
hoist cylinders.
Boom length and boom angle are transmitted by length/angle CAN bus node mounted on the
side of the boom in the angle sensor box. The length sensor/cable reel is mounted inside the
base which measures the boom length.
The PAT RATB works like our normal Anti-Two-Block. It alerts to an impending two-block
condition. This alert can come in the form of an audible alarm and visual LED or with the
optional function lockout if the crane is so equipped. The radio anti two block transmitter switch
transmits a error condition when the switch closes or transmits an OK signal, no less than every
two seconds to the receive. The transmitters send a unique serialized frequency on up to three
separate channels to ensure accurate and consistent reception of data and to reduce the
possibility of unnoticed failure. The transmitter is powered by 4 C batteries with an expected
battery life of 1 year with normal usage. The receiver is mounted into a receiver box locate near
the operating station. The receiver box provides the following indications: Power (status), LINK,
Low Battery, and A2B. The receiver will work 10..32VDC and fused to 1 Amp.
8' 10'
1 Operating Console POWER LINK
LOW
BATT.
A2B
ALARM
3 Length Sensor 7
6
12
1
PAT
1
4 3
POWER
LOCKOUT
System Function
START
The operator’s console is mounted by the operating station in the operator’s field of vision. For a
better identification of displays and operating elements, they are continuously backlit during
operation.
7 Selection button up
6 Indicator overload
8 Selection button down
3 Symbols
9 OK acknowledgement
Data display
The Data display (1) is an illuminated LC display which shows
several values.
The figure shows the display during normal operating, limit setting,
error codes, and service information.
The display level label (I or II, at the left) marks the level selected.
Display level selection is made by way of the selection buttons up (7)
or down (8), respectively.
Prewarning indicator
The yellow prewarning light (5) will light up when the load on the
crane is over 90 % of the crane rating, indicating that an overload
condition is approaching
IMPORTANT
Overload indicator
The red overload light (4) warns the operator that a rated load
condition has been reached.
up Selection button
OK Acknowledgement button
An acoustical alarm message can be acknowledged by activation of
this selection button.
3.3.1 Receiver
3.3.1.A LEDs:
1.The POWER LED (Green) Shows that there is power to the system.
2.The LINK LED (Green) Indicates the status of the communication link
between the main hoist A2B transmitter and the
receiver. Failure of the communication link will
turn off the Green LED and turn off the output to
the lockout relay.
3.The LOW BATTERY LED (Yellow) Indicates that the battery of the main transmitter
needs to be replaced.
3.3.1.B ID button
The yellow ID button, located in the lower right-hand corner of the receiver board, is used to set
the transmitter ID of the transmitter into the receiver.
The transmitter and battery housing are made of a special plastic that
resists impact and will not become brittle even in low temperatures.
Transmitter LED
The transmitter has an LED on the bottom for diagnostics. The LED should
be on when in a two-block condition or when the weight is lifted. The LED
will flash rapidly during a 2-block condition and will stop flashing after the
switch is in a two-block condition for more than 15 seconds. The LED will
flash randomly approximately every 2 seconds when the switch is
transmitting. When in sleep mode, the LED will not flash.
The weight and chain must be hung from the switch and/or the chain
must be unhooked before the crane is operated.
4 CONFIGURATION SETUP
The LMI setup procedure allows the operator to input the crane operating mode through the text
displays and enter the reeving or parts of line used. The operator must correctly setup the Load
Moment Indicator system when the crane operation configuration has been changed or after
turning on the system powered.
The correct setting of the Operating Mode Code (Reeving) is of utmost importance for
the proper function of the system and the crane. Therefore, only operators who are
thoroughly familiar with the load capacity charts and the use and operation of the
system shall set the Operating Code.
Failure to properly program the LMI with the correct operating mode code may result
in property damage or serious bodily injury or death to personnel.
To assure the crane is properly programmed, verify that the operating mode code
shown at data display (1) and the load capacity chart match the lifting configuration of
the crane.
...at power up: System performs a system test and will display the
software version in the DS85 system 7-10 seconds.
The system will then display an operating mode scroll
through the operating codes and select the mode
matching the crane configuration then
Press .
Reeving will be displayed, scroll up or down to display the
correct parts of lines configured on the crane
Press .
The system should then be ready to operate.
Text messages can optionally be displayed in German, English, French or Italian. It is not
necessary to repeat this language adjustment when starting the system as it will be stored until
the next adjustment. The procedure is described as follows:
ENGLISH
0
FRANCAIS
1
DEUTSCH
2
ESPANOL
3
Note: The language will only displayed if the manufacturer defines the operating mode verbiage.
• Visual indication of receiver power, radio links (sensor on line), sensors low battery, and
alarm conditions.
• Installs/uninstalls a sensor
• Allows a zero point and output adjustment of a load sensor.
4.3.2 LEDs
Red Power LED Power is applied to the circuit board.
Red alarm LED An installed sensor is indicating an alarm, or communication as been
lost to an installed sensor.
Green LED 1 ON Sensor on channel #1 is installed and communicating correctly.
Green LED 1 FLASHING Sensor #1 is not communicating correctly.
Green LED 1 OFF No sensor is installed on channel #1.
Yellow LED 1 ON Sensor #1 batteries are low and need replaced. Note that the sensor
is still operating correctly.
Green LED 2 ON Sensor #2 is installed and communicating correctly.
Green LED 2 FLASHING Sensor #2 is not communicating correctly.
Green LED 2 OFF No sensor is installed on channel #2.
Yellow LED 2 ON Sensor #2 batteries are low and need replaced. Note that the sensor
is still operating correctly.
Green LED 3 ON Sensor #3 is installed and communicating correctly.
Green LED 3 FLASHING Sensor #3 is not communicating correctly.
Green LED 3 OFF No sensor is installed on channel #3.
Yellow LED 3 ON Sensor #3 batteries are low and need replaced. Note that the sensor
is still operating correctly.
Green LED 4 ON Sensor #4 is installed and communicating correctly.
Green LED 4 FLASHING Sensor #4 is not communicating correctly.
Green LED 4 OFF No sensor is installed on channel #4.
Yellow LED 4 ON Sensor #4 batteries are low and need replaced. Note that the sensor
is still operating correctly.
Green Heartbeat LED This will flash during normal operation. If it is a solid or off, the
receiver has a software error or the board has a component failure.
ID button
power (red), sensor link 1-4 left
to right (green)
LEDS
1-4 left to right (yellow)
Heartbeat LED: When blinking, this small surface board mounted green LED indicates the
system is operation properly.
ID button: The red ID button, located below the software chip on the receiver board, is used to
setup the sensor transmitter to the receiver.
5 OPERATION
5.1 RECEIVER
Upon switching on crane ignition switch, the system starts with an automatic test of the receiver
board, LEDs and electronic components. The red power LED should be on and the green LEDs
that sensors have been linked to should also be on.
If an alarm condition exists investigate and clear the condition before operation and using the
system.
During the normal operation of the system, the POWER and SENSOR ON LINE (if linked to a
sensor) LEDs should be on.
POWER LED
The POWER LED shows that the receiver is getting power from the crane. The receiver is on
any time the crane is operating and supplying power to the system.
ALARM LED
This LED will light simultaneously with the engaging of the lock out solenoids (if installed).
If a green sensor on line LED starts to flash, this means a sensor is installed and the
communication link has been lost. When communication has been lost to a load cell, the
receiver will output the maximum voltage signal for the output sensor (9VDC).
If a low battery LED is on, replace the batteries in the linked transmitter, refer to Battery
Replacement.
The TRS 05 setup/calibration procedure allows the operator to input the type of sensors being
used, and adjust the zero point and output adjustment of a load sensor. The operator must
complete the setup procedure for each sensor.
While the ID button is held or in the calibration process, the sensor outputs will not correctly
indicate the status of other installed sensors. Correct operation will return when the menu is
exited or calibration process is complete or system is powered off/on.
The sensor setup and calibration is completed with the one ID button, pressing it starts the
menu and releasing the button selects the menu or action the operator want to complete. If an
incorrect menu is activated or the button is released accidentally, simply cycle the power and
start over.
As the ID button is held and released at the blinking LED, the following actions will occur:
Green LED 1 Blinking: Search for / Install sensor 1. LED will turn solid when the sensor is
found.
Green LED 2 Blinking: Search for / Install sensor 2. LED will turn solid when the sensor is
found.
NOTE: A new sensor or transmitter maybe install over an existing link, when this occurs the
previous link and code are removed from memory and the new one stored.
Mount the antennas in identical positions (90° / perpendicular to the boom) and in a direct
line between transmitter and receiver, ensuring that no obstructions will interfere with the
transmission of the radio signal.
As the ID button is held (16-28 seconds) through the Install Sensor mode (blinking LEDs1-4)
and released at the solid LED, the following actions will occur:
Green LED 1 solid: Uninstall sensor 1.
Green LED 2 solid: Uninstall sensor 2.
Green LED 3 solid: Uninstall sensor 3.
Green LED 4 solid: Uninstall sensor 4.
This is a basic overview table of the menu selections fro the TRS 05. Press and hold ID button,
release the button at the desired indication (or the number seconds) defined in the following
table.
NOTE: If an incorrect menu is activated or the button is released accidentally, simply cycle the
power and start over.
Indication Indication
Starts Ends
Menu Selection Release ID Button Indication (Sec) (Sec)
Install/setup sensor on channel 1 blinking green LED 1 3 6
Install/setup sensor on channel 2 blinking green LED 2 6 9
Install/setup sensor on channel 3 blinking green LED 3 9 12
Install/setup sensor on channel 4 blinking green LED 4 12 15
Uninstall a sensor on channel 1 solid LED 1 16 19
Uninstall a sensor on channel 2 solid LED 2 19 22
Uninstall a sensor on channel 3 solid LED 3 22 25
Uninstall a sensor on channel 4 solid LED 4 25 28
Set all the analog outputs for voltage 0-5V All 4 green LEDs blinking 29 32
Set all the analog outputs for 4..20ma All 4 green LEDs solid 33 36
Set all the analog outputs for voltage 1-9V All 4 yellow LEDs blinking 37 40
Set all the analog outputs for voltage 0-9V All 4 yellow LEDs solid 40 43
Calibrate load/angle sensor on channel 1 blinking yellow & green LEDs 1 43 46
Calibrate load/angle sensor on channel 2 blinking yellow & green LEDs 2 46 49
Calibrate load/angle sensor on channel 3 blinking yellow & green LEDs 3 50 53
Calibrate load/angle sensor on channel 4 blinking yellow & green LEDs 4 53 56
Service information on channel 1 blinking yellow LED 1 56 59
Service information on channel 2 blinking yellow LED 2 59 63
Service information on channel 3 blinking yellow LED 3 63 66
Service information on channel 4 blinking yellow LED 4 67 70
Exit/No action LEDs off no 71
7 INSTALLATION
7.1 RECEIVER
The receiver module should be mounted so the operator can view the LEDs and setup the
system for operation. The location of the receiver should be in direct line of site of the
transmitter and blocked by as little metal as possible between the transmitter and receiver.
However, in some cases the receiver has been installed surrounded by metal and worked well.
The location needs to be tested before mounting the hardware. If the signal is lost, the
box/receiver indicates a link error.
Securely attach the receiver onto a solid surface using the mounting holes.
CORRECT INCORRECT
press to select the limit marked at the upper left of the screen.
7.2.1 ANGLE
OR EXIT
OR EXIT
DELETE LIMIT
EXIT
7.2.2 RADIUS
OR EXIT
OR EXIT
DELETE LIMIT
EXIT
OR EXIT
DELETE LIMIT
EXIT
EXIT
EXIT
Be sure the weight of the anti two-block switch is properly installed on the main hoist load line.
With even parts of hoisting line, the weight shall be attached to the dead-end line. With odd
parts of hoisting line, the weight shall be attached to the line of lowest speed.
If the boom extension is in the operating position and no load line is being used on main boom,
to prevent injury or damage to equipment, the weight shall be removed from main boom switch.
In that case the anti two-block switch has to be locked with the red Anti Two-Block Retainer,
which is fixed with a red lanyard (not shown) at the anti two-block switch.
Failure to re-position the anti two-block switch weight will prevent the overhoist
system from functioning properly. No weight shall be on the main hoist anti two-block
switch when the boom extension is being used.
3. Straighten the cable completely into the slot and release the cable (4).
4. Turn the flag of the retainer for best visibility for the operator (5).
After the electrical connections have been checked to insure that the system is properly
connected for the crane configuration, the following checks shall be made:
1. Check the electrical wiring connecting the various parts of the system for physical damage.
2. Check the anti two-block switches and weights for free movement.
3. Check the spring-loaded cable reel to be sure it is free to rotate, has tension and the cable is
reeled properly.
The following tests shall be performed with care to prevent damage to the machine or
injury to personnel. Proper functioning of the system requires successful completion
of these tests before operating the machine.
If the light and audible alarm do not function as described and the crane movements
are not stopped, the system is not working properly. The malfunction shall be
corrected before operating the crane.
If the operator cannot see the load handling device approaching the boom nose, he shall have
an assistant (signal person) watch the load handling device. The operator shall be prepared to
stop the machine immediately should the LMI system not function properly as indicated by
lighting the red warning light (4), sounding the audible alarm and locking the crane movements,
hoist up, telescope out and boom down.
1. Check the anti two-block alarm light (4) and the audible alarm by performing one of the
following tests:
a) By manually lifting the weight attached to the anti two-block switches. When the weight
is lifted, the audible alarm should sound, the anti two-block alarm light (4) should light.
b) Slowly raise the main boom load handling device to create a potential two-block
condition. When the load handling device lifts the weight, the audible alarm should
sound, the anti two- block alarm light (4) should light and the motion of the load handling
device should be stopped. Lower the load handling device slightly to eliminate this
condition.
c) Slowly lower the boom to create a potential two-block condition. When the load handling
device lifts the weight, the audible alarm should sound, the anti two-block alarm light (4)
should light and the boom lowering function should be stopped. Lower the load handling
device slightly to eliminate this condition.
d) Slowly extend (telescope) the boom to create a potential two-block condition. When the
load handling device lifts the weight, the audible alarm should sound, the anti two-block
alarm light (4) should light and the boom telescope out function should be stopped.
Lower the load handling device slightly to eliminate this condition.
2. If the crane is equipped with a boom extension, repeat the test procedure for the boom
extension anti two-block switch. Check that the display of the main boom length agrees with
the actual boom length.
3. Check that the display of the main boom angle agrees with the actual boom angles.
4. Check that the display of the operating radius of the crane agrees with the actual radius.
5. Check the load display by lifting a load of known weight.
2. If the insulation is worn on the length sensor cable or cable guides are damaged, these
parts shall be replaced.
5. Check the pressure transducers at the hoist cylinder(s) and the connecting hoses for oil
leakage.
6. During battery replacement, use caution when opening the battery cover and transmitter to
avoid damage to the gasket causing moisture ingress which could corrode the batteries and
terminals. Inspect the gasket surface on the transmitter for nicks or other damages that
may prevent the gasket from sealing. If it appears to be damaged, a replacement gasket
should be installed.
Other than correcting the problems identified in the Malfunctions Table and replacing faulty
mechanical parts and cables, no other repairs shall be performed by non expert personnel.
10 TROUBLESHOOTING
10.1 GENERAL
In case of a malfunction of the system, the display (1) will indicate a code that identifies the
system malfunction.
The error codes listed in the Malfunction Table will identify various faults that can occur with the
LMI. Following the Malfunction Table are pages which explain each fault and describe the
action which shall be taken to correct the fault.
Faults within the electronic microprocessor shall be repaired by factory trained service
personnel. When these faults occur, the competent service organization shall be contacted.
press to select the limit marked at the upper left of the screen.
Scroll through the following screen to see piston and rod side voltages and pressures.
Error Error
Code
E01 Fallen below the radius or above angle range
E02 Radius range exceeded or fallen below angle range
E03 Boom position is out of the permissible working area
E04 Operating mode not existing
E05 Prohibited length range
NOTE:
If there is any Error Code displayed on the console which is not listed in the Malfunctions
Table you shall call the Local Distributor.
Malfunctions in the system which are caused by range exceeding or operating errors by the
crane operator himself are indicated on the display together with an explanation. These error
codes are E01, E02, E03, E04, and E05 and they can normally be eliminated by the crane
operator himself.