IFLEX5 für FA043

Crane Electronics Specification for FA043

Version: V 1.0

Person in charge: Brückner

Project start: 18.07.2005

Last modification: 07.06.2006

Printed on: 06.07.2006

Signature/date:
Verified:

Distribution list: FAUN – E.80

FAUN – P.22

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 IFLEX5 für FA043

1.1.1 Overview

Sensor Actuators:
system: 16 x AIN Master 40 x DOUT Winch
VG (12 x PWM) Boom elevation
(Precontrol 45 x DIN GG (Counter-
transmitter) iFlex5/0001 weight)
Winch CAN-Node 2 Swing
Counter- A932 mechanism
weight Hydraulic
Hydraulic Crane drive system
system assemblies

RS232/Engineering
RS232/Service (38400 Bd)

ASLI
Sensor Actuators:
8 x AIN 16 x DOUT
system: ASLI shut-off
Tele
iFlex5/0004 (4 x PWM)
feature
21 x DIN CAN-Node 3
sections Tele sections
Boom A910
elevation ALSI/Tele
Swing me- control
chanism

RS232/Engineering
RS232/Service (9600 Bd)

CAN

Display

Console
IK1368
CAN-Node 1
Length angle A901
transmitter
521
RS232/Service (19200 Bd)

Hoist limit
switch

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 IFLEX5 für FA043

Unless otherwise described, the further specifications of this documentation are referred to the
central unit's components.

1.2 Supply
1.2.1 External fuse protection
iFlex5/0001, Basic module
Pin Signal designation Fuse protection Remark
X1/01
X1/23 +UB_Power (supply of
External fuse protection - 20A
X1/24 power outputs)
X1/47
+UB_System
X1/25 (supply module) External fuse - 4 A

iFlex5/0001, Extension module

Pin Signal designation Fuse protection Remark
X2/01
X2/23 +UB_Power (supply of
External fuse protection - 20A
X2/24 power outputs)
X2/47

iFlex5/0004, Basic module

Pin Signal designation Fuse protection Remark
X1/01
X1/23 +UB_Power (supply of
External fuse protection - 20A
X1/24 power outputs)
X1/47
+UB_System
X1/25 (supply module) External fuse - 4 A

1.3 Serial communication

1.3.1 CAN
iFlex5/0001, Basic module
Pin Signal designation Application Remark
X1/10 CAN + CAN H, In iFlex5/0004/X1/10
X1/11 CAN - CAN L, In iFlex5/0004/X1/11
X1/30 CAN - CAN L, Out Length/angle transmitter
X1/31 CAN + CAN H, Out Length/angle transmitter
X1/32 CAN_TR Terminating resistor n.c., included in length/angle
transmitter

iFlex5/0004, Basic module

Pin Signal designation Application Remark
X1/10 CAN + CAN H, In iFlex5/0001/X1/10
X1/11 CAN - CAN L, In iFlex5/0001/X1/11
X1/30 CAN - CAN L, Out IK1368
X1/31 CAN + CAN H, Out IK1368
X1/32 CAN_TR Terminating resistor n.c., included in IK1368

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 IFLEX5 für FA043

1.3.2 RS232, PC ↔ iFlex5

Within iFlex, the RS232 is used as diagnostic, service and development interface. Its fields of
application include SW uploads and downloads.
It makes sense to connect the ports, amongst other things the RS232 parts, with easily accessible
SubD connectors, e.g. on the relay plate. For the wiring, refer to the following tables.

iFlex5/0001, Basic module

RS 232 via flange connector M12, 8-pin. Diagnostic and service interface.

P913, Relay plate Signal designation Flange connector M12

1 - -
2 RxD (Receive Data) 3
3 TxD (Transmit Data) 5
4 DTR (Data Terminal Ready) 7
5 GND (Signal Ground) 8
6 DSR (Data Set Ready) 2
7 RTS (Request To Send) 4
8 CTS (Clear To Send) 6
9 RI (Ring Indicator) 1

iFlex5/0001, Extension module

RS 232 via system connector, 70-pin. Development interface.

P914, Relay plate Signal designation X2, 70-pin

1 - -
2 RxD (Receive Data) 12
3 TxD (Transmit Data) 13
4 DTR (Data Terminal Ready) -
5 GND (Signal Ground) Term. 31
6 DSR (Data Set Ready) -
7 RTS (Request To Send) -
8 CTS (Clear To Send) -
9 RI (Ring Indicator) -

iFlex5/0004, Basic module

RS232 via SubD connector, 9-pin on iFlex5/0004 housing. Diagnostic and service interface.

P912, Relay plate Signal designation SubD, iFlex5/0004

1 - 1
2 RxD (Receive Data) 2
3 TxD (Transmit Data) 3
4 DTR (Data Terminal Ready) 4
5 GND (Signal Ground) 5
6 DSR (Data Set Ready) 6
7 RTS (Request To Send) 7
8 CTS (Clear To Send) 8
9 RI (Ring Indicator) 9

There are two ways how to use the RS232 development interface on the iFlex5/0004:
1. Reconfiguring the RS232 diagnostic and service interface and using the diagnostic interface.
2. Plugging an additional interface module (available from PAT) onto the socket connectors of the
opened (!) control unit.

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 IFLEX5 für FA043

1.4 Analog Input (Iin = 4..20 mA)

iFlex5/0001/Master/CAN-Node 2, Basic
Pin Signal name Use Remark
Display (Wiring Diag.)
X1/34 AI0 (AIN01) Hydraulic pressure in control
block
X1/35 AI1 (AIN02) Precontrol transmitter, left-
hand, x direction
X1/36 AI2 (AIN03) Precontrol transmitter, left-
hand, y direction
X1/37 AI3 (AIN04) Precontrol transmitter, right-
hand, x direction
X1/38 AI4 (AIN05) Precontrol transmitter, right-
hand, y direction
X1/39 AI5 (AIN06) Reserve
X1/40 AI6 (AIN07) Reserve
X1/41 AI7 (AIN08) Reserve

iFlex5/0001/Master/CAN-Node 2, Extension
Pin Signal name Use Remark
Display (Wiring Diag.)
X2/34 AI0 (AIN09) Reserve
X2/35 AI1 (AIN10) Reserve
X2/36 AI2 (AIN11) Reserve
X2/37 AI3 (AIN12) Reserve
X2/38 AI4 (AIN13) Reserve
X2/39 AI5 (AIN14) Reserve
X2/40 AI6 (AIN15) Reserve
X2/41 AI7 (AIN16) Reserve

iFlex5/0004/ASLI/CAN-Node 3, Basic
Pin Signal name Use Remark
Display (Wiring Diag.)
X1/34 AI0 (AIN01) Pressure in lower chamber of
boom elevation cylinder
(piston end)
X1/35 AI1 (AIN02) Pressure in upper chamber of
boom elevation cylinder (rod
end)
X1/36 AI2 (AIN03) Length of tele cylinder
X1/37 AI3 (AIN04) Reserve
X1/38 AI4 (AIN05) Swing angle, channel 1 Optional
X1/39 AI5 (AIN06) Swing angle, channel 2 Optional
X1/40 AI6 (AIN07) Reserve
X1/41 AI7 (AIN08) Measurement of wind speed Optional

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 IFLEX5 für FA043

1.5 Digital Input

iFlex5/0001/Master/CAN-Node 2, Basic
Pin Signal name Use Remark
Display (Wiring Diag.)
X1/49 DI0 (DIN01) Cnt.1 Dir., Reserve
X1/50 DI1 (DIN02) Cnt.1 Imp. , Reserve
X1/51 DI2 (DIN03) Cnt.2 Dir. , Reserve
X1/52 DI3 (DIN04) Cnt.2 Imp. , Reserve
X1/53 DI4 (DIN05) Cnt.3 Dir. , Reserve
X1/54 DI5 (DIN06) Cnt.3 Imp. , Reserve
X1/55 DI6 (DIN07) Cnt.4 Dir. , Reserve
X1/56 DI7 (DIN08) Cnt.4 Imp. , Reserve
X1/57 DI8 (DIN09) Reserve
X1/58 DI9 (DIN10) Auxiliary winch, winch limit Optional
switch
X1/59 DI10 (DIN11) Counterweight cylinder 1 TOP
X1/60 DI11 (DIN12) Counterweight cylinder 2 TOP
X1/61 DI12 (DIN13) Counterweight cylinder 1
center
X1/62 DI13 (DIN14) Counterweight cylinder 2
center
X1/63 DI14 (DIN15) Counterweight cylinder 1
BOTTOM
X1/64 DI15 (DIN16) Counterweight cylinder 2
BOTTOM
X1/65 DI16 (DIN17) Counterweight cylinder 1
locked
X1/66 DI17 (DIN18) Counterweight cylinder 2
locked
X1/67 DI18 (DIN19) Counterweight cylinder 1
unlocked
X1/68 DI19 (DIN20) Counterweight cylinder 2
unlocked
X1/33 DI23 (EXTCUTOFF) Switch emergency off if (low) active, switch off
outputs, do not analyse
inputs (test mode).

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 IFLEX5 für FA043

iFlex5/0001/Master/CAN-Node 2, Extension
Pin Signal name Use Remark
Display (Wiring Diag.)
X2/49 DI0 (DIN21) Precontrol transmitter left-
hand (forw)
X2/50 DI1 (DIN22) Precontrol transmitter left-
hand (rev)
X2/51 DI2 (DIN23) Precontrol transmitter left-
hand (left)
X2/52 DI3 (DIN24) Precontrol transmit-ter, left-
hand (right)
X2/53 DI4 (DIN25) Precontrol transmitter right-
hand (forw)
X2/54 DI5 (DIN26) Precontrol transmitter right-
hand (rev)
X2/55 DI6 (DIN27) Precontrol transmitter, right-
hand (left)
X2/56 DI7 (DIN28) Precontrol transmitter right-
hand (right)
X2/57 DI8 (DIN29) Counterweight detection Optional
X2/58 DI9 (DIN30) Counterweight detection Optional
X2/59 DI10 (DIN31) Vehicle stabilized Optional
X2/60 DI11 (DIN32) Detection of extension width Optional
X2/61 DI12 (DIN33) Detection of extension width Optional
X2/62 DI13 (DIN34) Main winch, winch limit switch
X2/63 DI14 (DIN35) Engine running
X2/64 DI15 (DIN36) Swing / counterweight
override feature
X2/65 DI16 (DIN37) Armrest switch
X2/66 DI17 (DIN38) Dead man's switch
X2/67 DI18 (DIN39) Precontrol transmitter, left-
hand (tip switch cancel tel.
sequence)
X2/68 DI19 (DIN40) Precontrol transmitter left-
hand (switch, swing brake)
X2/30 DI20 (DIN41) Precontrol transmitter, right-
hand (switch, 2nd winch)
X2/31 DI21 (DIN42) Precontrol transmitter right-
hand (switch, counterweight)
X2/32 DI22 (DIN43) Precontrol transmitter right-
hand (tip switch, high speed)
X2/33 DI23 (DIN44) DIN/NEN Block change-over

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 IFLEX5 für FA043

iFlex5/0004/ASLI/CAN-Node 3, Basic
Pin Signal name Use Remark
Display (Wiring Diag.)
X1/49 DI0 (DIN01) Tele section left-hand locked
X1/50 DI1 (DIN02) Tele section left-hand
unlocked
X1/51 DI2 (DIN03) Cylinder left-hand locked
X1/52 DI3 (DIN04) Cylinder left-hand unlocked
X1/53 DI4 (DIN05) Tele section right-hand locked
X1/54 DI5 (DIN06) Tele section right-hand
unlocked
X1/55 DI6 (DIN07) Cylinder right-hand locked
X1/56 DI7 (DIN08) Cylinder right-hand unlocked
X1/57 DI8 (DIN09) Tele ID top left-hand
X1/58 DI9 (DIN10) Tele ID center left-hand
X1/59 DI10 (DIN11) Tele ID bottom left-hand
X1/60 DI11 (DIN12) Tele ID top right-hand
X1/61 DI12 (DIN13) Tele ID center right-hand
X1/62 DI13 (DIN14) Tele ID bottom right-hand
X1/63 DI14 (DIN15) Light barrier, tele
X1/64 DI15 (DIN16) Radio control active Optional, high-active
X1/65 DI16 (DIN17) Hoist limit switch override
feature
X1/66 DI17 (DIN18) Superstructure lock
X1/67 DI18 (DIN19) Switch emergency control High active
X1/68 DI19 (DIN20) ASLI override feature
X1/33 DI23 (EXTCUTOFF) Switch emergency off if (low) active, switch off
outputs, do not analyse
inputs (test mode).

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 IFLEX5 für FA043

1.6 Digital/Analog Output

iFlex5/0001/Master/CAN-Node 2, Basic
Pin Signal name Use Remark
Display (Wiring Diag.)
X1/02 AO0 (OUT01) Pump 1 Current control 2A, PWM
X1/03 DO1 (OUT02) Reserve, 1A
X1/04 AO1 (OUT03) Pump Current control 2A, PWM
X1/05 DO3 (OUT04) Reserve, 1A
X1/06 AO2 (OUT05) Boom elevation “up” *) Current control 2A, PWM
X1/07 DO5 (OUT06) Reserve, 1A
X1/08 AO3 (OUT07) Reserve, 2A, PWM
X1/09 DO7 (OUT08) Reserve, 1A
X1/14 DO8 (OUT09) Reserve, 2A
X1/15 DO9 (OUT10) High speed valve Y914, 1A
X1/16 DO10 (OUT11) Reserve, 2A
X1/17 DO11 (OUT12) Swing mechanism active Linkbelt warning horn, 1A
X1/18 DO12 (OUT13) Reserve, 2A
X1/19 DO13 (OUT14) Release swing brake Y910, 1A
X1/20 DO14 (OUT15) Reserve, 2A
X1/21 DO15 (OUT16) Reserve, 1A

iFlex5/0001/Master/CAN-Node 2, Extension
Pin Signal name Use Remark
Display (Wiring Diag.)
X2/02 AO0 (OUT17) Winch 1 "up" Current control 2A, PWM
X2/03 DO1 (OUT18) Winch 1 hourmeter Additional SW counter,
1A
X2/04 AO1 (OUT19) Winch 1 "down" Current control 2A, PWM
X2/05 DO3 (OUT20) Reserve, 1A
X2/06 AO2 (OUT21) Winch 2 "up" Current control 2A, PWM
X2/07 DO5 (OUT22) Winch 2 hourmeter Additional SW counter,
1A
X2/08 AO3 (OUT23) Winch 2 "down" Current control 2A, PWM
X2/09 DO7 (OUT24) Reserve, 1A
X2/14 AO4 (OUT25) Slewing to the left *) Current control 2A, PWM
X2/15 DO9 (OUT26) Reserve, 1A
X2/16 AO5 (OUT27) Boom elevation "down" Current control 2A, PWM
X2/17 DO11 (OUT28) Reserve, 1A
X2/18 AO6 (OUT29) Brake valve, boom elevation Current control 2A, PWM
X2/19 DO13 (OUT30) Reserve, 1A
X2/20 AO7 (OUT31) Slewing to the right *) Current control 2A, PWM
X2/21 DO15 (OUT32) Reserve, 1A
X2/26 DO16 (OUT33) Counterweight up Y932, 2A
X2/27 DO17 (OUT34) Counterweight down Y931, 1A
X2/28 DO18 (OUT35) Lock counterweight Y933, 2A
X2/29 DO19 (OUT36) Unlock counterweight Y934, 1A
X2/42 DO20 (OUT37) Activate counterweight Y927, 2A
X2/43 DO21 (OUT38) Reserve, 1A
X2/44 DO22 (OUT39) Reserve, 2A
X2/45 DO23 (OUT40) Reserve, 1A
*) These outputs are not activated before CPM 1003 = 1.

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iFlex5/0004/ASLI/CAN-Node 3, Basic
Pin Signal name Use Remark
Display (Wiring Diag.)
X1/02 AO0 (OUT01) Extend tele section Current control 2A,
PWM
X1/03 DO1 (OUT02) Reserve, 1A
X1/04 AO1(OUT03) Hoist limit switch relay Current control 2A,
PWM
X1/05 DO3 (OUT04) Safety relay, emergency HIGH, if min. 1 tele ID
control tele. active, 1A
X1/06 AO2 (OUT05) Retract tele section Current control 2A,
PWM
X1/07 DO5 (OUT06) Reserve, 1A
X1/08 AO3 (OUT07) Reserve, 2A, PWM
X1/09 DO7 (OUT08) Reserve, 1A
X1/14 DO8 (OUT09) V4 Interlock/ *** Y972, 2A
X1/15 DO9 (OUT10) Reserve, 1A
X1/16 DO10 (OUT11) V5 Interlock./retention valve Y973, 2A
X1/17 DO11 (OUT12) Reserve, 1A
X1/18 DO12 (OUT13) V6 Interlock/connection Y971, 2A
control pressure
X1/19 DO13 (OUT14) Reserve, 1A
X1/20 DO14 (OUT15) Reserve, 2A
X1/21 DO15 (OUT16) Prewarning, crane shut-off Warning lamp, outside
1A

1.7 Overload relay

iFlex5/0004/ASLI/CAN-Node 3, Basic
Pin Signal name Use Remark
Display (Wiring Diag.)
X1/22 REL_MK (E) Supply of shut-off valve
X1/46 REL_RK (A)
X1/69 REL_AK (A) Crane shut-off for motions Y941
increasing the load moment

1.7.1.1
.

1.7.1.2 Valve activation

Status V4/Y972 V5/Y973 V6/Y971
Lock tele section O O O
Lock cylinder O O O
Hold tele unlocking ♦ ♦ O
Hold cylinder unlocking O ♦ O
Move tele unlocking ♦ ♦ ♦
Move cylinder O ♦ ♦
unlocking
♦ Valve switched
O Valve spring-centered

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 IFLEX5 für FA043

1.7.1.3 Locking positions

T1 T2 T3 T4 T5
█1 █1 1 1 █1 █1 █1 █1 █1 █1
Ids █2 █2 █2 █2 █2 █2 2 2 █2 2
█3 █3 █3 █3 3 3 █3 █3 █3 █3
Pos. 0% in [m] 0.00 0.25 0.55 0.80 1.10
Pos. 50% in [m] 3.75 4.05 4.35 4.65 4.85
Pos. 100% in [m] 7.50 7.80 8.15 8.40 8.50

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