- Dorman Long Technology
Contents
1. Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual DL P40 Release 3 Computer Control System DL P40 Strand Jack Mode sim 1 40 jacks System View Help Manual um Manual Mode Open Top DS Dg DS Dd DS P3 ee BBB D DE BB Ur ial fo Close Top 100 75 Extend 50 Retract 25 0 BH gH m m m m m mm m mm mm mm m HN NH HB Base anchor Total 3100 3101 3102 3103 3104 3105 3106 J107 3108 3109 3110 1111 J112 3113 3114 J115 3116 J117 3118 3119 Jack Close Base 6401 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 Load MT 6400 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 Monitor MT 96 95 96 96 95 94 96 96 96 96 95 95 96 95 96 95 95 95 96 94 Stroke mm 69 70 69 70 70 69 6 70 70 70 70 69 69 70 69 70 69 69 69 70 68 Lift mm Stroke BON ON ON ON X NON ON ON NON NX NON OH ON B 2 0 mm 100 Reset Lift Totals 75 50 25 0 Base Anchor 2120 1121 1122 1123 3124 J125 3126 1127 J128 J129 1130 3131 3132 3133 3134 1135 1136 1137 3138 3139 Jack 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 Load MT 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 Monitor MT 95 95 96 95 95 95 95 96 96 96 95 95 95 95 95 94 95 95 95 95 Stroke mm 69 69 69 69 70 69 70 69 69 69 69 69 68 69 69 69 69 Lift mm 25 Feb 2010 13 55 13 69 69 70 O2. 4 0 Operation and maintenance of the system 4 1 Setting up reconfiguring and dismantling the system on site The exact layout of the CAN nodes and data cables for each system will vary with the number and type of power packs you have however the basic principles given here will apply to all systems 4 1 1 Connecting the components together at the start of a project The components of the DL P40 system comprise the control PC the USB to CAN signal converter the data cables the Power pack CAN nodes the Jack CAN nodes and the sensors These components are described in section 1 3 and the precise layout for your system will be shown on a drawing within the Operation and Maintenance manual that you should have with your system The sequence for connecting the components together is as follows 1 Ensure that the 24V d c power supply to the control system is switched off at every power pack The on off switch for this power supply will usually be a red circular isolator switch but please see your Operation and Maintenance manual for details There will be a separate power on off switch for each power pack Note that the power pack motors and the control computer can be either on or off at this stage 2 Ensure that all the ball valves on all the power packs are closed to prevent any possibility of any unwanted actions 3 Connect all the components of the DL P40 system together including the USB connection to the control computer following
3. CAN ID Node Type Type Number Serial Number Inverted Encoder Milliamp Encoder Stroke mm Dead zone at top stroke mm Dead zone at bottom stroke mm Safe working load of jack Metric tonnes Safe working pressure of jack Bar Full bore to annular area ratio Transducer pressure At 20mA Bar Transducer at zero pressure Piston extend overun mm Piston retract overun mm Full Extend Screen stroke Reading Full Retract Screen stroke Reading mE 227 223 Strand Jack Strand Jack 5227 5223 228 No 500 0 j 120 0 120 0 1185 0 295 1 75 400 0 10 0 10 0 2800 0 1100 0 112136 1000 Primary Node Loading Value 2 Pos n MJ valves 1 lead When this screen is first shown the values will be in light gray and are the values currently stored in the memory of the computer To show a full list of current parameter values in the CAN nodes press Read The system will then be interrogated and a full set of values will be shown in black as shown above The parameters are the same as for the single node screen see section 2 4 1 except with the following slight variations Read Write Reads and writes to all of the displayed nodes After reading changes from the previous values will be highlighted in yellow to aid checking of your work Manual calibration of stroke encoders The jack stroke encoders can be manually calibrated using the node configuration screen V 3 016a Pa
4. DL P40 CAN nodes should be mounted on the jacks and power packs in an easily viewed location but out of danger of direct impact It is not necessary to mount the CAN nodes using rubber isolation mounts The individual hardware components are as follows Jack CAN node Dorman Long Heavy Lift Controller 8 SerialNo MEME Status A Status B CAN line to power pack Connections to jack node sensors and hydraulic valves V 3 016a Page 7 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual Power Pack CAN Node Any unused connections must be fitted with a termination plug or the system will be unstable Jack 1 ee Jack 2 CAN line pack node CAN line Dorman Long Heavy Lift Controller Serial No 8 amp StstusA Power in Connections to power pack hydraulic valves and sensors Control computer The control computer can be any PC or laptop running Windows XP No other programs should be running at the same time as the DL P40 USB CAN adapter The USB to CAN adapter can be plugged into any USB2 port on the control computer The DL P40 is designed to work with the IXXAT USB to CAN Compact Mains power to 24 V DC power supply to the CAN line for working with nodes on the bench Not required during normal operation CAN communication line to the first power pack CAN node USB connection to the control compute
5. closed In 2 the program checks if the minimum allowable load has been reached by the time the piston has extended by the load transfer distance It is usual to set the load transfer distance to slightly above the expected value e g for strand jacks and climbing jacks set to 10mm Max allowable Load Per Jack The max allowable load is set as a of the Monitor Load By default it is set to 125 If this value is exceeded during an operation the running operation will be stopped and cannot be resumed until the problem has been resolved using manual mode Minimum transfer load per jack The minimum load as a of the Monitor Load that a jack should achieve when the piston is extended by the load transfer distance with the grips closed The program ignores this feature is a value of Zero is entered The default setting is Zero Max Allowable Stroke Range Specifies the maximum allowable difference in stroke between the leading and trailing jack when more than one jack is extending or retracting In Auto Lift and Auto Lower modes and in Manual Mode when the Synchronise in Manual Mode option is selected the DL P40 will automatically V 3 016a Page 19 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual adjust the Monitor Load The monitor load is the load that will show as 10096 load for each jack on the Main Screen The Monitor load can be selected as either the Expected Load for each jack or
6. 28 39 J100 1001 0 0 1 812 6 Top Unknown Base Unknown J101 1002 0 0 1 29 09 06 16 14 28 39 gt Manual Mode Close Base Anchor Invoked 30 09 06 16 14 28 39 gt Manual Mode Stop 31 09 06 16 14 28 40 gt Manual Mode Close Base Anchor Invoked 32 09 06 16 14 28 41 J100 1001 0 0 1 812 6 Top Unknown Base Closed Loaded J101 joo2 0 0 1 t 33 09 06 16 14 28 42 gt Manual Mode Stop 34 09 06 16 14 28 42 gt Manual Mode Close Top Anchor Invoked 35 09 06 16 14 28 43 J100 1001 0 0 1 812 6 Top Unknown Base Closed Loaded J101 joo2 0 0 1 36 09 06 16 14 28 44 gt Manual Mode Stop 37 09 06 16 14 28 45 J100 1001 0 0 1 812 6 Top Closed Base Closed Loaded J101 joo2 0 0 1 t 38 09 06 16 14 28 46 gt Auto Lift Full Stroke Selected 39 09 06 16 14 28 47 gt Operation Started 40 09 06 16 14 28 47 1100 1001 0 0 1 812 6 Top Closed Base Closed Loaded J101 joo2 0 0 1 41 09 06 16 14 28 49 J100 1001 1570 3 19 814 5 Top Closed Loaded Base Closed J101 joo2 1570 3 19 1 42 09 06 16 14 28 51 J100 1001 1570 30 8 826 3 Top Closed Loaded Base Unknown 1101 joo2 1570 30 5 43 09 06 16 14 28 53 J100 1001 1570 3 32 8 828 3 Top Closed Loaded Base Open J101 joo2 1570 3 32 5 i 44 gt WorkLog 16 06 09 J 4 NE Ready g V 3 016a Page 36
7. Transducer pressure at 20 mA A value that will be shown in the jack data at the bottom of the main screen and in the node configuration screen No other effect usually 0 400 bar 4 20 mA transducers used so set to 400 V 3 016a Page 11 20 21 22 23 24 25 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual Piston extend overrun x 0 1 mm A value that will be shown in the jack data at the bottom of the main screen and in the node configuration screen and is used by the simulator to model the distance that the piston will overrun after the command to stop has been sent Set to about 20 i e 2mm Piston retract overrun x 0 1 mm A value that will be shown in the jack data at the bottom of the main screen and in the node configuration screen and is used by the simulator to model the distance that the piston will overrun after the command to stop has been sent Set to about 40 i e 4mm Piston extend acceleration mm s 2 Acceleration of the piston at the start of an extend stroke Typically 500 mm s 2 Piston extend acceleration mm s 2 Deceleration of the piston at the end of an extend stroke Typically 500 mm s 2 Piston retract acceleration mm 2 2 Acceleration of the piston at the start of a retract stroke Typically 1 000 mm s 2 Piston retract acceleration mm s 2 Deceleration of the piston at the end of a retract stroke Typically 1 000 mm s
8. are as follows Index A simple row number value Bow Type The power pack type as reported by the power pack node Pack Serial No The power pack serial number as reported by the power pack node Indicates the main and boot loader software loaded into both the power Software pack nodes connected to a Power Pack Index A simple row number value Type The jack type as reported by the jack node Serial No The jack serial number as reported by the jack node Software Indicates the main and boot loader software loaded into the jack nodes Name Specifies the user selectable name that will be used in the jack tray Specifies the slot jack tray slot in which the jack will be chosen The Jack Display Slot value must be between 1 and 40 and must not conflict with any other jacks in the list Expected m oad Specifies the expected load value Awa ead Lists the Actual Load values read by the computer when the Read Actual Loads button is pressed in the Main Screen The calculated difference between the expected load and the set load for Difference each jack Load Transfer Distance The distance in mm that the jack has to travel to transfer the load between top to the bottom anchors The program uses this value 1 in auto lower mode to work out where to stop the piston at the end of a stroke to leave enough distance to transfer the load and 2 in auto lift and auto lower mode to check if there has been a gripping failure when the piston is extended with grips
9. for the first time Usually set to about 700 The second section is a table of the virtual jacks This section is delimited by the Jacks and Jacks tags The contained table consists of 25 columns The column headings are not necessary but make reading table less confusing Serial Number The jack CAN node Serial Number to be reported by the software Type The Type value must be a single character either S for a strand jack or C for a climbing jack Max Stroke mm The length of the virtual jack s stroke Typically 500 Raise Speed mm s The rate at which the jack extends Typically 30mm second for a jack lifting at 60 m hour Lower Speed mm s The rate at which the jack retracts Typically 60 mm second for a jack lifting at 60 m hour Bleed Speed mm s The rate at which the jack retracts while bleed lowering Typically 0 5 mm second Expected Load kN The load that you want the jack to see in the simulation can be any value Absolute Max Load kN The safe working load of the jacks you want to simulate e g for a DL 185 strand jack you should enter 185 x 9 81 1815 kN Open Minijack Velocity The time taken to open a minijack The units arbitrary 0 1 is a reasonable value Close Minijack Velocity The time taken to close a minijack The units arbitrary 0 1 isa reasonable value Upper Dead Band mm The upper dead band length of the jack Typically 20 mm Lower Dead Band mm The lower dead band leng
10. mA Bar 40 Transducer m at zero pressure 10 0 Piston extend overun mm 11 0 Piston retract overun mm Manual calibration of stroke encoder 500 0 Screen stroke reading Fully extended 0 0 Screen stroke reading Fully retracted 65535 Stroke gain 0 Stroke Reset stroke gain and ENC For manual calibration Sets stroke gain to 65535 and ENC to 0 when pressed Power Pack Mode Config Loading Valve V 3 016a Page 21 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual CAN ID Enter the CAN ID of the node you wish to communicate with for example for CAN ID 77 enter 77 Head Pressing this button reads the parameters currently set in the selected node Write Pressing this button overwrites the parameters in the selected node with the values shown on the screen Node type Select either Strand jack S Climbing Jack C or Power Pack L Primary Node For power pack nodes only Set to checked Yes or unchecked No The only effect of this parameter is on the settings screen where the connection is shown as A or B for primary nodes and C or D for other nodes This facility can be useful for 4 outlet power packs as it allows the user to set outlets A B C amp D This parameter has no other effect Type Number 7 character text field that will appear on the Settings screen You can enter any text you want but no spaces The usual convention is to enter the CAN no
11. n it 160 0 0 0 160 0 rere ja sur 5185 2 sim v1 2 1160 0 0 0 m 15111 s185 3 sim v1 2 1160 0 0 0 160 0 5111 5185 4 sim v1 2 1160 0 0 0 160 0 Sm v1 2 5185 5 sim v1 2 160 0 0 0 T 5185 6 sim v1 2 1160 0 0 0 n 5185 7 sim v1 2 160 0 0 0 1160 0 0 0 160 0 0 0 1160 0 0 0 1160 0 0 0 1160 0 0 0 22 23 24 25 26 Jy 28 29 210 Sim v1 2 OO A Kn aw nw 15111 51858 sm 1 2 sui Sim v1 2 5185 9 sim v1 2 2 S111 5185 10 sim v1 2 11 5185 11 sim v1 2 205 5 12 12 5111 s185 12 sim v1 2 o ren 41 i1 i il l4i i14il4i41i41 O n o jo jn jmc jo jn m o 12 D The system is running in Strand JackMode Synchronise Extend and Retract Load Transfer Distance A mm In Manual Mode Strand Jacks C Top Grips Closed on Auto Lift Retract Stroke Btm Grips Closed on Auto Lift Extend Stroke Max allowable load per jack monitor load Minimum transfer load per jack A for auto lift amp auto lower modes monitor load load Climbing Jacks 9 Monitor Against Expected Load v Top Grips Open on Auto Lift Extend Stroke Psi CSE OLS O Monitor Against Actual Load Btm Grips Open on Auto Lift Retract Stroke V 3 016a Page 18 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual The table contents
12. required during load testing Display Jack Name in Jack Tray Option to turn on off the jack name in the Main Window Highlight Most Extended and Retracted Selected Jacks if selected then the most extended jack will be shown in red and the least extended jack shown in blue Enable tool tips enables useful information to be shown when the mouse hovers over items on the Screens Load last project at start up f selected the user will be asked if they want to load the last project file when starting the DL P40 V 3 016a Page 17 r Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual Beep on complete auto lift and auto lower cycle select if you want an audible beep when the system completes an auto lift or auto lower cycle as a reminder that you need to press the Start button again for the next cycle 2 3 Settings screen The settings screen is where you can check that all the CAN nodes are present on the system define the layout of the jacks on the main screen enter the expected loads for each jack and set the main parameters for carrying out the operation The settings screen cannot be used to set the parameters into the CAN nodes This is done in the Node Configuration Screen System Settings Power Pack Jack Type Serial No CAN ID Software Type Serial No can D Software Connection Name Display Slot Actual Load MT Difference MT 2o lmi iL 211 81851 100 sim v1 2
13. the Actual Load for each jack The expected load is typed into the setting screen by the user The set load for each jack is an as measured load that is read into the computer when the Set Load button is pressed in the main screen So for example if the load is much lighter than expected then the Set loads can be read into the computer and used as the Monitor Load in place of the expected loads Synchronise Manual Mode Extends and Retracts Tick this box to enable synchronization of the jacks during extend and retract when in manual mode Strand Jacks Top Bottom grips Close on Auto Lift Extend Retract Stroke Allows the unloaded grips to closed in auto lift mode when the piston is extending or retracting The default setting is to select this only for the bottom grips Opening the top grips during a retract stroke helps to prevent birds nesting of the strands Opening the bottom grips during and extend stroke helps to reduce wear and dirt build up in these grips but reduces safety as the bottom grips are not able to act as a back up to the top grips if they are held open during an extend stroke Climbing jacks Top Bottom grips Open on Auto Lift Extend Retract Stroke Allows the unloaded grips to be held open in auto lift mode when the piston is extending or retracting The default setting is for both top and bottom grips to be held open Interrogate Network Click this button auto detect any nodes present on the network The procedure will tak
14. the system For details of these screens please see the relevant sections of this manual The main screen Used for lifting and lowering operations and for calibrating the jack stroke encoders The settings screen Used for setting the parameters for the lifting and lowering operations The CAN node configuration screens Used for checking and amending the user parameters in each of the CAN nodes Operating modes The DL P40 has three operating modes For details of these screens please see the relevant sections of this manual Manual mode Full manual control of all jack functions Auto lift mode Automatic load lifting for one full stroke of the jacks Auto lower mode Automatic load lowering for one full stroke of the jacks Other software on the control computer There are no known conflicts between the DL P40 and other software that may be running on the control computer but nevertheless it can not be ruled out that a conflict does may exist with come software and in some circumstances It is also imprtant the the operator is concentrating 10096 on the DL P40 and not on other programs It is therefore ESSENTIAL that all other software programs on the control computer are stopped before running the DL P40 In particular Virus guard programs Internet browsers Games V 3 016a Page 3 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 1 2 Software The DL P40 contr
15. 1 gt USB CAN Adaptor Connect Reconnect 4 09 06 16 14 28 12 gt Mode Unselected 5 09 06 16 14 28 12 gt INTERROGATION Sending All Stop 6 09 06 16 14 28 14 gt INTERROGATION Querying Type Numbers 7 09 06 16 14 28 16 gt INTERROGATION Querying Serial Numbers 8 09 06 16 14 28 17 gt INTERROGATION Querying Connections 9 09 06 16 14 28 19 gt INTERROGATION Querying Jack Attributes 10 09 06 16 14 28 21 gt INTERROGATION Querying Software Version 11 09 06 16 14 28 22 gt INTERROGATION Querying Boot Loader Version 12 09 06 16 14 28 24 gt INTERROGATION Finalising Interrogation 13 09 06 16 14 28 24 Read Jack Node Parameters 14 09 06 16 14 28 25 Read Jack Node Parameters 15 09 06 16 14 28 26 Read Jack Node Parameters 16 09 06 16 14 28 27 Read Jack Node Parameters 17 09 06 16 14 28 28 Read Jack Node Parameters 18 09 06 16 14 28 29 Read Jack Node Parameters 19 09 06 16 14 28 30 Read Jack Node Parameters 20 09 06 16 14 28 31 Read Jack Node Parameters 21 09 06 16 14 28 32 Read Jack Node Parameters 22 09 06 16 14 28 33 Read Jack Node Parameters 23 09 06 16 14 28 34 Read Jack Node Parameters 24 09 06 16 14 28 35 Read Jack Node Parameters 25 09 06 16 14 28 35 1100 1001 0 0 0 Top Unknown Base Unknown J101 joo2 0 26 09 06 16 14 28 37 J100 1001 0 0 1 812 6 Top Unknown Base Unknown J101 joo2 0 0 1 t 27 09 06 16 14 28 39 gt Manual Mode Selected 28 09 06 16 14
16. 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 Monitor MT 95 95 96 95 95 95 95 96 96 96 95 95 95 95 95 94 95 95 95 95 Stroke mm 25 Feb 2010 13 55 13 69 69 70 69 69 69 69 70 69 70 69 69 69 69 69 63 69 69 69 69 Lift mm Operating Mode Setup Auto Lift Auto Lower Manual Calibrate Stroke Read Actual Loads L Settings L Jack Details Jack Name J127 Stroke mm 500 0 SWL MT 185 0 20 pressure Bar 400 0 Jack CAN I D 127 Top dead Zone 20 0 SWL pressure bar 292 0 Zero Pressure mA 4 0 Click to Park Mouse Jack Serial No s185 28 Bottom dead Zone 20 0 Area ratio 1 690 Scrn Full extended mm 2610 0 Jack Type 5111 Extend overrun mm 2 0 Retract overrun mm 4 0 Scrn Full retracted mm 58 0 Messages window Information messages are shown here They can include status information warnings or errors If multiple errors have been reported click on the pane to see a complete list To cancel warning messages press the Manual Mode button Jack representation on the main screen Each jack on the system is represented by a vertical line onto which is placed a stroke indicator and a load indicator Up to 40 No jacks can be shown on the screen 20 across the top row and 20 across the bottom row The position of each jack on the screen is set by the user in the Settings Screen At the top and bottom of the jack line is a grip open close indicator Below each jack line the values o
17. 2 V 3 016a Page 12 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 2 0 Operating screens 2 1 Main screen The main screen is were you can see the status of all the jacks in the system and carry out the heavy lifting operations The main screen is as shown below DL P40 Strand Jack Mode sim 1 40 jacks DR System View Help Manual me Manual Mode Open Top Dg DS PS DE DE DX D D D D M b Close Top 10095 75 Extend 50 Retract 25 0 Open Base BB B Total 1100 3101 J102 1103 3104 3105 3106 J107 3108 3109 J110 1111 3112 3113 3114 1115 3116 1117 3118 3119 Jack Close Base 6401 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 Load MT 6400 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 Monitor MT 96 95 96 96 95 94 96 96 96 96 95 95 96 95 96 95 95 95 96 94 Stroke mm Bleed lover 69 70 69 70 70 69 70 7 70 70 6 69 70 69 69 69 69 70 68 Lift mm Stroke sc oe BOBO OM ON ON ON ON OX EON ON ONE NOE ON DM 2 0 mm ix 10095 Reset Lift Totals 75 50 25 0 BH HN NN NE NH NE NE HH NEN E B 2120 1121 1122 1123 1124 3125 3126 J127 1128 J129 1130 3131 J132 3133 3134 1135 J136 J137 3138 3139 Jack 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 Load MT 160 160 160 160
18. Before using the Auto Lift Lower modes the user must use Manual Mode to V 3 016a Page 27 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 1 close all top and bottom anchors 2 Put all the jack strokes within the Maximum Allowable Stroke Range value in the Setting screen 3 Put all of the jack strokes outside of the Top and Bottom Dead Zones set into the jack CAN nodes using the Node Configuration Screen To start the Auto Lift Lower cycle press the relevant button Operating and then press the Start button START At any point in the auto lift lower cycles the user can Stop the operation by pressing the Stop Button or any other key on the Keyboard After pressing the Stop button the user can Resume the operation by pressing the Resume button The Auto Lift and Auto Lower routines will automatically use the jack Extend and Retract Overrun parameters set by the user for all jacks in the Node Configuration Screen to stop the jacks clear of the top and bottom Dead Zones also set by the User for all jacks in the Node Configuration Screen If for any reason the jacks do go into the Dead Zones then the Auto Lift Lower routine will stop and give an error message The user must use Manual Mode to move all jacks out of the Dead Zones before being able to continue with Auto Lift Lower In this case it would be advisable to increase the Extend and Retrac
19. Modes 3 1 Manual Mode Manual Mode allows you to take direct control over the system hardware giving you more freedom Manual Mode can be activated by clicking the Manual button from the Operating Mode buttons in the Main Screen Note that manual mode cannot be selected when another operation running Once manual mode is active the seven manual mode buttons are enabled Open Top Close Top Extend Retract Open Base Close Base and Bleed Lower These buttons will send commands to each of the selected jacks The seven buttons will only cause activity while the button remains pressed The Up and Down keyboard arrow keys have the same effect as the Extend and Retract buttons respectively Left and right keyboard arrows have the same effect as Open Base and OPen Top buttons respectively Extend and Retract operations can be synchronized or free according to the users selection in the Settings Screen When synchronized the DL P40 will automatically keep all the jack strokes within the Stroke Range entered by the user in the Setting Screen When in synchronized mode Synchro Extend and Synchro Retract are displayed in place of Extend and Retract respectively Synchronizing during extend and retract operations leads to more stable distribution of load between the jacks but may slow the operation down a little as all jacks are forced to go at the speed of the slowest jack The bleed lower function operates a bleed valv
20. aster in Manual mode transfer the load to the other anchors by extending or retracting the main cylinders as appropriate and check the correct operation of the load and stroke readings as you do so 6 If 5 was possible ask your Lift Master In Manual mode open all the unloaded anchors Check that the anchor colours all go from green through yellow to red Then close all these anchors 7 If checks 5 and 6 were performed then transfer the load back to the safe anchor bottom anchor for strand jacks top anchor for climbing jacks 8 If itis necessary to change any of the components of the system to correct a fault then follow the procedure in 4 1 2 and then re check to see that the fault has been cleared Remember to close all ball valves and turn off the power to the system at all power packs before working on the system 9 The system is now checked and ready for use 4 2 4 Carrying out a lifting or skidding operation The most important criteria for a safe operation is that there is a detailed plan of work and that all the staff involved are competent properly trained and properly briefed on the specific operation to be carried out There needs to be a single person in overall control of the operation the Lift Master who is in communication with the DL P40 operator and all other staff involved in the operation The DL P40 operator should not be the Lift Master as well General guidance on the safe planning and execution of a lif
21. ays be entered in Bar eg for a jack with 185 tonnes safe working load 290 Bar enter 290 Full bore to annular area ratio Enter ratio of full bore to annular area ratio Consult the user manual for the jack to obtain this value Typically between 1 6 and 2 5 Transducer pressure at 20 mA bar 1 Bar 0 1 N mm2 0 1 mpa 14 504 psi Enter the max rated pressure for the transducer at which it will output a 20mA signal This value must be entered in Bar for example a 0 400 bar 0 20 mA pressure transducer enter 400 Transducer mA at zero pressure mA Enter the mA signal for the pressure transducers used that equate to zero pressure For example for a 0 400 bar 4 20 mA pressure transducer enter 4 Piston extend and retract overrun parameters mm This parameter is to allow for the distance the piston will travel from the time that the DL P40 sends the signal to stop to the piston actually stopping due to inertial forces This distance can vary from a few mm for slow systems 2 10 m hour to as much as 30 mm for very fast systems 40 60 m hour If this parameter is set too low then the piston will overrun into the dead zone at the top and bottom of stroke and the DL P40 will stop in auto lift and auto lower modes If it is set too high then some of the available stroke will be lost It is better to set this parameter too high V 3 016a Page 23 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manua
22. cking the system before each use 4 2 4 Carrying out a lifting or skidding operation 4 2 5 Closing down the system 4 3 Maintenance of the system 5 Advanced 5 1 Fault diagnosis 5 2 Work log files V 3 016a Page 2 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 1 0 Introduction 1 1 General The DL P40 computer control system is designed to be reliable safe simple to set up and simple to use The DL P40 system can be used for the control of up to 40 No strand jacks or climbing jacks The program can also be run in simulation mode where the jack data is taken from a csv file on the computer rather than from real jacks on a CAN network This is useful as a demonstration and training aid The system comprises CAN nodes mounted on the jacks and power packs that collect sensor information and directly control the hydraulic valves and a control computer that the operator will use to set up monitor and control the complete system Communication between all these components is via a CAN line Control Area Network For details of the hardware and software please see the relevant sections of this manual This complete manual is contained in the DL P40 help file that the operator can view on the control computer at any time by clicking on help in the Main Screen Operating screens The control computer has three main operating screens that the operator will use to set up and operate
23. creen where the user can view and change the main parameters for all the selected active jacks and power pack CAN nodes See the separate section on this topic for a detailed description of how to use the Node Configuration Screens Preferences Selecting this option brings up the Preferences window Preferences General Jack Visualisation Options Length Units 090107 M Weight Units Metric Tonnes Column Percentage 125 v Indicate Jacks which are Inactive with Loaded Top Anchors After 10 minutes M C Display Load Percent v Display Jack Name in Jack Tray v Highlight Most Extended and Retracted Selected Jacks Workspace ptions v Enable Tooltips v Load last project at startup Other Options C The computer will beep when auto lift amp auto lower cycle is complete Cancel Help Length units can be mm or inches Weight units can be Tonnes KN or US Short tonnes 2000 Ibs Max column percentage sets the max of the Monitor Load that can be shown on the screen Indicate Jacks which are inactive with Loaded Top Anchors sets the time after which a warning will be given as care will be needed when retracting the jack and opening the top anchors if the load has been held for some time Display Load Percentage the load will be displayed as a number next to the load arrow on the main screen Useful if you are trying to load the jacks up to specified expected loads typically
24. d again after re starting the DL P40 system They contain all of the information entered by the User in the Setting Window New Project clears all the data in the Settings Screen Open Project loads a saved project file Save project As allows the current project file to be saved under another name Save Project saves the current project file using the same name Reconnect USB Hardware Selecting this option causes the DL P40 to interrogate the CAN network Viewer Mode Selecting this option makes all the controls inactive but all the jack loads grip states and jack strokes will be visible in real time So this option turns the control computer into a Viewing window Console This facility allows for viewing and instructing the system using CAN commands in Hex language This facility is only intended for use by trained DLT engineers and for safety is password protected It is not necessary for normal operation of the system Node Configuration Utility Single Selecting this option opens the Single Node Configuration Screen where the user can view and change the main parameters in each of the CAN nodes one at a time See the separate section on this topic for a detailed description of how to use the Node Configuration Screens V 3 016a Page 16 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual Node Configuration Utility Multi Selecting this option opens the Multi Node Configuration S
25. de number The S C or L are added automatically from the Node Type setting Serial Number 8 character text field that will appear on the Settings Screen You can enter any text you want but no spaces Usual convention is to enter the jack or power pack type E g S588 or L120 2 D JACK PARAMETERS Inverted Encoder If the jack stroke indicator on the Main Screen goes down when the jack is extended then the encoder reading needs to be inverted Check this box to invert the encoder Milliamp encoder Check this box if variable ampage encoders are used DLT standard supply is variable voltage encoders so this box should normally be left blank Stroke mm Enter the stroke of the jack in mm eg of the full stroke of the jack is 500mm then type 500 Dead Zone at top of stroke mm An area of the jack stroke that will not be used by the auto lift and auto lower modes to prevent the possibility of fully extending the jack to the top of stroke whilst under load usually set to 20 mm enter 20 In Manual Mode this dead zone is ignored and the cylinder will only stop extending V 3 016a Page 22 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual when the full stroke of the jack is reached If you want to extend the jack beyond the full stroke in manual mode to apply full pressure to the full bore side of the ram then set the Dead Zone at top of stroke to Zero THe DL P40 will then not st
26. e around 10 seconds to complete V 3 016a Page 20 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 2 4 Node configuration screens The Node configuration Screens are used to view and change the CAN node parameters which tell the CAN node the properties of the jack or power pack that it is connected to There are two types of Node Configuration Screens which can be accessed via the System menu single node and multi node Single node is used to view and edit the node parameters one node at a time Multi node is used to view and update all the selected active jacks together Jacks are selected and unselected in the main screen before entering the multi node screen The multi node screen is therefore the most useful of the two as it will be quicker to set parameters in all the nodes and easier to spot any discrepancies in values between the nodes 2 41 Single node configuration Select Node Config Utility Single from the System Menu and the following screen will pop up Dorman Long Node Configuration Utility CAM ID 100 Node Type strand Jack Node P Type Number 5 Serial Number 22277 Ram Mode Config C Inverted Encoder Milliamp Encoder Stroke mm m Dead zone at top of stroke mm Dead zone at bottom of stroke mm 185 0 Safe working load of jack Metric tonnes Safe working pressure of jack Bar indes Full bore to annular area ratio Transducer pressure at 20
27. e fitted to the extend port of the jack Pressing the bleed lower button will open this bleed valve and allows oil to flow out of the jack at a slow speed typically causing the piston to retract at about 1 mm per 3 seconds Bleed Lower mode is useful for very slowly lowering a load onto it s supports or for precise alignment of a load so that bolted joints can be made Not all the commands are allowed all the time Sometimes buttons will become disabled to indicate that their action is impossible or unsafe The extend and retract buttons will not allow any of the jacks to go beyond their end of stroke unless the Dead Zone parameter is set to Zero using the Node Configuration Screen and at least one of the anchors must be closed all the times 3 2 Auto lift and Auto lower modes The Auto Lift and Lower operations are used to automatically extend or retract the selected jacks for one complete cycle of the ram or to the end of the current cycle For Auto Lift the cycle starts and stops with the jacks retracted the load in the base anchors and all grips closed For Auto Lower the cycle starts and stops with the jacks extended the load in the base anchors and all grips closed At the end of each cycle the user must press the Start button again to commence the next cycle For safety reasons the DL P40 is not fitted with a lift lower to a distance facility as this would allow the user to walk away from the control computer for extended periods
28. enance Manual Auto lower mode or in manual mode with Synchro extend retract turned on Auto lift or Auto lower routines are stopping with the error message that jack xx is out of range Jacks are seen to extend on the screen when they are actually retracting or visa versa The reported jacks loads are incorrect Any of the above or other symptoms V 3 016a Some of the jacks are too near the Dead Zones at the top of bottom of the jack stroke Use manual mode to move them away form the dead zones The jacks are overrunning too far and going into the dead zones at the top or bottom of the stroke Increase the Overrun parameter in the affected jacks using the Node Configuration Screen Change the inversion of the stroke encoders using the Node Configuration Screen The jack loads are calculated by the DL P40 from the pressures at both ports of the jack the jack area and the Main bore to Annular area ratio Check that these parameters have been correctly entered into the jack CAN nodes using the Node Configuration Screen Check that all other software on the control computer is closed In particular Internet browsers Virus protection programs Games Page 35 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 5 2 Work Log files The DL P40 automatically creates a detailed log file of all operations every time that the system is run The log file contains the l
29. er packs are closed to prevent any possibility of any unwanted actions 3 Start the DL P40 program and go to the Main Screen if not already there 4 Follow the procedures in section 2 4 for checking and amending the parameters On exiting the node configuration screens the system will re interrogate the system 5 Wait until the system re interrogation is complete and you are returned to the Main Screen 6 You can now open all the ball valves at the power packs although generally it is a good idea to keep them closed at all times when not operating the system 7 The control system is now ready for use V 3 016a Page 31 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 4 2 3 Checking the system before each use At the start of each shift it is an important safety requirement to check that the system is still functioning correctly using the following procedure 1 Start up the system as described in 4 2 1 2 Check the CAN node parameters as described in section 4 2 2 To quickly scan the node parameters it is best to use the multiple node option 3 On the Main Screen check that all the anchors are shown as closed green and the load and stroke readings are showing and look approximately right 4 In Manual mode open all the unloaded anchors Check that the anchor colours all go from green through yellow to red Then close all these anchors 5 If itis safe to do so ask your Lift M
30. errun 0 1mm Piston retract overrun 0 1mm Piston Extend Acceleration mm s 2 Piston Extend Acceleration mm s 2 Piston retract Acceleration mm s 2 Piston retract Acceleration mm s 2 J001 S 500 10 20 0 5 1570 1815 0 1 0 1 20 20 0 1 12840 580 19775 9888 6229 400 20 40 490 490 980 980 J002 S 500 10 20 0 5 1570 1815 0 1 0 1 20 20 0 1 12840 580 19775 9888 6229 400 20 40 490 490 980 980 J003 S 500 10 20 0 5 1570 1815 0 1 0 1 20 20 0 1 12840 580 19775 9888 6229 400 20 40 490 490 980 980 J004 S 500 10 20 0 5 1570 1815 0 1 0 1 20 20 0 1 12840 580 19775 9888 6229 400 20 40 490 490 980 980 J005 S 500 10 20 0 5 1570 1815 0 1 0 1 20 20 0 1 12840 580 19775 9888 6229 400 20 40 490 490 980 980 J006 S 500 10 20 0 5 1570 1815 0 1 0 1 20 20 0 1 12840 580 19775 9888 6229 400 20 40 490 490 980 980 LdaeksE 5 siii The first section of the file is delimited by the GlobalParams and GlobalParams tags and defines the global parameters of the simulation Within these tags the global parameters must be specified V 3 016a Page 10 10 11 12 13 14 15 16 17 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual E The stiffness of the simulated structure Usually set to 0 02 Jacks per power pack The number of jacks to be attached to each power pack A The A value specifies how quickly the load on the virtual jacks arrives at their expected value as the load is lifted off the ground
31. es for the complete system Stroke dispersion The difference in measured stroke between the most extended jack and the least extended jack System Menu The system menu gives access to preferences project files and to the Node Configuration Utility Start Button The Start button is used to start or stop in auto lift and auto lower modes The button has four possible states O Indicates that the system is not ready to start work The The button is shown in hardware must be Bc ae pm this state when the ready and connected y Press to E the system is running an and an operation must operation Click to Stop be specified before the P P that operation button becomes available The button in this state has exactly the same effect as the button in the Start state but is shown if an operation as been interrupted by a warning or by the Stop button V 3 016a Page 14 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual Operating Mode Buttons Use Operating mode buttons to select from one of three operating modes Head Actual Loads Click to take a snapshot of the current loads for each jack to populate the Actual Load values in the Settings Screen for each selected jack These values can then be used as the Monitor Load if they are more useful than the expected loads Calibrate stroke Press this button to start the automatic stroke cal
32. f load and stroke are given A detailed explanation of each of these elements is as follows Load indicator Load is shown as a of the monitor load for each jack THe monitor load is set by the user in the Settings Screen V 3 016a Page 13 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual Stroke indicator Stroke is shown as a 96 of the full stroke of the jack The most extended jack is shown in red the least extended jack is shown in blue Grip state indicators there are 4 possible grip states as shown below Closed x Loaded State Jack The name of the jack This is set by the user in the Settings Screen Load the measured load in the jack This can be shown in metric tonnes KN or US short Tons 2 000 lbs as selected by the user in System Preferences Monitor the monitor load This is a load set by the user in the Setting Screen for each jack It can be different for each jack THe monitor load can either be the expected load for each jack or an actual value read by the system when the Set Load button is pressed Stroke The jack stroke Note that the stroke counter will only start once the load in the jack has reached 5096 of the expected load set by the user in the Settings Screen Lift The total movement of the load at each jack since the last time that the Reset Lift Totals button was pressed Total Column Displays the total loads and lift distanc
33. ge 25 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual although using the Stroke Calibration button on the Main Screen is a much quicker and simpler method Manual calibration of selected jacks using the Node Configuration Screen multi is carried out as follows T 2 B 8 Press the Read button Click in each of the stroke Gain boxes and select Yes in the pop up window that will appear asking you if you wish to reset the stroke encoder Gain and EMC values They will then be re set to default values for taking stroke encoder readings Do this for all of the jacks Press the Write button Exit the Node Configuration Screen Select manual mode and fully retract all the selected jacks Write down the jack stroke readings shown on the Main Screen Disconnect one end of the stroke encoders from the jacks and fully extend the jacks in Manual mode Reconnect the stroke encoders and write down the jack stroke readings shown on the Main Screen Open the Node Configuration screen Multi Press the Read button 10 Enter the values collected in 5 amp 7 above into the Screen stroke reading fully extended and Screen stroke reading fully retracted boxes 11 Press the Write button The stroke encoders for the selected jacks are now calibrated V 3 016a Page 26 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 3 0 Operating
34. hift the system should be shut down as follows 1 Make sure the jacks are in a safe condition with all anchors confirmed closed Close all the ball valves on all the power packs Close the DL P40 program on the control PC Turn off the 24V dc electric supply to the control system on all the power packs and turn off the control computer in any order N C 4 3 Maintenance of the system The control systems are designed for minimal maintenance but it is recommended that the following maintenance procedures are followed Prior to the start of each project e Thoroughly clean all the cables and connections using white spirit and dry Spray water dispersal oil WD40 onto the connection pins Visually check the condition of all components looking for damage or corrosion Replace plug caps on any plugs not be used Fully assemble the system on the power packs and jacks and carry out a function testing to check that all required components are present and working correctly e Pack spare parts for maintenance on site Between successive operations on each project e Visually check the condition of all components looking for damage or corrosion At the end of each project Thoroughly clean all the cables and connections using white spirit e Spray water dispersal oil WD40 on all the connecting pins e Replace plug caps on all plugs e Coil and tie all the cables and place in a box for transportation and storage between pro
35. ibration routine Settings Click to go to the settings screen Manual Control Buttons The seven manual mode buttons are only enabled in manual mode Reset Lift Totals Click to reset all the lift values including the total lift value to zero Select All amp Select None Use the Select All and Select None buttons to change the selection state of jacks displayed in the tray Jacks which are not selected will be excluded from any operation Jack Details area Full details of all the jack parameters currently set into the Jack CAN nodes Hover the mouse over a jack to see its parameters Mouse Park The mouse park is a convenient way of keeping the cursor held out of reach of possibly safety critical buttons when it is not in use To park the mouse left click the on the DL logo To release the mouse double click with right mouse button V 3 016a Page 15 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 2 2 System menu on the main screen The system menu is located at the top left hand corner of the DL P40 window DL P40 Strand Jack Mo EPUM View Help New Project Open Project Save Project As Save Project Reconnect USB Hardware Viewer Mode Console Node Config Lltiliby Single Node Config Utiliby Multi Preferences Exit ee Project Files Project Files are used to store information about the current system setup so that they do not need to be entere
36. ing V 3 016a Page 30 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 4 2 Using the system on site This control system should only be operated by competent trained staff working under the overall direction of a competent trained Lift Master Please refer to the Operation and Maintenance manual for your system for specific guidance on using the equipment to carry out a heavy lifting or skidding operation This section covers the basic procedures common to all DL L40 systems for starting commissioning operating and shutting down the system 4 2 1 Starting up the system Every time you turn on the system it is important that you use the following procedure to ensure the safety of the site and to avoid any damage to the system 1 Ensure that the 24V d c power supply to the control system is switched off at every power pack There will be a separate power on off switch for each power pack Note that the power pack motors and the control computer can be either on or off at this stage 2 Visually inspect all the components of the system to make sure no physical damage has occurred since last use and that all the data cables are properly connected 3 Ensure that all the ball valves on all the power packs are closed to prevent any possibility of any unwanted actions 4 Turn on the 24V d c power supply to the control system at every power pack and turn on the control computer if not on a
37. jack pump back to tank and is not available to open and close the mini jacks which open and close the grips In the On position oil is directed to the mini jack valves at the pressure set by the mini jack pressure relief valve usually 50 bar The loading valve can be set to either be on all the time but will heat up the oil on only when the mini jacks are extending retracting or on when ether the mini jacks or the main cylinders are extending retracting only needed for special power packs The usual setting is On for the mini jack only 2 Pos n MJ valves 1 lead The are two possible types of valve used to extend and retract the mini jacks a 2 position or3 position valve DLT standard valve is a 2 position valve which is open when energized and closed when not energized These can be easily recognized by counting only one electrical solenoid lead to each valve A 3 position valve will have 2 leads to each valve The DL P40 needs to be told which type of valve is fitted by correctly setting this parameter in the power pack CAN node V 3 016a Page 24 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 2 4 2 Multiple node configuration In the Main Screen select only the jacks for which you wish to view and edit the node parameters Then select Node Config Utility Multi from the System Menu and the following screen will pop up Dorman Long Selected Nodes List Configuration Utility Jack Nodes List
38. jects to minimise the chances of damage e The jack sensors can remain on the jacks for transport between sites but should be properly protected from damage during handling V 3 016a Page 33 IL Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 5 0 Advanced 5 1 Fault diagnosis Use the following guide to understand and correct faults that may occur in the DL P40 system Symptom No CAN nodes shown in the setting Screen after completing system interrogation Or Not all the CAN nodes are showing in the setting screen after completing system interrogation Jacks do not extend or retract in Auto lift or V 3 016a Possible Causes amp remedies Thoroughly check all CAN cables for loose or dirty connections and broken wires Check that all unused plugs on the power pack nodes have termination plugs fitted Check that the USB to CAN Compact is connected to the control computer and is showing a green light i e communication has been made between the computer and the CAN to USB compact If no green light on the CAN to USB compact then try another one to see if the first unit is the problem Try another USB port to see if that is the problem If not then re install the IXXAT drivers on the control computer Using the Node Configuration Screen check that all the power pack nodes have been configured to be power pack nodes Serial number begins with L not S Power suppl
39. l than too low Manual calibration of stroke encoders The jack stroke encoders can be manually calibrated using the node configuration screen if preferred although using the Stroke Calibration button on the Main Screen is a much quicker and simpler method Manual calibration using the Node Configuration Screen is carried out as follows for each jack Enter the CAN ID of the node Press the Read button Press the reset stroke gain and ENC for manual calibration button Press the Write button Exit the Node Configuration Screen Select manual mode and fully retract the jack Write down the jack stroke reading shown on the Main Screen 7 Disconnect one end of the stroke encoder from the jack and fully extend the jack in Manual mode 8 reconnect the stroke encoder and write down the jack stroke reading shown on the Main Screen 9 Open the Node Configuration screen 10 Enter the CAN ID of the node 11 Press the Read button 12 enter the two values collected in 6 amp 8 above into the Screen stroke reading fully extended and Screen stroke reading fully retracted boxes 13 Press the Write button The stroke encoder for that jack is now calibrated Og dcos qo POWER PACK PARAMETERS Loading valve The loading valve is an electronically controlled valve in mini jack circuit of the power pack that has two positions On or Off In the Off position oil is circulated at a nominal pressure from the mini
40. lready 5 Start the DL P40 program by clicking on the desk top icon 6 Select CAN Adaptor Type Ixxat CAN to USB Compact when asked and press OK 7 Wait whilst the DL P40 system is interrogated During the interrogation phase the system is communicating with all the Power pack and Jack CAN nodes 8 Enter the project settings After system interrogation is complete you have the option to either load a previous project settings System gt Open Project or go to the Settings screen to enter the project settings manually see section 2 3 It is always a good idea to open the settings screen first to check that all the nodes on the system have been identified 9 You can now open all the ball valves at the power packs although generally it is a good idea to keep them closed at all times when not operating the system 10 The control system is now ready for use 4 2 2 Checking and amending the CAN node parameters The CAN node parameters define the properties of the jacks and power packs in the system and itis therefore important that they are set correctly The following procedure should be used to check and amend these parameters 1 Ensure that the control computer and the 24V d c power supply to the control system is switched on at every power pack There will be a separate power on off switch for each power pack Note that the power pack motors can be either on or off at this stage 2 Ensure that all the ball valves on all the pow
41. n fill in 34 in both boxes In Save File Path you can select where you want the generated files to be saved The default is to create a new folder on the desk top and put the files in that folder This is the most convenient place to find these files so it is recommended that you do not change this default setting In Exe File Version select whether you wish to generate Power pack CAN node files or Jack CAN node files After completing the above 3 steps press the Generate Node Exe Files button to create the node files You can repeat the above steps as often as you wish to create all the CAN node installation files you need To install the new CAN node software simply connect a powered node to a computer through the USB CAN converter and then run the relevant CAN node software file This is best done with a single node connected directly to the PC via the USB CAN converter with a termination plug in any unused connections but can also can be done on a fully wired system on site with the CAN nodes mounted on the jacks and power packs The installation sequence is as follows 1 Ensure that the control computer and the 24V d c power supply to the control system is switched on at every power pack There will be a separate power on off switch for each power pack Note that the power pack motors can be either on or off at this stage 2 Ensure that all the ball valves on all the power packs are closed to prevent any possibility of a
42. ny unwanted actions 3 Run the CAN node software file for the nodes that you want to update one at a time The following screen will appear after running the software file Press Download to install the new program into the node X CAN Firmware Downloader v1 0 re Downloader 2005 www controldevelopments com HEX File Embedded S_xx_ 301_Temp Hex CAN Adaptor Ixxat USB to CAN Compact BaudRate 50 kbps Source ID HEX 0x07FF Target ID HEX xo ES C Full Memory Write Start Offset HEX 0 0000 4 Turn off the power to all the nodes Wait 30 seconds and then turn the power back on The nodes will then re boot with the new software loaded 5 Follow the procedures in section 2 4 for checking and amending the parameters On exiting the node configuration screens the system will re interrogate the system 6 Wait until the system re interrogation is complete and you are returned to the Main Screen 7 You can now open all the ball valves at the power packs although generally it is a good V 3 016a Page 5 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual idea to keep them closed at all times when not operating the system 8 The control system is now ready for use The IXXAT CAN USB compact drivers must be loaded onto the control computer before it can communicate with the CAN network through the CAN USB converter This is proprietary software pr
43. oad stroke and anchor Clamp states of all of the jacks at no more than 2 second intervals and all of the commands given by the user to the nearest second Log files are useful in analyzing what has happened after the operation has finished or has been stopped The log files are written in CSV format which enables them to be processed by popular data analysis tools such as Microsoft Excel The current log file can not be read whilst the operation is continuing as the file is open until the DL P40 program is closed A typical log file is a follows it is fairly self explanatory but for a detailed evaluation of log files please contact Dorman Long Technology ido c amp WorkLog 16 06 09 csv Microsoft Excel mom ooo Insert Page Layout Formulas Data Review View Acrobat P X cari ju Ax Paste B I U xo TUN WI mom SF General j amp a3 mee rjr d4 EXE 3 Delete 9 H 09 50 8 Conditional Format Cell pa Sort amp Find amp L Bd E E E Formatting as Table Styles Ej Format Q7 Filter Select Clipboard Font fa Alignment Number Styles JU j Editing c nn 1 G fe Date Time I B G D E G H 1 1 K a Date Time Name Serial Load kN Stroke mm Lift mm Clamps Name Serial Load kN Stroke m Lift 2 09 06 16 14 26 51 gt Session Start 3 09 06 16 14 26 5
44. ol system uses CAN nodes on the jacks and power packs to collect sensor information and to send instructions to control valves on the power packs and jacks Each CAN node is intelligent and can make its own decisions using the software loaded onto it to achieve the instructions sent to it by the DL P40 control computer The DL P40 control computer is in overall control of the system Communication between the CAN nodes and the DL P40 control computer is made via a 4 wire CAN Controller Area Network line which connecters to the PC via a USB CAN converter There are therefore 3 separate software programs on the DL P40 system plus drivers for the IXXAT CAN USB Compact DL P40 PC software version 3 xx DL P40 CAN node program generator Jack version 3 xx Power pack V 3 xx IXXAT CAN USB compact drivers version 2 18 All the above software is available to download over the internet at www dormanlongtechnology com DL P40 htm After down load the DL P40 PC software and IXXAT CAN USB compact drivers should be installed on the control computer To install these programs simply run the file after download and follow the instructions The DL P40 CAN node program installation files link will down load a program that once installed on your PC will be able to create all required CAN node installation files which can be installed into a CAN from a PC through the CAN network Each CAN node has its own unique CAN ID number which is what the CAN network u
45. op extending in Manual mode when the full stroke is reached Dead Zone at bottom of stroke mm An area of the jack stroke that will not be used by the auto lift and auto lower modes to prevent the possibility of fully retracting the jack to the bottom of stroke whilst under load usually set to 20 mm enter 20 In Manual Mode this dead zone is ignored and the cylinder will only stop extending when the stroke of the jack is Zero If you want to retract the jack beyond the fully closed in manual mode to apply full pressure to the annular bore side of the ram then set the Dead Zone at bottom of stroke to Zero The DL P40 will then not stop retracting in Manual mode when zero stroke is reached Safe working load of Jack metric tonnes 1 metric tonne 9 8066 kN 1 1023 US short tons 2 000 Ibs Enter the safe working load of the jack This value is always in metric tonnes regardless of the load units chosen in preferences eg for a jack with 185 tonnes safe working load enter 185 The DL P40 will automatically stop an operation in Auto Lift and Auto Lower modes if the safe working load of any of the jacks is reached In manual mode a warning will be given but the operator can continue to operate the jack if absolutely necessary Safe working pressure of Jack bar 1 Bar 0 1 N mm2 0 1 14 504 psi Enter the extend port pressure at the jack safe working load This value can be obtained form the user manual for the jack It must alw
46. ovided by the manufacturers of the CAN USB compact unit The DL P40 is designed only to work with version 2 18 of this software and will not work with earlier or later versions V 3 016a Page 6 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 1 3 Hardware The DL P40 hardware comprises the CAN nodes the sensors the data cables and the control computer For the detailed layout of your complete system please refer to the user manual The DL P40 hardware has been engineered for work in a building site environment but nevertheless the hardware can suffer damage from the following 1 Connecting or disconnecting any of the data cables including the USB connection to the control computer when the 24v d c power to any of the nodes is switched on Always switch off the power to all nodes in the system at the power packs whilst connecting or disconnecting any component of the control system Welding Never connect a welding earth through a structure onto which a DL P40 node is mounted e g a power pack Heat Never use flame cutting equipment near a DL P40 node or data cable Impact The DL P40 nodes should be handled with care and not dropped or hit Water jet Never point a high pressure water jet towards any DL P40 components e g when cleaning strand Damage to cable connectors Rough handling of the cable connectors can bend and break connection pins so always handle with care
47. perating Mode Setup Select All Auto Lift Calibrate Stroke Read Actual Loads Settings rm L Jack Details Select None Jack 2127 Stroke mm 500 0 SWL MT 185 0 20 mA pressure Bar 400 0 Jack CAN I D 127 Top dead Zone 20 0 SWL pressure bar 292 0 Zero Pressure mA 4 0 Click to Park Mouse Jack Serial No 5185 28 Bottom dead Zone 20 0 Area ratio 1 690 Sern full extended mm 2610 0 Jack Type 5111 Extend overrun mm 2 0 Retract overrun mm 4 0 Scrn Full retracted mm 58 0 Operation and Maintenance Manual V 3 016a Page 1 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual Index 1 Introduction 1 1 General 1 2 Software 1 3 Hardware 1 4 Simulation mode 2 Operating Screens 2 1 Main screen 2 2 System menu on main screen 2 3 Settings screen 2 4 Node configuration screens 2 4 1 single node configuration 2 4 2 multiple node configuration 3 Operating modes 3 1 Manual Mode 3 2 Auto lift and Auto lower modes 3 3 Jack stroke encoder calibration 4 Operation and maintenance of the system 4 1 Setting up reconfiguring and dismantling the system on site 4 1 1 Connecting the components together at the start of a project 4 1 2 Changing the layout or replacing components during a project 4 1 3 Dismantling the system at the end of a project 4 2 Using the system on site 4 2 1 Starting up the system 4 2 2 Checking and amending the CAN node parameters 4 2 3 Che
48. properly To use the simulation mode you select Virtual System Simulator as your CAN adaptor as the program starts Please Select a CAN Adaptor CAN Adaptor Type Ixxat CAN to USB Compact You will then be prompted to select a CSV file which contains all the information needed on the number and type of jacks power pack arrangement jack speeds jack loads etc The DL P40 then uses this information in place of the information that it would normally receive from the CAN nodes A number of example simulation files are automatically loaded to the desktop when you install the DL P40 The CSV files can easily be created and edited using Microsoft Excel The best way to create new CSV files is to open and edit an existing file then save with a new name An example CSV file is automatically loaded onto the desktop when the DL P40 is installed into your computer A typical CSV file is as follows when viewed in a text editor such as Windows Word Pad Global Params aa Jacks per power 1 AOO eT PGlobalParams jis od Serial Number Stroke mm Raise Speed mm s Lower Speed mm s Bleed Speed mm s Expected Load KN Absolute Max Load kN Open Minijack Velocity Close Minijack Velocity Upper Dead Band mm Lower Dead Band mm Randomisation Factor K Stroke Gain ENC Full Bore Gain Annular Gain FourMA Transducer Pressure At 20MA Piston Extend ov
49. r V 3 016a Page 8 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual Jack sensors climbing jacks similar Top anchor grip open closed sensors 2 No sensors for open and 2 No sensors for closed positioned on either side of the anchor Retract port pressure sensor Accurate to 0 25 Stroke sensor Sensor accurate to 0 015 Strand jack electrical dressing set Common to both DL P40 and DL M control systems DL P40 strand jack CAN node within a protective enclosure box Extend port pressure sensor Accurate to 0 25 Extend port bleed valve Operated by the CAN node for extremely accurate alignment of the load and for smooth load transfer to other support Bottom anchor grip open closed sensors 2 No sensors for open and 2 No sensors for closed positioned on either side of the anchor V 3 016a Page 9 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 1 4 Simulation mode As a useful alternative to running the full system with CAN nodes connected the DL P40 can be run from a CSV file Comma Separated Values containing all the information that the system would normally obtain from the CAN nodes This is useful for learning to use the DL P40 and for demonstration purposes All functions of the DL P40 are available in simulation mode except for stroke calibration which needs real world sensor information to work
50. ses to identify each node The CAN ID is written on the front of the CAN node and is also shown on the Settings screen of the DL P40 The software for each CAN node is loaded into the node at manufacture but may need to be updated from time to time as new releases are issued A separate CAN node software installation file is released by DLT for each node and is named after the CAN ID of the node The file name begins with an L for a power pack node or an S for a jack node e g File name L 109 V3 01 exe is the version 3 01 installation file for power pack node with CAN ID 109 File name S 110 V3 01 is the version 3 01 installation file for the jack node with CAN ID 110 To generate these CAN node software installation files first download and install the DL P40 CAN node program generator and install on your PC then run this program You will then see a screen as follows Dorman Long DL P40 Code Generator 1 004 Set Parameters Generate Node Exe Files CANID From 100 To 101 Cancel Save File Path C Documents and Settings 800231 Desktop DL P40 Node File Exe File Version DL P40 V3 016 Power Pack Node V3 01 V 3 016a Page 4 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual In Set Parameters put in the first and last CAN ID numbers that you wish to generate For example if you want CAN ID s 50 to 58 the fill in From 50 To 58 If you just want CAN ID 34 the
51. t Overrun parameter values before continuing V 3 016a Page 28 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 3 3 Jack stroke encoder calibration The quickest simplest and most accurate way to calibrate all the jack stroke encoders is to use the Calibrate stroke button on the Main Screen The procedure is as follows 1 2 In the main Screen select only the jacks for which you want to calibrate the stroke encoders Press the Calibrate Stroke Button if it is greyed out then press the Manual Mode button first You will then be asked whether you want to reset the stroke encoder parameters for all the selected jack Press yes The jack CAN Nodes will automatically be re set and the system re interrogated You will then be asked to fully extend all the selected jacks to the end of stroke and press the Set Stroke button which appears in place of the bleed button at the bottom of the manual buttons and then fully retract all the jacks to bottom of stroke and press the Set Stroke button again Press OK and carry out these 2 operations The system will then automatically update the stroke parameters on all the selected nodes and re interrogate the system For the alternative method using the Node Calibration Screen see the description on that page of this help file V 3 016a Page 29 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual
52. th of the jack TYpically 20 mm Randomisation Factor K The K value allows a certain amount of random variation to be added to the raise and lower speed A value of 0 will cause no variation while a value of 1 will cause a random variation of between 0 and 200 of the speed entered into 4 amp 5 above Typically set to 0 1 Stroke Gain A value that will be shown in the jack data at the bottom of the main screen and in the node configuration screen No other effect Typically between 10 000 and 14 000 ENC A value that will be shown in the jack data at the bottom of the main screen and in the node configuration screen No other effect Typically between 1500 and 3000 Full bore gain A value that will be shown in the jack data at the bottom of the main screen and in the node configuration screen For the correct settings see the table below Annular gain A value that will be shown in the jack data at the bottom of the main screen and in the node configuration screen For the correct settings see the table below 01 515 01 546 DL S62 01 5108 01 5185 1 5294 DL S418 DL S588 DL S697 01 5836 01 51022 DL C125 DL C450 Full bore gain 752 3171 3171 3931 6480 10702 14743 21480 24332 31554 34845 4566 16439 Annular gain 430 1887 1887 2246 3835 6258 8935 12416 13904 19123 19686 1827 6575 FourMA A value that will be shown in the jack data at the bottom of the main screen and in the node configuration screen No other effect usually set to 6229
53. the layout drawing given in your Operation and Maintenance manual 4 The system can then be switched on at the power packs and used see section 4 2 4 1 2 Changing the layout or replacing components during a project 1 Ensure that the 24V d c power supply to the control system is switched off at every power pack There will be a separate power on off switch for each power pack Note that the power pack motors and the control computer can be either on or off at this stage 2 Ensure that all the ball valves on all the power packs are closed to prevent any possibility of any unwanted actions 3 Make the required changes to the DL P40 system and then connect all the components of the DL P40 system together including the USB connection to the control computer following the layout drawing given in your Operation and Maintenance manual 4 The system can then be switched on at the power packs and used see section 4 2 4 1 2 Dismantling the system at the end of a project 1 Ensure that the 24V d c power supply to the control system is switched off at every power pack There will be a separate power on off switch for each power pack Note that the power pack motors and the control computer can be either on or off at this stage 2 Ensure that all the ball valves on all the power packs are closed to prevent any possibility of any unwanted actions 3 Dismantle the system and pack away See section 4 3 for maintenance tasks prior to pack
54. ting and skidding operation are given in the Operation and Maintenance manual that came with your system It is not uncommon in complex heavy lifting operations for there to be a pause whilst events are considered by the team and in these satiations it is always a good idea to close all anchors and then close all the ball valves on all the power packs This action will leave the system safe and prevent any unwanted actions whilst the site team consider their next move The basic steps for performing an operation with the DL P40 are as follows 1 Start up the system as described in 4 2 1 including entering the project settings The project settings will include the expected load in each jack the maximum allowable load in each jack as a of the expected load and the maximum allowable stroke range to suit the load being lifted 2 Check the CAN node parameters as described in section 4 2 2 To quickly scan the node parameters it is best to use the multiple node option 3 Check the correct operation of the system as described in section 4 2 3 4 Operate the system as instructed using the Main Screen see section 2 1 5 On completion of the operation or at the end of each shift close down the DL P40 system as described in section 4 2 5 V 3 016a Page 32 Dorman Long Technology Limited DL P40 Release 3 Operation and Maintenance Manual 4 2 5 Shutting down the system At the end of an operation or at the end of each s
55. y failure to some of the nodes Check that all nodes have power lights flashing on the front of the node shows that they have power If all above OK then just make the connection to the first power pack node and put a termination plug in the CAN out connection Interrogate the system Can you see the first node If yes then progressively add power pack nodes to the network one at a time until the problem node is identified If no then disconnect the jack CAN lines and put in termination plugs If this helps then check the jack nodes one at a time to find the faulty node If this does not help then swap the first power pack node with another one to see if it is the first node that is the problem Follow this logical manner to identify the problem node s If a problem node is identified that will not communicate with the DL P40 try to repair the node by A reload the node software see software section then B use the Node Configuration Screen in the DL P40 to check and reset the node parameters If A fails then the node has been damaged and needs to be returned to DLT for repair Damage can be caused by lightening strikes high electrcal discharge close to the nodes welding excessive heat from flames and heavy impact and high pressure water jets The Stroke Range parameter in the Setting Screen has been set too low Increase the value Page 34 IL Dorman Long Technology Limited DL P40 Release 3 Operation and Maint
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