Hirschmann iFlex Operation Manual QUY260
Contents
1. 4 k5 L NUN 4 RE E 4 DOV R T UCUION GANAN UNAN 5 SUB IB WE 6 3 2 eT 7 SPAM WEEN 8 5 Reeving 9 53 2 VO POTECNECKIND GNG GEAR 12 3 5 9 14 C AINSDUS CHIECKIIS tip m 16 5 3 5 Angle limitation amp Time Settimo o nep tH E aA i 17 O sn Ee PAS lir 19 Te COBDe cO ioci is TA ANNA ien ta nive scien etus 25 User Manual 1 Breif introduction This manual is made for the crawler cranesQUY260 of Zoomlion Please read the manual carefully according the collocation of different types 2 General information The Hirschmann load moment indicator LMI 12 5 has been designed to provide the crane operator with the essential information required to operate the machine within its design parameters Using various sensing devices the Load Moment Indicator monitors various crane function and provide the operator with a continuous reading of the load capacity The readings continuously change as the crane moves and lifts The LMI provides the operator with information regarding the length and angle of the boom tip height working radius rated load and total weight of actual lift If non permitted condition is appro2. Kn Main Boom Load ct 23 4 188 6 is ok s Le 5 2 LMI main interface At 5 2 from the top to the bottom 15 Part 1 Operate State column Part 2 main interface Part 3 function key column 5 1 1 User Manual Operators could learn present crane state through the working mode icon on top part of the console A Error code icon B Reeving icon C OM code icon 8081 D CAN bus mode icon E A2B alarming icon F Pre warning icon G Stop movement icon H Time display icon To indicate which part of the LMI 15 abnormal Operators then can remove difficulties accordingly and the LMI will back to normal condition To display present reeving To display current OM code To display the CAN communication mode between the console and the controller When the light 15 on the CAN communication 15 abnormal This means the hook 15 reaching to the ultimate height operators shall stop movement of the hook right away This means the moment percentage is over 9076 operators shall be awared of that This means the movement of the crane is very dangerous operators shall back to the safe side Or the LMI 15 abnormal the problem shall be solved immediately To display the local time User Manual 5 2 Main interface Load 168 6 5 3 Presenting main interface DOM introduction Main boom length jib length Installed angle of the fix
3. gt ZOOMLION Mobile Crane Branch Company Ng QUY260 Load Moment Indicator User Manual fy Hirschmann Electronics Shanghai Co Ltd Apr 2009 Manual 2009 by Hirschmann Electronics Co Ltd Copyright Any reproduction modification and translation without official authorization in writing of Hirschmann Electronics Shangha1 Co Ltd shall be prohibited For reproduction of this manual please refer to Copyright Law Ist edition on Apr 2009 Guarantee The information in this document is subject to change without notice Hirschmann makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Hirschmann shall not be liable for errors contained herein for incidental or consequential damages connection with the furnishing performance or use of this manual Hirschmann Electronics Shanghai Co Ltd Suite 10 Huamin Empire Plaza No 728 West Yan An Road Shanghai P R China Tel 021 51082780 Fax 021 52375899 Zipcode 200050 Website http www hirschmann ac com User Manual Index PSD TOM MICE OUUCUION eR 2 2 GENEL AL normalios EE 2 N RI IEEE VID NRI pec E se treu d ties ten AA 2 4 System Conor OE oin E NANGKA BEIM n INVI IN 3 RIRI e c E 3 zu e M
4. The X will change itself 1 2 3 with the MB angle changed 85 T5 B5 5 5 d Luffing jib OM code After finish the setting press F8 backing to OM amp Reeving interface press F8 once again will come out dialogue frame of confirmation press F7 to safe this operation or press to cancel Set OM amp Reey 000100 Set OM amp Reey 000103 User Manual 11 User Manual 5 3 2 I O Port checking Press F3 at 1 interface to check the I O port information Analog Inputs Lage Foot point Force mp Pendant rere J Force sin pendant eet _ MB angle foot point Force jib pendant right PF Force pendant right 5 6 Analog input 1 Analog channel 2 Base board X1 expanded board X2 stitch No 8 Analog description 4 Analog A D exchange value 5 Analog actual measuring value k2 192 Hament Percent gt 902 Moment Percent 902 Homent Percent gt 1824 MB angle 83 NUN EN EM EE 83 _ NM mm BS Lj angle 857 197754177 65 V B6 ts om angle lt 65 ___ _ Eli EES EN BE B ENIM mn EI 12 Se NH BE LJ 0M MB angel LJ angle O angie gt upper Limit setting in Virtual wall _ Ei angie lt Lover limit setting in virtal wait shame CE 16 we angie O NN ab e E Pit LAM ee 5 7 Digital val
5. 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 4 System configuration 4 1 System configuration 4 1 Controller 4 2 Controller User Manual The system 15 composed of Expert console 1FLEX5 controller KMD force sensor angle sensor etc When operator sets current OM and reeving according to the key of the display the signal is transmitted to controller and display by pull sensor The display shows the actual weight and rated weight The actual weight and rated weight 19 compared in the controller Once the rated weight is reached the controller will indicate the overloading warning signal and send warning sound At this moment operator is forbidden to operate to dangerous direction Controller 32 digit industrial control PLC system and high powered processor qualify the requirements of bad environment for all kinds of industrial system IFLEX5 module is composed of base board or base board add expansion board Customers could choose different IFLEX5 module according to their own needs Fach module can be connected by CANBUS Due to the building block mode the IFLEXS is not only applicable to medium and small control systems but also to big and complicated control systems 4 2 Console 4 3 Console 4 3 KMD Force sensor 4 4 KMD force senso
6. jib Channel measuring parts broken Change KMD parts Sensor cable defective or plug G Change cable or plugs Main boom left KMD channel voltage is lower than KMD fault Change KMD of main boom Channel measuring parts broken Change KMD parts E14 voltage is lower than the Cable of the checking channel Change defective Sensor cable defective or plug CAR Change cable or plugs Main boom foot angle sensor channel voltage is lower than the min limitation KMD fault Change luffing jib KMD Channel measuring parts broken Change KMD parts Luffing jib foot angle sensor channel voltage is lower than the min Refer to E15 Refer to E15 limitation Left KMD of Luffing jib voltage 15 lower than the min limitation Refer to E14 Refer to E14 Main boom backstop pressure sensor channel voltage is lower than the min limitation Refer to E14 Refer to E14 Luffing jib top angle sensor channel voltage 15 lower than the min limitation Refer to E15 Refer to E15 20 User Manual code Change head angle sensor of main Top angle sensor of main defective Doom boom voltage is lower than the min limitation Connect or change Cable of the defective or unconnected checking channel Super lift mast angle if EID gt Refer to E15 Refer to E15 limitation system voltage is lower Refer to E14 Refer to E14 than the
7. key at 1 interface to enter into OM amp Reeving setting interface 5 4 amp Reeving setting Fl OM code checking key F4 OM code setting key F6 Reeving setting key F8 Enter key Manual Press F1 continuously press to turn pages at OM selecting interface to check the OM code System will display main OM code separately into 4 pages as follows length OM Code 0 000101 44 00009 68 000117 23 000118 6 000103 0001 14 000119 29 000104 o 000112 mmm 32 000105 56 000113 80 000121 _ 5 000106 59 000114 000122 _ 38 000107 62 000115 41 000108 65 000116 OM Code OM Code 000223 000225 000224 000226 5 5 4 T 50 53 59 65 20 23 000702 47 0000 e 000706 5s 0074 a Tom EE EE e 000823 92 000825 95 000826 89 5 5 b Main boom runner OM code 10 Angle FJLengthim OM Code ab mE AB WBlenzth m M anap 3 anap M asap 8 ita LJ Length OM Code LJ Length OM Code ME Length MB Length AB 21 020 42 map 23 02 09 O21 4 Lmmeap 26 03 a 10 2T 02288 48 O T 30 023AB 51 20304AB 33 54 36 032AB 39 o xU33AB
8. the min radius or exceed the Improper OM setting or enter into Boom down to a permitted radius or angle in the load chart Boom up to a permitted radius or angle in the load chart Properly choose the OM according to actual operation and slew back to a permitted range E05 Prohibited length range Choose a main boom length that Choose a proper main boom is not exist length The jib luffing down too much result in the actual angle is lower than the permitted value in the capacity chart Fallen below the Minimum angle range when luffing down or luffing up Over load relay act and controller switching value NO 20 input channel open Over load relay not act and controller switching value NO 20 input channel close Over load relay checking Luffing up the jib to a permitted radius or angle in the capacity chart Check the over load relay and cable of the controller switching value NO 20 input channel Check the over load relay Check the controller switching value NO 20 input channel 19 User Manual code Sensor cable defective or plug Main boom right KMD water inside h vol 15 tage KMD fault Change KMD of main boom than the min limitation Channel measuring parts broken Change KMD parts Change cable or plugs Sensor cable defective or plug Change cable or plugs right KMD channel voltage is lower than the min limitation KMD fault Change KMD of
9. J OM angle 75 output Press F4 will appear that present main boom angle is 75 If SET icon present at the top of F4 means F4 key is pressed down and when the main boom angle is 75 1 means one switching value channel put out If the F4 key is not pressed when the main boom angle is 75 1 no output exist Output mode 15 LJ OM angle 75 output 5 LJ OM angle 85 output Press F5 will appear that present main boom angle is 85 If SET icon present at the top of F5 means F5 key is pressed down and when the main boom angle is 85 1 means one switching value channel put out If the F5 key is not pressed when the main boom angle 15 85 1 no output exist Output mode is LJ OM angle 85 output 6 Cancel LJ OM MB angle output Press F6 if SET icon present at the top of F6 means F6 key is pressed down At that time cancel the setting of 3 4 and 5 the output mode is Cancel LJ OM MB angle output and the main boom angle 1s approved as 85 1 with one switching value channel put out the output mode is LJ OM angle85 output 15 User Manual 5 3 4 CAN bus checking Press F5 at 1 interface to check CAN bus mode CAN bus mode C 1 N g B U 5 N IN Left column console state Right column Controller state R expert Console iFLER5 Controller State icon and introduction operational C77 Operational mode preoperational lt gt Preoperational mode lost gt Lost mode stopped gt Stop
10. ached the 1FLEX5 Load Moment Indicator will warn the operator by sounding an audible alarm lighting a warning light and cutting off those functions that may aggravate the crane s condition 3 Warnings The LMI is an operational aid that warns a crane operator from approaching conditions of overloading and over hoisting which would cause great damage to the equipment and personnel The LMI could only prevent overload of the crane boom in lengthwise vertical level but could not prevent accidents caused by inclined hoisting wind loading inclination or foundering of the road and rail or driving oversteps So the operators and other people shall not ignore safe management and operating procedures of the crane because of the existence of the device It is not and shall not substitute for a good operator s judgment great experience or standard 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 Notice 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 1
11. are of the system Flash EPROM fault Change controller System program does not The LMI system program 19 Update effective system software comply with crane data file different from crane data file or crane data file E37 Logical programming fault System program does not comply with performance table The LMI system program 19 Update effective system program different from performance table or performance table Crane data file does not E3A comply with performance table RAM fault RAM or controller fault Change controller No readable crane data file Up date crane data file E51 Crane data file fault Flash EPROM defective Change Flash EPROM No readable crane performance Update crane performance table E52 Crane performance file fault table Flash EPROM fault Change Flash EPROM No effective data file during Resume and update effective crane 56 Crane data file fault adjustment data file Flash EPROM fault Change controller No effective data file in the E Update effective data fil E57 Crane serial data file fault adjusting data file Flash EPROM fault Change controller Sg Update effective performance file None identified base file Program correct base file 1 15 E60 NO and programming value EEE 1 2 is base 2 Performance table programming Checking the performance file of fault program base file CAN bus cable between controller and sensor defective or E61 CAN bu
12. b ffino iib abnormal at Luffing Jib cable of main boom angle channel Change channel cable defective Luffing jib angle exceed allowed dee E89 Luffing jib angle abnormal range when jib luffing at fixed or Luffing jib OM Wrong measurement of Luffing Check measurement of Luffing jib jib angle angle No data transfer from Ca E94 controller to console communication Check CAN bus cable Re start the system E98 LMI watch dog open LMI operated overtime Connect computer ports and observe wrong information A2B switch short circuit Change A2B switch EAB A2B switch short circuit A2B switch cable short circuit Change A2B switch cable A2B switch disconnect Change or connect A2B switch Change or connect A2B switch Wrong setting of range Check program of crane data file EAC A2B switch disconnect A2B switch cable disconnect cable Sensor function fault Change A2B switch EAD A2B switch inefficacy CAN bus delay Change A2B switch cable 23 User Manual code Adjust length of steel wir No measurable sensor exist for Install sensor and revise this hoisting function at program data Length checking channel Adjust steel wire length and Steel wire length no adjust well of the hoist steel wire surface voltage is lower than the Wrong steel wire hoist parameter DEENEN Check parameter of program data min limitation at program data No counter input defined at Change I O configurat
13. ed jib amp Mode display operating height 2 main boom angle radius Moment percentage barcode 2 Moment percentage value 3 Actual load capacity 4 Rated load capacity Still presenting luffing jib angle at luffing jib OM Operate State display presenting normal OM or error code information and trouble shooting when it is abnormal Notice when operating the crane operators shall observe changes of the aboved datas at this interface 5 3 Function key User Manual At the bottom of the main interface 15 the function key column F1 F8 are as below interface function key ROSE C 2 Tj F2 F3 F4 F5 F8 Main interface shift key press to enter into 2 interface OM amp Reeving setting key details refer to 5 3 1 Data checking press to check analog input amp digit output ofiFLEX5 details refer to 5 3 2 System setting key details refer to 5 3 3 CAN Bus checking press to check the bus mode between controller and console details refer to 5 3 4 Alarm stop key press to stop the alarming sound of the system 2 interface function key F1 Main interface shift key press to enter into 1 interface Angle limitation setting key details refer to 5 3 5 Time setting key details refer to 5 3 5 Alarm stop key press to stop system alarming User Manual 5 3 1 OM amp Reeving setting Press F2 OM amp Reeving setting
14. ion configuration Counter input fault Change Iflex Checking channel of hook No steel wire between hook and height voltage exceed the forward oriented wheel Refer to EB1 limitation Refer to EB1 Setting RTC and change battery Check out low voltage of the two Temporary measurement press Battery empty ports of battery alarm stop key when Operation without data loader After finish programming This function shall be started over LMB watch dog overtime E information is not automatically 5 min like writing flash PROM Length checking channel Steel wire completely twining l Adjust length of steel wire EB2 of steel wire on hoist hoist only possible at EB2 voltage exceed the ege Refer to Refer to EB1 limitation started 24 User Manual 7 System connection LGU 1 AA 1 Mut um I LU SONA 108098 9190 108028 22104 _____ EEG _____ 0011290002 100 0004 Ul D A 0011290002 do 0004 Urey ANA 208095 91901 004 Urey 2 2 9100 9 Uf T 9148 surd d 59104 01 8 105098 9180 uid u 3 i Wong uren 10811 0011290902 doy 25
15. main boom angle exceed 78 system will alarm operators to stop any dangerous movement Press F3 the setting will be canceled 2 Time setting Set Time 38 50 Operators can adjust time when the time displayed is not local time Dress F4 at 2 interface to set time F4 Turn left key 5 Turn right key F6 Value add key F7 Value reduce key SERRE F8 Confirm and back to main interface key After finish the related setting press F8 to confirm and back to main interface 18 User Manual 6 Trouble shooting In case of any improper operation or LMI malfunction during the crane s operation it will display some certain code error code for the user s information Some errors are caused by illegal operation some by people s cause ad some are caused by other factors The following codes can be an aid and help for how to use and maintenance the LMI system A Notice If you cannot solve the problem according to the following contents please contact us as soon as possible at Tel 021 51082780 Fax 021 52375899 code Due to the too much hoist up of Fallen below the radius the boom which result in lower range or angle range GE max angle in the capacity chart Due to the too much hoist down which result in exceed the max radius or lower than he min angle Exceed the max radius or lower than the min angle OM not exist or exceed the motion of rotary range prohibited slewing area than
16. min limitation Super lift mast angle sensor PO FIF channel voltage is lower Refer to E15 Refer to E15 than the min limitation 222 channel voltage exceed the Refer to E12 Refer to E12 limitation E23 voltage exceed the Refer to 14 Refer to E14 limitation Main boom KMD channel ann E24 voltage exceed the Refer to E14 Refer to E14 limitation boom foot angle sensor channel voltage E25 exceed the limitation Refer to E15 Refer to E15 Luffing Jib foot angle E26 sensor channel voltage Refer to E15 Refer to E15 exceed the limitation Angle sensor channel of E27 Luffing jib voltage exceed Refer to E14 Refer to E14 the limitation Mam boom Main boom E28 backstop EE Refer to E14 Refer to E14 channel voltage exceed the limitation Luffing jib Top angle E2B sensor channel voltage Refer to E15 Refer to E15 exceed the limitation Top angle sensor of main 2 boom voltage exceed the Refer to E15 Refer to E15 limitation Super lift mast angle if E2D support channel voltage Refer to E15 Refer to E15 exceed the limitation 21 User Manual Solution Error EN Malfunction Cause code Luffing jib system force E2E channel voltage exceed the limitation Refer to E14 Refer to E14 Super lift mast angle sensor checking channel voltage exceed the limitation E2F Refer to E14 Refer to 14 Programming file fault Update effective softw
17. ped mode Hardware failure Hardware failure 16 5 3 5 Angle limitation amp Time setting User Manual Angle limitation and Time setting is processed at 2 interface Press at 1 interface to enter into 277 interface 1 Angle limitation angle Press at 2 interface to set the limitation of main boom angle and Luffing jib 1 Main boom angle upper limit display 2 Main boom angle display 8 Main boom angle lower limit display 4 Main boom angle upper limit setting key 5 Main boom angle lower limit setting key 6 Main boom setting cancel key D jib upper limit display 2 Luffing jib angle display 3 Luffing jib lower limit display 4 Luffing jib upper limit setting key Luffing jib lower limit setting key 6 Luffing jib setting cancel key 7 Back to main interface 17 User Manual At this interface operators can set angle limitation of main boom and luffing jib When the crane boom approached the limitation press the related key it will present SET icon on top of the key which means the key is already pressed down At that time the ultimate angle will be recorded and when the boom reach to this angle next time system will alarm For example when the main boom angle is not allowed to exceed 78 due to the operating environment lift the main boom to 78 and press angle limitation setting key to set the upper limit After finish the setting when
18. r 4 4 Angle sensor 4 5 Angle sensor User Manual Console a 640 480 color LCD of industrial lattice screen graph liquid crystal It can display all the operational data that you are concerned The combination between the Graphical display and Genersys software achieve the on line program for graph The strong graph compiled capability 19 incomparable with other Industrial Control displays The system adopts shock proof anti electromagnetic interference and high precision and low zero drift As the sensor has the compensated function of temperature it can retain its own quality even with continuous and high intensive operation Remarks all the analog sensor for 1FLEX5 system must be current type or with CAN bus Voltage sensor have to change to current Sensor The WGC angle sensor 15 for exact measurement for angle of all kinds of construction machines Distinguished by its compact exterior the sensor has the feature of simple installation high efficiency and accuracy no hysteresis high protective class long time service life and suited to extreme ambient condition User Manual 5 System introduction When the iFLEXS control system is power the console will display QUY260 crawler crane as below gt ERT ZOOMLION HEAVY INDUSTRY amp SCIENCE QUY 260 fa tr 2 NI QUY260 Crawler Crane 5 1 Welcoming interface After 4 5 seconds main interface the LMI interface will present as below
19. s data unconnected communication fault Controller CAN bus port fault Change controller CAN bus cable short circuit Change Can bus cable Crane data file 1s different from Change data file or performance performance table table Check the connecting cable between controller and sensor 22 User Manual Error Luffing jib system force too Exceed the limitation of E AGO big destructive force Top or foot angle sensor of main Change top or foot angle sensor of Top angle and foot angle of boom defective main boom main boom differ too much Top or foot angle sensor cable of Change top or foot angle sensor main boom defective cable of main boom Top or foot angle sensor of Change top or foot angle sensor of Top angle and foot angle of Luffing jib defective Luffing jib Luffing jib differ too much Top or foot angle sensor cable of Change top or foot angle sensor Luffing jib defective cable of Luffing jib Main boom force value Main boom force too big Reduce main boom force exceed limitation of rope Cable of checking channel Ch destructive force defective ange channel cable The selected rigging condition is Select another rigging condition Wrong rigging condition not contained in the crane data Check the programming in the file crane data file Setting range of computer is too small negative deviation boom angle luff to allowed Ya Main boom angle abnormal Main boom position range E88
20. ue output 1 Digital value No 2 Function description 8 Port mode Blue means output existing User Manual Digit outputs 13 User Manual 5 3 3 System setting Press F4 at 1 interface to enter into system setting interface L T al ae a 5 8 System interface Fl Rigging mode key F2 Working mode key F3 Choose main boom angle 65 key at Luffing jib F4 Choose main boom angle 75 key at Luffing jib OM F5 Choose main boom angle 85 key at Luffing jib F6 Cancel setting key 14 User Manual 1 Selected Rigging Working Mode Operators can press F1 and F2 to select rigging working mode the related mode icon will be present at right column 2 Rigging Working Mode State Present working mode of the crane Rigging mode Working mode After rigging mode 15 selected the controller will judge whether the mode could shift to rigging mode according to the present crane OM if it could Rigging Working Mode State will show rigging mode if not Rigging Working Mode State will show working mode 3 LJ OM angle 65 output Press F3 will appear that present main boom angle is 65 If SET icon present at the top of F3 means F3 key is pressed down and when the main boom angle is 65 1 means one switching value channel put out If the F3 key is not pressed when the main boom angle 15 65 1 no output exist Output mode is LJ OM angle 65 output 4 L
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