PAT DS 350 User manual

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© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 1
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
The information in this document is subject to change without notice. PAT 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. PAT shall not be liable for errors contained herein or for identical or consequential damages
in connection with the furnishing, performance, or use of this manual. This document contains proprietary infor-
mation which is protected by copyright. All rights reserved. No part of this document may be photocopied, re-
produced, or translated to another language without the prior written consent of PAT.
USER MANUAL
IK 350 / 1272
part no. 50 350 19 1272 e
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 2
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
TABLE OF CONTENTS
1. General Information ................................................................ 3
2. Warnings .................................................................................. 4
3. System Description ................................................................. 5
3.1 System Function........................................................................ 6
3.2 Operator's Console.................................................................... 6
3.3 Control Identification.................................................................. 7
3.4 Data Display ............................................................................ 14
4. Programming ......................................................................... 18
4.1 Setup Operation Mode ............................................................ 18
4.2 Setup Reeving ......................................................................... 19
5. Pre-Operation Inspection and Calibration verification ...... 20
5.1 Operation................................................................................. 22
6. Service and Maintenance...................................................... 23
7. Troubleshooting .................................................................... 24
7.1 General.................................................................................... 24
7.2 System messages ................................................................... 24
7.3 Error Code Table ..................................................................... 25
Important Notes for crane operators and users .......................... 36
General Information
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 3
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
1. GENERAL INFORMATION
This manual describes the function, operation and maintenance of the DS 350 Load Mo-
ment Indicator1 (LMI).
The LMI has been designed to provide the crane operator with the essential information required to
enable the machine to be used within its design parameters.
Using various sensing devices, the Load Moment Indicator monitors various crane functions and pro-
vides the operator with a continuous reading of the crane's capacity. The readings continuously
change as the crane moves through the motions needed to make the lift.
The LMI provides the operator with information regarding the length and angle of the boom, tip height,
working radius, rated load and the total calculated weight being lifted by the crane.
If non permitted conditions are approached, the DS 350 Load Moment Indicator will warn the operator
by sounding an audible alarm, lighting a warning light and locking out those functions that may aggra-
vate the crane's condition.
1LOAD MOMENT: generally the product of a force and its moment arm; specifically, the product of the load and the load-
radius. Used in the determination of the lifting capacity of a crane.
General Information
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 4
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
2. WARNINGS
The LMI is an operational aid which warns a crane operator of approaching overload conditions and
also warns of overhoist conditions which could cause damage to equipment and personnel.
WARNING
The device is not, and shall not, be a substitute for good operator judgment, experience and
use of accepted safe crane operating procedures.
The responsibility for the safe operation of the crane shall remain with the crane operator
who shall ensure that all warnings and instructions supplied are fully understood and ob-
served.
Prior to operating the crane, the operator must carefully and thoroughly read and under-
stand the information in this manual to ensure that he knows the operation and limitations
of the indicator and crane.
Proper functioning is dependent upon proper daily inspection and observations of the op-
erating instructions set forth in this manual.
WARNING
The displays will only aid the operator when the LMI is properly programmed and the proper
load capacity chart is selected for the crane configuration being utilized. To prevent prop-
erty damage or serious bodily injury or death to personnel, ensure the LMI is properly pro-
grammed before operating the crane.
WARNING
This system is equipped with an override key on the central microprocessor unit. This key
switch bypasses control lever lock-out function of load moment indicator device. The
switch may only be used by authorized personnel during emergency situations. Failure to
follow this instruction may result in property damage and/or personal injury.
System Description
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 5
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
3. SYSTEM DESCRIPTION
The PAT Load Moment Indicator DS 350 consists of a central micro processor unit, operating console
and various peripheral sensors.
The system operates on the principle of reference/real comparison. The real value, resulting from the
pressure measurement is compared with the reference data, stored in the central processor memory
and evaluated in the micro processor. When limits are reached, an overload warning signal is gener-
ated at the operator's console. At the same time, the dangerous crane movements, such as hoist up,
telescope out and boom down, will be stopped.
The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity and
dimensions are stored in memory chips in the central processor unit. This data is the reference infor-
mation used to calculate the operating conditions.
System operation is controlled partially by automatic devices such as angle sensors and partially by
manual devices such as switches on the operator's console.
Boom length and boom angle are registered by the length/angle sensor, mounted inside the cable
reel which is mounted on the boom. The crane load is measured by pressure transducers attached to
the piston and rod side of the lift cylinders.
System Description
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 6
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
3.1 SYSTEM FUNCTION
After ignition of the engine, the system starts with an automatic test of all lamps, the displays, the
audible alarm and the complete system. All segments on the display are triggered. Upon completion
of the different tests without errors, the key "operating mode" (6) lights up. The system now awaits
either the acknowledgment of the operating mode code displayed in the field K of the data display
(1) or the input of a new operating mode code corresponding to the momentary crane configuration.
Then, real load, lifted load as well as different crane data are now displayed on the LCD screen. Only
now the system is in ready for operation.
Note: When turning off the system, the adjusted values for operating mode and reeving will be
stored.
In case of malfunction, the respective error code "E##" will be displayed on the data display (1) in the
field M (please refer to chapters 3.4 and 7).
3.2 OPERATOR'S CONSOLE
The console has two functions:
· terminal for input of instructions to the system by the crane operator
· display of important data and information
The operating console is located in the operator's cabin in front of the operator. For a better identifica-
tion of displays and operating elements they are permanently backlit during operation. The console
contains different operating elements as well as a multi-functional LC display which are described in
detail in chapters 3.3 and 3.4.
Control Identification
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 7
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
3.3 CONTROL IDENTIFICATION
Figure 1 illustrates the controls and displays of the DS 350 safe load indicator. The numbers of the
illustration correspond to the numbers in the following list which describes the function of each con-
trol:
1 data display, multi functional
2 A2B switch pilot lamp
3 Prewarning lamp (load moment)
4 Overload lamp (load moment)
5 Pilot lamp "Bridging LMI"
6 Button "operating mode"
7 Button "Reeving"
8 Button "Taring"
9 Button "Alarm off"
(10) without function (evtl. symbol w/o signification)
(11) without function
(12) without function
(13) without function
14 Numerical keys 0...9
15 Key "Acknowledgment"
16 Key "Asterix" (evtl. for comma inputs)
14
6
1
2
3
4
5
7
8
9
10...13
15
16
fig. 1
(standard)
Control Identification
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 8
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
(1) DATA DISPLAY
The DATA DISPLAY (1) is a multi-functional LC display which shows load, geometrical and crane
data. The display is further described at chapter 3.4.
(2) ANTI-TWO BLOCK INDICATOR
The red ANTI-TWO-BLOCK INDICATOR (2) will light up when the
anti-two-block limit switch contacts open, indicating that a two-
blocking condition is approaching. At the same time the audible
alarm will sound.
The following crane movements will be stopped subsequently:
hoist up, telescope out, boom down.
WARNING
This condition, if not prevented, will cause the wire rope to break, allowing the load to fall.
Two blocking can be caused by raising the load into the boom head, lowering the boom
without paying out hoist line and, in case of a hydraulic crane, by extending the boom with-
out paying out hoist line.
Control Identification
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 9
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
(3) LOAD MOMENT PREWARNING LIGHT
The yellow LOAD MOMENT PREWARNING LIGHT (3) will light up
when the load on the crane is between 90 and 100 % of the crane
rating, indicating that an overload condition is approaching.
A
TTENTION
This means for the operator to continue his crane operation with extreme caution.
(4) LOAD MOMENT LIMIT LIGHT
The red LOAD MOMENT LIMIT LIGHT (4) warns the operator that
a rated load condition has been reached. It lights up when the load
on the crane reaches the crane load capacity.
The audible alarm also sounds when this condition has been
reached. The following crane movements will be stopped concur-
rently: hoist up, boom down.
(5) OVERRIDE KEY WARNING LIGHT
This red pilot lamp lights up if the cutoff function of the LMI system
has been manually bridged. The manual bridging is done by a key
switch which is located at the side of the central unit housing.
This key may only be use in emergencies and by authorized per-
sonnel exclusively.
In this context, the safety instructions on page 4 of this manual
absolutely have to be followed.
Control Identification
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 10
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
(6) Button "Operating Mode"
The button „Operating mode" (6) is actuated if a new operating
mode code (e.g. upon modification of the operating state) is to be
entered.
The button "Operating mode" lights up upon actuation, thus indi-
cating that the function "Input of an operating mode code" has
been activated. At the same time, the A2B switch pilot lamp (2)
and the overload pilot lamp (4) light up and the crane movements
are interrupted.
WARNING
The correct setting of the Operating Code Switch is of utmost importance for the proper
function of the system and the crane. Therefore, only crane operators who are thoroughly
familiar with crane load capacity charts and the use and operation of the system shall set
the Operating Code Switch.
· The procedure on how to enter an operating mode code is described in chapter 4.1.
Control Identification
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 11
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
(7) Button "Reeving"
The button Reeving (7) is actuated if a new reeving is to be en-
tered.
The button Reeving lights upon actuation to indicate that the func-
tion "Enter the reeving" has been activated.
At the same time, the A2B switch pilot lamp (2) and the overload
pilot lamp (4) light up and the crane movements are interrupted.
WARNING
The correct setting is of utmost importance for the proper function of the system and the
crane.
· The procedure on how to enter the reeving is described in chapter 4.2.
(8) Button "Taring"
The button "TARE" (8) serves to output the net load on the load
display (see #F, chapter 3.4). The net load is the real load minus
tackle and hook block. The button "TARE" has to be actuated be-
fore starting the lifting procedure.
Upon actuation of the button "TARE" (8) the load display is set to
zero (tared) and the tare symbol (see #G, chapter 3.4) starts to
blink. When the load is lifted, the load display shows the net load
(payload).
As soon as the working radius (by angle or radius modification) is
modified, the display shows again the real load and the taring
function is completed.
NOTE
The real load contains hook block, lifting rope and all tackle. The net load is the present
load on the hook without tackle. Display errors can be caused by environmental influences
such as wind acting on boom or load.
Control Identification
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 12
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
(9) Button "Buzzer off"
Press this button to temporarily interrupt the audible alarm.
The audible alarm sounds in the following cases:
System test, overload, imminent hoist end situation (if A2B switch
function is registered by the LMI system, malfunction of the LMI as
well as recognized operator's errors.
(10)-(13) without function (evtl. existing symbol without signification)
(14) Numerical keypad
The numerical keys are used for the following inputs:
· Input of the operating mode code (see chapter 4.1)
· Enter the number of reevings (see chapter 4.2)
· Call the geometry data
During the crane operation it is possible to display certain geome-
try data such as length, angle, etc. on the data display (1) in the
field geometry data D (please refer to chapter 3.4).
Procedure on how to select geometry data:
a) Note the number(s) according to the assignment in the crane symbol (E) of the data display (1) or
the table
b) Enter digit(s) on the numerical keypad (14). Entered digits are shown in the text display (N)
c) Press "C" (15) to confirm the input. The respective arrow in the crane symbol (E) blinks.
Control Identification
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 13
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
Table: Standard version
input: display: unit: / notes:
1Length of the main boom meter
2Angle of Boom degrees
3Operating radius (incl. extension, if any) meter
4Angle of the jib or extension (if any) degrees
5Height of the boom tip (above the ground level) meter
6 Test position: All warning lights and characters of the
Data display (1) will be displayed in order to test the proper
function
7 - no function
8 Actual moment used for service only
9Length of the jib or extension (if any) meter
10 - no function
11 Actuation pressure in bars used for service only
12 Pressure luffing cylinder (piston side) in bar used for service only
13 Pressure luffing cylinder (rod side) in bar used for service only
14 Wind speed (if sensor is connected)
15 Length Tele 1+2 measured used for service only
16 Length Tele 1+2 corrected used for service only
Table: UK version
input: display: unit: / notes
1Radius (1A) or Angle (1B) of main boom unit depending on program
2Length of the main boom unit depending on program
3Height of the boom tip (above the ground level) unit depending on program
4 - no function
5 - no function
6 Test position: All warning lights and characters of the
Data display (1) will be displayed in order to test the proper
function
7Angle of the jib or extension (if any) degrees
8 Actual moment used for service only
9Length of the jib or extension (if any) unit depending on program
10 - no function
11 Actuation pressure in bar used for service only
12 Pressure luffing cylinder (piston side) in bar used for service only
13 Pressure luffing cylinder (rod side) in bar used for service only
14 Wind speed (if sensor is connected)
15 Length tele 1+2 measured used for service only
16 Length tele 1+2 corrected used for service only
Control Identification
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 14
19_1272E.DOC / 2001-04-02 / Rev. C / ko.
(15) Button "C"
This button is required to confirmed the following inputs (i.e. the
inputs become valid only after acknowledgment):
· Enter an operating mode code
· Enter a number of reeving
· Select geometry value
(16) Button "asterisk"
This key might be required for the input of decimals.
Data Display
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3.4 DATA DISPLAY
A Overload Symbol
This red symbol is permanently lit. It will flash when the load on the
crane is in excess of 100% of the crane rating.
B Prewarning Symbol
This yellow symbol is permanently lit. It will flash when the load on
the crane is between 90% and 100% of the crane rating, indicating
that an overload condition is approaching
C Anti Two-Block Indicator
This symbol will light when the hoist limit switch contacts open,
indicating that a two-blocking condition has occured.
The term "two block" is a crane term which refers to a condition which occurs when the hook block
comes into contact with the boom head. This condition, if not prevented, will cause the wire rope to
break, allowing the load to fall. Two blocking can be caused by raising the load into the boom head,
lowering the boom without paying out hoist line and, in case of a hydraulic crane, by extending the
boom without paying out hoist line.
representation: standard version
Data Display
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D Geometrical Data Display
Depending on the digit selected on the numerical keypad (14), this
display shows the corresponding geometrical value.
The digit to be selected corresponds to the assignment in the
crane symbol E. The proceeding on how to select a determined
geometry display is described under #14, in chapter 3.3.
E Crane Symbol
The Crane Symbol (13) indicates the geometry data which can be
selected by numerical keys 0...9. The respective values are then
displayed on the geometry data display D.
F Load Display
This digital display informs the operator about the actual load on
the crane (total load).
After pressing the button "TARE" (8), the net load will be dis-
played.
G Tare Symbol
This symbol will light after pressing the button "TARE" (8) to have
the net load displayed.
When changing the boom position, the net load indication disap-
pears and the taring will automatically be canceled
NOTE: The total load includes the load of the hook block, the hoist
line and all tackle. The net load is the actual load on the hook
block without tackle. Display errors can be caused by reason of
environmental factors such as wind acting upon the crane and the
load.
H Rated Load Display
This display shows the maximum load for the crane corresponding
to the actual radius and operating mode.
representation: standard version
Data Display
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J Load Moment Display
This bar graph display indicates how much of the crane's rated
capacity is being used.
As the rated capacity of the crane changes as it is moved through
its various motions, the utilization display will constantly change as
well.
The bar graph display has three sections:
· a green and safe section (0% to 90% of the rated cap.)
· a yellow prewarning section (90% to 100% of the rated cap)
· a red overload section (beyond 100% of safe working load).
K Operating Mode Display
This display provides the crane operator with information about the
operating mode number the load moment indicator works with.
The operating mode number must coincide with the number valid for the respective load curve
and must be checked.
This display also indicates automatic changes of the operating mode, e.g. with different load curves in
different slewing zones.
The machine configurations are listed in the separate table which is supplied with each load moment
indicator. The operating code is adjusted by means of button "operating mode" (6) (Þ see chapter 4.1
for the proceeding).
L Reeving Display
This display informs about the number of falls (parts of line) used
to reeve the hook block (ref. #7, chapter 3.3).
M Error Code Display
In case of an error, this red display will show a code number which
describes the reason. For decoding that number, refer to chapter
7, list of 'Error Codes'.
Data Display
© 1996-2001 by PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-141 18
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N Text Display / Tele Percentage Display
Depending on the program version, additional information are dis-
played in this field, e.g. the identification number for the geometry
data according to crane symbol E.
In versions with tele percentage display, the telescoping lengths
of the telescopes are displayed in the format: Tele 1 \ Tele 2 \ Tele
3 (+4) (in %)
If required, the following information are displayed:
· "SYSTST" during test mode
· "SYSERR" together with "E93" in error code display M
· "CU-ERR" together with "E94" in error code display M
P Symbol "On Outriggers"
This symbol is displayed when outriggers are required in the op-
erating mode adjusted.
R Symbol "On Rubber"
This symbol is displayed when "free, on rubber" is required in the
operating mode adjusted.
S Indicator Radius / Angle Program
Depending on the load chart, the cutoff in case of overload is car-
ried out via the radius or the boom angle. This indicator shows an
angle with arrow in angle-related programmings. At radius related
programming an angle with radius dimensioning is displayed.
Programming
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19_1272E.DOC / 2001-04-02 / Rev. C / ko.
4. PROGRAMMING
Upon switching on the system it is necessary to enter the operating parameters corresponding to the
actual equipment of the crane. Here, the correct inputs by the crane operator is of utmost importance.
This procedure consists of two parts:
· Programming of the LMI to the rigging state of the crane using the correct operating code for the
selected load chart
· Enter the reeving corresponding the actual reeving
4.1 Programming of the Operating Mode
The key operating mode (6) serves to adjust the LMI to the rigging condition of the crane. The re-
quired operating code is indicated in the load chart.
WARNING
The correct setting of the Operating Code Switch is of utmost importance for the proper
function of the system and the crane. Therefore, only crane operators who are thoroughly
familiar with crane load capacity charts and the use and operation of the system shall set
the Operating Code Switch.
The operating mode is adjusted as follows:
a) Please refer to the operating mode for the code number and to the load chart for the "operating
code".
This number is indicated in the load chart, such as "on outriggers", "on rubber", "with jib", etc..
b) Note the code number corresponding to the crane configuration.
c) Start programming by pressing button (6) "operating mode". The key lights up.
During the programming, the system temporarily interrupts the crane movements. Furthermore, pilot
lamps (2) and (4) light up.
d) Enter the code number on the numerical keypad (14). The code number is shown on data dis-
play K.
e) Confirm the input by pressing „C“ (15), or enter again the number.
The entered operating mode code is confirmed by pressing key „C“. The input becomes valid upon ac-
knowledgment. Upon acknowledgment, the key is normally lit again.
Programming
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19_1272E.DOC / 2001-04-02 / Rev. C / ko.
· Invalid operating modes are displayed by means of "EEEE".
The system is now ready for operation. The cutoff of the crane movements is canceled and pilot
lamps and audible alarms are turned off.
The data display (1) now shows the present data.
WARNING
Failure to properly program the LMI with the correct operating code may result in property
damage or serious bodily injury or death to personnel.
To assure the crane is properly programmed, verify that the operating code and the load
capacity chart match the lifting configuration of the crane.
4.2 Adjustment of the Reeving
The button "Reeving" (7) serves for the input of the present reeving of hook block. The number of
reeving is entered on the numerical keypad (14) by selecting the respective number. The reeving is
displayed on the data display (1) (see also #L; chapter 3.4).
The reeving is adjusted as follows:
a) Start the adjustment procedure by pressing the button "Reeving" (7).The key lights up.
b) Enter the reeving in the numerical keypad (14)
Now, the entered reeving is shown on the reeving display.
c) Acknowledge the input by pressing key „C“ (15)
Upon actuation of key „C“ (15) the entered reeving is acknowledged, i.e. the input is only valid after the
acknowledgment. The button Reeving (7) is normally lit again.
WARNING
The correct setting is of utmost importance for the proper function of the system and the
crane.
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