PAT IK350/1272 User manual

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-

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

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

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

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

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

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

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

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

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

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

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

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

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

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

19_1272E.DOC / 2001-04-02 / Rev. C / ko.

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

19_1272E.DOC / 2001-04-02 / Rev. C / ko.

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

19_1272E.DOC / 2001-04-02 / Rev. C / ko.

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

19_1272E.DOC / 2001-04-02 / Rev. C / ko.

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

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

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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