Bromma EH5U Eng 00

Operations manual for BROMMA TELESCOPIC SPREADER TYPE: EH5U General assembly drawing No: 1043059 Serial number:15487 SWL: 41 tonne Customer:Pt.Emitraco Inustama Mandiri / BICT Date of shipping: 2012

_____________________________________________________________________________________ BROMMA CONQUIP AB

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Warning! This Operations manual is intended as a guide to the use and maintenance of Bromma spreaders.

•

READ AND UNDERSTAND THE MANUAL BEFORE THE SPREADER IS PLACED INTO OPERATION!

•

Bromma Conquip AB or it’s affiliated - companies (to the extent permitted by law) accept no liability for loss or damage suffered as a result of the use of this manual.

•

If in doubt always refer to the original equipment manufacturer.

•

Refer at all time to the ”Safety precautions” under section 5!

•

DO NOT exeed the Safe Working Load (SWL) of the spreader bar. The Safe Working Load is found on the nameplate that is permanently affixed to the side frame of the spreader.

__________________________________________________________________________________ BROMMA CONQUIP AB

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Table of contents 1 • INTRODUCTION 2 • SPREADER DATA SHEET 3 • TECHNICAL DESCRIPTION SPREADER Functional description Design calculations Safety features In-plant testing 4 • TESTING RECORDS AND CERTIFICATE 5 • SAFETY PRECAUTIONS 6 • START-UP PROCEDURES 7 • MAINTENANCE PROCEDURES Maintenance instructions Periodic maintenance procedure Lubrication instructions Instructions for adjustment and repairs of major items 8 • SPARE PARTS AND SERVICE Spare parts list by major groups How to order spare parts and/or service 9 • HYDRAULIC CIRCUIT DIAGRAMS 10 • ELECTRICAL WIRING DIAGRAMS 11 • FAULT FINDING DIAGNOSTICS Hydraulic system Electrical system 12 • APPENDICES Units and conversion tables Hydraulic symbols Electrical symbols

_________________________________________________________________________________ BROMMA

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Bromma Group Manual

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Bromma Conquip

1 • Introduction BROMMA Conquip has since 1967 been the leading manufacturer of telescopic container handling spreaders. A great number of BROMMA spreaders are in service today in ports and terminals around the world. A complete range of fixed length and telescopic spreaders are available, and each one provides high handling efficiency, excellent reliability, ease of maintenance and repair. This Operation Manual describes the many features of the BROMMA spreader. It will guide you in: • • • • •

Maintenance. Repairs. Trouble-shooting. Service. Spare parts.

In the event You should need additional information or support, our sales and/or technical staff will be pleased to assist you.

BROMMA CONQUIP AB

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Bromma Group Manual

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Bromma Conquip

2 • Spreader - Datasheet Type

EH5U

Art.nr:

1043059

Container Range

20’- 40’

Capacity Lifting capacity (evenly loaded) Lifting capacity (10% gravity point off set) Lifting lug capacity (end beam) Lifting lug capacity (main beam)

41 tonne 41 tonne 4 x 10 tonne 4 x 10 tonne

Operating Movements Telescoping 20’ to 40’ or 40’ to 20’ Twistlock rotation locking or unlocking 90o

30 s 1,5 s

Electrical Equipment Power voltage Frequency Control voltage Control valve Total power consumption Electrical protection

400/ AC 50/ Hz 230 V AC 24 V DC 2x2,2+3+5,5=12,9 kW IP 65

Hydraulic Equipment Pump running pressure Pump flow Tank capacity Normal running temperature Filter type

100 bar 2x15 l/min 2 x 50 l 50 C 10 µm

Filter Pressure line

10 µm

Corrosion protection All surfaces are grit blasted Interzink 72 EPA 069/073 (Interzink 72 EPA 069/073) Intervinux VL-Serie (Intervinux VL-Serie) Intervinux VS-Serie (Intervinux VS-Serie) Min. coating thickness, total

SA 2.5 40 µm 100 µm 60 µm 200 µm

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3 • Technical description Functional description Bromma telescopic spreader EH5 (EH12 & EH170) are fabricated as all welded, high quality steel, construction. Two pairs of telescopic beams slide in the centre main frame construction. The telescopic beams are joined together at the ends by end beams, which house the twistlocks, flipper arms and hydraulic valves. The spreader has an inbuilt under clearance of 185 mm. This enables hatchcovers and containers with protrusions up to 185 mm to be handled. If larger clearances are required then overweight extension legs need to be fitted. The spreader is optionally fitted with one set of lifting lugs. Mostly, they are placed at each corner of the gable end. In case the spreader is provided with this device, it can be used for handling of badly damaged containers or noncontainerised cargo. Use only approved slings and shackles. Where the telescopic arms slide in the mainframe they are supported by a number of low friction slides plates, one at each corner of the mainframe (total 4) and on the top and bottom at the end on each telescopic arm (total 8). Sufficient clearance is provided between the slide plates and the structure to allow the beams to flex, enabling distorted containers to be handled. The spreader function (i.e. twistlocks, flippers, telescoping) is operated from the driver’s controls in the crane cab. TELESCOPIC SYSTEM The telescoping system is driven by means of an electric motor and reduction gearbox connected to an endless chain. This chain is titted with stacks of spring washers that work as chock absorbers where the chain attaches to the tension rods.. These tension rods are connected to the end beam. The springs allow for changes in the length of the spreader up to plus or minus 7 mm . The springs do not only act as shock absorbers; they also provide a floating possibility for the twistlocks to handle distorted containers. This "floating" action also eliminates the need for corner guide rollers. In the event of a power failure the telescoping motion can be handcranked. The positioning system works with proximity switches for positioning the spreader in the 20', 30' and 40' positions. This system enables the positioning of the twistlocks with an accuracy of plus or minus 3 mm (less than 1/8"). The drive motor incorporates an electric brake that is spring applied and takes electrical power to release.

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This brake not only controls the accuracy in stopping the expansion and retraction but also prevents changes from occurring in the spreader length during use. TOWER The main frame of the spreader is connected to the crane through a sliding tower assembly. This enables the centre of gravity lifting point to be moved a maximum of 1,2 meters toward each end of the spreader. This means that unevenly loaded containers can be picked up horizontally, which is specially important when loading or unloading in the guides in the ship´s cells. After unlocking an unevenly loaded container, the sliding tower assembly automatically returns to the central position FLIPPERS Flat gather guides, commonly called flippers, are fitted to each end beam of the spreader. They are of strong construction and are driven by a powerful hydraulic motor, which enables easy and fast location of the spreader onto the containers. The flipper gather is 155 mm and has a gathering torque of 1200 Nm. The flipper arms are always under pressure and each arm has a shock relief valve, which opens at a pre-set pressure of 45 bar above the normal working pressure. As soon as the shock load ends the flipper returns to the vertical position. Each flipper is controlled by its own solenoid valve and shock relief valve. The flippers work in pairs along the length of the spreader, individually at the gable ends, or all together. The speed of the flipper is approximately 180° in 6 seconds and is controlled by an orifice plug in the pipe connection to the motor. TWISTLOCK Four twistlocks for single container spreader are located in the corners of the spreader to engage and lift the container. A hydraulic cylinder rotates the twistlock and two sensors indicate the position of the twistlock, Locked or Unlocked. A landing pin safety system is provided to assure that the spreader is properly landed on the container before rotating the twistlocks. A spring loaded landing pin near each twistlock is pushed up into the twistlock housing when the spreader is landed on the container. When the spreader is properly landed on a container, the landing pin will activate a proximity switch. Only when all the corners of the spreader are landed, can the twistlocks be turned. At the same time, the blockading key is moved high enough so the blockading stop on the twistlock lever arm passes underneath it. If the spreader is not properly landed the proximity switch will not be activated and the ________________________________________________________________________________________________________ 2 of 3 BROMMA CONQUIP AB 03 08 ENG. rev. x

blockading key will get in the way of the blocking stop. This will stop the twistlocks from turning. SIGNAL LIGHT Near each end of the spreader mainframe there is a set of three signals light, one green, one red, one white, which can be clearly seen from the crane cabin. The green and red lights indicate if corresponding twistlocks are unlocked or locked respectively. The white light indicates when the spreader is properly "landed", and the twistlocks are correctly engaged in the container corner castings. HYDRAULIC UNITS The hydraulic units are protected inside each end beam. The unit consists of a built-in tank, variable displacement piston pump, motor valves and filter. The filter cap is fitted with a pressure relief valve plus or minus 0,14 bar to allow expansion and contraction of air inside the tank. The hydraulic components used are designed to work at over 200 bar but normal working pressure is 100 bar. The hydraulic valves are solenoid operated and can be tested by hand operating. MAIN ELECTRICAL CABINET The main electrical cabinet is mounted on heavy-duty rubber shock absorbers and is well protected being placed on the tower. Relays, transformers, circuit breakers, timers, hour counters and sockets are mounted in this cabinet. The PLC is also placed on the tower. A junction box including motor protectors is placed inside the main frame.

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• Design calculations The spreader structure is designed according to DIN15018 and to the following loading group which represents a container handling crane.

• •

HOISTING GROUP H2 LOADING GROUP B4

LIFTING CASES The following lifting cases are considered: 1. Most frequent load case A symmetrically loaded container of 41 tonne. The permissible stress is determined by analysis of direct loading and fatigue conditions. Depending on intensity of use the structure is suitable for: 2 X 106 lifting cycles "H” load case is determining. 2. Exceptional load cases Permissible stresses are determined by analysis of direct loading only. a) A container of 41 tonne weight but loaded unsymmetrically by 10% in the longitudinal direction. "H.Z" load case is determining. b) A container of 41 tonne weight but loaded unsymmetrically by 10% in the longitudinal and lateral direction. "H.S" load case is determining

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Safety features The following safety features are normally included in the crane: 1. The spreader should only be hoisted/lowered when all four twistlocks are fully locked/unlocked. 2. The spreader twistlocks should be locked/unlocked when the spreader is Properly "landed" on a container. This being when all four landing switches are actuated. 3. A delay feature on the twistlocks locked/unlocked circuit is installed to ensure the spreader is properly "landed" and not bouncing. This is in the form of a timer whom is adjustable, but normally set to between 1 and 2 seconds. 4. During hoisting the four blockading pins move to the "down" position. This prevents electrically the twistlocks from moving. NOTE ! When carrying out maintenance on the twistlocks, the blockading pin clamps can be fitted to each corner, to by pass the electric and mechanical blockading when running the twistlock.

5. Telescoping of the spreader is prevented unless all four blockading pins are in the "down" position and the twistlocks are unlocked. Individual switches indicate twistlocks locked, twistlocks unlocked and blockading pins "up". The following safety features are fitted on the spreader: 6. A mechanical blockading device prevents each twistlock from locking/ unlocking unless the blockading pin is "up" position.


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In-plant testing STRUCTURAL Each spreader is fully proof tested in the factory to a minimum of 50% overload prior to delivery. The proof test loading report enclosed illustrates the loads applied to the spreader. All lifting lugs are also proof tested in the factory. The testing is witnessed and certified by a third part inspection official. All spreader twistlocks are individually proof tested, stamped and certified to a loading of 37 tonne. FUNCTIONAL Each spreader is run in the factory prior to delivery being controlled by a specially designed simulator.


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4 • Testing records and certificates

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5 • Safety precautions Warnings

READ AND UNDERSTAND THE MANUAL BEFORE THE SPREADER IS PUT INTO OPERATION. The manual contains vital information for the safety of personnel and the correct use of the spreader. Bromma Group will not accept any liability for the use of the spreader for any purposes outside what is described in the manual. DO NOT exeed the Safe Working Load (SWL) of the spreader bar. The Safe Working Load is shown on the nameplate that is permanently affixed to the side frame of the spreader.

Safety precautions 1. The spreader shall be operated and serviced only by authorized personnel. 2. The spreader must only be used for the purpose for which it is designed. 3. DO NOT change system settings and functions. 4. Perform a functional test after any maintenance or repair work. 5. Stay clear of the spreader when in operation. 6. Stay clear of all moving parts, such as guide arms (flippers), moving beams, telescopic chains, etc. A safe distance is 5 meters. 7. DO NOT connect or disconnect electrical connectors while the power is on. 8. DO NOT tamper with hydraulic pressure settings once adjusted by qualified personnel. See chapter 9. Hydraulic system for proper pressure adjustment. 9. DO NOT unlock the spreader while a container is suspended in the air. It could cause personnel injury or property damage.

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10. Maintain adjustment of all electrical and hydraulic components 11. Inspect the spreader for damage daily. 12. Care must be taken when performing any maintenance inside the spreader frame. It must be carried out under extreme caution and by personnel familiar with risks related to spreader function and movements. Serious injury by crushing can occur 13. Contact Bromma Conquip AB before doing any repair work on the spreader apart from replacing normal wear parts. 14. DO NOT walk or stand beneath the spreader bar during operation. 15. DO NOT attempt to lift a container that is not level (+/- 5°). 16. DO NOT crawl beneath a spreader bar for maintenance, repair or adjustment. Never put any body extremity beneath the spreader bar. 17. NEVER STAND BENEATH A SUSPENDED LOAD. 18. DO NOT attempt to restrain the movement of a container, whether laden or empty, by hand or by tagline. 19. DO NOT stand between a container and any construction that many prevent your movement to safety. A definite hazard exists that could cause serious injury or death by being crushed between the container and an obstruction (such as a building or another container). 20. Mobile work platforms which are used in repair and service work on the spreader must be equipped with safety rails and kick plates. 21. It is incumbent on the operator in charge of the crane to restrict the movements of the crane when repair or service work is being performed on crane-mounted spreader. 22. The tower must be moved back to the centre of the spreader before it leaves the container. There must be a good clearance between the Spreader and the container before slewing the crane boom. 23. When welding might be needed on the spreader with SCS2 assembled, make sure that it is properly grounded or dismantle the plug connection and earth cable.

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WARNING! Because this spreader is equipped with double-coil flipper arm valves but connected as a single coil valve function, the following may occur: If the operating voltage to the flipper arm valves disappears (intentionally or accidentally), the FLIPPER ARMS move upwards to their starting position. If EMERGENCY STOP is used or if the power supply to the electric motor of the hydraulic power unit is cut of in some other way, the flipper arms stop immediately. The flipper arms start moving again when the power supply to the electric motor of the hydraulic power unit is restored. It is essential to inform the personnel who work close to the spreader about this.

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6 • Start - Up procedure ASSEMBLY OF TOWER (drg no 34476) 1 Check spreader and tower for damage. 2 Suspend the tower from a suitable forklift or crane (tower weight 1,4 t) using the main lifting pin (pos 1). 3 Remove the protective material from the robalon pads on tower (pos 2). Remove the drive sprocket cover (pos 6). Remove the (2) lifting lugs from main frame of the spreader at the assembly end (pos 3). 5 Lower the flipper arm, at assembly end of the spreader, by slackening hydraulic hoses on the motor. NOTE: Take care that flipper does not fall down and cause injury! 6 Remove top fixings for rubber covers (pos 4). 7 Remove lamp assembly by taking out the quick release fastening from the four pins and lay the lamp assembly in the main frame. 8 Release the gravity point chain, by removing the two screws and the locking device from adjuster. 9 You are now able to slide the tower into the main frame close to the centre. Note the direction of assembly. Arrows are painted on the tower and frame. 10 Now replace the lamp assembly, rubber covers and lifting lugs. If the flipper is rise at this time, care should be taken as it is liable to fall, now that the motor is empty.

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11 Remove the drive sprocket cover (pos 6). It is now possible to install the chain, complete with the anchor block fitted. The chain goes, under the first sprocket, over the centre one and under the third. To assist with the chain installation, pull the brake release lever, towards the back of the motor. It is then possible to turn the motor, using the handle supplied. 12 Replace the chain back into it's fixing point and tighten the adjusting screws, until the chain is tight (allow a sag of about 30 mm and place the tower in middle position) and replace the locking device. Grease the chain. 13 Replace sprocket cover. 14 Pass the main plug up through the tower and fix conduit pipes with screws supplied. 15 Place the cable into the top support clamp. 16 Connect the tower motor. The connections are marked u1 and w1 to give correct position. NOTE: Take care, incorrect rotation may result in serious damage! 17 Secure the cable to bracket with suitable cable ties. 18 Fix limit switch detection bar into place (pos 7). 19 Check all bolts are tight and the spreader is clear of all discarded material and tools. Take care that nothing had fallen into the chain.


TOWER FUNCTIONS AND TESTING The tower function is to level/unlevel loaded containers. Any other use of the tower is an abuse of the equipment and could result in serious damage. When the spreader is locked onto a container, it is possible to move the tower in any direction. The tower will stay where it is placed. The return to the middle position is done by the crane driver. When he has driven the tower to yellow or blue, it goes always to the middle position. To test the newly assembled unit, place the blockading pin clamps onto the spreader and lock the twistlocks. With the spreader on the ground, commence to travel the tower towards one end of the spreader. Now hold a piece of metal, i.e. spanner or screwdriver, in front of the stop switch, for the end that the tower is travelling. The tower should now stop. Try the other direction. If both of the limits work, travel the tower to both ends of the spreader, to confirm the limits work on the detection bar. When at each end, unlock the twistlocks and release a clamp, to confirm the tower returns to it's centre position. If any of these functions fail, please seek advice. WARNING! Use the tower only to level loads, or serious damage may occur! Never use the hand crank on the motor with power connected, or serious injury may occur!


Start - Up the spreader 1. Before any connection to container crane, place the main frame of the spreader on trestles or similar about 0,7 m height and in such a way that the flipper arms can be lowered. 2 Inspect the spreader for visible damage. 3. Connect the main current and control supply to the spreader. Connect the 24 pin plug to the service panel. 4. Start the electric motor of the hydraulic units by turning the ”pump on” switch on service panel. 5. For testing of the twistlocks all 4 blockading pins should be in ”up” position. This is achieved by using a blockading pin clamp. In the ”down” position the blockading pins electrically and mechanically block all twistlock rotation. 6. Test all functions of the spreader using the push buttons and switches on service panel.

the

a) When ”pump on” switch is on, both electric motors should be running in gable ends. b) Operate the push buttons to put the spreader in the different length positions. As an additional length, check that the twistlock centre length is marked on the plate positioned on side of the main beam. c) Check that the flippers works in pairs along the length of the spreader, individually at the gable ends, or all together by pressing the appropriate buttons. d) Check that when clamps are fitted to the blockading pins and all pins are up, this will be indicated by the white lights on the spreader. e) Check that the twistlocks lock/unlock and that the light indicators on the top of the spreader main frame indicate red when locked and green when unlocked. 7. Check that the pump operating pressure is 100 bar.


8. Check each end hydraulic assembly to ensure there are no oil leaks. 9. Note that the solenoid valves operating flippers and twistlocks can be manually operated if required.This is achieved by pushing the end of the solenoid with a small screwdriver. As power is generally always on the solenoid, the plug connection has to be disconnected first. 10. Service and lubrication should be carried out in accordance with the lubrication manual.


7 • Maintenance procedures Maintenance Instructions IMPORTANT! When the spreader is disconnected from the crane the heating function (if fitted) must always be connected and energised.

Pos. 1

TWISTLOCK (drg no 22808) All twistlock are to be greased through the greasecups 4 per spreader.

Pos. 2

TWISTLOCK CYLINDER & BEARING HOUSING IN TOWER (drg no 22808) Piston rod ends are to be greased. 8 per spreader. Bearing housing in tower. 2 per spreader.

Pos. 3

HYDRAULIC UNIT (drg no 22809) Oil is to be changed after first 50 hours, then after every 1000 hours.

Pos. 4

OIL FILTER (drg no 22809) Filter is to be changed after first 50 hours, then after every 1000 hours of operation or when the indicator is red.

Pos. 5

LIFTING SHAFTS (drg no 22808) (If the spreader/headblock is equipped with lifting shafts). ACTION! To be greased.

Pos. 6

GLIDE PLATE (drg no 22810) The robalon glide plates are to be replaced when the thickness is down to 17 mm. ACTION! To be checked.

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Pos. 7

GUIDE ARMS (drg no 22808) Shafts are to greased.

Pos. 8

TELESCOPIC GEARBOX (drg no 22808 & 22809) Oil level is to be checked through dismantled oil level plug. Bearings at the gearbox and the pedestal are to be greased through greasecups.

Pos. 9

ALL ROLLER CHAINS AND TENSION WHEEL (drg no 22808) Roller chains and tension wheel are to be checked from abrasion and greased.

Pos. 10

SIGNAL LAMPS (drg no 22810) Vibration proof glow lamp. ACTION! To be checked.

Pos. 11

TELESCOPIC BEAMS (drg no 22808) To be greased as follows: 1. In 20'- position, through greasenipple underneath the mainframe ca 50g/week. 2. In fully expanded position, with a brush on the sliding area under the telescopic beams ca 100g/ at interval min.1000 hour. The amount of grease and service interval depends on spreader use and environmental circumstances which vary from place to place.

Pos. 12

ELECTRICAL MOTORS (Only for EH5) Adjust brakes as per attached instructions.

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Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Quant 1 1 1 1 1 1 1 2 1 1 1 1 2 2 2 6 3 1 4 2 1 4 6 3 6 3 1

Article No: Drawing No: Serial No: Customer: Standard:

Title TWISTLOCK PIN GUIDE BLOCK SPHERICAL WASHER TWISTLOCK ARM, ASSY. TWISTLOCK KEY NUT SCREW SPACER RING HYDRAULIC CYLINDER BLOCKADING PIN SPRING NUT LOCK-KING WASHER NORD-LOCK LOCK PIN GREASE FITTING SWITCH ATTACH. STD. SCREW SWITCH PAD h=10 SCREW SCREW BLOCKADING PIECE NUT WASHER BOLTING PLATE WASHER NORD-LOCK COVER PLATE DEP4 SENSOR PLATE ASSY. LEFT

1002945 1002945 -

A4

A4 A4

A4 A4

A4

A4 A4

A4

Material / Article No.

TWISTLOCK ASSEMBLY ISO, STD, LEFT BGS

1002453

48916

43654

1001482

37704

41731

Dwg No. 1000431 1000430 41683 43653 1000434 1000432

sign: rev:

Art. No. 1000431 1000430 53968 43653 1000434 1000432 1000600 54049 74147 37704 70429 77891 701440 74044 71328 74970 1000596 1001482 1000585 1000587 43654 76460 77798 48916 701433 79850 1002453

PWH b / SC

M6S 6x55, Art. No. was 75694 M6S 6x65, Art. No. was 700686 FZB LOC-KING M8, Art. No. was 75090 BRB 8.4x16x1.6, Art. No. was 75328 FZB M6, Art. No. was 75268 FZB FZB

(CA 32/20-100/65) FZB SF-TF 4.5x22x90 SS 1774-04 M12, Art. No was 75055 M12, Art. No. was 75295 R.R 3.0 R 1/8" (SENSOR D=30) M6S 8x50, Art. No. was 75226

(M39x4-6H) M6S 8x75, Art. No. was 70165

TYPE 1

Remarks

date 18.2.2005 23.1.2007

Page 1 of 1

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Quant 1 1 1 1 1 1 1 2 1 1 1 1 2 2 2 6 3 1 4 2 1 4 6 3 6 3 1

Article No: Drawing No: Serial No: Customer: Standard:

Title TWISTLOCK PIN GUIDE BLOCK SPHERICAL WASHER TWISTLOCK ARM, ASSY. TWISTLOCK KEY NUT SCREW SPACER RING HYDRAULIC CYLINDER BLOCKADING PIN SPRING NUT LOCK-KING WASHER NORD-LOCK LOCK PIN GREASE FITTING SWITCH ATTACH. STD. SCREW SWITCH PAD h=10 SCREW SCREW BLOCKADING PIECE NUT WASHER BOLTING PLATE WASHER NORD-LOCK COVER PLATE DEP4 SENSOR PLATE ASSY. RIGHT

1002946 1002946 -

A4

A4 A4

A4 A4

A4

A4 A4

A4

Material / Article No.

TWISTLOCK ASSEMBLY ISO, STD, RIGHT BGS

1002454

48916

43654

1001482

37704

41731

Dwg No. 1000431 1000430 41683 43653 1000434 1000432

sign: rev:

Art. No. 1000431 1000430 53968 57059 1000434 1000432 1000600 54049 74147 37704 70429 77891 701440 74044 71328 74970 1000596 1001482 1000585 1000587 43654 76460 77798 48916 701433 79850 1002454

PWH b / SC

M6S 6x55, Art. No. was 75694 M6S 6x65, Art. No. was 700686 FZB LOC-KING M8, Art. No. was 75090 BRB 8.4x16x1.6, Art. No. was 75328 FZB M6, Art. No. was 75268 FZB FZB

(CA 32/20-100/65) FZB SF-TF 4.5x22x90 SS 1774-04 M12, Art. No was 75055 M12, Art. No. was 75295 R.R 3.0 R 1/8" (SENSOR D=30) M6S 8x50, Art. No. was 75226

(M39x4-6H) M6S 8x75, Art. No. was 70165

TYPE 2

Remarks

date 18.2.2005 23.1.2007

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A-A 1:5

A

A

H:\DWG\A3\A38\38073A.dwg

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PERIODIC MAINTENANCE PROCEDURE RUNNING-IN OF A NEW SPREADER After 50 and 250 hours 1. Lubricate and check the various points as per the lubrication instructions. 2. Check the telescopic chain. Tighten if it can be moved more than ± 25 mm in vertical direction. EVERY 100 WORKING HOURS

Nut

1. Twistlock: Check the nut and the floating mechanism and ensure that all parts are properly tightened down. Check that the locking pin can be moved easily and that it indicates the correct position (see 'Adjusting the locking pin'). 2. Check that all hydraulic tank mountings are tight.

Twistlock pin

3. Check that the hydraulic pump pressure is correct. 4. Carefully inspect all hoses, hose clips and hose connections. Defective hydraulic hoses and connections may cause personal injury when jets of liquid escape under high pressure. 5. Leaking hose connections and defective hoses should be rectified immediately. EVERY 1000 WORKING HOURS Lubricate and check the various points as per the lubrication instructions. CAUTION! When working on or in the vicinity of the spreader the electrical supply to the spreader should be disconnected, if possible, to prevent personal injury and material damage. This can be done using the main switch or by disconnecting the power cable. If the work requires that the electrical supply remains connected then staff on or in the vicinity of the spreader must be informed that it could move.

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TWISTLOCK MAINTENANCE Every 3000 working hours (100,000 containers handled2 or once annually3) 1. Dismantle all four twistlocks (eight on twin-liftspreaders).

Nut

2. Inspect all parts. Look for any damage which necessitate their replacement.

Spherical washer

3. Check that there are no cracks (or other faults) in the threads of the twistlock pins or 'heads'. Use penetrating fluid to detect fissures. 4. Replace the twistlock pin if cracks are detected.

Twistlock pin

5. Clean all parts. 6. Lubricate the parts. 7. Reassemble the twistlocks.

Every 6000 working hours (200,000 containers handled4 or every other year5) The twistlock pins and the spherical washers6 shall be replaced. NOTE. See the twistlock drawing and/or the separate adjustment instructions for the adjustment of the twistlock end stop switches after reassembly.

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If the spreader is equipped with twistlock counter If there is no hour counter or twistlockcounter 4 If the spreader is equipped with twistlock counter 5 If there is no hour counter or twistlock counter 6 Only for floating twistlocks 3

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BROMMA CONQUIP AB

07 02 ENG rev. x

PROCEDURE FOR ADJUSTMENT AND REPAIR OF MAJOR ITEMS OF THE SPREADER REPLACING THE HYDRAULIC PUMP When ordering a new hydraulic pump always state the direction of rotation as marked on the old pump housing. To replace the hydraulic pump (free-standing pump unit): 1.Turn off the electrical supply using the main switch. 2. Disconnect the inlet , outlet hoses and drainhoses from the pump. 3. Reconnect the inlet and outlet hoses once the pump has been fitted. 4. Reconnect the drain hose to the pump. 5. See drawing no.45316 for setting the pump flow and pressure. NOTE. Every time the pump is emptied, new oil must be added until it starts to run out of the drain hose. SHOCK RELIEF VALVES, general These are cross over relief valves which relieves excess hydraulic pressure caused by external forces on the flipper arms or the telescopic system. The rising hydraulic pressure acts against the spring to open the flow path to the other port. All leakage’s through these valves at the normal operating pressure of the pump (lower setting than the pump's operating pressure) cause a substantial increase in the temperature of the hydraulic oil. Leaks of this type are often indicated by a hissing sound coming from the relief valve. Possible causes are: * Slides jamming due to poor hydraulic oil * Defective seals * Incorrect pressure setting

3 of 10

BROMMA CONQUIP AB

07 02 ENG rev. x

ADJUSTING THE TELESCOPIC CHAIN (Drawing no. 38073) 1. Run the spreader to the maximum position (40 foot). 2. Disconnect the power. 3. Remove the locking screws from the adjuster nut. 4. Tighten the adjuster nuts on both sides with a torque wrench to 50 Nm (37 ft-lbs.) alternately one turn at a time . It is important to adjust both sides equally. If not done properly this could cause future problems in operation and reduce the life of the chain. 5. Reinstall the locking screws in the adjusting nut .

Locking screws

Adjusting nut

Cotter pin

Chain lock

REPLACING A BROKEN CHAIN If the chain should break and jump over the chain wheel, repair as follows: 1. Disconnect the electrical supply in the spreader control cabinet by turning off the main switch. 2. Place the telescopic beams in the approximate position for a 30 foot container using a fork lift truck or similar. 3. Turn the adjusting nut counterclockwise a quarter of a turn. 4. Remove the chain pin connected to the shock absorber by pulling out the cotter pin. 5. Remove the chain. 6. Install a new chain or insert a joining link and reinstall the chain and the adjusting nut. 7. Perform the steps described above (Adjusting the telescopic chain). 8. Connect the power supply and make a fine adjustment as per the instructions in 'Setting the spreader length'. 9. Check the distance between the twistlocks as per the instructions in Spreader lengths with different twistlocks'. 10. Lubricate the chain according to drawing 22808, Lubrication points. 4 of 10

BROMMA CONQUIP AB

07 02 ENG rev. x

REPLACING ROBALON PLATES Robalon plate in main frame 1. Extend the spreader to at least the 30 foot position. 2. Remove the locking plate and replace the Robalon plate.

Telescopic beam lower plates 1. Set the spreader to at least the 20 foot position. 2. Remove the electrical connectors from the electromagnetic telescopic valves. 3. Operate the telescopic drive by manually pressing the valves until the Robalon plate mounting bolts are accessible through the aperture in the lower flange of the main beam. Replace the plates.

Telescopic beam upper plates 1. Set the spreader to at least the 20 foot position. 2. Remove the electrical connectors from the electromagnetic telescopic valves. 3. Operate the telescopic drive by manually pressing the valves until the Robalon plate mounting bolts are accessible. 4. Replace the plates.

DISMANTLING THE TELESCOPIC BEAMS AND END BEAM UNIT If the telescopic beams require checking. 1. Start by removing all the Robalon plates from the ends of telescopic beams. Leave the plates on the main frame in place. 2. Disconnect the power cables and the hydraulic hoses from the end units. Seal all hydraulic hoses correctly. 3. Remove the stud from the drawbar connection in the end beam. 4. Take the weight off the end unit using a fork lift truck and extend the unit to the 40 foot position. 5 of 10

BROMMA CONQUIP AB

07 02 ENG rev. x

5. Secure a spacer between the telescopic beams to prevent lateral movement. 6. Extract the beams from the main frame and inspect them as required. 6. Reassemble the beams and the end units in the reverse order to that in the instructions above.

FLIPPER ARM UNIT (AUTOMATIC FLIPPER ARMS) 1. Remove the outlet plug to alter flipper arm speed. NOTE. When replacing the flipper arm motor ensure that the outlet plug is correctly positioned. 2. Removing and installing bearings a) Remove the flipper arms b) Remove the key c) Drift out the shaft. Once the shaft has been removed the bearing will be pushed out by the middle key. d) Drift out the second bearing. e) Install the parts in the reverse order to dismantle except for that both bearings have to be drifted into position using a pipe of a suitable bore.

6 of 10

BROMMA CONQUIP AB

07 02 ENG rev. x

ADJUSTING SPREADER LENGTH Sensors: a) Adjust the centre to centre distance between twistlocks for each position by moving the sensors. b) For 30' check the centre to centre distance between twistlock both when extending and retracing the spreader. The accurate distances between the twistlocks are shown in ”Spreader length with different twistlocks”.

Sensor

Sensor plate

SPREADER LENGTH WITH TWISTLOCKS BROMMA ISO Twistlock 20' 30' Floating:

5852

8918

40' 11984

ADJUSTING THE LANDING PIN a) Attach blockading pin clamps at three of the corners. b) At the fourth corner, press the pin upwards. c) When the lower part of the pin is 6 - 7 mm from the bottom plate of the corner, the lamp indicating "spreader landed", shall go on.

Landing switch

d) If the distance is not correct, adjust the landing switch and do the test again.

Landing pin

7 of 10

BROMMA CONQUIP AB

07 02 ENG rev. x

e) Proceed in the same way for all four corners. DISMOUNTING THE TWISTLOCK PIN 1. Dismout the twistlock cylinder as described on the next page. 2. Remove the M6 screw and nut from the top of the twistlock. 3. Grab hold of twistlock head. 4. Slack off the twistlock nut. 5. Lower the twistlock pin and guide block. 6. Do not lose the twistlock pin key.

Twistlock nut

M6 nut

M6 screw

Guide neck

Twistlock MOUNTING housing 1. Perform the steps above in the Twistlock head reverse order. 2. Carry out the adjustment below 3. before mounting the M6 screw and nut. 4. Lubricate according to instructions on drawing 22808, Lubrication points.

Distance between top of twistlock head and bottom of guide block 1-2 mm

Checking the Float 1. Grab hold of the twistlock head. 2. Push or pull the twistlock to one of the corners. 3. Ensure the guide block is touching the twistlock housing bottom plate. If not, the twistlock needs to be adjusted /lowered. 4. If the twistlock is touching the bottom plate, press the twistlock upwards while holding it in the corner. 5. The twistlock should be moving up slightly. If it moves a lot, adjust it higher. 6. If the twistlock does not move at all, it needs to be adjusted down. Adjusting 1. Remove the M6 screw from the top of the twistlock. 2. To lower the twistlock, loosen the twistlock nut slightly. To raise the twistlock, tighten the nut. The distance between the top of twistlock head and the bottom of guide block 1 -2 mm 3. Recheck the float of the twistlock. 4. Reinstall the M6 screw.

8 of 10

BROMMA CONQUIP AB

Twistlock nut Spherical washer

Key

Twistlock pin

Twistlock head 07 02 ENG rev. x

Removing the Twistlock Cylinder 1. Make sure the power supply is disconnected and the oil pressure is relieved from the Split pin system. 2. Remove the hoses from the cylinder. 3. To avoid oil leakage, thread a plastic bag Spacer over the end of the hoses and secure ring them with straps. 4. Pull out the split pins. Remove the spacer rings and the cylinder. Installing the Twistlock Cylinder 1. Perform the steps above in the reverse order. 2. The hoses must be tightened to 95 Nm (70 ft-lbs) torque. 3. De-aerate the system by running the cylinder several times.

Cylinder

Removing Sensors 1. Unscrew the cable connection from the sensor. 2. Loosen the two screws on the switch attachment. 3. Remove the sensor. Installing Sensors 1. Perform the steps above in the reverse order, using blue Loctite to the cable connection. 2. The distance between sensor face and flag is approximately 5-6 mm. Check the sensor by grabbing the twistlock head and moving it around in different positions. If the signal is lost, adjust the sensor closer to its flag. Make sure the flag does not come in contact with the sensor.

9 of 10

BROMMA CONQUIP AB

Sensor

Signal cable connection

07 02 ENG rev. x

Checking the tower motor brake 1. Disconnect the power. 2. Remove the crank from its stowed position in the tower. 3. Install the crank at the rear end of the tower motor. 4. Place a torque wrench in the ½” socket on the crank 5. Adjust the torque to 65 Nm. 6. If the torque wrench releases as the 65 Nm torque is reached, the brake adjustment is OK. If it does not release and the motorshaft rotates, the brake must be adjusted. See Inspection and maintenance of BGM8 Tower motor at the end of this section.

Tower motor

Crank

65 Nm

Torque wrench

10 of 10

BROMMA CONQUIP AB

07 02 ENG rev. x

Bromma Manual

Important tightening torques EH5/EH170 Tower and main frame

331Nm

165Nm

331Nm 331Nm

331Nm

End beam

68Nm

6.5 Nm

40Nm

Telescopic motor EH5 / EH170

Telescopic motor EH5U / EH170U

331Nm

40Nm 331Nm

7-1- Febr. 10 rev.01

Bromma Conquip

Bromma Manual

Limit switch box EH5 / EH170 91Nm

Twistlock EH5 / EH170

Twistlock EH5U / EH170U

100 Nm 95 Nm

91Nm

Flipper motor and gearbox 165Nm after 200 test cycles

331Nm 56Nm

103Nm after 200 test cycles

Bromma Conquip

7-2- Febr . 10 rev.01

8

Inspection and maintenance periods

8

Inspection and Maintenance • • • •

8.1

Inspection and maintenance periods Equ ipm ent/com po nen ts

Frequency

BMG4 =Telescopic Motor

Every Year

BMG8 = Tower Motor

Every third month

What to do ? Inspecting the brake: • Mea sure and set working air gap • brake disc, lining • P ressure plate • C arrier / gearing • P ressure rings • E xtract the ab raded ma tter • Inspect the switch elemen ts and repla ce if necessary (e.g . in case o f burn-out)

1

8

Inspection and maintenance of brake BMG 4 and 8

8.6

Inspection and maintenance of brake BMG4 = Telescopic Motor BMG8 = Tower Motor

9 8 6

7

5 2

3

4

1

22 21 e 10 b

20

c

19

a 15 11

2

12 13

14

16

17

18

8


Inspecting brake BMG 4 and 8

, setting the working air gap

1. Isolate the moto r and brake from the supply, safeguarding them against un inten tional power -up. 2. Remove the following: – If fitted, forced- cooling fan for motor and brake maintenance. – F lange co ver or fa n guard (21 ). 3. Pu sh the rubber sealing co llar (5) aside. – R elease the clip to do this, if necessary . – E xtract the abr aded ma tter. 4. Measure the brake disc (7 ): If the brak e d isc is: – ≤ 9 mm on b rake motors up to size 100 .(BMG4) – ≤ 10 mm on bra ke motor s up to size 1 12.(BMG8) Fit a new brake disc (→ Section "Ch anging brake disc on BMG

4 and 8

A

.

3


8

Changing thebrake disk BMG 4 and 8 When fitting a ne w brake disc, in spect the other removed pa rts as well and fit new one s if nece ss ary 1. Iso late the moto r and brake from the supply,, safeguarding them against un inten tional power -up. 2. Remove the following: – If fitted, forced coolin g fan – F lange co ver or fa n guard (21 ), ci rclip (2 0) and fan (19). 3. Rem ove the ru bber sea ling colla r (5 ) an d the ma nual brake release: – S etting nuts ( 18), con ica l coil sp rings (1 7), studs (16), rele ase lever (1 5), dowel pin (1 4). 4. Unscr ew hex nuts (1 0e ), ca refully pull off the brake co il body (1 2) (brake ca ble!) an d take out the brak e spr ings (11). 5. Rem ove the dam ping plate (9 ), pres sur e pla te (8) and brake disc (7, 7b) an d cle an the br ak e com ponents . 6. Fit a ne w brake d isc. 7. Re- install th e br ake comp onents. – E xcept fo r the r ubber sea ling colla r, fan and fan guard, se t the working air gap (→ ”Inspe cting brake BMG 4 and 8, settin g the wor king air gap” , points 5 through 8) 8. With m anual brake r elease: Use se tting n uts to set the flo ating clear ance "s" between the conical co il springs (pressed flat) an d the settin g nuts ( → following illustration).

s

Brak e BMG 4 and 8

Floa ting clear ance s [mm] 2

Importan t: This flo ating clerance "s" is necessary so that the pressure plate can move up as the brake lining wears. Otherwise, reliable braking is not gu ara nteed. 9. Fit the r ubber sea ling colla r ba ck in place and re-install th e dismantled pa rts.

Note:

•

T he locka ble man ual brake r elea s e ( type HF) is a lready r elea s ed if a re sistan ce is encountered whe n ope rating the gr ub scre w. • T he se lf-reengaging manual b rake re lea s e (type HR) ca n be operated with normal hand pressu re. Imp ortant: In brake motors with self-reengaging manual brake release, the manual brake release lever must be removed after startup/maintenance. A bracket is provided for storing it on the outside of the motor.

4

8


Changing Springs

1. Isolate the moto r and brake from the supply, safeguarding them against un inten tional po wer -up. 2. Remove the following: – If fitted, fo rced -cooling fan , For motor and brake ma intenance . – F lange cover or fa n guard (21 ), ci rclip (2 0) and fan (19). 3. Remove the ru bber sea ling colla r (5) an d the ma nual brake release: – s etting nuts (18 ), conical coil sp rings (1 7), studs ( 16) , release le ver ( 15) , dowel pin (1 4). 4. Unscrew he x nuts ( 10e ), pull o ff the co il body ( 12) . – B y app rox. 50 mm (watch the bra ke ca ble!) . 5. Cha nge

brake springs (11).

– P os ition the bra ke sp rings symme trically. 6. Re- install th e br ake components.. – E xcept fo r the r ubber sea ling colla r, fan an d fan gu ard, set the wor king air ga p (→ ”Ins pecting brake BMG 4 and 8 setting the working air gap ” , points 5 th rough 8) 7. With manual brake release: Use setting nuts to s et floating c learance "s" between the co nical coil springs (pressed fla t) an d the setting nuts ( → following illustration.)

s

Brak e

Floa ting clear ance s [mm]

BMG 4 and 8

2

Importan t: This floating clearance "s" is necessary so that the pressure plate can move up as the brake lining wears. Otherwise, reliable braking is not gu aranteed. 8. Fit the rubber sealing colla r ba ck in place and re-install th e dismantled pa rts.

Note

5

Fit new settingnuts (18) an d hexag on nuts ( 10e ) if the re moval pr oced ure is r epeated!

kVA

9

i 9.3

Brak e type

f

n

Work done, working air gap, braking torques of brake BMG 4 - 8

P Hz

Work done, working air gap, braking torques of brake BMG 4-8

Fo r motor size

Work do ne until main tenance [10 6 J]

Workin g air gap [mm] min. 1)

0.25

ma x.

Br aking torque se ttings Br aking torque [N m]

Type an d n o. of springs

Order n umber o f spr ings

Nor mal

Norma l

Red

Red

0.6

135 150 8 135 151 6 BMG 4

BMG 8

1)

6

100

112M 132S

40

6

-

75

6

-

260

600

0.3

1.2

184 845 3 135 570 8

Please note when checking the air gap: Parallelism tolerances on the brake disk may give rice to deviation of ±0.1 after a test run.

A ddres s lis t

C o n t a c t y o u r B R O M M A l o c a l r e p r e s e n t a t i v e o r S E W A ddres s es below. G ermany Headquarters P roduc tion S ales S ervic e

B ruc hs al

S E W-E UR ODR IV E G mbH & C o E rnst-B lickle-S traß e 42 D-76646 B ruchs al P.O. B ox P os tfach 3023 · D-76642 B ruchsal

Tel. (0 72 51) 75-0 F ax (0 72 51) 75-19 70 http://www.S E W-E UR ODR IV E .de s ew@ s ew-eurodrive.de

P roduc tion

G raben

S E W-E UR ODR IV E G mbH & C o E rnst-B lickle-S traß e 1 D-76676 G raben-Neudorf P.O. B ox P os tfach 1220 · D-76671 G raben-Neudorf

Tel. (0 72 51) 75-0 F ax (0 72 51) 75-29 70 Telex 7 822 276

A s s embly S ervic e

G arbs en (near Hannover)

S E W-E UR ODR IV E G mbH & C o Alte R icklinger S traß e 40-42 D-30823 G arbs en P.O. B ox P os tfach 110453 · D-30804 G arbs en

Tel. (0 51 37) 87 98-30 F ax (0 51 37) 87 98-55 s cm-garbs en@ s ew-eurodrive.de

K irc hheim (near München)

S E W-E UR ODR IV E G mbH & C o Domagks traß e 5 D-85551 K irchheim

Tel. (0 89) 90 95 52-10 F ax (0 89) 90 95 52-50 s cm-kirchheim@ s ew-eurodrive.de

L angenfeld (near Düs s eldorf)

S E W-E UR ODR IV E G mbH & C o S iemens s traß e 1 D-40764 Langenfeld

Tel. (0 21 73) 85 07-30 F ax (0 21 73) 85 07-55 s cm-langenfeld@ s ew-eurodrive.de

Meerane (near Zwickau)

S E W-E UR ODR IV E G mbH & C o Dänkritzer Weg 1 D-08393 Meerane

Tel. (0 37 64) 76 06-0 F ax (0 37 64) 76 06-30 s cm-meerane@ s ew-eurodrive.de

Additional address es for s ervice in G ermany provided on reques t! F ranc e P roduc tion S ales S ervic e

Haguenau

S E W-US OC OME S AS 48-54, route de S oufflenheim B . P. 185 F -67506 Haguenau C edex

Tel. 03 88 73 67 00 F ax 03 88 73 66 00 http://www.us ocome.com s ew@ us ocome.com

A s s embly S ales S ervic e

B ordeaux

S E W-US OC OME S AS P arc d’a ctivité s de Magellan 62, avenue de Magellan - B . P. 182 F -33607 P es s ac C edex

Tel. 05 57 26 39 00 F ax 05 57 26 39 09

Lyon

S E W-US OC OME S AS P arc d’A f faires R oos evelt R ue J acques Tati F -69120 Vaulx en Velin

Tel. 04 72 15 37 00 F ax 04 72 15 37 15

P aris

S E W-US OC OME S AS Zone indus trielle 2, rue Denis P apin F -77390 Verneuil I’E t ang

Tel. 01 64 42 40 80 F ax 01 64 42 40 88

Additional address es for s ervice in F rance provided on reques t! A rgentina A s s embly S ales S ervic e

B uenos A ires

S E W E UR ODR IV E AR G E NT INA S .A. C entro Indus trial G arin, Lote 35 R uta P anamericana K m 37,5 1619 G arin

Tel. (3327) 45 72 84 F ax (3327) 45 72 21 s ewar@ s ew-eurodrive.com.ar

Melbourne

S E W-E UR ODR IV E P T Y. LT D. 27 B everage Drive Tullamarine, Victoria 3043

Tel. (03) 99 33 10 00 F ax (03) 99 33 10 03

S ydney

S E W-E UR ODR IV E P T Y. LT D. 9, S leigh P lace, Wetherill P ark New S outh Wales , 2164

Tel. (02) 97 25 99 00 F ax (02) 97 25 99 05

Wien

S E W-E UR ODR IV E G es .m.b.H. R ichard-S traus s -S tras s e 24 A-1230 Wien

Tel. (01) 6 17 55 00-0 F ax (01) 6 17 55 00-30 s ew@ s ew-eurodrive.at

A us tralia A s s embly S ales S ervic e

A us tria A s s embly S ales S ervic e

7

Address list

Belgium Assembly Sales Service

Brüssel

CARON-VECTOR S.A. Avenue Eiffel 5 B-1300 Wavre

Tel. (010) 23 13 11 Fax (010) 2313 36 http://www.caron-vector.be [email protected]

Sao Paulo

SEW DO BRASIL Motores-Redutores Ltda. Rodovia Presidente Dutra, km 208 CEP 07210-000 - Guarulhos - SP

Tel. (011) 64 60-64 33 Fax (011) 64 80 33 28 [email protected]

Brazil Production Sales Service

Additional addresses for service in Brazil provided on request! Bulgaria Sales

Sofia

BEVER-DRIVE GMBH Bogdanovetz Str.1 BG-1606 Sofia

Tel. (92) 9 53 25 65 Fax (92) 9 54 93 45 [email protected]

Toronto

SEW-EURODRIVE CO. OF CANADA LTD. 210 Walker Drive Bramalea, Ontario L6T3W1

Tel. (905) 7 91-15 53 Fax (905) 7 91-29 99 www.sew-eurodrive.ca

Vancouver

SEW-EURODRIVE CO. OF CANADA LTD. 7188 Honeyman Street Delta. B.C. V4G 1 E2

Tel. (604) 9 46-55 35 Fax (604) 946-2513

Montreal

SEW-EURODRIVE CO. OF CANADA LTD. 2555 Rue Leger Street LaSalle, Quebec H8N 2V9

Tel. (514) 3 67-11 24 Fax (514) 3 67-36 77

Canada Assembly Sales Service

Additional addresses for service in Canada provided on request! Chile Assembly Sales Service

Santiago de Chile

SEW-EURODRIVE CHILE Motores-Reductores LTDA. Panamericana Norte No 9261 Casilla 23 - Correo Quilicura RCH-Santiago de Chile

Tel. (02) 6 23 82 03+6 23 81 63 Fax (02) 6 23 81 79

Tianjin

SEW-EURODRIVE (Tianjin) Co., Ltd. No. 46, 7th Avenue, TEDA Tianjin 300457

Tel. (022) 25 32 26 12 Fax (022) 25 32 26 11

Bogotá

SEW-EURODRIVE COLOMBIA LTDA. Calle 22 No. 132-60 Bodega 6, Manzana B Santafé de Bogotá


Zagreb

KOMPEKS d. o. o. PIT Erdödy 4 II HR 10 000 Zagreb

Tel. +385 14 61 31 58 Fax +385 14 61 31 58

Praha

SEW-EURODRIVE S.R.O. Business Centrum Praha Luná 591 16000 Praha 6

Tel. 02/20 12 12 34 + 20 12 12 36 Fax 02/20 12 12 37 [email protected]

Kopenhagen

SEW-EURODRIVEA/S Geminivej 28-30, P.O. Box 100 DK-2670 Greve

Tel. 4395 8500 Fax 4395 8509 http://www.sew-eurodrive.dk [email protected]

Tallin

ALAS-KUUL AS Paldiski mnt.125 EE 0006 Tallin

Tel. 6 59 32 30 Fax 6 59 32 31

China Production Assembly Sales Service Colombia Assembly Sales Service Croatia Sales Service Czech Republic Sales

Denmark Assembly Sales Service Estonia Sales

8

Address list

Finland Assembly Sales Service

Lahti

SEW-EURODRIVE OY Vesimäentie 4 FIN-15860 Hollola 2

Tel. (3) 589 300 Fax (3) 780 6211

Normanton

SEW-EURODRIVE Ltd. Beckbridge Industrial Estate P.O. Box No.1 GB-Normanton, West- Yorkshire WF6 1QR

Tel. 19 24 89 38 55 Fax 19 24 89 37 02

Athen

Christ. Boznos & Son S.A. 12, Mavromichali Street P.O. Box 80136, GR-18545 Piraeus

Tel. 14 22 51 34 Fax 14 22 51 59 [email protected]

Hong Kong

SEW-EURODRIVE LTD. Unit No. 801-806, 8th Floor Hong Leong Industrial Complex No. 4, Wang Kwong Road Kowloon, Hong Kong

Tel. 2-7 96 04 77 + 79 60 46 54 Fax 2-7 95-91 29 [email protected]

Budapest

SEW-EURODRIVE Kft. H-1037 Budapest Kunigunda u. 18

Tel. +36 1 437 06 58 Fax +36 1 437 06 50

Baroda

SEW-EURODRIVE India Pvt. Ltd. Plot No. 4, Gidc Por Ramangamdi · Baroda - 391 243 Gujarat

Tel. 0 265-83 10 86 Fax 0 265-83 10 87 [email protected]

Dublin

Alperton Engineering Ltd. 48 Moyle Road Dublin Industrial Estate Glasnevin, Dublin 11

Tel. (01) 8 30 62 77 Fax (01) 8 30 64 58

Milano

SEW-EURODRIVE di R. Blickle & Co.s.a.s. Via Bernini,14 I-20020 Solaro (Milano)

Tel. (02) 96 98 01 Fax (02) 96 79 97 81

Toyoda-cho

SEW-EURODRIVE JAPAN CO., LTD 250-1, Shimoman-no, Toyoda-cho, Iwata gun Shizuoka prefecture, P.O. Box 438-0818

Tel. (0 53 83) 7 3811-13 Fax (0 53 83) 7 3814

Ansan-City

SEW-EURODRIVE KOREA CO., LTD. B 601-4, Banweol Industrial Estate Unit 1048-4, Shingil-Dong Ansan 425-120

Tel. (031) 4 92-80 51 Fax (031) 4 92-80 56 [email protected]

Brüssel

CARON-VECTOR S.A. Avenue Eiffel 5 B-1300 Wavre

Tel. (010) 23 13 11 Fax (010) 2313 36 http://www.caron-vector.be [email protected]

Skopje

SGS-Skopje / Macedonia "Teodosij Sinactaski” 6691000 Skopje / Macedonia

Tel. (0991) 38 43 90 Fax (0991) 38 43 90

Johore

SEW-EURODRIVE SDN BHD No. 95, Jalan Seroja 39, Taman Johor Jaya 81000 Johor Bahru, Johor West Malaysia

Tel. (07) 3 54 57 07 + 3 54 94 09 Fax (07) 3 5414 04

Great Britain Assembly Sales Service Greece Sales Service Hong Kong Assembly Sales Service

Hungary Sales Service India Assembly Sales Service Ireland Sales Service

Italy Assembly Sales Service Japan Assembly Sales Service Korea Assembly Sales Service Luxembourg Assembly Sales Service Macedonia Sales

Malaysia Assembly Sales Service

9

Address list

Netherlands Assembly Sales Service

Rotterdam

VECTOR Aandrijftechniek B.V. Industrieweg 175 NL-3044 AS Rotterdam Postbus 10085 NL-3004 AB Rotterdam

Tel. +31 10 44 63 700 Fax +31 10 41 55 552 http://www.vector.nu [email protected]

Auckland

SEW-EURODRIVE NEW ZEALAND LTD. P.O. Box 58-428 82 Greenmount drive East Tamaki Auckland

Tel. 0064-9-2 74 56 27 Fax 0064-9-2 74 01 65 [email protected]

Christchurch

SEW-EURODRIVE NEW ZEALAND LTD. 10 Settlers Crescent, Ferrymead Christchurch

Tel. 0064-3-3 84 62 51 Fax 0064-3-3 85 64 55 [email protected]

Moss

SEW-EURODRIVE A/S Solgaard skog 71 N-1599 Moss

Tel. (69) 2410 20 Fax (69) 2410 40 [email protected]

Lima

SEW DEL PERU MOTORES REDUCTORES S.A.C. Los Calderos # 120-124 Urbanizacion Industrial Vulcano, ATE, Lima

Tel. (511) 349-52 80 Fax (511) 349-30 02 [email protected]

Lodz

SEW-EURODRIVE Polska Sp.z.o.o. ul. Pojezierska 63 91-338 Lodz


Coimbra

SEW-EURODRIVE, LDA. Apartado 15 P-3050-901 Mealhada

Tel. (0231) 20 96 70 Fax (0231) 20 36 85 [email protected]

Bucuresti

Sialco Trading SRL str. Madrid nr.4 71222 Bucuresti


St. Petersburg

ZAO SEW-EURODRIVE P.O. Box 193 193015 St. Petersburg

Tel. (812) 3 26 09 41 + 5 35 04 30 Fax (812) 5 35 22 87 [email protected]

SEW-EURODRIVE PTE. LTD. No 9, Tuas Drive 2 Jurong Industrial Estate Singapore 638644

Tel. 8 62 17 01-705 Fax 8 61 28 27 Telex 38 659

Pakman - Pogonska Tehnika d.o.o. UI. XIV. divizije 14 SLO – 3000 Celje

Tel. 00386 3 490 83 20 Fax 00386 3 490 83 21 [email protected]

New Zealand Assembly Sales Service

Norway Assembly Sales Service Peru Assembly Sales Service Poland Sales

Portugal Assembly Sales Service Romania Sales Service Russia Sales

Singapore Assembly Sales Service Slovenia Sales Service

10

Celje

Address list

South Africa Assembly Sales Service

Johannesburg

SEW-EURODRIVE (PROPRIETARY) LIMITED Eurodrive House Cnr. Adcock Ingram and Aerodrome Roads Aeroton Ext. 2 Johannesburg 2013 P.O.Box 90004 Bertsham 2013

Tel. + 27 11 248 70 00 Fax +27 11 494 23 11 [email protected]

Capetown

SEW-EURODRIVE (PROPRIETARY) LIMITED Rainbow Park Cnr. Racecourse & Omuramba Road Montague Gardens Cape Town P.O.Box 36556 Chempet 7442 Cape Town

Tel. +27 21 552 98 20 Fax +27 21 552 98 30 Telex 576 062

Durban

SEW-EURODRIVE (PROPRIETARY) LIMITED 2 Monaceo Place Pinetown Durban P.O. Box 10433, Ashwood 3605

Tel. +27 31 700 34 51 Fax +27 31 700 38 47

Bilbao

SEW-EURODRIVE ESPAÑA, S.L. Parque Tecnológico, Edificio, 302 E-48170 Zamudio (Vizcaya)

Tel. 9 44 31 84 70 Fax 9 44 31 84 71 [email protected]

Jönköping

SEW-EURODRIVE AB Gnejsvägen 6-8 S-55303 Jönköping Box 3100 S-55003 Jönköping

Tel. (036) 34 42 00 Fax (036) 34 42 80 www.sew-eurodrive.se

Basel

Alfred lmhof A.G. Jurastrasse 10 CH-4142 Münchenstein bei Basel

Tel. (061) 4 17 17 17 Fax (061) 4 17 17 00 http://www.imhof-sew.ch [email protected]

Chon Buri

SEW-EURODRIVE (Thailand) Ltd. Bangpakong Industrial Park 2 700/456, Moo.7, Tambol Donhuaroh Muang District Chon Buri 20000

Tel. 0066-38 21 40 22 Fax 0066-38 21 45 31 [email protected]

Istanbul

SEW-EURODRIVE Hareket Sistemleri San. ve Tic. Ltd. Sti Bagdat Cad. Koruma Cikmazi No. 3 TR-81540 Maltepe ISTANBUL

Tel. (0216) 4 41 91 63 + 4 41 91 64 + 3 83 80 14 + 3 83 80 15 Fax (0216) 3 05 58 67 [email protected]

Production Assembly Sales Service

Greenville

SEW-EURODRIVE INC. 1295 Old Spartanburg Highway P.O. Box 518 Lyman, S.C. 29365

Tel. (864) 4 39 75 37 Fax Sales (864) 439-78 30 Fax Manuf. (864) 4 39-99 48 Fax Ass. (864) 4 39-05 66 Telex 805 550

Assembly Sales Service

San Francisco

SEW-EURODRIVE INC. 30599 San Antonio St. Hayward, California 94544-7101

Tel. (510) 4 87-35 60 Fax (510) 4 87-63 81

Philadelphia/PA

SEW-EURODRIVE INC. Pureland Ind. Complex 200 High Hill Road, P.O. Box 481 Bridgeport, New Jersey 08014

Tel. (856) 4 67-22 77 Fax (856) 8 45-31 79

Dayton

SEW-EURODRIVE INC. 2001 West Main Street Troy, Ohio 45373

Tel. (9 37) 3 35-00 36 Fax (9 37) 4 40-37 99

Dallas

SEW-EURODRIVE INC. 3950 Platinum Way Dallas, Texas 75237

Tel. (214) 3 30-48 24 Fax (214) 3 30-47 24

Spain Assembly Sales Service Sweden Assembly Sales Service Switzerland Assembly Sales Service Thailand Assembly Sales Service

Turkey Assembly Sales Service USA

11

Address list

USA Additional addresses for service in the USA provided on request! Venezuela Assembly Sales Service

12

Valencia

SEW-EURODRIVE Venezuela S.A. Av. Norte Sur No. 3, Galpon 84-319 Zona Industrial Municipal Norte Valencia

Tel. +58 (241) 8 32 98 04 Fax +58 (241) 8 38 62 75 [email protected] [email protected]

Bromma Group Manual

0-1-may 02 rev.00

Bromma Conquip

8 • Spare parts and service Spare parts list by major groups

BROMMA CONQUIP AB

08 01 ENG rev.

Bromma Group Manual

0-1-may 02 rev.00

Bromma Conquip

12 7 4 5 2 6 3 14 13 10 11 15 16 19 20 8 9 1 18 17

F/N

Name

1041820 2.0 17021 1.0 17023 1.0 23854 1.0 23855 2.0 24142 1.0 24143 1.0 24161 2.0 24169 2.0 34375 2.0 37409 1.0 39047 1.0 39055 1.0 44768 2.0 1001444 1.0 1002656 2.0 1002945 2.0 1002946 1.0 1017506 1.0 1041686 1.0 1041819

Qty

General Assembly, 1041820 rev. Title GENERAL ASSEMBLY HYDRAULIC ASSY EH 5 TOWER STD. TENSION ROD TENSION ROD TELESCOPIC BEAM UNIT FRAME TOWER FLIPPER ARM ASS. PUMP UNIT ASSY. CABLE CHAIN ASSY. TOWER CABLE CHAIN GEARBOX ASSY GEARBOX ASSY. LED-PANEL MOUNT. DET. INPUT MODULE KIT 230VAC TWISTLOCK ASSYEMBLY TWISTLOCK ASSYEMBLY FRAME EH5U Electrical circuit diagram DECORATION

Title2 SN: 15216 YSX 40/45E EH5-EH170 ISO, STD, LEFT ISO, STD, RIGHT CANOPEN EH5U, SN: 15216 -

Specification 1041820 17021 g 17023 b 23854 a 23855 a 24142 24143 b 24161 c 24169 d 34375 f 37409 b 39047 a 39055 b 44768 e 1001444 - 1001444 1002656 a 1002945 c 1002946 c 1017506 - 1017506 1041686 1041819 -

Page - 1

KSI 1/19/12

F/N

Part, 24161 rev. c

Qty

24161

Name TOWER

Title -

Title2 24161 c

Specification

Page - 1

KSI 10/21/11

F/N

Qty

Welded Component, 23854 rev. a

23854

Name

Title TENSION ROD

-

Title2 23854 a

Specification

Page - 1

KSI 10/21/11

F/N

Qty

Welded Component, 23855 rev. a

23855

Name

Title TENSION ROD

-

Title2 23855 a

Specification

Page - 1

KSI 10/21/11

2 3 13 14 1 12 9 11 10 15 4 5 7 6 8

F/N

Frame, 24143 rev. b

24143 1.0 16441 1.0 38073 2.0 38084 1.0 38085 4.0 38861 1.0 38862 1.0 38863 2.0 38864 4.0 43072 4.0 48392 2.0 400242 2.0 400244 4.0 401277 4.0 401279 4.0 401401

Qty

Name

Title FRAME TELESC. DRIVE ATT. ASSY. CHAIN ASSY SINGLE SENSOR ASSY. DUAL SENSOR ASSY. GLIDE PLATE ASSY PEDESTAL BEARING TOWER CHAIN ASSY END BEAM COVER ASSY LIFTING LUG ASSY. CLIP TENSION ROD PIN ASSY. END STOP ASSY LANDING BUFFER 20' - STOP ASSY. FRAME COVER ASSY

-

Title2

Specification 24143 b 16441 a 38073 c 38073 c 38084 d 38085 d 38861 a 38862 38863 38864 a 43072 d 48392 d 48392 d 400242 a 400244 c 400244 c 401277 401279 b 401401 a

Page - 1

KSI 10/21/11

F/N

Part, 17023 rev. b

Qty

17023

Name TOWER STD.

Title -

Title2 17023 b

Specification

Page - 1

KSI 10/21/11

10 3 8 4 21 24 11 15 14 9 16 22 23 12 26 25 13 2 1 6 5 19 20 17 7 18 27

F/N

Name

1002945 1.0 37704 1.0 53968 2.0 54049 1.0 43653 1.0 43654 3.0 48916 1.0 70429 2.0 71328 2.0 74044 1.0 74147 6.0 74970 4.0 76460 6.0 77798 1.0 77891 3.0 79850 6.0 701081 2.0 701440 1.0 1000430 1.0 1000431 1.0 1000432 1.0 1000434 4.0 1000585 2.0 1000587 3.0 1000596 1.0 1000600 1.0 1001482 1.0 1002453

Qty

Twistlock Assy, 1002945 rev. c Title TWISTLOCK ASSYEMBLY BLOCKADING PIN SPHERICAL WASHER SPACER RING TWISTLOCK ARM ASSY TYPE 1 BLOCKADING PIECE BOLTING PLATE SPRING SF-TF 4,5x22x90 GREASE FITTING G1/8 IN LOCK PIN HYDRAULIC CYLINDER CLAMP 04-430 NUT LOC-KING M8 WASHER BRB 8,4x16x1,6 NUT LOC-KING M12 COVER PLATE DP4 FZB WASHER NORD-LOCK M6 WASHER NORD-LOCK M12 GUIDE BLOCK TWISTLOCK PIN ISO TWISTLOCK NUT TWISTLOCK KEY SCREW M6S 6x55 SCREW M6S 6x65 SCREW M6S 8x50 SCREW M6S 8x75 SWITCH PAD SENSOR PLATE ASSY

Title2 ISO, STD, LEFT EH 190/195 27x21x6 HYDRAULIC ASP 4 SS 1774-04 R.R 3.0 25 CA-32/20-100/85 A4, DIN 985, KLASS 70 A4, ISO 7089 DIN 985, A4, KLASS 70 A4 A4 MACHINED A4, CLASS 70, ISO 4014 A4, CLASS 70, ISO 4014 A4, CLASS 70, ISO 4014 A4, CLASS 70, ISO 4014 10x30x60 LEFT TWISTLOCK ENDBEAM

Specification 1002945 c 37704 e 37704 e 41683 i 41683 i 41731 b 41731 b 43653 - 43653 43654 b 43654 b 48916 d 48916 d 70429 - 70429 71328 74044 74147 a 74147 a 74970 - 74970 76460 77798 77891 79850 - 79850 701081 701440 1000430 d 1000430 d 1000431 f 1000431 f 1000432 b 1000432 b 1000434 - 1000434 1000585 1000587 1000596 1000600 1001482 - 1001482 1002453 b 1002453 b

Page - 1

KSI 10/21/11

F/N

Part, 37409 rev. b

Qty

37409

Name

Title CABLE CHAIN ASSY.

YSX 40/45E

Title2 37409 b

Specification

Page - 1

KSI 10/21/11

1 3 4 2

F/N

Mounting Assy, 39047 rev. a Name

39047 1.0 38996 4.0 76460 4.0 77798 4.0 1019493

Qty

Title TOWER CABLE CHAIN CABLE CHAIN TOWER NUT LOC-KING M8 WASHER BRB 8,4x16x1,6 SCREW MF6S 8x35

Title2 EH5 A4, DIN 985, KLASS 70 A4, ISO 7089 A4, CLASS 70, DIN7991

Specification 39047 a 38996 a 76460 77798 1019493 -

Page - 1

KSI 10/21/11

F/N

Qty

Hydraulic System, 17021 rev. g

17021

Name

Title HYDRAULIC ASSY EH 5

-

Title2 17021 g

Specification

Page - 1

KSI 10/21/11

F/N

Part, 34375 rev. f

Qty

34375

Name

Title PUMP UNIT ASSY.

-

Title2 34375 f

Specification

Page - 1

KSI 10/21/11

A-A 1:5

A

A

1.0 60629

1.0 24167 1.0 24168 1.0 62595 10.0 47678 6.0 72010 12.0 75052 24.0 75292 12.0 76842 3.0 401528

2

5 3 4 9 10 7 8 6 11

24169

2.0 60628

Qty

1

F/N

Mounting Assy, 24169 rev. d Name

Title FLIPPER ARM ASS. GEARBOX ASSY FLIPPER T.1 SMAL GEARBOX ASSY FLIPPER T.2 SMAL FLIPPER ARM FLIPPER ARM FLIPPER ARM SPACER KEY 20X12X30 NUT LOC-KING M20 WASHER BRB 21x36x3 SCREW M6S 20x110 BUFFER ASSY.

Title2

TK, SMS 2307 DIN 985, FZB, CLASS 8 FZB, SMS 70 CLASS 8.8, ISO 4014 -

-

Specification

24167 c 24168 c 24168 c 47678 d 47678 d 72010 a 75052 75292 76842 401528 -

24169 d

Page - 1

KSI 10/21/11

F/N

Part, 39055 rev. b

Qty

39055

Name

Title GEARBOX ASSY

-

Title2 39055 b

Specification

Page - 1

KSI 10/21/11

16.0 1028199

2.0 1000785 2.0 1029307 1.0 78127 4.0 78126

2.0 1015779

1.0 1027882

3

4 5 6 7

8

9

Name

1 2

Qty

1041334 2.0 37759 16.0 700097

F/N

Decoration, 1041334 rev. Title

PAINT DECAL TEMPLATE KIT

WARING SIGN

DECORATION SIGN SWL SCREW MC6S 6X10 NYLON WASHER BRB 6,4x12x1,6 SIGN BROMMA LOGO WARNING SIGN WARNING SIGN

Title2

JIB / ROTATOR PAINT DECAL TEMPLAT WARNING SIGN TRIANGLE 40x40 EH5U & EH170U

Polyamid, DIN 125, ISO 7089

A4 KLASS 70 ISO 4762

Specification

1000785 c 1029307 78127 a 78126 - 78126 -

1028199 -

1041334 37759 e 37759 e 700097 a

Page - 1

KSI 10/21/11

F/N

Qty

Mounting Assy, 1001444 rev. Name

1001444

Title LED-PANEL MOUNT. DET.

-

Title2

Specification 1001444 - 1001444 -

Page - 1

KSI 10/21/11

F/N

Qty

Telescopic Beam Unit, 24142 rev. -

24142

Name

Title TELESCOPIC BEAM UNIT

-

Title2 24142 -

Specification

Page - 1

KSI 1/19/12

F/N

Part, 34375 rev. f

Qty

34375

Name

Title PUMP UNIT ASSY.

-

Title2 34375 f

Specification

Page - 1

KSI 1/19/12

F/N

Part, 37409 rev. b

Qty

37409

Name

Title CABLE CHAIN ASSY.

YSX 40/45E

Title2 37409 b

Specification

Page - 1

KSI 1/19/12

Manufacturer: B rommaConquipAB

SWL

Serial No.

Type

Weight

Tonne

Manufacturing Year

POW ER SUPPL Y 40 0 VAC 44 0 VAC 46 0 VAC

FREQUENCY 50 Hz 60 Hz

CONT ROL VOL T AGE 24 VDC 11 5 VAC 23 0 VAC

Name

1.0 1027882 2.0 37759 4.0 78126 1.0 78127 16.0 700097 2.0 1000785

16.0 1028199

2.0 1029307

9 1 7 6 2 4

3

5

1043058

2.0 1015779

Qty

8

F/N

Decoration, 1043058 rev. Title

PAINT DECAL TEMPLATE KIT SIGN SWL WARNING SIGN WARNING SIGN SCREW MC6S 6X10 SIGN NYLON WASHER BRB 6,4x12x1,6 BROMMA LOGO

WARING SIGN

DECORATION

Title2

PAINT DECAL TEMPLAT

Polyamid, DIN 125, ISO 7089

WARNING SIGN TRIANGLE 40x40 EH5U & EH170U A4 KLASS 70 ISO 4762 JIB / ROTATOR

Specification

1029307 -

1028199 -

37759 e 37759 e 78126 - 78126 78127 a 700097 a 1000785 c

1043058 -

Page - 1

KSI 2/3/12

9 • Hydraulic circuit diagrams

BROMMA CONQUIP AB

09 01 ENG rev.

10 • Electrical wiring diagrams

BROMMA CONQUIP AB

10 01 ENG rev

F

E

D

C

B

A

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

1

SIGN.

:

Manufacturing site

DATE

2

By

3

This drawing is copyright, and is the property of BROMMA CONQUIP AB. The design and/or constructions contained therein, may not be copied or reproduced, whitout the written consent of the owner.

: muhamaz

: BICT Indonesia : 15487 : EH5U :

Project name Serial Number Type Responsible for project

: 11/20/2009 : 12/15/2011

: BROMMA CONQUIP

S-164 22 KISTA SWEDEN Email: [email protected] +46 (0)8 620 09 00 Tel:

MALAXGATAN 7

Manufacturer (Company)

Created on the The latest revition

3

BROMMA CONQUIP

2

: BICT : A1 : 1043066 :

1

Customer Plant designation Drawing Number Revision

0

4

4

STOCKHOLM SWEDEN

5

5

7

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

6

muhamaz 09/19/2001

15487

EH5U

UNIT (+)

PLANT (=)

:

:

7

FILENAME:

PLOTTED:

12/15/2011

8

16:42

DRAWING NO.

TOTAL SH.

CONT.

SHEET

40

9

9

1043066

Number of pages :

8

BICT Indonesia Flyleaf

BROMMA SPREADER EH5U

BICT Indonesia

6

REV.

1 2 F 40

E

D

C

B

A

Location

X0 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X0 X0 X0 X0 X0 X0 X0

X0 X0 X1 X0 X1 X0

Plant des.

A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1

A1 A1 A1 A1 A1 A1

Page

Table of content

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Rev


Page description Flyleaf Table of contents Table of contents Connector designation Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram Circuit diagram PLC diagram I/O card overview I/O card overview I/O card overview Cabinet layout Cable/ Sensor Layout Cabinet layout Cable/ Sensor Layout

STOCKHOLM SWEDEN

Revision note

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

EH5U

muhamaz 11/02/2001

15487

UNIT (+)

PLANT (=)

:

:

FILENAME:

PLOTTED:

12/15/2011

16:42

Table of contents

BICT Indonesia DRAWING NO.

Date 12/15/2011 12/15/2011 12/15/2011 01/24/2005 12/15/2011 11/20/2009 03/02/2009 12/15/2011 03/04/2009 01/19/2005 03/02/2009 12/15/2011 03/02/2009 12/15/2011 01/19/2005 03/04/2011 01/24/2005 03/04/2011 01/24/2005 03/04/2011 01/18/2005 12/15/2011 12/15/2011 12/15/2011 12/15/2011 12/15/2011 12/15/2011 12/15/2011 12/15/2011 12/15/2011

1043066

TOTAL SH.

CONT.

SHEET

Editor muhamaz muhamaz muhamaz bln muhamaz sharifsy krpulha muhamaz krpulha bln krpulha muhamaz krpulha muhamaz bln muhamaz bln muhamaz bln muhamaz bln muhamaz muhamaz muhamaz muhamaz muhamaz muhamaz muhamaz muhamaz muhamaz

REV.

2 3 40

Plant des. A1 A1 A1

Location X0 X0 X0

Page

Table of content

31 32 33 34 35 36 37 38 39 40

Rev


Page description Cable/ Sensor Layout Cable/ Sensor Layout Spreader layout Parts list: (79125 - 70592) Parts list: (1028417 - 73983) CABLE LIST CABLE LIST CABLE LIST CABLE LIST CABLE LIST

STOCKHOLM SWEDEN

Revision note

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

EH5U

muhamaz 11/03/2004

15487

UNIT (+)

PLANT (=)

:

:

FILENAME:

PLOTTED:

12/15/2011

16:42

Table of contents

BICT Indonesia DRAWING NO.

Date 12/15/2011 12/15/2011 12/15/2011 12/15/2011 12/15/2011 12/15/2011 12/15/2011 12/15/2011 12/15/2011 12/15/2011

1043066

TOTAL SH.

CONT.

SHEET

Editor muhamaz muhamaz muhamaz muhamaz muhamaz muhamaz muhamaz muhamaz muhamaz muhamaz

REV.

3 4 40

F

E

D

C

B

A

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

0

2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

L1

SIGN.

DATE

2

PE

1

L3

POWER SUPPLY

L2 PE

3

3

4

5

4

STOCKHOLM SWEDEN

5

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

16 23

10

29

17

5

30

18

6

35

25

12

2

31

19

7

36

26

13

3

32

20

8

37

27

14

4

MALE INSERT

34

24

11

1

33

21

9

22

8

RED POINT

28

15

XP1 PIN DESCRIPTION

7

6

bln 05/08/2002

15487

EH5U

UNIT (+)

PLANT (=)

A1 : X0

:

7

FILENAME:

PLOTTED:

12/15/2011

8

16:42

DRAWING NO.

BICT Indonesia Connector designation

PLUG= ODU 309 012 000 554 000 BROMMA Nr.71480 INSERT = ODU 309 803 150 037 151 BROMMA Nr.74410

6

SPREADER CONNECTOR


(OPTION) L1

SPARE SPARE PROTECTION EARTH

POWER SUPPLY PROTECTION EARTH

H.I.S OR TTDC SIGNAL POWER SUPPLY

L2 SPARE POWER SUPPLY L3 N CONTROL VOLTAGE L CONTROL VOLTAGE CONTROL VOLTAGE PILOT MOVE TELESCOPE TO 20FT CMD MOVE TELESCOPE TO 40FT CMD ALL FLIPPERS UP COMMAND GREEN FLIPPERS DOWN COMMAND YELLOW FLIPPER DOWN COMMAND BLUE FLIPPER DOWN COMMAND RED FLIPPERS DOWN COMMAND TWL LOCK COMMAND TWL UNLOCK COMMAND LOCKED SIGNAL UNLOCKED SIGNAL MOVE G.P. TO BLUE COMMAND MOVE G.P. TO YELLOW COMMAND G.P. IN CENTRE SIGNAL LANDED SIGNAL MOVE TELESCOPE TO 30FT CMD SPARE SPARE SPARE SPARE SPARE SPARE

POWER SUPPLY

POWER SUPPLY

XP1 SPREADER MALE CONTACT

1

9

1043066

TOTAL SH.

CONT.

SHEET

9

REV.

4 5 F 40

E

D

C

B

A

F

E

D

C

B

ITEM

-

-

-

-

A1 +X0

:L1

1

SUBJECT OF CHANGE

0

1

/7.01

31

:L1

2

-K1

-Q1

-X2

-WXP1

-XP1

/6.01 / -Phase L1

A

4

3

4

3

:L2

4

32

1

6

5

6

5

:L3

:L3

1

SIGN.

25

34

24

4

Supply 400VAC 50Hz

2

1

2

1

:L2

2

2

/6.01 / -Phase L2

0

/6.01 / -Phase L3

DATE

:PE

33

33

:PE

PE

37

2

2

-K8

-XP23

/10.04

A1 +X100

3.0KW

-M4

3

8

4

3

4

V

M 3 ~

2

:8

8

I>

3

9

6

5

6

5

3

PE

W

:9

9

I>

4

4

-K9

PE

:PE

21

21

/10.05

2

3

4

3

-BRAKE2

2

1

STOCKHOLM SWEDEN

-M4 Telescopic motor

U

1

-WM4

7

2

1

2

:7

7

I>

1

-X2

-WXP23

-QM8


A1 +X0

3

6

5

5

5

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

6

-K2

1

U

4

3

4

V

M 3 ~

2

:2

I>

3

7

6

5

6

3

PE

W

:3

I>

5

UNIT (+)

PLANT (=)

A1 : X1

:

7

PE

:PE

-K3

2

3

/10.02

-BRAKE1

2

1

8

4

3

FILENAME:

PLOTTED:

12/15/2011

8

16:42

BICT Indonesia Circuit diagram

-M1 Gravity point motor

5.5KW

-M1

2

1

2

1

:1

I>

-X2

/10.01

-WM1

-QM1

muhamaz 05/14/2002

15487

EH5U

6

DRAWING NO.

6

5

2A

-F1

-P1

h

TOTAL SH.

CONT.

SHEET

2

1

9

1043066

2

1

9

REV.

5 6 F 40

E

D

C

B

A

F

E

D

C

B

A

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

0

A1 +X0

1

/5.01 / -Phase L1

/5.01 / -Phase L2

/5.01 / -Phase L3

1

-XP23

SIGN.

1

U

V

M 3 ~

2

:2

2

2

4

DATE

2

3

6

5

6

5

3

PE

W

:3

3

I>

-M2 Hydralic pump left

2.2KW

-M2

1

2

3

1

I>

4

3

2

1

:1

1

I>

-X2

-WM2

A1 +X100

-WXP23

-QM6

-K6

/10.03

2

3

1

U

5

4

3

V

M 3 ~

2

:5

5

I>

4

4

6

6

5

PE

W

PE

:PE

20

20

:PE

PE

PE

STOCKHOLM SWEDEN

3

:6

6

I>

-M3 Hydralic pump right

2.2KW

4

2

1

:4

4

I>

-M3

-WM3

-QM7


PE

:PE

22

22

3

5

5

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

6

sharifsy 05/14/2002

15487

EH5U

6

UNIT (+)

PLANT (=)

A1 : X1

:

7

7

N

L

11

12

/7.07

-KA1

:103

FILENAME:

PLOTTED:

12/15/2011

8

16:42


Cabinet heater

14

:101

-EH1

/7.07

-KA1

-X2

8

21

22

:104

DRAWING NO.

24

:102

9

1043066

TOTAL SH.

CONT.

SHEET

9

REV.

6 7 F 40

E

D

C

B

A

F

E

D

C

ITEM

-

-

-

-

/14.00 / -Spreader stop

0

SUBJECT OF CHANGE

.01

-SS1

4/5.01

6/5.01

.04

3

5

7

1

Spreader stop

8

2/5.01

12

11

A1

A2

22

21

:107

1

-K1

-SS1

.01

-X2

6

SIGN.

:105

2

1

14

13

YL/GL

BK BK

- -

RD RD

+ +

2

24VDC

:1

-X1

5

4

3

-G1

-X1 :3

:2

3

7 .01


:106

5

BU

N

90-255VAC ---24VDC

BN

L

DATE

10A

-F2

/5.01

-Q1

:108

7

PE

-WXP1

7

-K1

4

-XP21

8

1

:+

/8.08 / -XP21:2

3

:+

:L

:L

:N

:N

4

:+

/8.09 / -XP21:5

/8.09 / -XP21:4

STOCKHOLM SWEDEN

+ 24VDC

2

:+

-X2

-X2

/8.09 / -XP21:3

6

4

5

:+

5

5

:+

6

7

8

:+

8

:-

6

03/22/2002

DRAWING DATE:

9

:-

krpulha

15487

EH5U

0 VDC

7

:-

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

6

:-

NOTE: Wire for 24VDC shall bee 2,5mm² with blue colour.

:-

UNIT (+)

PLANT (=)

10

:-

A1 : X1

:

22

12 24

14

21/6.08

11/6.08

A2

A1

7

FILENAME:

PLOTTED:

12/15/2011

8

16:42


-KA1 Cabinet heater

:-

-KA1

DRAWING NO.

NOTE: All 24vdc supply should be ring Connected

/8.07 / -XP21:6

-XP1

3

/8.07 / -XP21:7

2

/8.08 / -XP21:8

B

A1 +X0

1

/8.08 / -XP21:9

A

0

/8.08 / -XP21:10

/8.08 / -XP21:1

TOTAL SH.

CONT.

SHEET

9

1043066

-0VDC / /10.00

-24VDC / /9.00

-24VDC SCS² / /15.00

-L.VAC / /12.00

-N.VAC / /13.00

9

REV.

7 8 F 40

E

D

C

B

A

F

E

D

C

B

ITEM

-

-

-

-

:1

0

:8

-+VBB X2 / /17.09

red

-WXP22

-X1

-WX2

-GND X2 / /17.09

blue

SUBJECT OF CHANGE

A1 +X0

A1 +X100

A1 +X0

-Can high X2 / /16.09

white

:15

White

/15.06 / -CAN high X1

1

:22

-WX3

:2

:9

:16

-Can high X3 / /18.09

white

-GND X3 / /19.09

blue

-+VBB X3 / /19.09

red

DATE

-Can low X3 / /18.09

brown

SIGN.

2

:23

:10

:17

:24 :4

:11

3


:3

:18

4

:25

-WX8

:5

:12

:19

-Can high X8 / /20.09

white

-GND X8 / /21.09

blue

-+VBB X8 / /21.09 red STOCKHOLM SWEDEN

-Can low X8 / /20.09 brown

A

-Can low X2 / /16.09

brown

Brown

/15.06 / -CAN low X1

5

:26 :6

:20

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

:13

6

muhamaz 08/27/2004

15487

EH5U

:27

:7

:21

UNIT (+)

PLANT (=)

A1 : X1

:

-WXP21

:14

7

:28

7

7

8

9

10

/7.06 / -XP21:10

6

1

FILENAME:

12/15/2011

8

16:42

3

DRAWING NO.

2

-0VDC / +X1/9.00

8


/7.06 / -XP21:7 PLOTTED:

/7.06 / -XP21:6

6

/7.06 / -XP21:8

5

/7.06 / -XP21:9

4

/7.04 / -XP21:1

3

/7.04 / -XP21:2

2

/7.05 / -XP21:3

1

4

5

TOTAL SH.

CONT.

SHEET

9

9

1043066

/7.05 / -XP21:4

0

/7.05 / -XP21:5

REV.

8 9 F 40

E

D

C

B

A

F

E

D

C

ITEM

-

-

-

-

A1 +X0

0

SUBJECT OF CHANGE

-WHL 1-4

+X1/8.08 / -0VDC

A1 +X100

PIN NO: 44

1

2

2

1

:13

13

13

1

-HL1 Unlocked left

Green

-HL1

-X2

-WXP23

-XP23

O

/7.08 / -24VDC

I

B

:31

SIGN.

3

2

1

:14

14

14

:41

DATE

2

-HL2 Locked left

Red

-HL2

O

:44

I

+B1-XPX1

4

2

1

:15

15

15

:43

3

3


-HL3 Landed left

White

-HL3

O

2 I

1

5

2

1

:16

16

16

:42

4

-WHL 5-8

4

PIN NO: 21

1

2

2

1

:17

17

17

:3

5

5

6

3

2

1

:18

18

18

:2

6

EH5U

05/14/2002

DRAWING DATE:

6

krpulha

15487 DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

-HL6 Locked right

Red

-HL6

COMMON GROUP 2

-HL5 Unlocked right

Green

-HL5

:21

STOCKHOLM SWEDEN

-HL4 Tower in center left

Yellow

-HL4

O

A I

COMMON GROUP 1

O

-B1 I

5

O

4

I

3

UNIT (+)

PLANT (=)

A1 : X1

:

4

2

1

:19

19

19

:11

7

7

8

2

1

FILENAME:

12/15/2011

8

16:42

DRAWING NO.

-HL8 Tower in centre right

Yellow

-HL8

5

:16

TOTAL SH.

CONT.

SHEET

-24VDC / /10.00

9

9

1043066

I/O 8 SPARE

:1

8

BICT Indonesia Circuit diagram PLOTTED:

-HL7 Landed right

White

-HL7

7

O

2

I

1

O

0

I

9

REV.

10 F 40

E

D

C

B

A

F

E

D

C

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

/7.08 / -0VDC

1

SIGN.

-K3

6 /5.08

4 /5.08

2 /5.08

A2

A1

:16

DATE

2

K3 Gravity point to right

5

6 /5.07

5

K2 Gravity point to left

3

4 /5.07

1

2 /5.07

3

A2

A1

1

-K2

O

/9.09 / -24VDC

I

B

:26

O

:8

I

PIN NO: 44

+B1-XPX1

6 /6.02

4 /6.02

2 /6.02

A2

A1

:6

11

3


K6 Hydralic pump left/right gable

5

3

1

-K6

O

10 I

9

4

PIN NO: 21

:35

5

3

1

5

-K9

6 /5.05

4 /5.05

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

6

:5

14

6

bln 06/29/2004

15487

EH5U

Not connected MACHINE TYPE:

COMMON GROUP 4

2 /5.05

A2

A1

:4

13

K9 Extend telescope

STOCKHOLM SWEDEN

6 /5.04

4 /5.04

2 /5.04

A2

A1

:7

12

K8 Retract telescope

5

3

1

-K8

O

A I

COMMON GROUP 3

O

-B1 I

5

O

4

I

3

UNIT (+)

PLANT (=)

:

:

7

:25

15

A1 X1 7

8

Not connected

:15

16

FILENAME:

12/15/2011

8

16:42


Not connected

O

2

I

1

O

0

I DRAWING NO.

9

1043066

TOTAL SH.

CONT.

SHEET

-0VDC / /11.00

-24VDC / /11.00

9

REV.

11 F 40

10

E

D

C

B

A

SIGN.

DATE

Not connected

Not connected

:40

-P2

:50

1

:46

21

MACHINE TYPE:

Not connected

:47

22

PLANT (=)

:

A1 X1

7

Not connected

:49

23

8

Not connected

:48

24

F

E

ITEM

-

-

-

0

SUBJECT OF CHANGE

1

2

3


4

STOCKHOLM SWEDEN

5

Container Counter

2

EH5U

11/23/2004

6

krpulha DRAWING DATE:

15487 DRAWN BY:

CHECKED BY:

SERIAL NO.

UNIT (+)

:

7

FILENAME:

PLOTTED:

12/15/2011

8

16:42

BICT Indonesia Circuit diagram DRAWING NO.

9

1043066

TOTAL SH.

CONT.

SHEET

-0VDC / /14.00

-24VDC / /14.00

9

11

B

A

REV.

12 F 40

E

D

Not connected

:30

20

COMMON GROUP 6

6

D

-

PIN NO: 9

C

Not connected

:20

19

PIN NO: 50

C

/10.09 / -0VDC

O

/10.09 / -24VDC

I

B

:10

O

:9

I

+B1-XPX1

O

18 I

17

O

A I

COMMON GROUP 5

O

-B1 I

5

O

4

I

3

O

2

I

1

O

0

I

F

E

D

C

B

ITEM

-

-

-

-

A1 +X0

0

SUBJECT OF CHANGE

/7.08 / -L.VAC

17

17

:109

:21

1

Locked signal

-XP1

-WXP1

-X2

O

:11

I

PIN NO: 11

+B1-XPX3

SIGN.

DATE

18

18

:110

:31

26

2

Unlocked signal

O

25

I

A

22

22

:111

:41

27

3


Spreader landed signal

O

COMMON GROUP 7

I

-B1

21

21

:112

:42

28

4

G.p. in centre signal

O

4

I

3

PIN NO: 43

29

:113

:24

5

5

G.p. to left signal

STOCKHOLM SWEDEN

:43

O

2

I

1

MACHINE TYPE:

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

:114

:35

30

6

muhamaz 03/12/2001

15487

EH5U

G.p. to right signal

COMMON GROUP 8

6

O

0

I UNIT (+)

PLANT (=)

:

:

A1 X1 7

7

:116

:45

FILENAME:

12/15/2011

8

16:42

9

DRAWING NO.

9

1043066

TOTAL SH.

CONT.

SHEET

230 VAC INPUT MODULE BROMMA part no. 1001747


:115

:44

8

REV.

13 F 40

12

E

D

C

B

A

F

E

D

C

B

A

ITEM

-

-

-

-

-B1

0

SUBJECT OF CHANGE

+B1-XPX3

/7.08 / -N.VAC

A1 +X0

PIN NO: 1

0

:1

O

33

:5

:117

8

8

1

SIGN.

I

O

34

:4

:118

23

23

2

2

Telescope to 30' CMD

DATE

COMMON GROUP 9

Telescope retract / to 20´ CMD

I

-X2

-WXP1

-XP1

1

O

35

3


Telescope expand / to 40´ CMD

I

:3

:119

9

9

3

O

36

4

Flippers all up CMD

I

:2

:120

10

10

4

:15

I

O

37 COMMON GROUP 10

I

5

38

EH5U

09/26/2002

6

krpulha DRAWING DATE:

15487 DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

Flipper right down CMD

O

:16

:122

:121

:6

12

12

6

11

11

5

Flipper waterside down CMD

STOCKHOLM SWEDEN

PIN NO: 15

UNIT (+)

PLANT (=)

:

:

O

39

A1 X1 7

Flipper left down CMD

I

:25

:123

13

13

7

O

40

FILENAME:

PLOTTED:

12/15/2011

8

16:42


Flipper landside down CMD

I

:26

:124

14

14

8

DRAWING NO.

TOTAL SH.

CONT.

SHEET

9

1043066

-N.VAC / /14.00

9

REV.

14 F 40

13

E

D

C

B

A

F

E

D

C

B

A

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

-B1

+B1-XPX3

/13.08 / -N.VAC

/11.09 / -0VDC

/7.00 / -Spreader stop

/11.09 / -24VDC

A1 +X0

PIN NO: 36

0

:36

O

41

:49

:125

15

15

1

Twl lock CMD

I

-X2

-WXP1

-XP1

1

SIGN.

DATE

COMMON GROUP 11

O

42

:48

:126

2

Twl unlock CMD

I

16

16

2

O

43

:47

:127

3


G.p. move to left CMD

I

19 19

3

O

44

:46

:128

4

PIN NO: 8

:8

I

O

45

:7

5

5

Not connected

STOCKHOLM SWEDEN

G.p. move to right CMD

I

20 20

4

PIN NO: 10 DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

I

O

46

:9

6

muhamaz 07/07/2004

15487

EH5U

Not connected MACHINE TYPE:

:10

6

PIN NO: 40 UNIT (+)

PLANT (=)

:

:

A1 X1

:40

O

47

:50

7

:30

I

O

48

:20

14

13

G.p. auto return

-SB1

8

FILENAME:

12/15/2011

8

16:42


Spreader stop

I

7

PIN NO: 20

DRAWING NO.

9

1043066

TOTAL SH.

CONT.

SHEET

-0VDC / /15.00

GRAV.POINT AUT. RETURN OFF ON

E

D

C

B

A

15 F 40

14

REV.

230 VAC INPUT MODULE BROMMA part no. 1001747

9

F

E

D

C

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

.

/7.08 / -24VDC SCS²

/14.09 / -0VDC

1

.

SIGN.

-B1

+B1-XPX2

:43

GND

+24V

:44

DATE

2

Main supply node B1

:42

:10 :9

ID1

Node Address

:19

ID3

3


:45

-KEY1

:29

:39

4

4

:49

-X2

:30

:129

5

STOCKHOLM SWEDEN

B-Can L

5

B-Can

B-Can H

B

+24V

3

WH

GND

2

WH;BN

ID0

:40

:130

6

brown

:20

:50

3

white

2

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

Can-GND

6

bln 07/07/2004

15487

EH5U

Can-open MACHINE TYPE:

-WXP22

-XP22

-CAN high X1 / /8.01

Can-open H

A

1

BN;GN

ID4

-CAN low X1 / /8.01

Can-open L

0

GN

ID5

:48

6

BLACK UNIT (+)

PLANT (=)

:

:

GND

16

:16

26

A1 X1 7

:36

8

FILENAME:

12/15/2011

8

16:42


:26

36

PLOTTED:

EEPROM

:6

7

EEPROM

BLUE

SD

GREEN

SC

RED

VCC

GND

DRAWING NO.

9

1043066

TOTAL SH.

CONT.

SHEET

.

9

REV.

16 F 40

15

E

D

C

B

A

F

E

D

C

B

A

-X2

ITEM

-

-

-

-

/17.00

0

SUBJECT OF CHANGE

-S1

I

4

4

1

O

4

+

1

1

-

In 1

-S1 Unlocked left landside

+X2-XP1

-WS1-S5

Left gable end

Node ID: 2

0

SIGN.

3

I

2

4

1

O

2

+

DATE

2

-

In 5

-S5 Locked left landside

-S5

2

3

I

4

1

O

4

A

+

In 2

-

3

3


-S2 Unlocked left waterside

+X2-XP3

-WS2-S6

-S2

3

I

4

1

O

2

B

+

4

3

I

4

4

1

O

4

+

5

5

-

In 3

-S9 Landed left landside

+X2-XP5

-WS9

-S9

STOCKHOLM SWEDEN

In 6

-

-S6 Locked left waterside

-S6

4

3

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

O

2

In 7

6

muhamaz 03/12/2001

15487

EH5U

Spare

I

6

UNIT (+)

PLANT (=)

I

4

4

1

O

4

+

:

:

A1 X0 7

-

In 4

O

2

Spare

I

8

In 8

FILENAME:

12/15/2011

8

16:42


3

PLOTTED:

-S10 Landed left waterside

+X2-XP7

-WS10

-S10

7

DRAWING NO.

+X2-X0

:1

-R2

-Can high X2 / +X1/8.01

2

1

9

:2

9

1043066

TOTAL SH.

CONT.

SHEET

E

D

C

B

A

17 F 40

16

REV.

CAN-open Interface / Supply

CAN_high

-Can low X2 / +X1/8.01 CAN_low

F

E

D

C

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

O

2

1

A

1

-Y7 Twistlock unlock left

A

-Y7

-WY7-Y8

I

B

4

SIGN.

DATE

B

2

2

-Y8 Twistlock lock left

B 2

1

O

+X2-XP2

I

Left gable end

2

1

A

4

-Y1 Flipper 1 up left landside

A

-Y1

-WY1-Y2

+X2-XP4

Out 2

3


-Y8

Out 5

O

Out 1 I

Node ID: 2

B

2

-Y2

Out 6

4

2

1

A

4

Out 3

5

-Y3 Flipper 2 up left waterside

A

-Y3

-WY3-Y4

+X2-XP6

STOCKHOLM SWEDEN

-Y2 Flipper 1 down left landside

B 2

1

O

/16.00

I

A

O

5 I

4

CHECKED BY:

DRAWING DATE:

DRAWN BY:

B

2

-Y4

Out 7

6

bln 06/22/2004

15487

EH5U

-Y4 Flipper 2 down left waterside MACHINE TYPE: SERIAL NO.

1

B 2

6 O

3 I

2

UNIT (+)

PLANT (=)

:

:

2

1

A

4

A1 X0 7

1

B

2

FILENAME:

PLOTTED:

12/15/2011

8

16:42

+X2-X0

DRAWING NO.

-Y6

Out 8

-Y6 Flipper 5 down left centre

B 2

8


Out 4

-Y5 Flipper 5 up left centre

A

-Y5

-WY5-Y6

+X2-XP8

7

9

:5

9

1043066

TOTAL SH.

CONT.

SHEET

E

D

C

B

A

18 F 40

17

REV.


:3

GND +X1/8.01 / -GND X2

+VBB +X1/8.00 / -+VBB X2

O

1 I

0 O

-X2 I

F

E

D

C

B

A

-X3

ITEM

-

-

-

-

/19.00

0

SUBJECT OF CHANGE

-S3

+X3-XP1

-WS3-S7

I

4

4

1

O

4

+

1

In 1

-

1

-S3 Unlocked right waterside

Right gable end

Node ID: 3

0

SIGN.

3

I

2

4

O

2

+

1

In 5

-

DATE

2

-S7 Locked right waterside

-S7

2

3

I

4

O

4

A

+

1

In 2

-

3

3


-S4 Unlocked right landside

+X3-XP3

-WS4-S8

-S4

3

I

4

O

2

B

+

1

4

-

3

I

4

4

O

4

+

1

5

In 3

-

5

-S11 Landed right waterside

+X3-XP5

-WS11

-S11

STOCKHOLM SWEDEN

In 6

-S8 Locked right landside

-S8

4

3

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

O

2

In 7

6

muhamaz 06/22/2004

15487

EH5U

Spare

I

6

UNIT (+)

PLANT (=)

I

4

4

O

4

+

1

:

:

A1 X0 7

-

In 4

O

2

Spare

I

8

In 8

FILENAME:

12/15/2011

8

16:42


3

PLOTTED:

-S12 Landed right landside

+X3-XP7

-WS12

-S12

7

DRAWING NO.

+X3-X0

:1

-R3

-Can high X3 / +X1/8.02

2

1

9

:2

9

1043066

TOTAL SH.

CONT.

SHEET

E

D

C

B

A

19 F 40

18

REV.


CAN_high


F

E

D

C

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

O

2

1

A

1

-Y15 Twistlock unlock right

A

-Y15

-WY15-Y16

I

B

4

SIGN.

DATE

B

2

2

-Y16 Twistlock lock right

B 2

1

O

+X3-XP2

I

Right gable end

2

1

A

4

-Y9 Flipper 3 up right waterside

A

-Y9

-WY9-Y10

+X3-XP4

Out 2

3


-Y16

Out 5

O

Out 1 I

Node ID: 3

B

2

-Y10

Out 6

4

2

1

A

4

Out 3

5

-Y11 Flipper 4 up right landside

A

-Y11

-WY11-Y12

+X3-XP6

STOCKHOLM SWEDEN

-Y10 Flipper 3 down right waterside

B 2

1

O

/18.00

I

A

O

5 I

4

CHECKED BY:

DRAWING DATE:

DRAWN BY:

B

2

-Y12

Out 7

6

bln 06/22/2004

15487

EH5U

-Y12 Flipper 4 down right landside MACHINE TYPE: SERIAL NO.

1

B 2

6 O

3 I

2

UNIT (+)

PLANT (=)

:

:

2

1

A

4

Out 4

A1 X0 7

1

B

2

FILENAME:

PLOTTED:

12/15/2011

8

16:42

+X3-X0

DRAWING NO.

-Y14

Out 8

-Y14 Flipper 6 down right centre

B 2

8


-Y13 Flipper 6 up right centre

A

-Y13

-WY13-Y14

+X3-XP8

7

9

:5

9

1043066

TOTAL SH.

CONT.

SHEET

E

D

C

B

A

20 F 40

19

REV.


:3

GND +X1/8.02 / -GND X3

+VBB +X1/8.01 / -+VBB X3

O

1 I

0 O

-X3 I

F

E

D

C

B

A

-X8

ITEM

-

-

-

-

/21.00

SUBJECT OF CHANGE

I

4

4

1

O

4

+

1

1

-

In 1

-S54 G.P tower left stop

+X8-XP1

Centre landside

0

-S54

-WS54-S55

Node ID: 8

0

SIGN.

3

I

2

4

1

O

2

+

DATE

2

-

In 5

-S55 GP tower right stop

-S55

2

3

I

4

4

1

O

4

+

-

In 2

3

3


-S52 G.P tower left centre

+X8-XP3

-WS52-S53

-S52

3

I

2

4

1

O

2

+

4

-

3

I

4

4

1

O

4

+

5

5

-

In 3

-S13 20' telescope position

+X8-XP5

-WS13-S16

-S13

STOCKHOLM SWEDEN

In 6

-S53 G.P tower right centre

-S53

4

3

MACHINE TYPE:

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

I

2

4

1

O

2

+

In 7

-

3

6

-S14

PLANT (=) UNIT (+)

I

4

4

1

O

4

+

7

:

:

A1 X0 7

-

In 4

I

2

4

1

O

2

+

FILENAME:

12/15/2011

16:42

8

-

In 8

-S114 30' telescope positon

-S114

8


3

PLOTTED:


+X8-XP7

-WS14-S114

muhamaz 06/23/2004

15487

EH5U


-S16

6

+X8-X0

DRAWING NO.

3 -Can high X8 / +X1/8.05 :1

9

:2

9

1043066

TOTAL SH.

CONT.

SHEET

E

D

C

B

A

21 F 40

20

REV.


CAN_high


F

E

D

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

O

C

1

Spare

I

B

4

SIGN.

DATE

2

Spare

O

+X8-XP2

I

Centre landside

2

Spare

+X8-XP4 4

Out 2

3


Out 5

O

Out 1 I

Node ID: 8

4

Spare

O

/20.00

I

A 2

5

Spare

+X8-XP6

STOCKHOLM SWEDEN

Out 6

O

5 I

4

4

Out 3

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

2

Out 7

6

bln 06/23/2004

15487

EH5U

Spare

6 O

3 I

2

UNIT (+)

PLANT (=)

:

:

A1 X0 7

4

Spare

8

2

FILENAME:

12/15/2011

8

16:42


Out 4

PLOTTED:

Spare

+X8-XP8

7

+X8-X0

DRAWING NO.

Out 8

9

:5

9

1043066

TOTAL SH.

CONT.

SHEET

E

D

C

B

A

22 F 40

21

REV.


:3

GND +X1/8.05 / -GND X8

+VBB +X1/8.04 / -+VBB X8

O

1 I

0 O

-X8 I

F

E

D

C

B

A

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

0

1

1

SIGN.

DATE

3


L1 L2 L3

U1 V1 W1

2

3

4

5

6

4

TS

BS

STOCKHOLM SWEDEN

bl

5

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

bl

ws

rt

rt

ws

ws

SR

6

muhamaz 05/09/2003

15487

EH5U

MOTOR WITH BRAKE AND CURRENT RELAY

W2 U2 V2

2

UNIT (+)

PLANT (=)

:

:

A1 X0

5

4

3

2

1

7

7

FILENAME:

PLOTTED:

12/15/2011

8

16:42


BGE

8

DRAWING NO.

9

1043066

TOTAL SH.

CONT.

SHEET

9

REV.

23 F 40

22

E

D

C

B

A

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

TYPE

-HL1 Unlocked left

-HL2 Locked left

-HL3 Landed left


-HL5 Unlocked right

-HL6 Locked right

-HL7 Landed right

Not connected

K2 Gravity point to left

K3 Gravity point to right

K6 Hydralic pump left/right gable

K8 Retract telescope

K9 Extend telescope

Not connected

Not connected

Not connected

Not connected

Not connected

Not connected

Not connected

Container Counter

Not connected

Not connected

Not connected

-XPX1:31

-XPX1:41

-XPX1:43

-XPX1:42

-XPX1:3

-XPX1:2

-XPX1:11

-XPX1:1

-XPX1:26

-XPX1:16

-XPX1:6

-XPX1:7

-XPX1:4

-XPX1:5

-XPX1:25

-XPX1:15

-XPX1:10

-XPX1:20

-XPX1:30

-XPX1:40

-XPX1:46

-XPX1:47

-XPX1:49

-XPX1:48

CREATED: 12/15/2011 16:42


DESCRIPTION

PIN NR.

I/0 OVERVIEW

I/O

NODE

STOCKHOLM SWEDEN

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

-B1

NODE

48

47

46

45

44

43

42

41

40

39

38

37

36

35

34

33

30

29

28

27

26

25

I/O

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

Digital input

Digital input

Digital input

Digital input

Digital input

Digital input

Digital input

Digital input

Digital input

Digital input

Digital input

Digital input

Digital input

Digital input

Digital input

Digital input

Digital output

Digital output

Digital output

Digital output

Digital output

Digital output

TYPE

muhamaz 01/04/2005

15487

EH5U

-XPX3:20

-XPX3:50

-XPX3:9

-XPX3:7

-XPX3:46

-XPX3:47

-XPX3:48

-XPX3:49

-XPX3:26

-XPX3:25

-XPX3:16

-XPX3:6

-XPX3:2

-XPX3:3

-XPX3:4

-XPX3:5

-XPX3:35

-XPX3:24

-XPX3:42

-XPX3:41

-XPX3:31

-XPX3:21

PIN NR.

UNIT (+)

PLANT (=)

:

:

FILENAME:

12/15/2011

16:42

PLC diagram

BICT Indonesia PLOTTED:

G.p. auto return

Spreader stop

Not connected

Not connected

G.p. move to right CMD

G.p. move to left CMD

Twl unlock CMD

Twl lock CMD

Flipper landside down CMD

Flipper left down CMD

Flipper right down CMD

Flipper waterside down CMD

Flippers all up CMD

Telescope expand / to 40´ CMD

Telescope to 30' CMD

Telescope retract / to 20´ CMD

G.p. to rightsignal

G.p. to leftsignal



Unlocked signal

Locked signal

DESCRIPTION

DRAWING NO.

1043066

TOTAL SH.

CONT.

SHEET

REV.

24 40

23

Not connected

Not connected

-B1

CREATED: 12/15/2011 16:42

I/0 OVERVIEW

XP1


STOCKHOLM SWEDEN DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

muhamaz 01/04/2005

15487

EH5U

115/230VAC / Input yellow


MACHINE TYPE:



24VDC / Output red

UNIT (+)

PLANT (=)

XP3


115/230VAC / Output black

24VDC / Output red

XP2


24VDC / Output red


24VDC / Output red

24VDC / Output red



24VDC / Output red

24VDC / Output red


24VDC / Output red

24VDC / Output red


24VDC / Output red

24VDC / Output red


24VDC / Output red

24VDC / Output red 115/230VAC / Output black

CMD

CMD


CMD Twl unlock

Telescope to 30'

Twl lock

retract / to 20´ CMD

Telescope

CMD Flipper landside down CMD

left down

CMD Flipper waterside down CMD Flipper right down CMD Flipper

all up

:

:

FILENAME:

PLOTTED:

12/15/2011

16:42

I/O card overview

BICT Indonesia

24VDC / Input white

24VDC / Input white



G.p. auto return

Spreader stop

Not connected

Not connected

CMD G.p. move to right CMD

G.p. move to left

Telescope

expand / to 40´ CMD Flippers


Not connected

Not connected

G.p. to left signal

Container Counter

Not connected


Not connected

-HL7 Landed right


Not connected

G.p. to right signal

Unlocked signal

Not connected

Not connected

Locked signal

Not connected

Not connected

telescope

Extend

left/right gable K8 Retract telescope K9

K2 Gravity point to left K3 Gravity point to right K6 Hydralic pump

-HL6 Locked right

-HL5 Unlocked right


-HL3 Landed left

-HL2 Locked left

-HL1 Unlocked left

DRAWING NO.

1043066

TOTAL SH.

CONT.

SHEET

REV.

25 40

24

-S10 Landed left waterside

4

-S9 Landed left landside

4

-S2 Unlocked left waterside

4

-S1 Unlocked left landside

4

CREATED: 12/15/2011 16:42

I/0 OVERVIEW

-S5 Locked left landside

2

Connector 1

-S6 Locked left waterside

2

Connector 3

Spare

2

Connector 5

Spare

Connector 7

2

Pin

INPUTS

Module ID: 2

4

2

4

2

4

2

4

2

Pin

-Y7 Twistlock unlock left

-Y8 Twistlock lock left

Connector 2

-Y1 Flipper 1 up left landside

-Y2 Flipper 1 down left landside

Connector 4

-Y3 Flipper 2 up left waterside

-Y4 Flipper 2 down left waterside

Connector 6

-Y5 Flipper 5 up left centre

-Y6 Flipper 5 down left centre

Connector 8

OUTPUTS


Left gable end

-X2 INPUTS

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

-S3 Unlocked right waterside

-S7 Locked right waterside

Connector 1

-S4 Unlocked right landside

-S8 Locked right landside

Connector 3

-S11 Landed right waterside

Spare

Connector 5

-S12 Landed right landside

Spare

Connector 7

STOCKHOLM SWEDEN

4

2

4

2

4

2

4

2

Pin

CAN-Open I/O

EH5U

muhamaz 12/03/2004

15487

UNIT (+)

PLANT (=)

:

:

A1 X0

4

2

4

2

4

2

4

2

Pin

FILENAME:

12/15/2011

16:42

I/O card overview DRAWING NO.

TOTAL SH.

CONT.

SHEET

1043066

-Y15 Twistlock unlock right

-Y16 Twistlock lock right

Connector 2

-Y9 Flipper 3 up right waterside

-Y10 Flipper 3 down right waterside

Connector 4

-Y11 Flipper 4 up right landside

-Y12 Flipper 4 down right landside

Connector 6

-Y13 Flipper 6 up right centre

-Y14 Flipper 6 down right centre

Connector 8

OUTPUTS

BICT Indonesia PLOTTED:

Module ID: 3

Right gable end

-X3

REV.

26 40

25


4

-S13 20' telescope position

4

-S52 G.P tower left centre

4

-S54 G.P tower left stop

4

CREATED: 12/15/2011 16:42

I/0 OVERVIEW

-S55 GP tower right stop

2

Connector 1

-S53 G.P tower right centre

2

Connector 3


2

Connector 5


Connector 7

2

Pin

INPUTS

Module ID: 8

4

2

4

2

4

2

4

2

Pin

Spare

Spare

Connector 2

Spare

Spare

Connector 4

Spare

Spare

Connector 6

Spare

Spare

Connector 8

OUTPUTS


Centre landside

-X8

Connector 1

Connector 3

Connector 5

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

INPUTS Connector 7

STOCKHOLM SWEDEN

4

2

4

2

4

2

4

2

Pin

CAN-Open I/O

EH5U

muhamaz 01/04/2005

15487

UNIT (+)

PLANT (=)

:

:

A1 X0

Module ID:

FILENAME:

PLOTTED:

12/15/2011

16:42

I/O card overview DRAWING NO.

TOTAL SH.

CONT.

SHEET

1043066

Connector 2

Connector 4

Connector 6

Connector 8

OUTPUTS

BICT Indonesia

4

2

4

2

4

2

4

2

Pin

REV.

27 40

26

F

E

D

C

B

A

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

0

1

SIGN.

Distance between cable trunk and edge 45mm

1

DATE

15mm

2

2

30x90x115mm

3

2A

-P1

/5.09

-F2

10A

/7.02

/5.09

-QM6

/6.02

733mm

-F1

-K6

/10.03

XP2


40mm

Power supply

G1

X1

XP1

290mm

4

5

4

-K8

/10.04

STOCKHOLM SWEDEN

-EH1

-QM7

/6.04

30x90x640mm

XP3

5

-K1

/7.01

-K2

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

-QM1

/5.07

6

muhamaz 11/02/2001

15487

EH5U

/10.01

MACHINE TYPE:

60x90x520mm

-KA1

/7.07

30x90x490mm

-QM8

/5.04

6

B1

Internal layout X1 cabinet EH5U

3

30x90x380mm

UNIT (+)

PLANT (=)

X2

:

:

-P2

A1 X1

/11.05

7

7

FILENAME:

PLOTTED:

12/15/2011

8

16:42

BICT Indonesia Cabinet layout

740mm

8

DRAWING NO.

9

1043066

TOTAL SH.

CONT.

SHEET

Rubber boot

9

REV.

28 F 40

27

E

D

C

B

A

F

E

D

C

B

A

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

0

1

1

SIGN.

DATE

2

2

5 1

3

4

-

5 -

PG36

4

7

M25

3

-

M25

2

6

PG11

GLANDS

1


6

4

5

6

STOCKHOLM SWEDEN

XP23

XP22

XP21

WXP1

WM1

Plug

EEPROM

CABLE

5

3

2

.

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

4

7

6

muhamaz 05/16/2002

15487

EH5U

External cable connection X1 cabinet / EH5U

3

UNIT (+)

PLANT (=)

:

:

A1 X0 7

7

FILENAME:

PLOTTED:

12/15/2011

8

16:42

DRAWING NO.

BICT Indonesia Cable/ Sensor Layout

8

9

1043066

TOTAL SH.

CONT.

SHEET

9

REV.

29 F 40

28

E

D

C

B

A

SUBJECT OF CHANGE

F

E

D

ITEM

-

-

-

0

1

SS1

SB1

SIGN.

DATE

2


4

4

STOCKHOLM SWEDEN

5

5

MACHINE TYPE:

EH5U

6

PLANT (=)

:

A1 X1 7

7

3

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

6

muhamaz 09/02/2002

15487

UNIT (+)

:

FILENAME:

PLOTTED:

12/15/2011

8

16:42

BICT Indonesia Cabinet layout

GORETEX VENT PLUG 700984, 700985 Assembly from the outside

8

DRAWING NO.

SHEET

9

29

A

9

1043066

TOTAL SH.

CONT.

REV.

30 F 40

E

D

C

-

3

C

Q1

2

B

GORETEX VENT PLUG 700984, 700985 Assembly from the outside

1

B

A

0

F

E

D

C

B

A

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

0

1

15

1

SIGN.

DATE

2

2

4

5

6

8

2

3


M16

8

M16

5

M16

M16

4

7

M16

3

M16

M16

2

6

M16

1

GLAND

1

PLUG

PLUG

CABLE

10

4

4

WX2

WM4

WM3

WM2

5

M16 M32 M25

15 16

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

WHL1

M16

13 14

WM5

M16

12

6

muhamaz 11/17/2004

15487

EH5U

WXP21

WXP23

WHL2

WXP22

WX8

WX3

CABLE

M16

14

11

MACHINE TYPE:

13

7

M16

M16

GLAND

12

6

10

9

11

5

STOCKHOLM SWEDEN

WX13 (OPTION)

WX10 (OPTION)

9

3

External cable connection X100 cabinet / EH5U

3

UNIT (+)

PLANT (=)

:

:

A1 X0 7

7

FILENAME:

PLOTTED:

12/15/2011

8

16:42

DRAWING NO.


16

8

9

1043066

TOTAL SH.

CONT.

SHEET

9

REV.

31 F 40

30

E

D

C

B

A

F

E

D

C

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

1

SIGN.

DATE

Sheild CANopen cable

Terminal fuses Marking 1,2,......7.

2

5

3


Shield plate

4

5

Terminal 24V GND Marking 1,2,......7

STOCKHOLM SWEDEN

Terminal Canopen Low Marking 1,2,......7

Terminal CANopen High Marking 1,2,......7

Cabinet X100

4

6

PLANT (=)

:

A1 X0 7

7

Terminals for -M,-HL. Marking 1,2,3......19.

8

SHEET

9

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

EH5U

6

muhamaz 01/27/2009

15487

UNIT (+)

:

FILENAME:

PLOTTED:

12/15/2011

8

16:42

DRAWING NO.


9

1043066

TOTAL SH.

CONT.

31

REV.

32 F 40

E

D

C

B

3

B

2

A

1

A

0

F

E

D

C

B

A

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

0

1

1

XP22

SIGN.

DATE

WXP22 Part no. 1001863

3



2

3

4

5

6

4

STOCKHOLM SWEDEN

5

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

6

muhamaz 06/12/2002

15487

EH5U


UNIT (+)

PLANT (=)

External cable connection between X1, X100 cabinet / EH5U

CABINET X1

2

XP23

XP21

:

:

A1 X0 7

8

FILENAME:

PLOTTED:

12/15/2011

8

16:42

DRAWING NO.


CABINET X100

7

9

1043066

TOTAL SH.

CONT.

SHEET

9

REV.

33 F 40

32

E

D

C

B

A

F

E

D

C

B

A

ITEM

-

-

-

-

0

SUBJECT OF CHANGE

LEFT

5 WHITE BLUE

Y1-Y2 FLIPPER1 Y3-Y4 FLIPPER2 Y5-Y6 FLIPPER5 Y7-Y8 TWISTLOCK

0

1

1 RED

2 GREEN

1

SIGN.

DATE

S1 UNLOCK S5 LOCK S9 LANDED

M2

X2


2

M4

S13 20' POS.

S14, S114 30' POS.

M1

3


X8

4

STOCKHOLM SWEDEN

5

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

S53 TOWER RIGHT CENTRE

6

6

muhamaz 08/20/2002

15487

7

UNIT (+)

:

:

A1 X0 7

8

FILENAME:

PLOTTED:

12/15/2011

8

16:42

DRAWING NO.

9

1043066

TOTAL SH.

CONT.

SHEET

RIGHT

4 RED

9

E

D

C

B

A

34 F 40

33

REV.

Y9-Y10 FLIPPER3 Y11-Y12 FLIPPER4 Y13-Y14 FLIPPER6 Y15-Y16 TWISTLOCK

6 YELLOW BLACK

3 GREEN

BICT Indonesia Spreader layout


X3

M3


HL8 = YELLOW HL7 = WHITE HL6 = RED HL5 = GREEN

PLANT (=)

S55 TOWER STOP RIGHT

B1

EH5U

S16 40' POS.

X1 CABINET

WATERSIDE

XP1

5

LANDSIDE

4

S52 TOWER LEFT CENTRE

X100 CABINET

3

S54 TOWER STOP LEFT

HL1 = GREEN HL2 = RED HL3 = WHITE HL4 = YELLOW

2

-S114

-X2

-X3

-X8

-X8

-XP1

X0

X0

X0

X0

X0

X0

=A1+X0/16.03

=A1+X0/18.01

=A1+X0/18.03

=A1+X0/16.02

=A1+X0/16.04

=A1+X0/18.02

=A1+X0/18.04

=A1+X0/16.05

=A1+X0/16.07

=A1+X0/18.05

=A1+X0/18.07

=A1+X0/20.05

=A1+X0/20.07

=A1+X0/20.06

=A1+X0/20.03

=A1+X0/20.04

=A1+X0/20.01

=A1+X0/20.02

=A1+X0/20.08

=A1+X0/16.00

=A1+X0/18.00

=A1+X0/20.00

=A1+X0/20.00

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

Part list

1

=A1+X0/16.01

=A1+X1/6.03

1

1

=A1+X1/6.03

1

1

=A1+X1/6.03

2

=A1+X0/18.09

=A1+X1/6.03

1

1

=A1+X1/6.04

1

=A1+X1/6.03

=A1+X1/5.04

1

=A1+X0/16.09

=A1+X1/5.04

1

1

=A1+X1/5.08

1

1

=A1+X1/5.08

1

70592

1001762

79282

1001762

1001762

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1034213

1002390

1002390

1002607

1002490

1002520

1002018

1002595

1018972

79125

700026

700026

79125

QTY DIAGRAM REF BROMMA No.

CREATED: 12/15/2011 16:42

-S55

X0

-S8

X0

-S54

-S7

X0

X0

-S6

X0

-S53

-S5

X0

-S52

-S4

X0

X0

-S3

X0

X0

-S2

X0

-S16

-S1

X0

X0

-R3

X0

-S14

-R2

X0

X0

-HINK_X0

X0

-S13

-HINK_X0

X0

X0

-HINK_X0

X0

-S12

-HINK_X0

X0

X0

-HINK_X0

X0

-S11

-CABINET_X100

X0

X0

-BRAKE2

X0

-S9

-BRAKE2

X0

-S10

-BRAKE1

X0

X0

-BRAKE1

X0

X0

ITEM

UNIT


PLUG ODU 309 LOCK RING

IFM MODULE CAN-OPEN

GLAND PLUG

IFM MODULE CAN-OPEN

IFM MODULE CAN-OPEN

PROXIMITY SWITCH M30 F




















RESISTOR 120ohm 0,25W

RESISTOR 120ohm 0,25W

CABLE AND ITEM MARKING

X1 cabinet EH5 ASSY

PROTECTION COVER HTS

PROTECTION COVER HTS

CABLE AND ITEM MARKING

CABINET X100 CANopen

CURRENT RELAY SR15

GLAND ADAPTER

GLAND ADAPTER

CURRENT RELAY SR15

DENOMINATION

ODU

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

GUNNAR PETTERSON AB

IFM-Electronic

MILTRONIC AB

IFM-Electronic

IFM-Electronic

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

Elfa

Elfa

MILTRONIC

BROMMA

ABB

ABB

MILTRONIC

SEW

MILTRONIC AB

MILTRONIC AB

SEW

SUPPLIER

STOCKHOLM SWEDEN

IFM-Electronic

MURR

IFM-Electronic

IFM-Electronic

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

IFM

Elfa

Elfa

FLEXIMARK

ABB

ABB

FLEXIMARK

Bromma

SEW

LAPP

LAPP

SEW

MANUFACTURE

SR15

muhamaz 10/03/2001

15487

EH5U

UNIT (+)

PLANT (=)

309 021 018 200 000

CR9011

ZVKM12

CR9011

CR9011

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

60-103-83

60-103-83

5DLN296350-C

5DLN296350-A

1018972

SR15

12 67 42

12 67 42

:

:

FILENAME:

PLOTTED:

12/15/2011

16:42

SIZE1

SIZE4

END BEAM 3-FLIPPER

Mobile Spreader 10 fuse

BSR 150-500VAC M25

SKINDICHT M32/M25

SKINDICHT M32/M25

BSR 150-500VAC M25

DRAWING NO.

1043066

TOTAL SH.

CONT.

SHEET

35 40

34

REV.

309 021 018 200 000

8 in / 8 out

ASB BOX PLUGS M12

8 in / 8 out

8 in / 8 out

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

M30 SN:15 10-36VDC M12 3WIRE

TOWER JIB

Complete with SCS² for CAN open

Parts list: (79125 - 70592)

BICT Indonesia

309 021 018 200 000

CR9011

40 57 05

CR9011

CR9011

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

II5945

60-103-83

60-103-83

1002490

5DLN296350-C

5DLN296350-A

1018972

8267626

12 67 42

12 67 42

8267626

TYPE / ARTICLE NUMBER / TECHNICAL DATA

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

X0

X0

X0

X0

X0

X0

73272

71480

74410

75618

73983

1

1

1

1

2

Part list

1028417

1

QTY DIAGRAM REF BROMMA No.

CREATED: 12/15/2011 16:42

ITEM

UNIT


CRIMPING HOSE

SHRINK HOUSE 85/25

INSERT 37P (M) ODU

PLUG ODU 309

GLAND SR PG42 32-35mm

COVER FOR ODU 309 PLUG

DENOMINATION

NELCO

NELCO CONTACT

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

GUNNAR PETTERSON AB

GUNNAR PETTERSON AB

MILTRONIC AB

ODU

SUPPLIER

STOCKHOLM SWEDEN

NELCO CONTACT

ODU

ODU

LAPP

ODU

MANUFACTURE

muhamaz 01/28/2009

15487

EH5U

UNIT (+)

PLANT (=)

:

:

MWTM-85/25-1000/172

309 803 150 037 151

309.021.000.554

SKINDICHT-SR 42/35

309.097.002.924.000

FILENAME:

PLOTTED:

12/15/2011

16:42

for Plug 309.021

1043066

TOTAL SH.

CONT.

SHEET

36 40

35

REV.

ODU 309 37 POL MALE

EXCL.Lock ring IP56 PG42

DRAWING NO.

Parts list: (1028417 - 73983)

BICT Indonesia

309 803 150 037 151

309.021.000.554

12 02 35

309.097.002.924.000

TYPE / ARTICLE NUMBER / TECHNICAL DATA

-M2

-M2

-M3

-M3

-M3

-M3

-M4

-M4

-M4

X0

X0

X0

X0

X0

X0

X0

X0

X0

Cable list

4

4

4

4

4

4

4

PE

W

V

U

PE

W

V

U

PE

W

V

U

PE

W

V

U

1

1

1

1

2

1

1

1

1

2

PIN No.

-WS2-S6

-WS1-S5

-WS1-S5

-WS12

-WS11

-WS10

-WS9

-WM4

-WM4

-WM4

-WM4

-WM3

-WM3

-WM3

-WM3

-WM2

-WM2

-WM2

-WM2

-WM1

-WM1

-WM1

-WM1

-WHL 5-8

-WHL 5-8

-WHL 5-8

-WHL 5-8

-WHL 5-8

-WHL 1-4

-WHL 1-4

-WHL 1-4

-WHL 1-4

-WHL 1-4

CABLE

CREATED: 12/15/2011 16:42

-S2

-M2

X0

-S5

-M2

X0

X0

-M1

X0

X0

-M1

X0

-S1

-M1

X0

-XP7

-M1

X0

X0

-HL8

X0

X3

-HL7

X0

-XP5

-HL6

X0

-XP7

-HL5

X0

X3

-HL5

X0

X2

-HL4

X0

-M4

-HL3

X0

-XP5

-HL2

X0

X2

-HL1

X0

X0

-HL1

X0

FROM

A

2

4

4

4

4

4

PE

3

2

1

PE

3

2

1

PE

3

2

1

PE

3

2

1

5

4

3

2

1

5

4

3

2

1

CORE

CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CONNECTOR 2,5M CABLE CONNECTOR 1,5M CABLE CONNECTOR 2,5M CABLE CONNECTOR 1,5M CABLE CONNECTOR 2,5M CABLE CONNECTOR 2,5M CABLE CONNECTOR 2,0m

-X2 :1 -X2 :2 -X2 :3 -X2 :PE -X2 :4 -X2 :5 -X2 :6 -X2 :PE -X2 :7 -X2 :8 -X2 :9 -X2 :PE -S9 4 -S10 4 -S11 4 -S12 4

-XP1 4 -XP1 2 -XP3 4

STOCKHOLM SWEDEN

CABLE

-X2 :PE

LED LAMPS

-X2 :19

CABLE

LED LAMPS

-X2 :18

CABLE

LED LAMPS

-X2 :17

-X2 :3

LED LAMPS

-X1 :14

-X2 :2

LED LAMPS

-X2 :16

LED LAMPS

LED LAMPS

-X2 :15

CABLE

LED LAMPS

-X2 :14

-X2 :1

LED LAMPS

-X2 :13

-X2 :16

LED LAMPS

-X1 :14

TERMINAL No.


X2

X2

X2

X0

X0

X0

X0

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X1

X1

X1

X1

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

TO

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

TYPE

EH5U

muhamaz 01/24/2002

15487

UNIT (+)

PLANT (=)

:

:

1023804

1023805

1023805

79292

79294

79292

79294

78173

78173

78173

78173

78173

78173

78173

78173

78173

78173

78173

78173

70996

70996

70996

70996

1001883

1001883

1001883

1001883

1001883

1001883

1001883

1001883

1001883

1001883

FILENAME:

PLOTTED:

12/15/2011

16:42

CABLE LIST

BICT Indonesia

M12 Twin cable Prox.



M12 2xANGLE

M12 2xANGLE

M12 2xANGLE

M12 2xANGLE

4x1,5mm² PUR

4x1,5mm² PUR

4x1,5mm² PUR

4x1,5mm² PUR

4x1,5mm² PUR

4x1,5mm² PUR

4x1,5mm² PUR

4x1,5mm² PUR

4x1,5mm² PUR

4x1,5mm² PUR

4x1,5mm² PUR

4x1,5mm² PUR

4x2,5mm² PUR

4x2,5mm² PUR

4x2,5mm² PUR

4x2,5mm² PUR

24VDC, GN, RD, WH,YE










=A1+X0/16.03

1043066

TOTAL SH.

CONT.

REV.

37 40

36

=A1+X0/16.02

1

SHEET

=A1+X0/16.01

=A1+X1/6.04

1

=A1+X1/6.04 11

=A1+X0/18.07

=A1+X1/6.04 11

1

=A1+X1/6.02 11

=A1+X0/18.05

=A1+X1/6.02 12

1

=A1+X1/6.02 12

=A1+X0/16.07

=A1+X1/6.02 12

1

=A1+X1/5.07 12

=A1+X0/16.05

=A1+X1/5.07

3

1

=A1+X1/5.07

3

=A1+X1/5.04

=A1+X1/5.07

3

1

=A1+X1/9.08

3

=A1+X1/5.04

=A1+X1/9.07

1

3

=A1+X1/9.06

1

=A1+X1/5.04

=A1+X1/9.05

1

3

=A1+X1/8.07

1

3

=A1+X1/9.04

1

=A1+X1/6.04

=A1+X1/9.03

1

=A1+X1/5.04

=A1+X1/9.02

1

3

=A1+X1/9.01

1

11

=A1+X1/8.07

1

SHEET

1

QTY

DRAWING NO.

ART. NR.

-S53

-S54

-S55

-X0

-X0

-X0

-X0

-X0

-X0

-X0

-X0

-X0

-X0

-X0

-X0

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

X0

X0

X2

X2

X2

X2

X3

X3

X3

X3

X8

X8

X8

X8

X0

X0

X0

X0

X0

X0

X0

X0

Cable list

8

7

6

5

32

2

31

1

:3

:5

:2

:1

:3

:5

:2

:1

:3

:5

:2

:1

4

4

4

4

4

4

4

4

4

4

4

4

4

PIN No.

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WX8

-WX8

-WX8

-WX8

-WX3

-WX3

-WX3

-WX3

-WX2

-WX2

-WX2

-WX2

-WS54-S55

-WS54-S55

-WS52-S53

-WS52-S53

-WS14-S114

-WS14-S114

-WS13-S16

-WS13-S16

-WS4-S8

-WS4-S8

-WS3-S7

-WS3-S7

-WS2-S6

CABLE

CREATED: 12/15/2011 16:42

-S52

-S16

X0

X0

-S13

X0

X0

-S8

X0

-S14

-S4

X0

-S114

-S7

X0

X0

-S3

X0

X0

-S6

X0

FROM

8

7

6

5

4

2

2

1

blue

red

brown

white

blue

red

brown

white

blue

red

brown

white

2

4

2

4

2

4

2

4

B

A

2

4

B

CORE

CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE

-X1 :2 -X1 :9 -X1 :19 -X1 :26 -X1 :5 -X1 :12 -X2 :L1 -X2 :L1 -X2 :L2 -X2 :L2 -X2 :106 -X2 :107 -X2 :108 -X2 :117

STOCKHOLM SWEDEN

CABLE CONNECTOR 3,5M

-XP1 2

CABLE


-XP1 4

CABLE


-XP3 2

-X1 :23


-XP3 4

-X1 :16


-XP7 2

CABLE


-XP7 4

CABLE


-XP5 2

-X1 :8


-XP5 4

-X1 :1

CABLE CONNECTOR 2,0m

-XP3 2

CABLE


-XP3 4

CABLE


-XP1 2

-X1 :22


-XP1 4

-X1 :15


-XP3 2

TERMINAL No.


X1

X1

X1

X1

X1

X1

X1

X1

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X8

X8

X8

X8

X8

X8

X8

X8

X3

X3

X3

X3

X2

TO

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

TYPE

EH5U

muhamaz 05/16/2002

15487

UNIT (+)

PLANT (=)

:

:

701222

701222

701222

701222

701222

701222

701222

701222

1001860

1001860

1001860

1001860

1001860

1001860

1001860

1001860

1001860

1001860

1001860

1001860

1023807

1023807

1023805

1023805

1023802

1023802

1023807

1023807

1023804

1023804

1023805

1023805

1023804

FILENAME:

PLOTTED:

12/15/2011

16:42

CABLE LIST

BICT Indonesia

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

Can-Open 3x2x0,25 + 3x1.0












M12 Twin cable prox.













=A1+X0/18.02 =A1+X0/18.03 =A1+X0/18.04 =A1+X0/20.05 =A1+X0/20.06 =A1+X0/20.07 =A1+X0/20.08 =A1+X0/20.03 =A1+X0/20.04 =A1+X0/20.01 =A1+X0/20.02 =A1+X1/8.01 =A1+X1/8.01 =A1+X1/8.00 =A1+X1/8.01 =A1+X1/8.02 =A1+X1/8.02 =A1+X1/8.01 =A1+X1/8.02 =A1+X1/8.05 =A1+X1/8.05 =A1+X1/8.04 =A1+X1/8.05 =A1+X1/5.00 =A1+X1/5.01 =A1+X1/5.01 =A1+X1/5.01 =A1+X1/7.02 =A1+X1/7.01 =A1+X1/7.02 =A1+X1/13.01

1 1 1 1 1 1 1 1 1 1 12 12 12 12 11 11 11 11

3 3 3 3 7 7 7 7 7 7 7 7

1043066

TOTAL SH.

CONT.

REV.

38 40

37

=A1+X0/18.01

1

SHEET

=A1+X0/16.04

1

SHEET

1

QTY

DRAWING NO.

ART. NR.

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP1

-XP21

-XP21

-XP21

-XP21

-XP21

-XP21

-XP21

-XP21

-XP21

-XP21

-XP22

-XP22

-XP23

-XP23

X0

X0

X0

X0

X0

X0

X0

X0

X0

X0

X0

X0

X0

X0

X0

X0

X0

X0

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

Cable list

2

1

3

2

9

8

7

6

10

5

4

3

2

1

37

33

34

4

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

PIN No.

-WXP23

-WXP23

-WXP22

-WXP22

-WXP21

-WXP21

-WXP21

-WXP21

-WXP21

-WXP21

-WXP21

-WXP21

-WXP21

-WXP21

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

-WXP1

CABLE

CREATED: 12/15/2011 16:42

-XP1

X0

FROM

2

1

Brown

White

10

9

8

7

6

5

4

3

2

1

PE

33

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

CORE

CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE 10POL CONTACT-OPEN END CABLE 10POL CONTACT-OPEN END CABLE 10POL CONTACT-OPEN END CABLE 10POL CONTACT-OPEN END CABLE 10POL CONTACT-OPEN END CABLE 10POL CONTACT-OPEN END CABLE 10POL CONTACT-OPEN END CABLE 10POL CONTACT-OPEN END CABLE 10POL CONTACT-OPEN END CABLE 10POL CONTACT-OPEN END CABLE 7POL CONTACT-OPEN END CABLE 7POL CONTACT-OPEN END CABLE 42POL HTS CONTACT-OPEN END CABLE 42POL HTS CONTACT-OPEN END

-X2 :121 -X2 :122 -X2 :123 -X2 :124 -X2 :125 -X2 :126 -X2 :109 -X2 :110 -X2 :127 -X2 :128 -X2 :112 -X2 :111 -X2 :118 -X2 :L3 -X2 :L3 -X2 :PE -X2 :PE -X1 :7 -X1 :7 -X1 :7 -X1 :7 -X1 :7 -X1 :14 -X1 :14 -X1 :14 -X1 :14 -X1 :14 -X1 :15 -X1 :22 -X2 :1 -X2 :2

STOCKHOLM SWEDEN

CABLE

-X2 :120

TYPE

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

CABLE

-X2 :119

TERMINAL No.


X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

TO

EH5U

muhamaz 09/14/2004

15487

UNIT (+)

PLANT (=)

:

:

1001865

1001865

1001863

1001863

1001864

1001864

1001864

1001864

1001864

1001864

1001864

1001864

1001864

1001864

701222

701222

701222

701222

701222

701222

701222

701222

701222

701222

701222

701222

701222

701222

701222

701222

701222

701222

701222

FILENAME:

PLOTTED:

12/15/2011

16:42

CABLE LIST

BICT Indonesia

25x1,5mm² PUR

25x1,5mm² PUR

3X2X0,25+3X1,0 + gn/yn

3X2X0,25+3X1,0 + gn/yn

12x2,5mm² PUR

12x2,5mm² PUR

12x2,5mm² PUR

12x2,5mm² PUR

12x2,5mm² PUR

12x2,5mm² PUR

12x2,5mm² PUR

12x2,5mm² PUR

12x2,5mm² PUR

12x2,5mm² PUR

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX

37x2,5mm² NEOFLEX


7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1043066

TOTAL SH.

CONT.

REV.

39 40

38

=A1+X1/13.04

7

SHEET

=A1+X1/13.03

7

SHEET

7

QTY

DRAWING NO.

ART. NR.

-XP23

-XP23

-XP23

-XP23

-XP23

-XP23

-XP23

-XP23

-XP23

-XP23

-XP23

-XP23

-XP23

-XP23

-Y2

-Y1

-Y4

-Y3

-Y6

-Y5

-Y8

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X0

X0

X0

X0

X0

X0

X0

-Y11

-Y14

-Y13

-Y16

X0

X0

X0

X0

X0

Cable list

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

PE

22

21

20

19

18

17

16

15

14

13

9

8

7

6

5

4

3

PIN No.

-WY15-Y16

-WY13-Y14

-WY13-Y14

-WY11-Y12

-WY11-Y12

-WY9-Y10

-WY9-Y10

-WY7-Y8

-WY7-Y8

-WY5-Y6

-WY5-Y6

-WY3-Y4

-WY3-Y4

-WY1-Y2

-WY1-Y2

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

-WXP23

CABLE

CREATED: 12/15/2011 16:42

-Y9

-Y12

X0

-Y7

-XP23

X1

-Y10

-XP23

X1

X0

-XP23

X1

X0

-XP23

X1

FROM

B

A

B

A

B

A

B

A

B

A

B

A

B

A

B

PE

22

21

20

19

18

17

16

15

14

13

9

8

7

6

5

4

3

CORE

CABLE 42POL HTS CONTACT-OPEN END CABLE 42POL HTS CONTACT-OPEN END CABLE 42POL HTS CONTACT-OPEN END

-X2 :16 -X2 :17 -X2 :18

CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M CABLE CONNECTOR 0,6M

-XP4 4 -XP6 2 -XP6 4 -XP8 2 -XP8 4 -XP2 2 -XP2 4 -XP4 2 -XP4 4 -XP6 2 -XP6 4 -XP8 2 -XP8 4 -XP2 2

STOCKHOLM SWEDEN


-XP4 2

TYPE

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

CABLE 42POL HTS CONTACT-OPEN END


-X2 :15

-X2 :PE


-X2 :14



-X2 :13



-X2 :9

-X2 :PE


-X2 :8

-X2 :PE


-X2 :7



-X2 :6



-X2 :5

-X2 :PE


-X2 :4

-X2 :19


-X2 :3

TERMINAL No.


X3

X3

X3

X3

X3

X3

X3

X2

X2

X2

X2

X2

X2

X2

X2

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

X100

TO

EH5U

muhamaz 09/14/2004

15487

UNIT (+)

PLANT (=)

:

:

700970

700970

700970

700970

700970

700970

700970

700970

700970

700970

700970

700970

700970

700970

700970

1001865

1001865

1001865

1001865

1001865

1001865

1001865

1001865

1001865

1001865

1001865

1001865

1001865

1001865

1001865

1001865

1001865

1001865

FILENAME:

PLOTTED:

12/15/2011

16:42

CABLE LIST

BICT Indonesia

M12 Ang Twin suppress 24VDC















25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR

25x1,5mm² PUR


1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1043066

TOTAL SH.

CONT.

REV.

40 40

39

=A1+X1/6.04

1

SHEET

=A1+X1/6.02

1

SHEET

1

QTY

DRAWING NO.

ART. NR.

:10

:9

:39

:50

:20

-XPX2

-XPX2

-XPX2

-XPX2

-XPX2

-E2

B1

B1

B1

B1

B1

X0

-WXP22

-WXP22

-WXP22

-KEY1

-KEY1

-KEY1

-WY15-Y16

CABLE

CREATED: 12/15/2011 16:42

Cable list

1

-Y15

PIN No.

X0

FROM

Sheild

brown

white

GN

BN

WH

A

CORE

CABLE CABLE

-XP22 2 -XP22 3

STOCKHOLM SWEDEN

IDENTIFICATION KEY FOR SCS²

-XPX2 :49

CABLE


-WXP22


-XPX2 :39


-XPX2 :9

-XP2 4

TERMINAL No.


X1

X1

X1

B1

B1

B1

X3

TO

DRAWING DATE:

DRAWN BY:

CHECKED BY:

SERIAL NO.

MACHINE TYPE:

TYPE

EH5U

muhamaz 09/14/2004

15487

UNIT (+)

PLANT (=)

:

:

1001860

1001860

1001860

38905

38905

38905

700970

FILENAME:

PLOTTED:

12/15/2011

16:42

CABLE LIST

BICT Indonesia





=A1+X1/15.04 =A1+X1/15.04 =A1+X1/15.06 =A1+X1/15.06 =A1+X1/15.06

1 1 1 1

1043066

TOTAL SH.

CONT.

REV.

40

40

=A1+X1/15.03

1

SHEET

=A1+X0/19.01

1

SHEET

1

QTY

DRAWING NO.

ART. NR.

GETTING STARTED WITH

SCS²

1

REV 3

Index Node Hardware ............................................................................................................... 4 DIGITAL I/O ................................................................................................................................................ 4

General............................................................................................................................ 4 The X2 connector............................................................................................................ 5 Node ID....................................................................................................................... 5 Main Supply................................................................................................................ 6 CAN ............................................................................................................................ 6 The X1 and X3 connectors (I/O-connectors).................................................................. 7 I/O Groups .................................................................................................................. 7 Common junction........................................................................................................ 8 Internal jumper bars .................................................................................................... 8 Connecting a switch.................................................................................................... 9 Connecting a valve...................................................................................................... 9 I/O Modules .............................................................................................................. 10 APPLICATION .......................................................................................................................................... 10

ABE (Application Builder Environment) ................................................................................... 10 System view .............................................................................................................. 10 Pin configuration....................................................................................................... 11 Component view ....................................................................................................... 11 Load view.................................................................................................................. 14 ANYBUS ..................................................................................................................................................... 15

General.......................................................................................................................... 15 Connecting the B1 node............................................................................................ 15 Connecting the A1 node............................................................................................ 16 The Anybus card (in this case for Profibus) ............................................................. 16 APPLICATION WITH A ANYBUS INTERFACE ................................................................................ 18

ABE............................................................................................................................... 18 ANYBUS GATEWAY................................................................................................................................ 20

General.......................................................................................................................... 20 BCAN - Status LEDs ................................................................................................ 21 Power connector........................................................................................................ 21 BCAN connector....................................................................................................... 21 Node address key switches ....................................................................................... 21 Serial port connector ................................................................................................. 21 APS .............................................................................................................................................................. 22

Absolute encoder on the telescope................................................................................ 22 General...................................................................................................................... 22 The RS485 component.............................................................................................. 22 From bits to millimetres (scale) ................................................................................ 23

2

REV 3

Teach......................................................................................................................... 23 EXTERNAL EE-PROM ............................................................................................................................ 24

General...................................................................................................................... 24 Hardware................................................................................................................... 24 Software .................................................................................................................... 25 Activate the EE-prom ............................................................................................... 26

3

REV 3

Node Hardware Below is a picture of a SCS2 node.

X2- I/O, bus & supply Connector

X1- I/O Connector

X3- I/O Connector

I/O LED 1-48

Field bus

RS232 (X5)

Digital I/O General Here follows an example of how to build up a Can bus system with two nodes one with one input and the other with one output. Switch Input Slave (A1)

SCS2

CAN network (BCAN)

B1 Master Output

Valve

4

REV 3

Display & Power LEDS

The X2 connector The three connectors X1,X2&X3 have different connection keys to avoid the possibility of connecting them in the wrong place. It is important to choose the correct one.This is easy to check, on the connecting side of the connector just below the mounting screw there is a number 7, 8 or 9. connection key

The X2 should be marked “8” Front view of X2 connector

Node ID All nodes in a system must have a unique identity. This is read from the Id pins 9,19,29,39,49 on the X2 connector, where pins being connected to the ground pin (10) correspond to ”zeroes” and pins left unconnected are correspond to ”ones”. A master node (B1) has pins 10,9,19,29,49 connected together. (Commonly used as a spreader Node) A slave node on the crane A1 has pins 10,19,29,39,49 connected together. Start with making “ID” jumpers.

And connect to the X2 connectors, one as B1 and one as A1.

5

REV 3

Main Supply 24Volt AC or DC powers the node internally. The signals are doubled in the connector due to the current limit of single pins. DC voltage can be applied in either direction. The potential is measured between the A section and the B section. Name Pin number in connector 24INA X2/42 Potential 1 24INA X2/43 24INB X2/45 Potential 2 24INB X2/44

CAN The CAN net connection is placed in the X2 connector. All nodes in the system have to be connected equal (bus topology) to CAN High and CAN Low to be able to establish communication. Name Pin number in connector CAN High X2/30 CAN Low X2/40 Here is a schematic with the X2 connectors of two nodes, one A1 and one B1 with node id, CAN bus and power supply connected. ID SUPPLY CAN BUS + -

24V Supply Low

CAN Bus High ID 9 10 19 29

30 40 42 43 44 45 49

10 19 29

B1 X2

30 39 40 42 43 44

45 49

A1 X2 Pin no.

CAN-bus

24V SUPPLY

6

REV 3

The X1 and X3 connectors (I/O-connectors) Just like the X2 connector the X1 and X3 connectors are keyed to avoid connecting them in the wrong place. The X1 can be identified by the number “7” on the front of the connector, and the X3 connector by the number “9”. connection key

Front view of X1 connector


I/O Groups There are 48 digital I/O on a node. Each I/O can be configured as either an input or an output via the software. The I/O 1 to 44 are joined in groups of 4 resulting in 11 groups. I/O 45 to 48 are single I/O’s. Each group has a “Common” junction. This makes it possible to have different voltages in each group. Name

Description

X1 pin number

I/O-9 I/O-10 I/O-11 I/O-12 Common/Supply 3

General purpose input or output General purpose input or output General purpose input or output General purpose input or output Common junction for I/O-9 to I/O-12 Description

26 16 6 7 8

Name

I/O-48 General purpose input or output Common/Supply 15 Common junction for I/O-48

7

X3 pin number

30 20

REV 3

Common junction This point is to be connected to live or neutral depending on if the group is used for inputs or outputs, Inputs need neutral and outputs need live as showed below. Inputs can be viewed upon as relay coils and outputs as switching contacts.

G roup used as O utput

G roup used as Input L/24V D C N / 0V D C

SC S 9

8

26

10

16

11

6

12

9

7

8

26

SC S 10 SC S 11

16

6

12

7

I/O M oduls

In the picture is one I/O group used as inputs on the left, and on the right the same group is used as outputs.

Internal jumper bars To make linking of common supplies easier the X1 and the X3 connector also has groups of pins linked together to be used basically as jumper bars with the same potential. The following pins are linked together internally for the purpose of feeding switches/valves with common potential. Pin number

Link configuration

Pin number

12 13 14 22 23 32 33 34

17 18 19 27 28 29 37 39 38

(Only in X1) 45

(Only in X1) 36

(Only in X1)

24

8

Link configuration

REV 3

Connecting a switch Here is one example of how to use the internal jumpers while connecting the switch into A1. One of the jumper groups is fed with live and supplies the switch, the other jumper group is connected to neutral and supplies the I/O group. L/24V Supply N/0V Supply

Internal jumper groups

Switch

Cablage 6

7

8 12 13 1 4

16 17 18 19

22 23 24 26

27

X1 Connector

11 12 10

One Input group

9

SCS Internal

Connecting a valve Here is one example of how to use the internal jumpers while connecting the valve into B1. One of the jumper groups is connected to Neutral and supplies the valves secondary side, the other jumper group is connected to live and supplies the I/O group. L/24V Supply N /0V Supply

Internal jumper groups

Valve

Cablage 6

7

11 12

8 12 13 1 4

16 17 18 19

10

22 23 24 26

One output group

9

9

27

X1 Connector

SCS² Internal

REV 3

I/O Modules To be able to adapt the I/Os to the system voltage each I/O channel have a solid-state interface relay (OPTO 22). This makes it possible to choose input or output and a voltage range of 12-230 VAC/DC. Each module has a led indicating active state. On the output modules there is a 3 Amp fuse. These modules are located inside the SCS² cover. The cover has a lens for each channel, so the I/O status can be seen from the outside.

LED FUSE

Application ABE (Application Builder Environment) System view When ABE is started a new application is automatically started, and the default view is the system view. The system view enables the user to select a node configuration in the software, the application compares the hardware with the software configurations and these have to be equal to work. You may also set system properties in this view. Some properties will be updated automatically when a project is saved.

In the system view we have to activate the A1 node in the soft ware. The B1 is the master and is active per default.

Menu tabs

System properties

10

REV 3

Pin configuration Next menu tab is “pin configuration”, all present nodes are visible as tabs in this view. (1) Make sure tab A1 is activated in the view. Give Port id# 9 the following name ”switch”. (2) Comment field is optional. (3)

Activate tab B1 in the view (1) and do the same for Port id# 9 with following name ”VALVE”. (2)

Note: The red color of the fields indicates that the ports are not yet connected or that any of the letters are unaccepted. Space between words is not accepted instead use “_”. A red field makes it impossible to compile the application.

Component view Next menu tab is the “component view” The component view is where components are deployed and connected. A palette displaying all components is available in the view. The palette can be made visible by pressing “components” if it is not already visible.

Available component pallet

11

REV 3

Select the OD timer (On Delay timer) component from the available component pallet (1). It’s located in the Digital tab (2).

2

1 Place the component on Page 1 in the view with the left mouse button. Then press the right button to get the arrow back.

Right click the mouse on the left red dot and work your way to the input ”SWITCH” and left click.

Do the same thing on the right red dot and choose the output in this case “VALVE”

12

REV 3

Put the arrow on the component and right click, and select “properties”.

Put the delay time to two seconds (in mille seconds). The instance name is an internal component address and should not be changed. When ready press “OK”. Instance name

Delay time

If the application needs to be saved before it is ready choose “Save”. The file will be stored as a “spi” file.

When the application is ready choose “Compile”. The file will then be saved as a loadable file “spr” and is of curse editable.

13

REV 3

Load view The last view is the “Load view”. From this view it is possible to download and up load applications to and from a connected SCS² system. Press the “Download” button and a dialogue box will appear, choose the desired “spr” file and press the “Open” button.

Download

Choose file and press open

Then ABE verifies the action in the progress bar. First ABE sends the file to the connected node. The progress is displayed in the connected node bar as percent. Current transfer completed (%) Then the system distributes the file over the CAN-bus to the rest of the nodes (if necessary). When the download is ready this dialogue box appears. Current transfer completed (%) Total transfer completed (%)

14

REV 3

Anybus General Here follows an example of how to build up the same system as before with two nodes, but the B1 node has one output and one input and on the A1 node is the input replaced with an Anybus interface Outside net

Slave (A1) with anybus

SCS2

CAN network (BCAN) B1 Master Input

Output

Switch

Valve

Connecting the B1 node Connect the B1 node as in the Digital I/O chapter, and add a switch to Port id# 1 as in the picture below G roup used as O utput

G roup used as Input L /24V D C N / 0V D C

SC S² 1

44

31

2

41

3

43

4

9

42

8

26

SC S² 10 SC S 11

16

6

12

7

I/O M oduls

15

REV 3

Connecting the A1 node Connect power supply, can bus and an ID jumper as A1 in the X2 connector. An “Anybus card” is also to be mounted and connected inside the hood where the digital I/Os are located.

The Anybus card (in this case for Profibus) This card is used for translation between different field buses and a standardized format read by the SCS² system.

There is a D-sub connector on the card for connecting to outside net (1), and a selector for termination resistance (2) and two selectors used for setting hard ware identification of the unit in the outside net (3). 1

2

3

1

2

Item 3.

HW address

*10

*1

4 3 The four LEDs are used for showing the state of the communication from the Anybus-card and the outside net. 1:not used 2:(green) on-line on the Fieldbus 3:(red) off-line on the Fieldbus 4:(red) indicate faults on the Fieldbus side as follows: Flashing 1hz-Error in configuration: IN and/or OUT length set during initialization of the module is not equal to the length set during configuration of the network. Flashing 2hz-Error in user parameter data: the length/contents of the user parameter data set during initialization of the module is not equal to the length/contents set during configuration of the network. Flashing 4hz-Error in initialisation of the Profibus communication ASIC.

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The Anybus card is to be mounted inside the hood on the right upper corner of the node

Connect an Anybus jumper to the D-sub connector on the Anybus card. And connect to the outside connector on the connection rail beside the card. On the connection rail the wires from the D-sub should be connected in the following order from the right 8 3 5 (for Profibus) Fieldbus connector used for connecting to the outside interface.

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Application with a Anybus interface ABE Open the application used in the digital chapter. Get in to the ”pin configuration” view and remove the switch from A1, add a new “switch” to B1 in Port id# 1 Then get in to the “component view” and set the cursor on the OD timers input connector (on the left) and press Disconnect, the connection point turns red if a connection is acquired for the component to function.

Get an “Input bit”(1) from the “available component” menu under the “Anybus” tab (2) and place it out in front of the “OD timer” and also take an “or” gate from “gates” 1 and a “split” from “digital”.

2

Connect the switch to the “split”, the “input bit” and the “split” to the “or” and the “or” to the “OD timer”. Yore connection should now be as below.

Choose an “Output bit” and connect it to the “split”

Note: A red dot on any of the components makes it impossible to compile the application.

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Right click on in/output bits and choose properties. In the properties menu it is possible to configure following. “Note” is a free text field. Use this field for notes about the Anybus port. “Bit number” is the bit number of the chosen byte in Anybus interface. (0-7) “Byte number” is the start byte in the Anybus interface. (0-63) “Node” is where the any bus card is located (in this case A1)

Note: The size of the data areas is decided of the highest byte in the application, in both directions separately. The two sizes have to be equal on both sides of the Anybus card (outside master/any bus) to be able to establish contact. If the outside areas is bigger than in the application is it possible to put an empty byte to make the areas match.

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Anybus gateway General Compared to a conventional SCS² node the Anybus gateway does not have any digital or analogue I/O’s, no internal battery backing up the event log (locally The anybus gateway is used in cases where a physical I/O is not needed; one example is when the SCS² system is connected as a slave unit (via a anybus card in the crane node) on the crane PLC.

Status LEDs Power connector

Anybus card (in this case Profibus)

BCAN connector Node address key switches Serial port connector

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BCAN - Status LEDs There are three green LEDs for Power, BCAN and Anybus indicating operating status and one red LED indicating error status. Power LED is lit when power is applied and system starts to execute. BCAN LED is lit when the BCAN communication interface is operating normally and flashing when the communication interface is not working as intended. Anybus LED is flashing when the Anybus interface is not configured and lit when configured and operating normally. (Between the node and the anybus card) Error LED is unlit when system is running normally and lit when an error has occurred.

Power connector The power connector is a Phoenix Contact 2pin header (MC1,5/2-G-3,81). 24Volt DC powers the node internally.

NAME

DESCRIPTION

PIN NUMBER

VCC GND

10 to 28 V DC 1 Ground 2

NAME

DESCRIPTION

PIN NUMBER

CAN H CAN L

CAN high CAN low

1 2

BCAN connector The BCAN connector is a Phoenix Contact 3pin header (MC1,5/3-G-3,81). All nodes in the system have to be connected equal (bus topology) to CAN High and CAN Low to be able to establish communication.

Node address key switches There are five switches selecting node address. The node identity is defined by using the same bit pattern as the conventional nodes. For example to configure a gateway node as an A1 (crane) node: set DIPswitch 1 to ON and DIP switch 2-5 to OFF. Or to configure a gateway node as an A2 (crane) node: set DIPswitch 2 to ON and DIP switch 1,3,4 and 5 to OFF.

A1

A2

Serial port connector The serial port connector is used when connecting the SCS2 Anybus Gateway to a computer serial port. (Corresponds to X5 on the conventional SCS² nodes) Use a 9-pol D-sub extension lead to connect.

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APS Absolute encoder on the telescope General The absolute encoder should be connected to the RS485 port. (Channel A at X2/38 and channel B at X2/37) In the ABE component pallet under the “analogue” tab, the RS485 port component is located. It is also possible to rescale the information from the sensor to be able to work or monitor the actual measurements (in for instance mm), the tool for this is the “scale” component. The “scale” component is also located under the “analogue” tab. Teach is used for storing positions

Add the RS485 port component from the analogue tab The scale component makes it possible to translate the sensor value to the mechanical distance

The RS485 component This component is used to access the RS485 interface. The component is made to handle some different types of protocol in this case “slin”. The parameters: Node: each node has one RS485 input. To direct the component in the software to the correct hardware input, choose node corresponding to what node the sensor is wired to. Protocol: it is possible to choose between some different standardised protocols to suit the sensor used. When using the SSI protocol some more information is needed. (See sensor/manufacture for data) Code type: determines how the sensor value (bit pattern) shall be read when converting to a decimal value (made internally in the component). Gray or Binary. Input resolution: how many steps (bits) per revolution. Max revolutions: how many revolutions that are supported by the sensor.

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From bits to millimetres (scale) Retract the spreader to the mechanical end stop, measure the distance between the single twistlocks, note the value down, read the sensor value with the ABE online and make a note of this. Expand the spreader to the mechanical end stop and repeat the same procedure. Note: It is very important that the sensor doesn’t wraparound (when counting up, after the highest value it starts at zero again), the retracted value should be low and the expanded value should be larger. Right click on the scale component and choose “properties” And fill in the noted values as following. The measured max value in millimeters The measured min value in millimeters The up loaded max value from the ABE online The up loaded min value from the ABE online Then verify the scale, put the spreader in some different positions measure and compare with the scaled value.

Teach To be able to store positions the APS component is equipped with a storing function called “TEACH”. By giving the teach command and expand or retract command it is possible to move the spreader in a lesser speed (defied by the parameter “PWM value for teach” in APS properties) to the required length, for position “20ft”, hold the teach command and give the go to position “20ft” command. The value is now stored in the spreader memory (NV RAM). Repeat this procedure on all the required positions. The connection point for teach The connection points for position direct commands The connection points for expand/ retract commands

Note: If the scale is made correctly it is possible to verify the spreader length by activating the teach command, when the teach function is active the sensor value input on the APS is displayed on the B1 display. Beware of if a "position direct command" is given at the same time that position is destroyed.

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External EE-prom General In the external EE-prom it is possible to store information as spreader ID, twistlock counters, running time etc. this makes it possible to replace the node(s) in the system without loosing this information.

Hardware The EE-prom is to be connected in to the node as following. Name Pin number in Cable connector 10V supply X2/36 Red Serial data X2/16 Blue Serial clock X2/26 Green Signal ground X2/6 Black The EE-prom is located in a gland. The gland should be mounted solid near by the SCS² node within the cable range.

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Software A “spreader properties” component needs to be added in the application, that make the system try to find the “EE-prom” at boot. The “spreader properties” component (1) is located in the “misc…” tab (2) in the “available component” menu.

4 3

2

1

The “spreader properties” contains twistlock counters and a time counter etc. To make the counters work some info is needed, connect the available signals corresponding to the connection points on the left of the component (3). The information is possible to send out as analogue words true the bus to the outside net (if present), the connection points for these values is located on the right of the component (4).

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Activate the EE-prom The EE-prom is activated after the “Serial number” value is set. The BMS have to be connected to the node that the EE-prom is connected to. Left click on the “Serial number” key in the BMS “spreader info” tab. In the “current key” dialogue box down in the left corner there should now be seen “serial number”. Put the spreader serial number in the value bar and press the “set” button to store and activate the EE-prom. It now displays the different values.

The “Spreader info” tag

The “get all” button

The information from the EE-prom is possible to upload with the BMS from the “spreader info” tag. Connect the BMS to the system and press the “get all” button.

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User Manual

Version 1.0

Revision

Issued by

Gunnar Ohlsson, CC Systems Andy Lewis, Bromma Conquip Gunnar Ohlsson, CC Systems GO, AL Gunnar Ohlsson, CC Systems

2000-05-26 2000-08-09 2000-10-10 2000-10-10 2001-01-22

PB2 PB3 PB4

Hans Svanfeldt, CC Systems Hans Svanfeldt, CC Systems Hans Svanfeldt, CC Systems

2002-06-04 2003-06-10 2004-10-08

PA1 PA2 PA3 A PB1

Date

Measures

First draft. Corrections More corrections Version 1.0 PID component, Online monitoring (manual and tutorial), *.apd changed to *.spr, Figure numbering corrected, Allowed character set. Revision after system release 1.04 Revision after system release 1.05 Revision after system release 1.07

Printed: 05-2-23 13.40

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Table of contents 1

INTRODUCTION .............................................................................................................5

2

INSTALLING ABE...........................................................................................................5

2.1

HW requirements .................................................................................................................................................... 5

2.2

Installation ............................................................................................................................................................... 5

2.3

Disclaimer................................................................................................................................................................. 5

3

USER INTERFACE .........................................................................................................6

3.1

Main window............................................................................................................................................................ 6

3.2

Error control............................................................................................................................................................ 6

3.3

Multiple language support ...................................................................................................................................... 6

3.4 General functions..................................................................................................................................................... 6 3.4.1 File..................................................................................................................................................................... 6 3.4.2 Edit .................................................................................................................................................................... 7 3.4.3 Settings .............................................................................................................................................................. 7 3.4.4 Tools .................................................................................................................................................................. 7 3.4.5 Help ................................................................................................................................................................... 8

4 4.1

SYSTEM VIEW ................................................................................................................9 General ..................................................................................................................................................................... 9

4.2 Functionality ............................................................................................................................................................ 9 4.2.1 Author................................................................................................................................................................ 9 4.2.2 Last date saved .................................................................................................................................................. 9 4.2.3 Creation date.................................................................................................................................................... 10 4.2.4 Version number ............................................................................................................................................... 10 4.2.5 Revision number.............................................................................................................................................. 10 4.2.6 Spreader type ................................................................................................................................................... 10 4.2.7 Drawing number .............................................................................................................................................. 10 4.2.8 Customer.......................................................................................................................................................... 10 4.2.9 Comments........................................................................................................................................................ 10

5 5.1

PIN CONFIGURATION VIEW........................................................................................11 General ................................................................................................................................................................... 11

5.2 Functionality .......................................................................................................................................................... 11 5.2.1 Address key ..................................................................................................................................................... 11 5.2.2 Exists port........................................................................................................................................................ 11 5.2.3 Anybus I/O ...................................................................................................................................................... 12 5.2.4 CANopen I/O................................................................................................................................................... 12

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COMPONENT VIEW .....................................................................................................13 General ................................................................................................................................................................... 13

6.2 Page functionality .................................................................................................................................................. 14 6.2.1 Adding pages ................................................................................................................................................... 14 6.3 Component functionality ...................................................................................................................................... 14 6.3.1 Adding a component........................................................................................................................................ 14 6.3.2 Moving a component ....................................................................................................................................... 15 6.3.3 Selecting multiple components........................................................................................................................ 15 6.3.4 Cutting / coping / pasting components ............................................................................................................ 15 6.3.5 Delete a component ......................................................................................................................................... 15 6.3.6 Connecting / disconnecting components ......................................................................................................... 15 6.3.7 Online monitoring............................................................................................................................................ 15

7

LOAD VIEW...................................................................................................................16

7.1

General ................................................................................................................................................................... 16

7.2

Functionality .......................................................................................................................................................... 16

8

COMPONENTS .............................................................................................................17

8.1 Controllers.............................................................................................................................................................. 17 8.1.1 TLC4 – Twistlock Controller 4 ....................................................................................................................... 17 8.1.2 TLC8 – Twistlock Controller 8 ....................................................................................................................... 20 8.1.3 FAC – Flipper Arm Controller ........................................................................................................................ 24 8.1.4 DPS – Discrete Positioning System................................................................................................................. 26 8.1.5 Tower – Head block ........................................................................................................................................ 29 8.1.6 APS – Automatic Positioning System ............................................................................................................. 32 8.1.7 MPS – Memory position system...................................................................................................................... 36 8.1.8 Twin Telescope................................................................................................................................................ 40 8.1.9 TwinUpDown .................................................................................................................................................. 42 8.1.10 PID................................................................................................................................................................... 46 8.1.11 AutoTuner........................................................................................................................................................ 50 8.2 AnyBus ................................................................................................................................................................... 53 8.2.1 Introduction ..................................................................................................................................................... 53 8.2.2 Anybus System ................................................................................................................................................ 54 8.2.3 Output Word .................................................................................................................................................... 55 8.2.4 Output Byte ..................................................................................................................................................... 55 8.2.5 Output Bit ........................................................................................................................................................ 56 8.2.6 Input Word....................................................................................................................................................... 56 8.2.7 Input Byte ........................................................................................................................................................ 57 8.2.8 Input Bit........................................................................................................................................................... 57 8.3 CANopen ................................................................................................................................................................ 58 8.3.1 Introduction ..................................................................................................................................................... 58 8.3.2 PDO Read Bit .................................................................................................................................................. 58 8.3.3 PDO Read........................................................................................................................................................ 58 8.3.4 PDO Write Bit ................................................................................................................................................. 59 8.3.5 PDO Write ....................................................................................................................................................... 59 8.3.6 SDO Write ....................................................................................................................................................... 59 8.4

Guards .................................................................................................................................................................... 61

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Spreader stop ................................................................................................................................................... 61 TTDS -Twin Twenty Detection System .......................................................................................................... 61 Analogue guard ............................................................................................................................................... 62 Digital guard .................................................................................................................................................... 63

8.5 Gates ....................................................................................................................................................................... 64 8.5.1 AND ................................................................................................................................................................ 64 8.5.2 NAND.............................................................................................................................................................. 65 8.5.3 NOR................................................................................................................................................................. 65 8.5.4 OR ................................................................................................................................................................... 66 8.5.5 NOT................................................................................................................................................................. 67 8.5.6 XOR................................................................................................................................................................. 67 8.5.7 SR Latch .......................................................................................................................................................... 68 8.5.8 RS Latch .......................................................................................................................................................... 68 8.5.9 Logical gate ..................................................................................................................................................... 69 8.6 Digital ..................................................................................................................................................................... 69 8.6.1 OD Timer – On Delay Timer........................................................................................................................... 69 8.6.2 UpDn Counter – Up Down Counter ................................................................................................................ 70 8.6.3 OSC - Oscillator .............................................................................................................................................. 70 8.6.4 Split ................................................................................................................................................................. 71 8.6.5 Pulse ................................................................................................................................................................ 71 8.7 Miscellaneous ......................................................................................................................................................... 72 8.7.1 Constant........................................................................................................................................................... 72 8.7.2 Dead end.......................................................................................................................................................... 73 8.7.3 Spreader properties .......................................................................................................................................... 73 8.7.4 Memory ........................................................................................................................................................... 75 8.7.5 Digital buffer ................................................................................................................................................... 76 8.7.6 Analogue buffer............................................................................................................................................... 76 8.8 Analogue................................................................................................................................................................. 78 8.8.1 RS485 port....................................................................................................................................................... 78 8.8.2 IN0 > IN1 ........................................................................................................................................................ 78 8.8.3 IN0 * IN1......................................................................................................................................................... 79 8.8.4 IN0 / IN1.......................................................................................................................................................... 79 8.8.5 IN0 – IN1......................................................................................................................................................... 79 8.8.6 IN0 + IN1 ........................................................................................................................................................ 80 8.8.7 Scale ................................................................................................................................................................ 80 8.8.8 AnalogueLatch ................................................................................................................................................ 81 8.8.9 Filter ................................................................................................................................................................ 81 8.8.10 AuxAnalogue................................................................................................................................................... 82

9 10

TUTORIAL.....................................................................................................................83 CANOPEN TUTORIAL ...............................................................................................90

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1 Introduction ABE – Application Builder Environment has been developed to create and manage spreader programs specifically for the Bromma Conquip SCS2 system used on Spreaders. This tool gives the programmer/user the possibility of configuring and programming the logic of the SCS2 via a graphical interface. In principal ABE generates a binary file describing the interconnection between the graphical objects the user has tied together. This file, when downloaded onto the target system, connects the precompiled objects within the target system together according to the functionality described by the user. Hence all logical objects, components, reside within the target system and the program file generated by ABE determines their interconnection. The objects, from no on referred to as components, within ABE contain a varying amount of logic ranging from basic Boolean instruction sets to Spreader specific blocks of functionality which can be altered in behaviour via parameter settings. The components containing specified Spreader functions are developed to ensure that years of Spreader experience is re-used and also contain the interlocking for generating fault and event messages to the onboard NVRAM (log). This programming tool is intended for use by staff with adequate knowledge of both the system and the functionality of the Spreader/Crane in which it shall be used only. Any alterations or new programs causing failure in functionality due to logical faults in the program are the responsibility of the person/company carrying out this work.

2 Inst alling ABE 2.1

HW requirements

The minimum requirements to run this application on your PC are: • an Intel compatible PC running Windows 95 / 98 / NT 4.0 / 2000. • at least one serial communication port available (COM1 or COM2). • at least 2Mb of free disk space.

2.2 • • • •

2.3

Installation Close any other applications running under windows. Insert the CD into your station. Run the file Setup.exe. Follow the instructions on the screen.

Disclaimer

Copyright Bromma Conquip AB. All rights reserved. Products and company names mentioned herein may be trademarks or trade names of their respective owners. Bromma Conquip AB operates on a policy of continuous improvement. Therefore we reserve the right to make changes and improvements to any of the products described in this manual without prior notice. Bromma Conquip AB is not responsible for any loss of data, income or any consequential damage howsoever caused.

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3 User interface ABE-application is divided into four main functions. This chapter describes the four main functions of the program. Remark: Allowed characters when giving names to Item identifiers, Comments, Components and Tags are: [a, b, c..., z], [A, B, C..., Z], [0, 1, 2,..., 9] and “_” (underscore). No other characters must be used.

3.1

Main window

The main window of the application consists of one large frame. The four tabs at the bottom of this window represent the four main functions of the program. The toolbar at the top of the window is used for common operations. The application supports tool tips. The application is designed to work on a laptop computer with a display size of 800 * 600 pixels or more.

3.2

Error control

Error control of the program file is performed after every operation. The errors found are marked red. The error control can be turned off/on from the Settings menu.

3.3

Multiple language support

The default language is English. Additional languages can be requested from Bromma Conquip AB.

3.4

General functions

The toolbar functions are File, Edit, Settings, Tools and Help. Each function is described below.

3.4.1

File

Two types of files are available. Type *.spr is a compiled file ready to download onto the SCS2. Type *.spi is an intermediate file. Use Save or Save As... if you are not able to generate downloadable program file but want to continue your work later on. The file extension will then be *.spi.

3.4.1.1 New Creates a new program file for editing.

3.4.1.2 Open Opens a program file for editing/viewing.

3.4.1.3 Save As... Prompts the user to supply a new filename to which the project will be saved. The file extension will be *.spi.

3.4.1.4 Save Saves the current project. The file extension will be *.spi.

3.4.1.5 Compile Generates and prompts you to save a downloadable program file used in the SCS2. The file extension will be *.spr.

3.4.1.6 Print Prints the Component view.

3.4.1.7 Exit Exits the application.

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Edit

3.4.2.1 Cut Selected components will be cut and saved to the clipboard.

3.4.2.2 Copy Selected components will be copied to the clipboard.

3.4.2.3 Paste Content of clipboard will be pasted into selected page in the Component view. If connections match existing ports theses will also be pasted into the page.

3.4.2.4 Find Finds a text string in component comments, component identifiers or an actual component.

3.4.3

Settings

3.4.3.1 Error Control Turns the error control on/off.

3.4.3.2 Show hints Turns the tool tips on/off.

3.4.3.3 Show component connection info Turns information at component connection points on/off.

3.4.4

Tools

3.4.4.1 Export Pin configuration view Exports a list of current Pin configuration as an html page for viewing in a web browser.

3.4.4.2 Export Component documentation Exports a list of available components an their properties as a html page for viewing in a web browser.

3.4.4.3 Export parameters Exports the selected components parameters to a file.

3.4.4.4 Import parameters Imports parameters from a file to current project.

3.4.4.5 Show Ladder, Show function blocks Shows the current project in Ladder format. Note that one cannot add, delete or online monitor components when ladder look activated.

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Help

3.4.5.1 About Short information about ABE such as version, current number of components etc.

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4 Sy stem view 4.1

General

The system view provides a way of enabling and disabling (connecting/disconnecting) nodes and setting system properties such as version number, author, comments and date of modification. The nodes are named A1-A4 for the nodes intended to be fitted to the crane and B1-B8 for the nodes intended to be fitted to the Spreader. Each node name corresponds to a unique address key setting. The system view allows the user to set up the node configuration by checking the desired nodes. A fixed set of checkboxes are available that represent the used nodes in the system. The enabled nodes then have to be present in that system. An exception is if the “EXISTS” function is used. This function can then replace a node on the bus with an input on the master node. The B1-node is selected by default, since every system has to contain exactly one Master node, B1. Four crane nodes and seven spreader nodes are available for selection. Checkboxes for enabling Twistlock redundancy as well as “Spreader stop” have to be checked here as well if these functions are used.

Figure 4:1 System view

4.2

Functionality

The system view enables the user to select a node configuration. By filling in the checkboxes you determine the lay-out (topology) of the system. You also determine on which nodes (B1 & B2) you are to have the twistlock redundancy and Spreader stop enabled. Each node configuration gives the respective node a unique ID represented by the address key. You may also set system properties in this view. Some properties will be updated automatically when a project is saved. The properties are:

4.2.1

Author

This is the author of the spreader program. Contains text of max 80 characters.

4.2.2

Last date saved

Displays the date when the current project was last saved. Displayed in the format 1999-06-28 14:45.

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Creation date

Displays the date of the current project’s creation. The creation date is only changed upon creating a new project. Displayed in the format 1999-06-28 14:45.

4.2.4

Version number

A user selectable version number. Maximum version number is 99.99.

4.2.5

Revision number

The revision number is incremented each time the specific project is compiled.

4.2.6

Spreader type

A text field representing the type of spreader that the current program is intended for. Contains text of max 80 characters.

4.2.7

Drawing number

A number corresponding to the electrical drawing belonging to the current project. Contains text of max 80 characters.

4.2.8

Customer

This property is to contain the name of the customer who will use the Spreader program. Contains text of max 80 characters.

4.2.9

Comments

This is a text field intended for general comments regarding the Spreader program. Contains text of max 80 characters.

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5 Pin configuration view 5.1

General

The pin configuration view is presented as a tabular view of the system, where each tab represents a node. An I/O list corresponding tags will be available for all enabled nodes in the system. The top tabs indicate which node is displayed. A tag is composed of its Item identifier and its Comment. The used I/O not yet connected is marked red. The Port id# field contains a port id, the numerical ID of the I/O number of the SCS2. The Connection field is either IN, OUT or NC (Not connected) and if it’s a digital, analogue, PWM or Encoder signals. These fields cannot be edited. Remark: Allowed characters when giving names to Item identifiers, Comments, Components and Tags are: [a, b, c..., z], [A, B, C..., Z], [0, 1, 2,..., 9] and “_” (underscore). No other characters must be used.

Figure 5:1 Pin configuration view

5.2

Functionality

This view allows you to change the tag for all port numbers on all nodes in the system. Within this view you give each individual I/O its’ nick name, Item Identifier, to make the program more comprehensible, you also assign any comments to the I/O. The connection type (IN/OUT) will be updated automatically as the Spreader program is altered in the component view; i.e. the direction of the I/O point is decided when the I/O is connected. Note that ABE will only permit I/O configuration that is supported by the current SCS2 HW, hence the digital I/O direction can only differ outside of groups of four apart from the last four I/O points in the list (45-48) which can configured individually.

5.2.1

Address key

The “address key” field illustrates how the address key should be linked for the viewed node. This pattern corresponds to the required connection on the X2 connector on the SCS2 HW.

5.2.2

Exists port

The “exists port” is used in case versatility on the number of used nodes is required. By letting an Input “replace” a node within a system one can then have for instance three nodes active in one case and two node plus the selected input active in another case, and still run the system without having to re-configure it. This can be useful when different models of Spreaders are to be used within the same system.

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Anybus I/O

With this button you can view all Anybus inputs and outputs in current spreader program.

5.2.4

CANopen I/O

With this button the CANopen configuration form appears, from this view you can create the CANopen functionality. You can add up to 15 CANopen slaves and add inputs and outputs on each slave (Digital and Analogue). Advanced configuration of a CANopen slave can be done by using SDO:s (Service Data Object). For more information about CANopen see general available sources.

Figure 5:2:4 CANopen configuration view

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6 Component view 6.1

General

The component view is where components are deployed and connected. A palette displaying all components is available in the view. To add a component, select the component from the Palette and place it on your work space with the mouse. Remark: Allowed characters when giving names to Item identifiers, Comments, Components and Tags are: [a, b, c..., z], [A, B, C..., Z], [0, 1, 2,..., 9] and “_” (underscore). No other characters must be used.

Figure 6:1 Component view

Figure 6:2 Palette

Components may be dragged within a page to change the layout. Each page can be resized vertically.

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The following table describes some reoccurring terminology in this manual. Name Output tag

Symbol

Description An Output tag is an intermediate variable used for making the program more readable and efficient. Note. Changing the name of an Output tag must be followed by a change of the corresponding Input tag(s) An Input tag is used to connect to an existing Output tag. Note. Changing the name(s) on Input tag(s) must be followed by a change of the corresponding Output tag. A component contains logic. The components range from simple Boolean (AND, OR etc) to those with full functionality specifically for Spreaders (APS etc.). Some of the components contain parameters. By double clicking (or right clicking and selecting properties) the component, its’ properties/parameters are displayed and can be edited. A component also carries component connection points (round circles). A red coloured connection indicates that it has to be connected before a compilation can be performed. Once the connection point is connected it turns white. This means that it is connected correctly. If a connection point is white although it is not connected it is optional to connect it or not.

Input tag

Component

Component connection

Output port

A connection to a physical output. The displayed name is the Item identifier found in the Pin configuration view. Multiple connections are not possible for an Output port. A connection to a physical input. The displayed name is the Item identifier found in the Pin configuration view. A multiple connection to same Input port is indicated with two vertical lines on the connection. This is made to remind the user that the Input port has been connected at least once before. Information about the generic name of the component connection is shown above each connection point when turned on. The function can be turned on/off from the Settings menu.

Input port Multiple connections

Component connection information

6.2

Page functionality

One page contains one set of interconnected components with no feedback in the connections. Reuse of signals may be accomplished by adding variable tags, and referring to those tags wherever necessary. The component view provides the following functionality:

6.2.1

Adding pages

By clicking on the last page or by placing a component on the last page will add a new page below it.

6.3

Component functionality

In each page, components may be manipulated. Operations on components are:

6.3.1

Adding a component

This operation adds the component currently selected in the palette to a page. Simply click the desired component and then click the location you wish to place this component on the current page you’re working on.

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Moving a component

Moving a component is a matter of dragging it around using the mouse.

6.3.3

Selecting multiple components

Multiple selection of components is possible using key modifiers (shift / ctrl).

6.3.4

Cutting / coping / pasting components

The copied and cut components will be placed on the clipboard, allowing components to be pasted on pages in the same application or in other ABE applications.

6.3.5

Delete a component

By selecting a component and pressing delete it is removed from the page.

6.3.6

Connecting / disconnecting components

Drawing a line from one connection point to another makes connections between components. One can also connect a component by right clicking a connection point and selecting a connection from the available lists displayed (I/O, Components instances, Tags). Clicking with the right mouse button over a connected connection point will give you the option to disconnect.

6.3.7

Online monitoring

Online monitoring is performed under Component view. The same spreader program must be present in both ABE and SCS2. If you are not sure about this, you can always download your current spreader program to the SCS2 or upload the spreader program from the SCS2. Select COM1 or COM2 under selection depending on what serial port is connected to the SCS2. Start online monitoring by pressing the Start online monitoring button. Automatic update will be performed at an interval specified by Update interval, if Auto is checked The online monitoring starts by telling the SCS2 to add all visible components and their connections. This takes more or less time depending on the number of present components and connections in visible Page(s). A progress bar appears above the buttons, when adding the components, to show you current status. Stop online monitoring by pressing the Stop online monitoring button (same button as Start online monitoring button).

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7 Load view 7.1

General

The load view provides functionality to download and upload Spreader programs. The connection to the system is selected in the connection box; the possible choices are, Com1 and Com2. Current status of the transfer is displayed in the three progress bars.

Figure 7:1 Load view

7.2

Functionality

When the download button is pressed the user is prompted to point out the file to download to the system. It has to be a compiled downloadable program file (*.spr-file). The current status of a download process from the PC to the system is shown in the top progress bar. The distribution transfer between nodes is shown in the two progress bars at the bottom of the page. The upload button allows the user to retrieve a program file from a connected system and save it to a file.

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8 Component s Terminology: In this section the follow terms are used: False = 0 = logical low level True = 1 = logical high level Parameter – “Instance name”: Every component used in a project will be given a unique instance name, which can be seen by clicking the right mouse button on a component and selecting properties. This unique instance name is seen in the field next to the title “Instance name”. The instance name is used to be able to trace every component instance throughout the project. The name can be altered, but no two instances of a component can have the same name, since this is the ID used by the system to determine the interconnection between components. State transition diagrams: The state transition diagrams describe the behaviour of the components in general. Terminology in the diagrams is not the same as in the port listings found in corresponding subsections. The text found in the diagrams is more explicit than the complete listing. Example: In the state transition diagram for TLC4 the following text tag can be found: “not All unlocked” This text tag is equal to NOT (Unlocked 1 AND Unlocked 2 AND Unlocked 3 AND Unlocked 4). The latter expression is rather big and makes the diagram difficult to understand. Descriptions (when relevant) like the one above will be made for those sections that contain State transition diagrams.

8.1 8.1.1

Controllers TLC4 – Twistlock Controller 4

The Twistlock Controller 4 (TLC4) is used to control four Twistlocks at the same time. This component incorporates the functionality and interlocks for a standard Twistlock operation with four Twistlocks. The component prevents the Twistlock from changing state unless the landed pins have been active for the specified time, it also prevents pre-selection of unlock and always keeps the outputs from the component active. Apart from the pure functionality of this component it also sends event and warning messages to the log function of the system.

8.1.1.1 State transition diagram “Not All unlocked” = NOT (Unlocked 1 AND Unlocked 2 AND Unlocked 3 AND Unlocked 4) “All unlocked” = Unlocked 1 AND Unlocked 2 AND Unlocked 3 AND Unlocked 4 “Unlock after landed” = when an unlock command is given after landed on all corners (and delay has elapsed if any) “Lock after landed” = when a lock command is given after landed on all corners (and delay has elapsed if any) States: DISABLED: When enable goes false or Spreader Stop is activated this state is reached. All outputs are set false. STARTUP: This state is reached every time the system is starting up or when DISABLED state is left. A decision is made if lock or unlock sequence should be initiated (i.e. a transition to those states). LOCK_ALL: Lock all Twistlocks. UNLOCK_ALL: Unlock all Twistlocks. IDLE: When a lock or unlock command has resulted in a complete sequence this state is reached. Lock/unlock outputs are not changed from previous state.

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For all s tates : Trans ition is m ade to DISABLED s tate if SpreaderStop = 1or Enable = 0 LOCK_ALL [ Lock after landed OR (landed override AND Lock) ]

[ All locked ]

[ not All unlocked ]

STARTUP

[ Lock after landed OR (landed override AND Lock) ]

[ Unlock after landed OR (landed override AND Unlock) ]

IDLE

[ SpreaderStop = 0, Enable = 1 ]

[ All unlocked ] [ All unlocked ]

DISABLED

[ Unlock after landed OR (landed override AND Unlock) ] UNLOCK_ALL

Figure 8:1 State transition diagram: TLC4

8.1.1.2 Input ports Input Landed override

Type Digital

Description Overrides landed signals. Makes it possible to unlock/lock if not all sensors are active. This port must be connected if enabled in hardware configuration.

Enable

Digital

Enables component. If set to false component will set all outputs to false. Default value if not connected is true (i.e. no effect).

Unlock command

Digital

Unlock command to unlock all Twistlocks.

Lock command

Digital

Lock command to lock all Twistlocks.

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Unlocked 1,...,Unlocked 4

Digital

Sensor input from Twistlocks. Status on unlocked sensor 1 to 4.

Locked 1,..., Locked 4

Digital

Sensor input from Twistlocks. Status on locked sensor 1 to 4.

Landed 1,..., Landed 4

Digital

Sensor input from Twistlocks. Status on landed sensor 1 to 4

Output Unlock

Type Digital

Description Unlock signal to all Twistlocks.

Lock

Digital

Lock signal to all Twistlocks.

Locked signal

Digital

All Twistlocks are locked.

Unlocked signal

Digital

All Twistlocks are unlocked.

Landed signal

Digital

All Twistlocks are landed.

Parameter Delay

Unit Milliseconds [ms]

Description Time after all landed sensors are true and lock or unlock command will be able to execute.

Timeout Twistlocks

Milliseconds [ms]

Time until a warning message will be prompted if not all sensors are made follow an output from the component. (e.g. Locked 1,..., Locked 4 shall become true within this time when a lock output has gone high.)

Timeout landed

Milliseconds [ms]

Time from the first landed input has gone active until the system should expect all the landed inputs active and vice versa, the time from which the first landed signal goes low until all landed signals should have gone low

Enable logging

Digital

If set to true (checked) the logging of messages will be turned on otherwise no logging will occur.

8.1.1.3 Output ports

8.1.1.4 Parameters

8.1.1.5 Message logging This component generates the following messages stored in the fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check box Enable logging.

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Code 60

Message TLC_NO_SENSOR

61

TLC_MULTIPEL_SENSOR

62

TLC_LOCKED_SENSOR_MISSING

63

TLC_LOCKED_SENSOR_LOST

64

TLC_UNLOCKED_SENSOR_MISSING

65

TLC_UNLOCKED_SENSOR_LOST

66

TLC_LANDED_SENSOR_MISSING

67

TLC_LANDED_SENSOR_STUCK

118

TLC_LANDED_OVERRIDE_ACTIVAT ED TLC_LANDED_OVERRIDE_DEACTIV ATED TLC_LOCK_COMMAND TLC_UNLOCK_COMMAND TLC_LOCKED TLC_UNLOCKED TLC_LANDED TLC_UNLANDED

119 175 176 177 178 244 245

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Description No twist-lock sensor inputs active during system start. One twist-lock indicating both locked and unlocked. Timeout while locking. Locked signal has not been received after output to valve. Locked sensor lost during operation. Sensor lost without command/output when Twistlocks are all locked. Timeout while unlocking. Unlocked signal has not been received after output to valve. Unlocked sensor lost during operation. Sensor lost without command/output when Twistlocks are all unlocked. All landed sensors not received after first landed and timeout. Landed sensor not released when the other sensors not active and a timer has timed out When override input is set to true and previous state is false. When override input is set to false and previous state is true. Twist-lock lock command received Twist-lock unlock command received All Twistlocks have been locked All Twistlocks have been unlocked The spreader has been landed. The Spreader has been totally lifted (not landed)

TLC8 – Twistlock Controller 8

The Twistlock Controller 8 (TLC8) is used to control eight Twistlocks at the same time. This component incorporates the functionality and interlocks for a Twistlock operation with eight Twistlocks. The component prevents the Twistlock from changing state unless the landed pins have been active for the specified time, it also prevents pre-selection of unlock and always keeps the outputs from the component active. Apart from the pure functionality of this component it also sends event and warning messages to the log function of the system.

8.1.2.1 State transition diagram Twin is down (two containers): “not All unlocked” = NOT (Unlocked 1 AND Unlocked 2,..., AND Unlocked 8) “All unlocked” = Unlocked 1 AND Unlocked 2,..., AND Unlocked 8 Twin is up (single container): “not All unlocked” = NOT (Unlocked 1 AND Unlocked 2,...,AND Unlocked 4) “All unlocked” = Unlocked 1 AND Unlocked 2,..., AND Unlocked 4 “Unlock after landed” = when an unlock command is given after landed on all corners (and delay has elapsed if any) “Lock after landed” = when a lock command is given after landed on all corners (and delay has elapsed if any) States: DISABLED: When enable goes false or Spreader Stop is activated this state is reached.

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All outputs are set false. STARTUP: This state is reached every time the system is starting up or when DISABLED state is left. A decision is made if lock or unlock sequence should be initiated (i.e. a transition to those states). LOCK_ALL: Lock single and twin Twistlocks. LOCK_SINGLE: Lock single Twistlocks. UNLOCK_ALL: Unlock single and twin Twistlocks. UNLOCK_SINGLE: Unlock single Twistlocks. IDLE: When a lock or unlock command has resulted in a complete sequence this state is reached. Lock/unlock outputs are not changed from previous state.

For all states: T ransition is m ade to DISABLED state if SpreaderStop = 1or Enable = 0

LOCK_ALL

LOCK_SINGLE

[ T wi n i s down ] [ T wi n i s up ]

[ All locked ] [ All locked ]

[ Unlock after landed OR (landed override AND Unlock) ] ST ART UP



IDLE

[ Unlock after landed OR (landed override AND Unl ock) ]

enable = 1

[ All unlocked ]

[ All unlocked ]

DISABLED [ T wi n is down ]

T win is up

UNLOCK_SINGLE

UNLOCK_ALL

Figure 8:1 State transition diagram: TLC8

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8.1.2.2 Input ports Input Landed override

Type Digital

Description Overrides landed signals. Makes it possible to unlock/lock if not all sensors are active. This port must be connected if enabled in hardware configuration.

Enable

Digital


Unlock command

Digital

Unlock command to unlock all Twistlocks.

Lock command

Digital

Lock command to lock all Twistlocks.

Twin unlocked 1 … Twin unlocked 4

Digital

Sensor input from Twistlocks. Status on unlocked sensor

Single unlocked 1 …

Digital

Sensor input from Twistlocks. Status on unlocked sensor

Twin locked 1 … Twin locked 4

Digital

Sensor input from Twistlocks. Status on locked sensor

Single locked 1 …

Digital

Sensor input from Twistlocks. Status on locked sensor

Twin landed 1 … Twin landed 4

Digital

Sensor input from Twistlocks. Status on landed sensor

Single landed 1 … Single landed 4

Digital

Sensor input from Twistlocks. Status on landed sensor

Twin is up

Digital

Input signal telling that Twinboxes are up. Single Twistlocks are enabled only.

TTDS Fault

Digital

Input signal telling that there is a TTDS fault. Disables lock operations.

Type

Description

Single unlocked 4

Single locked 4

8.1.2.3 Output ports Output

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Unlock single

Digital

Unlock signal to single Twistlocks.

Unlock twin

Digital

Unlock signal to twin Twistlocks.

Lock single

Digital

Lock signal to single Twistlocks.

Lock twin

Digital

Lock signal to twin Twistlocks.

Locked signal

Digital

All Twistlocks are locked.

Unlocked signal

Digital

All Twistlocks are unlocked.

Landed signal

Digital

All Twistlocks are landed.

Parameter Delay


Description Time after all landed sensors are true and lock or unlock command will be able to execute.

Timeout Twistlocks

Milliseconds [ms]

Time until a warning message will be prompted if not all sensors are made follow an output from the component. (e.g. Locked single 1,..., Locked single 4 shall become true within this time when a lock output has gone high.)

Timeout landed

Milliseconds [ms]

Time from the first landed input has gone active until the system should expect all the landed inputs active and vice versa, the time from which the first landed signal goes low until all landed signals should have gone low

Enable logging

Digital


8.1.2.4 Parameters

8.1.2.5 Message logging This component generates the following messages stored in the fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check box Enable logging. Code 60

Message TLC_NO_SENSOR

61

TLC_MULTIPEL_SENSOR

62

TLC_LOCKED_SENSOR_MISSING

63

TLC_LOCKED_SENSOR_LOST

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Description No twist-lock sensor inputs active during system start. One twist-lock indicating both locked and unlocked. Timeout while locking. Locked signal has not been received after output to valve. Locked sensor lost during operation. Sensor lost without command/output when Twistlocks are all locked.

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64

TLC_UNLOCKED_SENSOR_MISSING

65

TLC_UNLOCKED_SENSOR_LOST

66

TLC_LANDED_SENSOR_MISSING

67

TLC_LANDED_SENSOR_STUCK

118

TLC_LANDED_OVERRIDE_ACTIVAT ED TLC_LANDED_OVERRIDE_DEACTIV ATED TLC_LOCK_COMMAND TLC_UNLOCK_COMMAND TLC_LOCKED TLC_UNLOCKED TLC_LANDED TLC_UNLANDED

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Timeout while unlocking. Unlocked signal has not been received after output to valve. Unlocked sensor lost during operation. Sensor lost without command/output when Twistlocks are all unlocked. All landed sensors not received after first landed and timeout. Landed sensor not released when the other sensors not active and a timer has timed out When override input is set to true and previous state is false. When override input is set to false and previous state is true. Twist-lock lock command received Twist-lock unlock command received All Twistlocks have been locked All Twistlocks have been unlocked The spreader has been landed. The Spreader has been totally lifted (not landed)

FAC – Flipper Arm Controller

The FAC component is used for grouping and controlling a number of Flippers determined by a parameter of the component. The function sets either the up or down output at all times depending on the parameter settings. The inputs to the component generate event messages to the onboard log if enabled.

8.1.3.1 State transition diagram States: DISABLED: When enable goes false or Spreader Stop is activated this state is reached. All outputs are set false. STARTUP: This state is reached every time the system is starting up or when DISABLED state is left. A decision is made if lock or unlock sequence should be initiated (i.e. a transition to those states). IDLE: This state is reached emedeately after UP or DOWN states have been reached. UP: All Flippers are sent up. DOWN: All Flippers are sent down.

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For all s tates : Trans ition is m ade to DISABLED s tate if SpreaderStop = 1or Enable = 0

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UP

[ UpCom m and ]

START_UP

IDLE

[ DownCom m and ]

DISABLED

DOWN

Figure 8:1 State transition diagram: FAC

8.1.3.2 Input ports Input Up command

Type Digital

Description Command to send all Flippers up.

Down command

Digital

Command to send all Flippers down.

Enable

Digital


Output Flipper up 1,..., Flipper up n

Type Digital

Description Up signal to Flipper 1 to n. The number of Flippers (n) is derived from the parameter Number of Flippers.

Flipper down 1,..., Flipper down n

Digital

Down signal to Flipper 1 to n. The number of Flippers (n) is derived from the parameter Number of Flippers.

Unit Number

Description The number of Flippers to be controlled.


8.1.3.4 Parameters Parameter Number of Flippers

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Operation mode

Option

Impulse (only impulse required for the command to execute) or Constant (constant command required).

Enable logging

Option



Code 246 247

8.1.4

Message FAC_UP_COMMAND FAC_DOWN_COMMAND

Description Flipper up command received Flipper down command received

DPS – Discrete Positioning System

The DPS is used for controlling the chain telescope of a Spreader with proximity switch or screw limit switch box indicating the stops. The component can be used both with telescopic system using direct commands for each position as well as systems using expand/retract commands to increment/decrement between the positions. The number of positions are chosen via a component parameter. Parts of its’ behaviour such as if it requires impulse commands or constant commands etc are selected by parameters. The intermediate positions are designed to have two sensors per stop but will perform correctly with one sensor per intermediate position provided it is connected (in the software) to both the inputs of that position on the component. The outputs of the component are interlocked to unlocked and landed. The feedback from the component is a signal indicating what position has bee reached as well as a signal indicating that any valid stop has been reached. The component generates a number of events and warnings if positions aren’t reached within a parameter adjusted time etc. The DPS component is equipped with an “fast I/O concept”, this means that the component sampels the input sensors at a higher frequency and sets the actuators according to the internal logic. This will improve the overall performance of the component. To utilise this feature please note that the position sensors and actuators must be physically connected to the same node and that no logic is to be placed on the components outputs (Expand, Retract). If sensors and actuators not connected to the same node the “fast I/O concept” will be disabled.

8.1.4.1 State transition diagram States: DISABLED: When enable goes false or Spreader Stop is activated this state is reached. All outputs are set false. STARTUP: Unconditional transition is made to IDLE state. IDLE: Waiting for command input. EXPAND: Expanding to next stop. Next stop is either next closest stop or a stop decided according to which Return to position X command is given. A transition is made to IDLE state when next stop is reached. RETRACT:

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Retracting to next stop. Next stop is either next closest stop or a stop decided according to which Return to position X command is given. A transition is made to IDLE state when next stop is reached. CONSTANT REPEAT: When stopped at a position a new constant command is required to go to another position. Depressed keys or similar must be released before a new command will be excepted. Example: 1. Expand command is given. 2. Next stop is reached. 3. The telescope stops. 4. Expand command is released. 5. New expand command is given. 6. The telescope continues. DELAY: A delay is made for a time defined by Stop delay time (parameter). This delay is only performed if Delay is set in Operation mode (parameter) else ignored. “currentCommand” = is always EXPAND or RETRACT. The command inputs Retract / Expand command or Return to position X. These command inputs are internally converted to EXPAND or RETRACT depending on current position and desired position. For all s tates : Trans ition is m ade to DISABLED s tate if SpreaderStop = 1or Enable = 0

[ desiredStop = currentStop, Operation m ode = Delay ]

[ desiredStop = current Stop, Operation m ode = Cons tant repeat ]

EXPAND

[ currentCom m and = EXPAND ]

DELAY

[ Delay perform ed ]

IDLE

[ com m andInput = NO_CMD ]

CONSTANT REPEAT

[ currentCom m and = RETRACT ] [ desiredStop = currentStop, Operation m ode = Cons tant repeat ] RETRACT [ desiredStop = currentStop, Operation m ode = Delay ] START_UP

DISABLED [ SpreaderStop = 0, Enable = 1 ]

Figure 8:1 State transition diagram: DPS

8.1.4.2 Input ports

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Input Expand command

Type Digital

Description Input command to expand telescope to next stop.

Retract command

Digital

Input command to retract telescope to next stop.

Return to position 0 … Return to position n

Digital

Input command to expand telescope to predefined stop. The number of predefined stops is set by the parameter Number of stops.

Sensor 0 ... Sensor n

Digital

Sensor input. Example with 4 stops: Stop number 1 has Stop sensor 1, Stop number 2 has Stop sensor 2 + 3, Stop number 3 has Stop sensor 4 + 5, Stop number 4 has Stop sensor 6. Etc..

Any landed

Digital

Sensor input from landed sensors. Prevents telescoping when landed.

All unlocked

Digital

Sensor input from unlocked sensors. Permits telescoping when unlocked.

Enable

Digital


Slave

Digital

Enables slave mode. Telescope will run at full speed, only Retract and Expand commands are enabled and no stops are enabled

Output Expand

Type Digital

Description Output to expand telescope.

Retract

Digital

Output to retract telescope.

In position 0,..., Reached stop n

Digital

Output signal indicating that the specific valid stop has been reached.

In position

Digital

Output signal indicating that a valid stop has been reached.

Unit

Description


8.1.4.4 Parameters Parameter

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Timeout

Milliseconds [ms]

Time permitted from when an output is turned on until a valid position should be reached. If this time is exceeded the motion will be stopped and a warning generated.

Operation mode

Option

Impulse, Delay and Constant repeat.

Delay at each stop

Milliseconds [ms]

Time the telescope is delayed (stopped) at each stop.

Number of stops

Number

The number of stops in use.

Enable logging

Option

If set to true (checked) the storing of messages will be turned on otherwise no generated messages will be stored.


8.1.5

Code 68

Message DPS_TIMEOUT

69

DPS_SENSOR_MISSING

70

DPS_SENSOR_LOST

71

DPS_MULTIPEL_SENSOR

179 180 181

DPS_EXPAND_COMMAND DPS_RETRACT_COMMAND DPS_GOPOS_COMMAND

182

DPS_STOP_REACHED

Description No valid stop reached within timeout time. The expected sensor has not been reached within specified sequence. Position sensor has been lost without any command given More than one position sensor active simultaneously. Expand command received Retract command received A command to go to a certain position received A valid position has been reached

Tower – Head block

The Tower component is used to adjust the point of gravity.

8.1.5.1 State transition diagram States: DISABLED: When enable goes false or Spreader Stop is activated this state is reached. All outputs are set false. STARTUP: Unconditional transition is made to IDLE state. IDLE: Waiting for command input. FEED_LEFT:

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Feeds the Tower to the left. FEED_RIGHT: Feeds the Tower to the right. CENTER: Centres the tower. The Tower is centred when both At left sensor and At right sensor is true. DELAY: A delay is performed for a time defined by Direction change time (parameter).

For all s tates : Trans ition is m ade to DISABLED s tate if SpreaderStop = 1or Enable = 0 FEED_LEFT

FEED_RIGHT

[ Feed right ]

[ Feed left ]

START_UP


IDLE

[ Center ]

[ Delay perform ed ]

DISABLED CENTER

DELAY

Figure 8:1 State transition diagram: Tower

8.1.5.2 Input ports Input Enable

Type Digital

Description Enables component. If set to false component will set all outputs to false. Default value if not connected is true (i.e. no effect).

Enable right

Digital

Enables feeding in right direction. Default value if not connected is true (i.e. no effect).

Enable left

Digital

Enables feeding in left direction. Default value if not connected is true (i.e. no effect).

Right end sensor

Digital

Position sensor input.

At right sensor

Digital


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At left sensor

Digital


Left end sensor

Digital


Right command

Digital

Input command to feed head block right.

Left command

Digital

Input command to feed head block left.

Centre command

Digital

Input command to feed head to the centre position.

Output In centre

Type Digital

Description Output signal telling Head block is in centre position.

At right side

Digital

Output signal telling Head block is to the right.

At left side

Digital

Output signal telling Head block is to the left.

Feed right

Digital

Output signal to feed Head block right.

Feed left

Digital

Output signal to feed Head block left.

Parameter Operation mode

Unit Option

Description Constant or Impulse. Impulse is only valid for the Centre command

Delay

Milliseconds [ms]

Time before a change of direction will take effect.

Timeout

Milliseconds [ms]

Time permitted from when an output is turned on until a valid position should be reached. If this time is exceeded the motion will be stopped.

Use end stops

Option

If set true (checked) Right end sensor and Left end sensor does not need to be connected.

Enable logging

Option



8.1.5.4 Parameters


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8.1.6

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Message TOWER_CENTER_COMMAND TOWER_LEFT_COMMAND TOWER_RIGHT_COMMAND TOWER_REACHED_CENTER_POS TOWER_REACHED_LEFT_POS TOWER_REACHED_RIGHT_POS TOWER_TIMEOUT

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Description Centre command is given. Feed left command is given. Feed right command is given. Tower has reached centre position. Tower has reached left position. Tower has reached right position. Tower has not reached the desired position within the time limit.

APS – Automatic Positioning System

The APS component is used for positioning the chain telescope using an absolute encoder input to read the position of the chain. Due to the feedback from the sensor, self-correcting is possible if the Spreader is knocked out of position. It is possible to use both proportional controls (PWM) as well as on/off control with this component. The component can be used both with telescopic system using direct commands for each position as well as systems using expand/retract commands to increment/decrement between the positions. The number of positions is chosen via a component parameter as well as are certain parts of its’ behaviour such as if it requires impulse commands or constant commands etc. The absolute value (count) for each position is done via teach in functionality.

8.1.6.1 State transition diagram States: DISABLED: When enable goes false or Spreader Stop is activated this state is reached. All outputs are set false. STARTUP: Unconditional transition is made to IDLE state. IDLE: Waiting for command input. Expand command or Go position command (depending on current position) makes a transition to EXPAND state. Retract command or Go position command (depending on current position) makes a transition to RETRACT state. EXPAND: Expands telescope. PWM expand output is set to maximum (High speed) if not in Low speed window or in Stop window. PWM expand output is set to minimum (Low speed) if in Low speed window. PWM expand output is set to zero if in Stop window. Digital expand output is set to false if in Stop window else true. RETRACT: Retracts telescope. PWM retract output is set to maximum (High speed) if not in Low speed window or in Stop window. PWM retract output is set to minimum (Low speed) if in Low speed window. PWM retract output is set to zero if in Stop window. Digital retract output is set to false if in Stop window else true. DELAY: Performs a delay (Stop delay time) at each stop if Delay is selected in Operation mode (parameter) Expand and retract outputs are set to false in this state.

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CONSTANT_REPEAT: A new Expand or Retract command must be given to leave this state if Constant repeat is selected in Operation mode (parameter). Expand and retract outputs are set to false in this state.


[ Operation m ode = Delay ]

EXPAND

DELAY

[ desiredPos ition > currentPos ition ] [ Operation m ode = Im puls e, des iredPosition = currentPos ition ]

[ Operation m ode = Delay, des iredPos ition = currentPos ition ]

[ Delay perform ed ] STARTUP

IDLE

[ no button is pres s ed ] [ SpreaderStop = 0, Enable = 1 ] [ Operation m ode = Im puls e, des iredPos ition = current Pos ition ]

[ Operation m ode = Cons tant repeat, des iredPos ition = currentPos ition ]

[ desiredPos ition < currentPos ition ]

DISABLED

[ Operation m ode = Cons tant repeat ]

RETRACT

CONSTANT REPEAT

Figure 8:1 State transition diagram: APS

8.1.6.2 Teaching telescope positions This component has to be taught the absolute value (encoder count) of each position. This is done by having the Teach input go high and at the same time giving the command of the current position to be taught. The current value of the encoder is then saved onboard the Spreader. All positions, that have been enabled via the parameter Number of stops, have to be taught a value.

8.1.6.3 Input ports Input

Type

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Description

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Enable

Digital


Teach

Digital

Command to teach in new positions. When this signal is true any Go position command will store a new position for corresponding stop.

Slave mode

Digital

Enables slave mode. Telescope will run at full speed, only Retract and Expand commands are enabled and no stops are enabled.

Hooks are up

Digital

Input signal indicating that all hooks are in up position. Only used for twin telescopic Spreaders. I.e. if nothing is connected here telescoping is permitted, can also be used as a general permit.

Any landed

Digital

Input result from landed sensors.

Go position 0 … Go position n

Digital

Command to feed to defined positions 0,...,n.

Retract command

Digital

Command to retract telescope.

Expand command

Digital

Command to expand telescope.

Current position

Analogue

Scaled input signal of the current position.

Output Stop position0 … Stop position n

Type Analogue

Description Output signal indicating the stored positions for the corresponding stop.

In position

Digital

Output signal indicating that a valid stop has been reached.

In position 0 … In position n

Digital

Output signal indicating that the specific valid stop has been reached.

PWM retract

PWM

PWM output to control the telescope.


Range 0-1000 PWM expand

PWM

PWM output to control the telescope.

Range 0-1000 Digital retract

Digital

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Digital output to control the telescope.

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Digital expand

Digital

Digital output to control the telescope.

Digital high speed

Digital

Digital output for high speed telescoping in two-speed system.

Parameter Delay at each stop


Description Delay time at each stop if Expand or Retract command is given and Delay is enabled under Operation mode.

Timeout

Milliseconds [ms]

Time until from when an output is turned on until a valid position should be reached. If this time is exceeded the motion will be stopped and a warning generated.

Number of stops

Number

The number of stops enabled.

Auto correction

Option

If enabled the APS will feed back the telescope to its original position if it of some reason has got out of position.

Operation mode

Option

Impulse: sequence completes until a new command is given

8.1.6.5 Parameters

Delay: delay at each stop Constant repeat: when a stop is reached a new expand or retract command must be given. Stop window

Millimetre [mm]

Distance from defined stop to be considered as a stop.

Signal window

Millimetre [mm]

Window around the desired position in which a signal indicating that the correct position has been reached is given.

Impact range

Millimetre [mm]

Hysterisis for impact detection.

Impact off delay timer

Milliseconds

Delay after impact detected to run.

[ms] Length of travel

Millimetre [mm]

Time of telescope

Milliseconds [ms]

Ramp Gain

Number

Distance between minimum and maximum positions. Time between minimum and maximum positions. Ramp gain.

[value *1000]

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Ramp offset

Millimetre [mm]

Ramp offset for stop speed

Time to reach max speed

Milliseconds

The time it shall take to reach max speed.

[ms] Proportional Gain

Number

Proportional part of the PI regulator

[value *1000] Integral Gain

Number

Integral part of the PI regulator

[value *1000] PWM value for teach

Number

PWM output when teach enabled.

Reverse Min PWM output

Number

Minimum value on PWM that causes a reversed movement.

Reverse Max PWM output

Number

Maximum value on PWM that causes a reversed movement

Forward Min PWM output

Number

Minimum value on PWM that causes a forward movement.

Forward Max PWM output

Number

Maximum value on PWM that causes a forward movement.

Enable logging

Option


8.1.6.6 Message logging The following messages are generated by this component. This component generates the following message stored in the fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check box Enable logging. Code 183

Message APS_TIMEOUT

184 185 186 187 272 396 397 398

APS_EXPAND_COMMAND APS_RETRACT_COMMAND APS_GOPOS_COMMAND APS_STOP_REACHED APS_TEACH_COMMAND APS_IMPACT_ON APS_AUTOCORR_ON APS_IN_VALUE_OUT_OF_T EACH_RANGE APS_IMPACT_OUT_OF_SIG_ WIN

399

8.1.7

Description The telescope hasn't reached its' position within time limit. Expand command received Retract command received Command to go to a specific position received The desired position reached Teach in command received Impact is detected Spreader is auto correcting The position value is not within the teached range. Spreader is bumped out of signal window.

MPS – Memory position system

The MPS component stores either a predefined value or a value set during run time and can then position the twin telescope to this/these positions on given commands. The MPS uses an absolute input value and can either be used to return the twin telescope to a number of predefined positions (taught in and stored in the NVRAM). The driver also has

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the possibility of storing the current position in a volatile memory of the SCS2 and then returning to this position via a command until the power is cycled or a new position is stored.

8.1.7.1 State transition diagram States: DISABLED: When enable goes false or Spreader Stop is activated this state is reached. All outputs are set false. STARTUP: Unconditional transition is made to IDLE state. IDLE: Waiting for command input. Expand command, Returned to logged position command (depending on current position) and Go to predefined position (depending on current position) makes a transition to EXPAND state. Retract command, Returned to logged position command (depending on current position) and Go to predefined position (depending on current position) makes a transition to RETRACT state. EXPAND: Expands the Twin boxes until position is within range Stop window from desired stop. RETRACT: Retracts the Twin boxes until position is within range Stop window from desired stop.


RETRACT

[ desiredPos ition < currentPos ition ]

[ desiredPos ition = currentPos ition ]

STARTUP

IDLE

[ desiredPos ition = currentPos ition ] [ SpreaderStop = 0, Enable = 1 ] [ desiredPos ition > currentPos ition ] DISABLED EXPAND

Figure 8:1 State transition diagram: MPS

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Type Digital


Current position

Analogue

Scaled input signal reading the current position.

Return to predefined position 0 ... Return to predefined position n

Digital

Command to feed Twin boxes to predefined position 0,...,n

Returned to stored position 0 ... Returned to stored position n

Digital

Command to feed Twin boxes to logged position 0,...,n

Store new position 0 ... Store new position n

Digital

Command to log new positions. When this signal is true the current position will be stored in the RAM of the SCS2.

Teach

Digital

Command to teach in new positions. When this signal is true any Go to pre-defined position command will store a new position for corresponding stop.

Output Current reference position

Type Analogue

Description Signal indicating the currently desired position.

Predefined position 0 … Predefined position n

Analogue

Signal indicating the positions for the corresponding predefined stop.

Predefined position 0 … Predefined position n

Analogue

Signal indicating the positions for the corresponding predefined stop.

Logged position 0 … Logged position n

Analogue

Output signal indicating the positions for the corresponding logged stop.

In position

Digital

Output signal indicating that any position has been reached & logged or predefined).

Expand

Digital

Output signal to expand Twin boxes.

Retract

Digital

Output signal to retract Twin boxes.


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8.1.7.4 Parameters Parameter Stop window

Unit Millimetre [mm]

Description Offset from stop to be considered as a stop.

Operation mode

Option

Impulse: sequence completes until a new command is given Constant: when a stop is reached a new expand or retract command must be given.

Predefined positions

Number

The number of stops that will be stored in none volatile memory. (I.e. positions will be available after shutting down system.)

Storable positions

Number

The number of stops that will be stored in volatile memory. (I.e. positions will be lost when shutting down system.)

Timeout

Milliseconds [ms]

Time from when an output is turned on until a valid position should be reached. If this time is exceeded the motion will be stopped and a warning generated.

Enable logging

Option


8.1.7.5 Message logging The following messages are generated by this component. This component generates the following message stored in the fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check box Enable logging. Code 281 282

Message MPS_TEACH_PREDEF_POS MPS_GO_PREDEF_POS

280

MPS_TEACH_LOGGED_POS

284

MPS_GO_LOGGED_POS

285

MPS_TIMEOUT

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Description Teach command received. Command to go to a pre-defined position has been received. A command to store a new value for a log position has been received. A command to return to a log position has been received. The twin-legs haven't reached their requested position within time limit.

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Twin Telescope

The Twin Telescope component transfers the commands to expand and retract the twin telescope to the necessary outputs. The component, although it doesn’t hold much functionality, is useful for the event log.

8.1.8.1 State transition diagram States: DISABLED: When enable goes false or Spreader Stop is activated this state is reached. All outputs are set false. STARTUP: Unconditional transition is made to IDLE state. IDLE: Waiting for command input. Expand command makes a transition to EXPAND state if In 45ft sensor is false. Retract command makes a transition to RETRACT state if one not In zero left sensor is true and if not In zero right sensor is false. EXPAND: Expands the Twin boxes as long as Expand command is given and In 45ft is false. RETRACT: Retracts the Twin boxes as long as Retract command is given and both In zero left and In zero right sensors are false.

For all s tates : Trans ition is m ade to DISABLED s tate if SpreaderStop = 1or Enable = 0 EXPAND

[ Expand, !in45Pos ] [ !Expand OR in45Pos ]

STARTUP

IDLE

[ !Retract OR (inZeroPos Left, in ZeroPos Right) ]

[ !SpreaderStop, Enable ] [ Retract, !inZeroPos Left, !inZeroPos Right ] DISABLED

RETRACT

Figure 8:1 State transition diagram: Twin Telescope

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Type Digital


In 45ft

Digital

Sensor input signal.

In zero right

Digital


In zero left

Digital


Retract command

Digital

Command input to retract the twin boxes.

Expand command

Digital

Command input to expand the twin boxes.

Output Retract

Type Digital

Description Output signal to retract twin boxes.

Expand

Digital

Output signal to expand twin boxes.

Parameter Timeout


Description Time until from when an output is turned on until a valid position should be reached. If this time is exceeded the motion will be stopped and a warning generated.

Enable logging

Option



8.1.8.4 Parameters

8.1.8.5 Message logging The following messages are generated by this component. This component generates the following message stored in the fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check box Enable logging. Code 273 274 275 276

Message TWINTELE_EXPAND_COMMAND TWINTELE_RETRACT_COMMAND TWINTELE_REACHED_ZERO_LEFT TWINTELE_REACHED_ZERO_RIGHT

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Description Expand command received Retract command received Left console reached zero gap position Right console reached zero gap position

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277

TWINTELE_EXPANDING

Twinlegs expand in motion

278 279

TWINTELE_RETRACTING TWINTELE_TIMEOUT

Twinlegs retract in motion Hasn't reached an end stop when in motion within time limit

TwinUpDown

The TwinUpDown component is designed to be used on the twin telescopic Spreaders. The component performs the twin up and twin down sequences automatically upon the commands twin up and twin down. The sequence for twin down consists of the twin units separating until the Left attach & right attach permits have been made. Thereafter the hooks situated on the tension rod are lowered and finally the twin boxes are lowered. The sequence for twin up consists of the hooks on the tension rod being raised followed by the twin boxes being raised. The twin consoles are now retracted until the zero position switches are made, the retract output is active for a short off-delay after that to ensure that both units are fully retracted. When a complete up sequence has been performed a pulse is given on the output “ Twin up ready pulse ”, which in turn can be used for instance to run the Spreader back to the correct single 40ft position.

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8.1.9.1 State transition diagram TWIN_DOWN

TWIN_UP 1 : [ !allTwinUp || !hookLeft Disconnected || !hookRight Disconnected ]

[ twinDownReques tM ]

2 : [ !allTwinUp || !(hook LeftDis connected && hookRightDis connected) ]

RAISE_BOXES

CONNECT

[ allTwinUp ]

[ !allTwinUp ]

[ hookLeftConnected && hook RightConnected ]

1 : [ !allTwinUp || !hookLeftDis connected || !hookRight Disconnected ]

RAISE_HOOKS

[ hookLeftDis connected && hookRightDis connected ] 2 : [ !(twinInZeroPos Left && twinInZeroPosRight) ]

BOXES_DOWN

INCH_IN

2 : [ las tTwinUpStateM != OFF _DELAY_INCH && twinInZero Pos Left && twinInZeroPos Right && energis eInchInM ]

[ anyTwinUp ]

[ !anyTwinUp ]

3: HOLD_DOWN

HOLD_UP 1 : [ !(twinInZeroPos Left && twinIn ZeroPos Right) || delayM.is Tim eout() ]

H*

OFF_DELAY_INCH

Trans ition to IDLE s tate if twinDownCom m and

H*

Trans ition to IDLE s tate if twinUpCom m and

[ twinUpCom m and ]

[ twinDownCom m and ]

1 : [ twinDownReques tM) || (twin DownCom m and && hookLeft Connected && hookRightConnected ]

IDLE 2 : [ anyTwinUp && !(hook LeftConnected && hook RightConnected) ]

1 : [ !anyTwinUp && hook LeftConnected && hook RightConnected ]

2 : [ twinUpReques tM ]

3: STARTUP



DISABLED

Figure 8:1 State transition diagram: TwinUpDown

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Type Digital


Twin box up 1 … Twin box up 4

Digital

Sensor input indicating that Twin boxes are up.

Hook connected right

Digital

Hook connected left

Digital

Sensor input indicating that right hook is down. Sensor input indicating that left hook is down.

Right attach permit

Digital

Sensor input indicating that position has been reached to attach twin boxes on right side.

Left attach permit

Digital

Sensor input indicating that position has been reached to attach twin boxes on left side.

Hook disconnected right

Digital

Sensor input indicating that hook is up on right side.

Hook disconnected left

Digital

Sensor input indicating that hook is up on left side.

Twin in zero right

Digital

Sensor input indicating that Twin boxes has reached zero position on right side.

Twin in zero left

Digital

Sensor input indicating that Twin boxes has reached zero position on left side.

Chain in 40ft

Digital

Sensor input indicating that chain is in 40ft position.

Permit twin down

Digital

Permits down motion if set to true.

Permit twin up

Digital

Permits up motion if set to true.

Twin down command

Digital

Command to send Twin boxes down.

Twin up command

Digital

Command to send Twin boxes up.

Output Twin up ready pulse

Type Digital

Description Signal telling that up sequence is completed.

Twin down

Digital

Signal to lower Twin boxes.

Twin up

Digital

Signal to raise Twin boxes.

8.1.9.3 Output port

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Disconnect twin unit left

Digital

Signal to disconnect left hook.

Disconnect twin unit right

Digital

Signal to disconnect right hook.

Connect twin unit left

Digital

Signal to connect left hook.

Connect twin unit right

Digital

Signal to connect right hook.

Inch to zero gap

Digital

Signal to inch in Twin boxes.

Inch to connect left

Digital

Signal to inch out left Twin box.

Inch to connect right

Digital

Signal to inch out right Twin box.

Parameter Timeout Twin down


Description Time until a warning message will be prompted if sequence doesn’t complete.

Timeout hook

Milliseconds [ms]

Time until a warning message will be prompted if sequence doesn’t complete.

Timeout Twin inching

Milliseconds [ms]

Time until a warning message will be prompted if sequence doesn’t complete.

Enable logging

Option


8.1.9.4 Parameters

8.1.9.5 Message logging The following messages are generated by this component. This component generates the following message stored in the fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check box Enable logging. Code 255

Message TWIN_BOXES_UP_TIMEOUT

256

TWIN_HOOK_LEFT_UP_TIMEOUT

257

TWIN_HOOK_RIGHT_UP_TIMEOUT

258

TWIN_ATTACHLEFT_TIMEOUT

259

TWIN_ATTACHRIGHT_TIMEOUT

260

TWIN_HOOK_LEFT_DN_TIMEOUT

261

TWIN_HOOK_RIGHT_DN_TIMEOUT

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Description Twin boxes have failed to get to their upper position within time limit. Left hook has failed to reach its' upper position within time limit. Right hook has failed to reach its' upper position within time limit. Twin boxes left timed out when expanding to their attach position. Failed to reach switch within time limit. Twin-boxes right timed out when expanding to their attach position. Failed to reach switch within time limit. Left hook has failed to reach its' lower position (connect) within time limit. Right hook has failed to reach its' lower position (connect) within time limit.

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262

TWIN_BOXES_DOWN_TIMEOUT

263

TWIN_TWIN_SENSOR_LOST

264

TWIN_BOXES_UP_SENSOR_LOST

265

TWIN_HOOK_DN_LEFT_SENSOR_LOST

266

TWIN_HOOK_DN_RIGHT_SENSOR_LOST

267 268 286 287 288

TWIN_HOOK_UP_LEFT_SENSOR_LOST TWIN_HOOK_UP_RIGHT_SENSOR_LOST TWIN_UP_COMMAND TWIN_DOWN_COMMAND TWIN_BOXES_ARE_UP

289

TWIN_BOXES_ARE_DOWN

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Twin-boxes have failed to get to their lower position within time limit. Twin up sensor lost unexpectedly. (not due to output). Twin up sensor received when twinboxes are down. Left hook down sensor lost unexpectedly. Right hook down sensor lost unexpectedly. Left hook up sensor lost unexpectedly. Right hook up sensor lost unexpectedly. Twin up command has been received. Twin down command has been received. Twin boxes have reached their upper position. Twin boxes have reached their lower position.

8.1.10 PID 8.1.10.1 Overview The PID components are used to control fast processes, e.g. positioning, syncronisation and control of hydraulic cylinders with special requirements. Each PID component controls a single cylinder, but usually they ared used in pair and then 2 PID components are needed. The PID component have the following features: Position control Velocity control Syncronisation of two cylinders Acceleration limitation These features are described in the following sections 8.1.10.2-8.1.10.5. The implementation and hands-on configuration are described in section 8.1.10.6.

8.1.10.2 Position control The PID component can use either position mode or velocity mode depending on which way to coontrol it. In position mode you give a reference position in millimeters. Then the cylinder moves to that position as fast as possible with configured constraints. The constraints are defined by the Acceleration limit (see 8.1.10.5). The position mode can be activated in run time.

8.1.10.3 Velocity control In velocity mode you give a reference velocity in percent (range –100 to 100) of the maximum speed. The cylinder then moves in correct direction and at reference speed. When giving a new reference speed the cylinder reaches that speed as fast as possible with configured constraints. The constraints are defined by the Acceleration limit (see 8.1.10.5). The velocity mode can be activated in run time. When you control the cylinder movement with a joystick velocity mode is the best way to do it.

8.1.10.4 Syncronisation of two cylinders Some systems want to syncronise two cylinders so that they move in parallel. A syncronisation regulator is available in the PID to handle this.

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There are two different kind of syncronisation modes: Parallel sync Non-parallel sync Parallel sync is used when the cylinders must be parallel all the time. In run time you can set the difference in position between the two cylinders. Usually this is set to zero. Parallel sync is valid for both positions mode and velocity mode. Non-parallel sync is used when the cylinders shall move syncronised, but not in parallel. In position mode this means that when you can move the two cylinders from separate source positions to two other separate destination positions during the same amount of time. This means that they can move in the same direction or in different directions. In velocity mode you can move the cylinders syncronised at a certain speed without loosing their difference in position. You can either move them in the same direction or in different directions.

8.1.10.5 Acceleration limitation Some systems cannot handle too high acceleration in the cylinder movements. Therefore an acceleration limiter is installed and can be used. The limiter works for both acceleration and retardation. The limiter is always active, independent of position/velocity mode or syncronisation mode.

8.1.10.6 Implementation Each node are equipped with two PID components that can be used. Each PID can control a single cylinder. All parameters for each cylinder are located in the corresponding PID. To identify the two PIDs each component has a parameter called Regulator index which has to be set to 0 and 1 respectively. When using sync mode both PID components cooperate and the sync parameters are taken from PID0. For more detailed information about the implementation, it is reffered to a special document describing the PID component and AutoTuner component.

8.1.10.7 Input Ports Input Enable

Type Digital

Description Enables regulator if set true.

Regulator mode

Digital

Sets the operational mode, POSITION (Low level, 0) or VELOCITY (High level, 1).

Sync parallel mode

Digital

Synchronise

Digital

Reference value

Analogue

Reference value. This signal is scaled within the component and must not be pre-scaled or scaled to desired value.

(Port not visible in ABE) Input Sensor value

Type Analogue

Description Depending on regulator index the sensor signal will be read from either analogue input 0 or analogue input 1. This signal is scaled within the component and must not be prescaled.

8.1.10.8 Output Ports

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Output Retract output (PWM)

Type Analogue

Description The actual value sent to the PWM when retracting. Remark: This output is not really needed cause the regulator will work anyway. This output is used to connect to other components for reference only.

Expand output (PWM)

Analogue

The actual value sent to the PWM when expanding. Remark: This output is not really needed cause the regulator will work anyway. This output is used to connect to other components for reference only.

Retracting

Digital

This signal indicates that the regulator is retracting.

Expanding

Digital

This signal indicates that the regulator is expanding.

(Ports not visible in ABE) Output PWM 0

Type Analogue

Description Used for forward output (PID 0 which is the same as Regulator index 0).

PWM 1

Analogue

Used for reverse output (PID 0 which is the same as Regulator index 0).

PWM 2

Analogue

Used for forward output (PID 1 which is the same as Regulator index 1).

PWM 3

Analogue

Used for reverse output (PID 1 which is the same as Regulator index 1).

Unit Percent

Description The percentage weight of the previously filtered signal.

8.1.10.9 Parameters Parameter Filter weight

[%] Aim window

Millimetres [mm]

The distance from the reference position where to aim for the nonlinear regulator. It is only used in Position mode.

Rate limiter gain

Number

This should be the frequency [Hz], i.e. 1/sample interval.

Fraction of square root

Percent

Fraction of the non-linear regulator signal to use. Should be between 6090.

[%]

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Millimetres [mm]

Time to reach input

Milliseconds [ms]

Sync max integrator

Percent [%]

Sync Integral (I)

Number [value * 1000]

Sync Proportional (P)


Sample interval

Milliseconds

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Distance from reference position where to switch from the non linear regulator to the PI regulator. This parameter must be higher than the Aim window parameter. It is only used in Position mode. Time to reach full effect of reference velocity. It is only used in Velocity mode. Maximum integrator percent in sync mode. It is only used in Sync mode. Integral part in sync regulator. It is only used in Sync mode. Proportional part in sync regulator. It is only used in Sync mode. Sampling interval.

[ms] Velocity window

Percent [%]

Position window

Millimetres [mm]

Device length

Millimetres [mm]

When regulating velocity and if the Reference value is inside Velocity window it is interpreted as zero. When regulating position the cylinder will stop when it reaches reference position +/- Position window. Length of cylinder that is to be controlled.

Insignal max

Number

Maximum insignal from analogue input.

Insignal min

Number

Minimum insignal from analogue input.

R Half PWM time

Milliseconds [ms]

Time for transportation between Device length and 0 at R Half PWM.

R Max PWM time

Milliseconds [ms]

Time for transportation between Device length and 0 at R Max PWM.

R Min PWM

Number

Minimum PWM output that causes movement of piston. (Lower threshold limit).

R Half PWM

Number

PWM output between R Min PWM and R Max PWM. Approx. (R Min PWM + R Max PWM) / 2

R Max PWM

Number

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Minimum PWM output at max speed. (Upper threshold limit).

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F Half PWM time

Milliseconds [ms]

Time for transportation between 0 and Device length at F Half PWM.

F Max PWM time

Milliseconds [ms]

Time for transportation between 0 and Device length at F Max PWM.

F Min PWM

Number

Minimum PWM output that causes movement of piston. (Lower threshold limit).

F Half PWM

Number

PWM output between F Min PWM and F Max PWM. Approx. (F Min PWM + F Max PWM) / 2

F Max PWM

Number

Minimum PWM output at max speed. (Upper threshold limit).

Pos. Integral (I)

Number

Integral part of PI regulator. Only used in Position mode.

[value * 1000] Pos. Proportional (P)


Acceleration limit

Milliseconds [ms]

Regulator index

Number

Proportional part of PI regulator. Only used in Position mode. Minimum time for valve to open full and to close full. Index 0 corresponds to PWM0, PWM1 and analogue input 0. Index 1 corresponds to PWM2, PWM3 and analogue input 1.

Node

Option

Location of regulator. Choose between B1 – B8 and A1 – A4.

Store mode

Option

Select which parameters to use: ALL PARAMS: use all parameters from NVRAM stored by AutoTuner REGULATOR PARAMS: use only the regulator parameters from NVRAM stored by AutoTuner LINEAR PARAMS: use only linear parameters from NVRAM stored by AutoTuner ABE ONLY: use parameters only from Spreader program file

8.1.11 AutoTuner This component is intended as a help when setting up the PID component. It will automatically move the cylinder(s) and measuring it’s characteristics when component is enabled. If one intentions are to synchronize two cylinders with PID components, it’s possible to adapt the two cylinders with the use of this component. This is done by enabling the check box Prepare for sync parameter.

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The AutoTuner will store it’s measured parameters in the onboard NVRAM. These parameters can then be uploaded and monitored/transferred to the matching PID component. It is important that the Record name is identical to the PID that is supposed to use the auto tuned parameters. For more detailed information about the implementation, it is reffered to a special document describing the PID component and AutoTuner component.


Type Digital

Description Enables component if set true. When the enable input goes from 0 to 1 the auto tune procedure is restarted.

Slave

Analogue

Sensor input signal for the slave cylinder. Only needed if prepare for sync is checked.

Main

Analogue

Sensor input signal for the cylinder to auto tune.

Output Finished

Type Digital

Description Output for telling when tuning is complete.

Slave Retract

Analogue

Output for retracting slave cylinder. Only needed if prepare for sync is checked. This shall be connected to the PWM output for the slave cylinder.

Slave Expand

Analogue

Output for expanding slave cylinder. Only needed if prepare for sync is checked. This shall be connected to the PWM output for the slave cylinder.

Main Retract

Analogue

Output for retracting main cylinder. This shall be connected to the PWM output for the cylinder to auto tune.

Main Expand

Analogue

Output for expanding main cylinder. This shall be connected to the PWM output for the cylinder to auto tune.

Unit

Description



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Millimeter [mm]

Velocity window

Percents [%]

Sync Proportional [P]


Sync Integral [I]


Sync max integrator

Percents [%]

Time to reach input

Milliseconds [ms]

Fraction of square root

Percents [%]

Filter weight

Percents [%]

Natural frequency

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When regulating position the cylinder will stop when it reaches reference position +/- Position window. When regulating velocity and if the Reference value is inside Velocity window it is interpreted as zero. Proportional part in sync regulator. It is only used in Sync mode. Integral part in sync regulator. It is only used in Sync mode. Maximum integrator percent in sync mode. It is only used in Sync mode. Time to reach full effect of reference velocity. It is only used in Velocity mode. Fraction of the non-linear regulator signal to use. Should be between 6090. The percentage weight of the previously filtered signal.


Moderation factor


Regulator index

Number

Index 0 corresponds to PWM0, PWM1 and analogue input 0. Index 1 corresponds to PWM2, PWM3 and analogue input 1.

Sample interval

Milliseconds

Sampling interval.

[ms] Acceleration limit

Milliseconds [ms]

Device length

Millimetre [mm]

Timeout

Milliseconds [ms]

Record name

Text

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Minimum time for valve to open full and to close full. Length of cylinder that is to be controlled. Timeout for a full cylinder stroke. This parameter must be greater than the tiem it takes for the cylinder to perform a full stroke. The instance name of the matching PID component.

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Prepare for sync

Option

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This shall be enabled when using syncronisation between two cylinders. Adapts the faster cylinder to the slower one.

8.1.11.4 Message logging The following messages are generated by this component. This component generates the following message stored in the fault and event log onboard the SCS2. Code 385

8.2 8.2.1

Message AUTOTUNER_STORED_IN_NVRAM

Description The component has stored it’s parameters in NVRAM.

AnyBus Introduction

Apart from the parallel I/O of the nodes, each node can be equipped with an AnyBus card used for external buses. This card is fitted into the node on the connector at the right side of the board when the cover is off. By using the Anybus the crane can utilise the SCS2 as an integrated slave on the PLC network or an Anybus card can be used as a Master bus for an internal I/O bus on the Spreader. The principal behind the Anybus is that the interface card translates a number of different bus protocols to a standardised format on the address and data bus of the node. To change between different buses one can then simply change the type of interface card. For details regarding configuration of a specific bus, please view the user manual for that specific card and the electrical documentation for your specific project. The size of the data exchange area between the SCS2 and the Anybus card is configurable up to 64 bytes in and 64 bytes out. The configuration is done via HMS standard files. This interface must be configured in the same way for both the Master and the SCS2 slave for the bus to work correctly. For each project a document has to be sent to the customer describing the used parts of the interface. When referring to in/out we view it from the SCS2 side, hence input for the SCS2 is an output from the master in the crane.

8.2.1.1 Mapping of I/O OUT Byte 0-63 Project specific outputs

IN Byte 0-63 Project specific inputs

Output Segment In the output segment it is possible to use a number of bytes for diagnostic information in the form codes. The diagnostics are handled by the Anybus System component. The code sent will be equivalent with the code displayed in the onboard display, hence there will be three levels of this code INFO, WARNING, ERROR. Apart from the code and the byte for

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indicating the type of code a counter will be incremented each time a code is sent. The counter is a 16bit value and therefore will begin from 0 if the counter overflows. The value of this counter will be sent each time that a new diagnostic message is transmitted. The start position of the diagnostic areas is configurable.

8.2.1.2 Spreader diagnostic area. The byte numbers below should be added to the offset defined in the Anybus System component. Byte 0 => Type of error (info, warning, error) Byte 1 => Node ID (the number of the node from which the message originates) Byte 2-3 (WORD) => Diagnostic code Byte 4-5 (WORD) => Sub Code for diagnostics Byte 6-7 (WORD) => Sequential counter value (message number)

8.2.1.3 System diagnostic area. This part is named the assert diagnostics and is basically only used to find discrepancies in the SCS2 system. The objective of it is mainly for Bromma Conquip AB’s R&D to identify unforeseen weaknesses in the system. If the customer wishes to implement/decode this it can help Bromma Conquip AB improve its’ equipment further, however the customer might find little or no use in this information on their own behalf. The assert part is configured in the following way. The byte numbers below should be added to the offset defined in the Anybus System component. Byte 0 => Node ID Byte 1-2 (WORD) => Row Number (of source code) Byte 3-8 (3 x WORD) => Filename (1:st 6 char.) Byte 9-10 (WORD) => Sequential counter The remaining bytes for output will be assigned the interface with the crane and will vary on each project. The assignments here are discrete outputs from the Spreader and current values (pressure etc.) from devices on the Spreader. These assignments are documented in the electrical documentation of the project. Input Segment The entire range of the input area is configurable per project. The assignments here are discrete inputs to the Spreader and set point values for the Spreader. These assignments shall be documented in the electrical documentation of the project.

8.2.2

Anybus System

The Anybus system component has the ability to handle downloading of new spreader program (*.spr). Note: To be able to download a spreader program via Anybus a specific PC software is needed.

8.2.2.1 Input ports Input Download start

Type Digital

Description If set true, component expects download data on Anybus.

Parameter Node

Unit Node id

Description The node identity of the node where the Anybus interface is located.

Log active

Option

Indicates if the log should be exported to the Anybus interface or not.

8.2.2.2 Parameters

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Log address

0-63

The Anybus output address in the access area where the log should be exported.

Assert active

Option

Indicates if the assert log should be exported to the Anybus interface or not.

Assert address

0-63

The Anybus output address in the access area where the assert log should be exported.

Type Analogue

Description Input from analogue input port.

Parameter Note

Unit Text

Description Free text field. Use this field for notes about the Anybus port.

Word number

Number

Word in Anybus interface to which the value from ”IN” is to be transferred to.

Node

Node id

The node identity of the node where the Anybus interface is located.

Type Analogue

Description Input from analogue input port.

Unit Text


Output Word

8.2.3.1 Input ports Input IN

8.2.3.2 Parameters

8.2.4

Output Byte


8.2.4.2 Parameters Parameter Note

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Byte number

Number

Byte in Anybus interface to which the value from ”IN” is to be transferred to.

Node

Node id


Type Digital

Description Input from digital input port.

Parameter Note

Unit Text


Byte number

Number

Start byte in Anybus interface.

Bit number

Number

Bit number of the chosen byte in Anybus interface.

Node

Node id


Type Analogue

Description The word number from the Anybus interface that is to be transferred to the “OUT” value.

Parameter Note

Unit Text


Word number

Analogue

The word within the Anybus interface from which

Output Bit


8.2.5.2 Parameters

8.2.6

Input Word

8.2.6.1 Output ports Output OUT

8.2.6.2 Parameters

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Node id


Type Analogue

Description The byte number from the Anybus interface that is to be transferred to the “OUT” value.

Parameter Note

Unit Text


Byte number

Number


Node

Node id


Type Digital

Description Digital value from Anybus interface.

Parameter Note

Unit Text


Byte number

Number


Bit number

Number

Bit number in Anybus interface.

Node

Node id


Input Byte


8.2.7.2 Parameters

8.2.8

Input Bit


8.2.8.2 Parameters

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CANopen Introduction

CANopen is a field bus protocol based on CAN and provides a flexible and powerful open industrial communication solution. Apart from the parallel I/O of the nodes the SCS2 master node can control up to 15 CANopen slaves. The SCS2 master node act’s as a CANopen master, this includes network management, SDO services and PDO handling. The SCS2 master node processes the CANopen slave data i.e reads inputs and controls outputs. All configuration of the CANopen functionality is made in the CANopen IO configuration view described in section 5.2.4. Note that the components described in the following section is not visible in the component palette. The following components is used to create CANopen IO and SDO objects.

8.3.2

PDO Read Bit


Type Digital

Description Digital value from CANopen slave

Parameter Slave node ID

Unit Number

Description Node id of CANopen slave

PDO number

Number

PDO number

Byte Number

Number

Byte in PDO

Bit number

Number

Bit in byte

Type Analogue

Description Analogue value from CANopen slave


Unit Number


PDO number

Number

PDO number

Start Byte in PDO

Number

Start Byte in PDO

Start Bit number

Number

Start bit in Byte

8.3.2.2 Parameters

8.3.3

PDO Read


8.3.3.2 Parameters

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Number

Length of data

Type Digital

Description Digital value written to CANopen slave


Unit Number


PDO number

Number

PDO number

Byte in PDO

Number

Byte in PDO

Bit number

Number

Bit in Byte

Type Analogue

Description Analogue value written to CANopen slave


Unit Number


PDO number

Number

PDO number

Start Byte in PDO

Number

Start Byte in PDO

Start Bit number

Number

Start Bit in Byte

Data Length

Number

Length of data

Unit Number


PDO Write Bit

8.3.4.1 Input ports Input Input

8.3.4.2 Parameters

8.3.5

PDO Write

8.3.5.1 Input ports Input Input

8.3.5.2 Parameters

8.3.6

SDO Write

8.3.6.1 Parameters Parameter Slave node ID

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OD index

Number

Index in OD (dec)

OD sub index

Number

Sub index in OD

Value

Number

Value written to OD

Size of data

Option

Unsigned 8: The size of data(value) is 1 byte Unsigned 16: The size of data(value) is 2 byte Unsigned 32: The size of data(value) is 4 byte

Sequence number

Number

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Specifies in which order all SDO objects will be sent

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Guards Spreader stop

The Spreader stop component stops all output functions from Spreader specific components, controllers, and causes them to go back to a boot state upon the release of the Spreader stop. It also generates a message to the log


Type Digital

Description Command to stop spreader. true = spreader stops false = spreader stop resumed

8.4.1.2 Parameters Parameter Enable logging

Unit Option

Description If set to true (checked) the logging of messages will be turned on otherwise no logging will occur.

8.4.1.3 Message logging The following messages are generated by this component. This component generates the following message stored in the fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check box Enable logging Code 97

8.4.2

Message SPREADER_STOP

Description Spreader stop has been activated/deactivated. 0 = deactivated, 1 = activated.

TTDS -Twin Twenty Detection System

The TTDS component implements the functionality of the twin twenty detection system, which is used to prevent lifting two twenty foot containers in a forty foot single lift position. The function should only be active to prevent wrongful lifting and not to actively control any other device. The logic is based on the Bromma seven sensor system and the output can be used to interlock the Twistlocks, but should also always when possible be sent to the crane. Since the logic is designed to be fail-safe, any type of fault of sensor or a misreading by the sensor will trigger the output and therefore an override has been implemented. For details regarding the TTDS system functionality see separate manual. The TTDS component generates log messages every time an override has been used.

8.4.2.1 Input ports Input Override

Type Digital

Description Overrides TTDS result. true = output (Twin) is always false false = normal output

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Input from TTDS sensors.

Type Digital

Description true = two containers detected

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false = one or none detected

8.4.2.3 Message logging The following messages are generated by this component. This component generates the following messages stored in the fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check box Enable logging. Code 290 291

8.4.3

Message TTDS_OVERRIDE_ACTIVATED TTDS_OVERRIDE_DEACTIVATED

Description Override request received. Override request ended.

Analogue guard

The Analogue guard is intended for use of monitoring a specific analogue value. A window around the min/max values can be defined. This component generates a log message classified as a warning, which is user defined. There are 10 (0-9) unique message tags to choose from and they generate the messages 146 – 155 within the log system. Apart from sending a message to the log, an output can trigger any other event if the input value exceeds the ranges specified in the parameters of the component.


Type Analogue

Description Analogue value from other component or analogue input port.

Type Digital

Description Signal indicating that Analogue input has gone outside lower or upper limit longer than the specified time Delay.

Unit

Description



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Note

Text

Descriptive string indicating the function of the component. (Only registered within ABE as memory note)

Delay

Milliseconds [ms]

Time until warning message is prompted if Analogue input has gone out of boundaries.

Lower limit

Number

Lower limit of allowable input range.

Upper limit

Number

Upper limit of allowable input range.

Warning code

Option

Warning code that will identify the component. (Same code can be used for different components.)

Enable logging

Option


8.4.3.4 Message logging The following messages are generated by this component. This component generates the following messages stored in the fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check box Enable logging. Code 146 … 155

8.4.4

Message USERDEFINED_0 ... USERDEFINED_9

Description User chooses what message to use. The messages generated in the log are identified as 146-155 when read out of the log.

Digital guard

The Digital guard triggers a user-defined message to be stored in the log.


Type Digital

Description Digital value from other component or digital input port.

Parameter Note

Unit Text

Description Descriptive string indicating the function of the component. (Only registered within ABE as memory note)

Input NO/NC

Option

Normally open or normally closed behaviour on input.

8.4.4.2 Parameters

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Delay

Milliseconds [ms]

Time until warning message is prompted if digital value is true or false (depending on input NO / NC setting).

Warning code

Option

Warning code that will identify the component. (Same code can be used for different components.)

Enable logging

Option


8.4.4.3 Message logging The following messages are generated by this component. This component generates the following messages stored in the fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check box Enable logging. Code 146 … 155

8.5

Message USERDEFINED_0 ... USERDEFINED_9

Description User chooses what message to use. The messages generated in the log are identified as 146-155 when read out of the log.

Gates

This section contains the simple Boolean instruction set.

8.5.1

AND

This function block performs the function of the logical AND with the number of inputs specified in the parameter settings. Basic function IN 0 IN n OUT 0 0 0 0 1 0 1 0 0 1 1 1

8.5.1.1 Input ports Input IN0 ... IN n

Type Digital


Type Digital

Description Digital output result from AND operation.


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8.5.1.3 Parameters Parameter Number of inputs

8.5.2

Unit Number

Description Number of inputs on component.

NAND

This function block performs the function of the logical NAND with the number of inputs specified in the parameter settings. Basic function IN 0 IN n 0 0 0 1 1 0 1 1

OUT 1 1 1 0

8.5.2.1 Input ports Input IN 0 ... IN n

Type Digital

Description Digital values from other component or digital input port.

Type Digital

Description Digital output result from NAND operation.

Unit Number




8.5.3

NOR

This function block performs the function of the logical NOR with the number of inputs specified in the parameter settings. Basic function IN 0 IN n 0 0 0 1 1 0 1 1

OUT 1 0 0 0

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Type Digital


Type Digital

Description Digital output result from NOR operation.

Unit Number




8.5.4

OR

This function block performs the function of the logical OR with the number of inputs specified in the parameter settings. Basic function IN 0 IN n 0 0 0 1 1 0 1 1

OUT 0 1 1 1


Type Digital


Type Digital

Description Digital output result from OR operation.


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8.5.5

Unit Number


NOT

This function block performs the function of the logical NOT with the number of inputs specified in the parameter settings. Basic function IN OUT 0 1 1 0


Type Digital


Type Digital

Description Digital output result from NOT operation.


8.5.6

XOR

This function block performs the function of the logical XOR (exclusive or) with the number of inputs specified in the parameter settings. Basic function IN 0 IN n 0 0 0 1 1 0 1 1

OUT 0 1 1 0

8.5.6.1 Input ports Input IN 0

Type Digital


IN 1

Digital

Digital value from other component or digital input port.

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8.5.7

Type Digital

Description Digital output result from XOR operation.

SR Latch

This function block performs the function of the logical SR latch with the number of inputs specified in the parameter settings. The output will go high at a high signal on the Set input and will go low again at a high signal on the Reset input. If both inputs are on simultaneously this latch will reset (output goes low).

8.5.7.1 Input ports Input Set

Type Digital


Reset

Digital


Type Digital

Description Digital output result from SR latch.


8.5.8

RS Latch

This function block performs the function of the logical RS latch with the number of inputs specified in the parameter settings. The output will go high at a high signal on the Set input and will go low again at a high signal on the Reset input. If both inputs are on simultaneously this latch will set (output goes high).

8.5.8.1 Input ports Input Set

Type Digital


Reset

Digital


Type Digital

Description Digital output result from RS latch.

8.5.8.2 Output ports Output Result

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Logical gate

The Logical gate component is used if one wishes to perform logical operations (bit wise) on two analogue values. Each analogue input is represented as a 32 bit value.


Type Digital

Description Enables component. If set to false component will set Result to zero. Default value if not connected is true (i.e. enabled all time).

IN 1

Analogue

Input value 1.

IN 2

Analogue

Input value 2.

Type Analogue

Description Result of logical operation.

Unit Option

Description Determents type of logical operation preformed on IN 1 and IN 2. The operations available are AND, OR and XOR.

8.5.9.2 Output ports Output Result

8.5.9.3 Parameters Parameter Operation mode

8.6 8.6.1

Digital OD Timer – On Delay Timer

The On Delay Timer is used to delay a signal from input to output.


Type Digital

Description Digital value from other component or digital input port. Starts the timer on positive flank.

Type

Description


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Digital

Digital output that goes high if the input is high and the specified time has elapsed.


Description Time that the in put signal is to be delayed before the output goes high

8.6.1.3 Parameters Parameter Delay

8.6.2

UpDn Counter – Up Down Counter

The Up Down Counter increments each time the UP input transits from low to high and decrements each time the DOWN input transits from low to high. The RESET input takes the counter value to zero. The range of the counter is from 0 to 231-1 (=2147483647).

8.6.2.1 Input ports Input Up

Type Digital

Description Increments the counter value

Down

Digital

Decrements the counter value

Reset

Digital

Sets the counter value to zero

Output OUT

Type Digital

Description OUT = 1 (high) when the counter value is equal to or above the specified value in the parameter listing

Counter value

Analogue

The current value of the counter

Unit Digital

Description The counter value when the digital output goes high. The output is on when the counter value is equal to or above this value.


8.6.2.3 Parameters Parameter Trigger count

8.6.3

OSC - Oscillator

The oscillator purely switches the output on and off with specified duty cycle adjusted in the parameters.

8.6.3.1 Input ports

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Type Digital


Type Digital

Description Clock pulse output.


Description Cycle time for Clock output.


8.6.3.3 Parameters Parameter Cycle time

8.6.4

Split

The split component is used to generate two or more signals available for connection from one signal line. I.e. it can in many cases replace the use of intermediate variables, since the signal value of the input and the outputs are always the same.


Type Digital


Type Digital

Description Outputs have same status as the IN input port

Unit Number

Description Number of outputs on component.

8.6.4.2 Output ports Output OUT 0 … OUT n

8.6.4.3 Parameters Parameter Number of outputs

8.6.5

Pulse

The Pulse component is used to generate a pulse. The duration of the pulse is set by a parameter. The pulse can be trigged on either positive or negative flank. The pulse is restarted if an new active flank is detected during the pulse. An output indicating time left until pulse is unlit is also available.

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Type Digital


Input

Digital

Trigger for starting pulse.

Output Time remaining

Type Analogue

Description Time remaining (ms) until pulse is unlit.

Output

Digital

Pulse output.

Parameter Active flank

Unit Option

Description Determines active flank of trigger, POS or NEG.

Length of pulse

Milliseconds [ms]

Duration of pulse.


8.6.5.3 Parameters

8.7 8.7.1

Miscellaneous Constant

The Constant component is used to store a Boolean or Analogue value as a constant variable to use within the logic. Note that any other value than zero is considered as a logical one when using this component for digital purposes.

8.7.1.1 Output ports Output Digital

Type Digital

Description Constant value > 0 : Digital output = true Constant value = 0 : Digital output = false

Analogue

Analogue

Analogue output = Constant value

Unit

Description


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Value to put on output ports.

Dead end

The Dead End component is used when one has to make a system where one or more of the mandatory outputs cannot be used for some reason. By connecting the Mandatory output from another component to the Dead end component that signal is terminated. This can be useful when controller components are to be used purely for log purposes and one doesn’t want the logic to control the outputs.


8.7.3

Output Digital IN

Type Digital

Description Terminates a digital connection.

Analogue IN

Analogue

Terminates an analogue connection.

Input Twin boxes are down

Type Digital

Description Input port telling that twin boxes are down.

Landed

Digital

Input port telling that spreader has landed.

Locked

Digital

Input port telling that all Twist locks are locked.

Unlocked

Digital

Input port telling that all Twist locks is unlocked.

Pump 1 on

Digital

Used for activating the clock for drive time 1. When this input is active the clock for drive time 1 counts.

Pump 2 on

Digital


Pump 3 on

Digital


Type

Description

Spreader properties

8.7.3.1 Input ports


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Number of lock operations on twin

Analogue

Number of lock operations performed on twin Twist locks. Saved in external EEPROM.

Number of lock operations on single

Analogue

Number of lock operations performed on single Twist locks. Saved in external EEPROM.

Number of containers

Analogue

Number of containers handled. When twin is down this number is incremented by two. Saved in external EEPROM.

Spreader serial number

Analogue

Spreader unique number. User defined. Read from external EEPROM.

Drawing number

Analogue

Spreader unique number. User defined. Read from parameter Drawing number.

Counter clock pulse

Digital

Clock pulse that toggles from false to true when container is handled. When a new sequence is ended output goes back to false.

Drive time 1 HI Word

Analogue

Accumulated drive time since delivery. The time is only measured when pump 1 is active. The time is divided into two words (2x16bits) where this output is the high word. Saved in external EEPROM.

Drive time 1 LO Word

Analogue

Accumulated drive time since delivery. The time is only measured when pump 1 is active. The time is divided into two words (2x16bits) where this output is the low word. Saved in external EEPROM.


Analogue



Analogue


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Analogue



Analogue


Parameter Enable logging

Unit Option

Description If set to true (checked) the logging of messages will be turned on otherwise no logging will occur.

Drawing number

Number

User defined number. Number is used to present the drawing number of the spreader.

8.7.3.3 Parameters

8.7.3.4 Message logging The following messages are generated by this component. This component generates the following messages stored in the fault and event log onboard the SCS2. The message log can be turned on/off in the parameter settings view via the check box Enable logging. Code 318 319 320 321 322 323

8.7.4

Message SPREADER_PROPERTIES_READ_E EPROM SPREADER_PROPERTIES_READ_D S SPREADER_PROPERTIES_DIFF SPREADER_PROPERTIES_SET_EEP ROM_OK SPREADER_PROPERTIES_SET_EEP ROM_FAIL SPREADER_PROPERTIES_NEW_N ODE_TO_EEPROM

Description Last saved properties are read from EEPROM. System has read properties from NVRAM. Spreader properties read from EEPROM and NVRAM differ. System succeeded to write properties to EEPROM. System failed to write properties to EEPROM. System detected that a new node is connected since last shut down.

Memory

The Memory component is used when one wishes to write or read an analogue value from or to the NVRAM.

8.7.4.1 Input ports Input

Type

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Description

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Enable

Digital

Enables component. If set to false component will set the Analogue OUT to zero. Default value if not connected is true (i.e. no effect).

Write

Digital

If set true, component reads Analogue IN and writes to NVRAM.

Read

Digital

If set true, component reads from NVRAM and writes to Analogue OUT.

Analogue IN

Analogue

Analoge value that is to be stored.

Type Analogue

Description Value stored in NVRAM.

8.7.4.2 Output ports Output Analogue OUT

8.7.5

Digital buffer

The Digital buffer component buffers digital values for a selected amount of execution cycles.


Type Digital


Digital IN

Digital

Digital value that is to be buffered.

Type Digital

Description Buffered values. The input value is shown on OUT 0 the next cycle. The same value is shown on OUT 1 the next cycle and so on.

Unit Number

Description Number of cycles to remember.

8.7.5.2 Output ports Output OUT 0 .. OUT n

8.7.5.3 Parameters Parameter Number of samples to hold

8.7.6

Analogue buffer

The Analogue buffer component buffers analogue values for a selected amount of execution cycles.

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Type Digital

Description Enables component. If set to false component will set all outputs to zero. Default value if not connected is true (i.e. no effect).

Analogue IN

Analogue

Analogue value that is to be buffered.

Type Analogue

Description Buffered values. The input value is shown on OUT 0 the next cycle. The same value is shown on OUT 1 the next cycle and so on.

Unit Number

Description Number of cycles to remember.

8.7.6.2 Output ports Output OUT 0 .. OUT n

8.7.6.3 Parameters Parameter Number of samples to hold

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Analogue

The Analogue components are used to work with analogue values.

8.8.1

RS485 port

This component is used to access the RS485 interface. Depending on what protocol is chosen from the parameter view the component can be used for a variety of purposes.


Type Analogue

Description Analogue value of output from sensor

Parameter Protocol

Unit Option

Description Type of protocol used (i.e. vendor specific protocol). Only SLIN is implemented SSI is implemeted.

Node

Option

Node the RS485 sensor is connected to.

Code Type

Option

Applys only if SSI protocol is selected

Input resolution

Number

Applys only if SSI protocol is selected. Specifies the resolution of the component.

Input IN 0

Type Analogue

Description Input

IN 1

Analogue

Input

Type Digital

Description IN 0 > IN 1 gives OUT = 1 IN 0 <= IN 1 gives OUT = 0

8.8.1.2 Parameters

8.8.2

IN0 > IN1

8.8.2.1 Input ports


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IN0 * IN1

8.8.3.1 Input ports Input IN 0

Type Analogue

Description Input

IN 1

Analogue

Input

Type Analogue

Description OUT = IN 0 * IN 1

Input IN 0

Type Analogue

Description Nominator input

IN 1

Analogue

Denominator input

Type Analogue

Description OUT = IN 0 / IN 1

Input IN 0

Type Analogue

Description Input

IN 1

Analogue

Input

Type Analogue

Description OUT = IN 0 – IN 1


8.8.4

IN0 / IN1

Note. Always avoid division by zero.

8.8.4.1 Input ports


8.8.5

IN0 – IN1

8.8.5.1 Input ports


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IN0 + IN1


Type Analogue

Description Inputs to be added together

Type Analogue

Description OUT = IN 0 + IN 1+, …,+ IN n

Unit Number

Description Number of input ports on component.


8.8.6.3 Parameters Parameter Input counter

8.8.7

Scale

The Scale components scales a analogue value according to the formula, OUT = ((scaledMax – scaledMin)/(INMax-INMin))*(IN - INMin) + scaledMin, which performs a linear scaling with an offset according to OUT = k*IN + m.


Type Analogue

Description Analogue value from other component or analogue input port.

Type Analogue

Description Scaled analogue value with constraints from parameter listing.

Parameter Max value after scale

Unit Number

Description Largest scaled value.

Min value after scale

Number

Smallest scaled value.


8.8.7.3 Parameters

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Max value of input

Number

The maximum value of input.

Min value of input

Number

The minimum value of input.

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AnalogueLatch

The Analogue latch is a component that stores a value internally when triggered by a digital input. The value stored in an internal variable can be read at the output of the component. As long as the digital trigger input is active the input value is directly transferred to the output value and as soon as the digital input goes low the output value remains constant at the current value until a new digital command is given.


Type Digital


IN

Digital

Input that trigger the component to read the value IN Value.

IN Value

Analogue

Input value that is read and stored in the component

Type Analogue

Description The stored value of the component


8.8.9

Filter

The Filter component is used to filter analogue signals from noise.

8.8.9.1 Input ports Input Analogue IN

Type Analogue

Description Unfiltered signal.

Type Analogue

Description Filtered signal.

8.8.9.2 Output ports Output Analogue OUT

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8.8.9.3 Parameters Parameter Filter type

Unit Option

Description Determines type of filter. Only MOVING AVR is implemented.

Filter weight

Number [%]

Determents how many percents of previous filtered signal that is to be used.

Output Port 5

Type Analogue

Description Analogue value

Port 4

Analogue

Analogue value

Unit Option

Description Specifies the node.

8.8.10 AuxAnalogue This component implements two more analogue inputs.


8.8.10.2 Parameters Parameter Node

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9 T utorial This tutorial will guide you through the process of designing a Spreader program using ABE. Steps covered in this tutorial. Creating a new project System view Pin configuration Component view Load view Step 1: Creating a new project Start ABE from your Start menu if it isn’t already started. If you just started ABE you already have a project created for you, If not create a new one by clicking the button showed in the picture below.

Figure 9:1 Create project Step 2: System view Activate the node B2 by checking corresponding Active checkbox. Node B1 is always present in the system.

Figure 9:2 Activating nodes

Fill in the Value fields in the parameter listing. Note that some of the fields are not editable.

Figure 9:3 Setting system parameters

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Step 3: Pin configuration All present nodes are visible as tabs in this view. Make sure tab B1 is activated in the view. Give Port id# 1 and 2 the following names. Comment field is optional.

Figure 9:4 Setting item identifiers on node B1 Make sure tab B2 is activated in the view and do the same for Port id# 1 to 4. Note: The red colour of the fields indicates that the ports are not yet connected.

Figure 9:5 Setting item identifiers on node B2 Step 4: Component view Select the FAC component from the available component pallet.

Figure 9:6 Choosing component If available components pallet is not visible. Activate it by clicking at the Components button shown in picture below.

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Figure 9:7 Bringing up Available components

Place the component on Page 1 in the view.

Figure 9:8 Default look of FAC component Note: Connections with red colour indicate that they are not yet connected. Connections with white colour indicate that they are optional to connect.

Double click on the component to open Properties for the FAC component. Change the property Number of Flippers to 2.

Figure 9:9 Changing properties for FAC component

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The new appearance for the component should look like this:

Figure 9:10 Look of FAC component after changing number of flippers

By placing the pointer over the component or one of its connections a hint (tool tip) will appear. The hint tells you about the properties for the component or its connection.

Figure 9:11 Look of component hint

Click with your right mouse button over a connection on the component. A pop up menu will appear. Move the cursor as shown in the picture below and click on your left mouse button over Flipper_Down.

Figure 9:12 Making component connections

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Your component should now look like this:

Figure 9:13 Appearance of a connection Continue with the remaining connections until you have all connections connected. If you want to disconnect a connection you click over the connection with your right mouse button and choose disconnect when it appears. When your system is complete there should not be any red coloured connections in the Component view or Item identifiers in the Pin configuration view. Your Component view should look like Figure 12 when all your connections are made.

Figure 9:14 Appearance of a connection

Now you are ready to generate downloadable Spreader program file. Select Compile from the File menu. If the following message box appears your system is not configured properly. Look for red coloured connections or item identifiers. If port is configured to be used but isn’t you must delete it. Save the output file (when compiling the spreader program) with the name “tutorial.spr”.

Figure 9:15 The Spreader program contains errors

When you have generated your downloadable program file it can be found at the location where it was saved. You must not edit this file.

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Step 5: Load view Downloading spreader programs 1. Select COM1 or COM2 under selection depending on what serial port is connected to the SCS2. In the picture below COM1 is selected.

Figure 9:16 Select Connection 2. 3. 4.

Press the Download button. Point out the spreader program that you want to download. (Spreader programs have extension *.spr). Observe the status bars. If connected node is the master node no distribution between nodes will appear. If not the master node is the point of connection the spreader program will first be downloaded to the local node (connected node) and than distributed to the master node.

Uploading spreader programs 1.

Select COM1 or COM2 under selection depending on what serial port is connected to the SCS2.

In the picture below COM1 is selected.

Figure 9:17 Select Connection 2. Press the Upload button. The two following dialogues will appear in sequence. Answer Yes to the first dialog if you are working on anything that you want to save else No.

Figure 9:18 Save current spreader program Answer Yes to the second dialog to open the uploaded spreader program in the editor. (If you press No, you have to manually open the uploaded spreader program.)

Figure 9:19 Open spreader program in ABE 3. Observe the status bar ABE --> Connected node. When 100% is reached the uploaded spreader program will appear in the editor.

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Step 6: Online monitoring Online monitoring is performed under Component view. 1.

Make sure you have the same spreader program in ABE and SCS2. If you are not sure about this, you can always download your current spreader program or upload the spreader program from the SCS2 (see Step 5).

2.

Select COM1 or COM2 under selection depending on what serial port is connected to the SCS2.

In the picture below COM1 is selected.

Figure 9:20 Select Connection 3.

Make sure Auto is not checked.

Figure 9:21 Deselect Auto option If Auto is checked, automatic update will be performed at an interval specified by Update interval. 4.

Start online monitoring

Figure 9:22 Start online monitoring The online monitoring starts by telling the SCS2 to add all visible components and their connections. This takes more or less time depending on the number of present components and connections in visible Page(s). A progress bar appears above the buttons, when adding the components, to show you current status. Once the online monitoring is started, the design window is locked for editing. If you want to monitor another part of your design (not visible at the moment); you have to stop the online monitoring and then scroll to that part and start the monitoring again.

5.

Update online values by pressing the Update button.

Figure 9:23 Updated online values

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Stop online monitoring by pressing button as shown below.

Figure 9:24 Stop online monitoring

10 CANopen tutorial This tutorial will guide you through the process of configuring a Spreader program containing CANopen functionality. The tutorial covers the following steps: Add a CANopen slave Add an input Connecting input to Spreader logic Step 1: Add a CANopen slave In the Component view activate the CANopen configuration view by clicking CANopen IO button. In this view click the Add slave button.

Figure 1. Add slave button When this button is clicked the following view appears. Here you can configure: ¾ Type of slave (predefined connection set or not). ¾ The name of the slave ¾ Slave options (CRITICAL or NON CRITICAL). ¾ Adress of slave 1-126 Click OK button when done

Figure 2. Slave properties

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Step 2: Add a CANopen input Make sure that the I/O leaf in the tree view is selected as in the picture below. Click on the Add input button.

Figure 2. Add input The following view appears.

Figure 3. Input properties In this view the properties of this input is set. ¾ Name of the input (in this example IN_1) ¾ PDO number ¾ Byte number ¾ Bit number ¾ Data length Click OK button when done The CANopen I/O configuration view now looks like the picture below.

Figure 4. CANopen I/O cunfiguration view after input is added

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Step 3: Connecting CANopen input to Spreader logic When no more configuration is to be done click the OK button to return to the Pin configuration view Add a component to page and right click on the input to bring up the pop up window Select the CANopen menu and the slave on where the input is configured and click on your left mouse button.

Figure 5. Making component connections Your component should now look like this:

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© 2000

User Manual BMS - Light Version 1.0

Revision

Issued by

Gunnar Ohlsson, CC Systems AB Gunnar Ohlsson, CC Systems AB Gunnar Ohlsson, CC Systems AB

2000-08-22 2000-10-13 2000-10-23

PA4

Gunnar Ohlsson, CC Systems AB

2001-01-10

PA5 A B C

Hans Svanfeldt, CC Systems AB Ken Lindfors, CC Systems AB Hans Svamfeldt, CC Systems AB Hans Svamfeldt, CC Systems AB

2001-10-29 2002-06-12 2003-06-11 2004-08-10

PA1 PA2 PA3

Date

Printed: 04-8-12 9.15

Measures

First draft. Added modem functions. Changes in GUI. Cancel buttons added. Height changed on cells in string grids. Changes in GUI. Cancel button moved. Some Anybus functions added. New pages added. CAN tester, Boot loader. Minor changes after release of System 1.04. Minor changes after release of System 1.05. Minor changes after release of System 1.07.

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Table of contents 1 2

Introduction ................................................................................................................................................................... 3 Installing BMS – Light .................................................................................................................................................. 3 2.1 HW requirements................................................................................................................................................... 3 2.2 Installation ............................................................................................................................................................. 3 2.3 Disclaimer.............................................................................................................................................................. 3 3 User interface................................................................................................................................................................. 4 3.1 Menu (top toolbar) options: ................................................................................................................................... 4 3.2 Status bars in main window................................................................................................................................... 5 4 Download view.............................................................................................................................................................. 6 5 Get log view .................................................................................................................................................................. 7 5.1 Filtering constraints ............................................................................................................................................... 8 6 I/O status view............................................................................................................................................................... 9 7 Misc. view ................................................................................................................................................................... 10 Anybus view........................................................................................................................................................................ 11 8 Spreader info view....................................................................................................................................................... 12 9 CANopen IO view ....................................................................................................................................................... 13 10 Upload view............................................................................................................................................................. 14 11 Advanced................................................................................................................................................................. 15 11.1 CAN Tester.......................................................................................................................................................... 15 11.2 Boot Loader ......................................................................................................................................................... 17 11.3 Asserts ................................................................................................................................................................. 18 11.4 POM Loader ........................................................................................................................................................ 19 11.5 Bluetooth ............................................................................................................................................................. 19 11.6 CANopen services ............................................................................................................................................... 20

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Introduction The BMS is a software tool used for monitoring and handling the Bromma system SCS2. This manual assumes the user has good knowledge of the SCS2 system as well as Windows environments.

Installing BMS – Light HW requirements • • •

An Intel compatible PC running Windows 95 / 98 / NT 4.0 / 2000. At least one serial communication port available (COM1 or COM2). At least 1Mb of free disk space.

Installation • • • •

Close any other applications running under Windows. Insert the first disc into your disc station (if installing from disc) Run the file BMSSetup.exe from the BMS folder on your provided disk. Follow the instructions on the screen.

Disclaimer Copyright Bromma Conquip AB. All rights reserved. Products and company names mentioned herein may be trademarks or trade names of their respective owners. Bromma Conquip AB operates on a policy of continuous improvement. Therefore we reserve the right to make changes and improvements to any of the products described in this manual without prior notice. Bromma Conquip AB is not responsible for any loss of data, income or any consequential damage howsoever caused.

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User interface Menu (top toolbar) options: File: Exit --- Terminates the application. View: Activates selected tab [Download, Get log, I/O status, Misc., Anybus, Spreader info, Upload] Tools: Connect serial cable: activates selected communication port [COM1, COM2]. Connect modem: activates modem connected to selected communication port [COM1, COM2]. The dialog below is used for making the connection. Once a connection has been made the dialog window disappears. The BMS commands are working via the modem if the modem has connected successfully.

Modem connection Connect to node: connects BMS to selected node [B1, B2,..., B8, A1, A2, A3, A4]. This connection is made over RS232 link through the CAN bus. Normally select Local node. Advanced options: Intended for Bromma R&D personnel. Help: About: shows the version of the BMS.

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Status bars in main window 1. 2. 3. 4. 5.

Status of last performed operation. Intended for Bromma personnel. Status of current operation. Serial cable connection (COM1 or COM2). Destination node (normally Local node) of all operations. Status of serial cable connection.

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Download view This tab is used to download the entire system program to the system. Note. It takes a considerable amount of time to update the system program and therefore make sure that the system can be down for this amount of time. 1. 2. 3. 4. 5. 6. 7.

Transfer status from BMS to the connected node [4]. PC downloading to the connected node. Transfer status from connected node [4] to node [5]. Distribution of the program via the bus lines to the other nodes on the bus. Total transfer status. Status of complete system to be downloaded. Connected node (to PC). Receiving node when distributing between nodes. Select file to download. Press here to select the file to be downloaded. When file is selected download process starts. Cancels current transfer to connected node. The operation just cancels the feedback of transfer status if distribution between nodes has started (i.e. the operation will not effect the transfer in this case).

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Get log view This used to retrieve the onboard error and event log. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Gets next set of logged messages (max 128 messages each time its’ pressed) Get all messages in log. If checked, auto mode is on. Auto mode triggers the Next button [1] at an interval of X seconds defined by [4]. Interval for reading via auto mode in seconds. Enable filtering. The filtered table is shown if checked. Filtering can be used to only view certain parts of the log. Opens the Filtering constraint dialog. Select the type of filtering here. Clears the log table on the PC. The log in the SCS2 remains unaffected. Saves the entire log table in a comma separated text file. Can be opened in for instance in Wordpad, Excel etc. Cancels current operation. Load button. Loads and displays a saved log file.

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Filtering constraints Select the type of filtering for the log view in this view. Checked Categories, Nodes, Sub codes and Codes will appear in the filtered table. Ex: APS_TEACH_COMMAND (of category Info) is checked but not Info under Category. The message will therefor not appear in the filtered table. 1. 2. 3.

Message categories Nodes that have reported messages. Message codes for entire table

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I/O status view This view is used to read (and force) the I/O status of the SCS2. 1. 2. 3. 4. 5. 6. 7. 8.

Select node to view. Enables override for I/O-port if checked. To force a value first check this box, then change the value and finally press Write [4] Current value/current overridden value of I/O. Write current override values to system. Only the viewed node is written to. A write for each node is required if values are to be forced on more than one node. Read values from SCS2. All nodes are read at once (Selected node [1] is shown). Enable automatic update of values. Triggers read operation [5] with interval determined by the value of: [6]. Update interval for Auto read [6]. Cancels current operation.

Note. To restore a port to its default value if overridden: Uncheck the corresponding I/O [2] and press Write [4]. (If a read operation is followed instead the unchecked port will be checked by the SCS2.) All forced values are reset if the system is re-started.

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Misc. view This view is used to get and set general information of the SCS2. 1. 2. 3. 4. 5. 6. 7. 8.

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Updates the Date and Time fields from the PC when pressed. Set the time and date on SCS2 according to Date and Time fields. Get current date and time from the SCS2. Displayed in Date and Time fields. Get address key information from the node [5]. Destination of question. Serial cable connection. Cancels current operation. Get version information. Software version and protocol version for Boot and System program. The Boot program version is Boot SW version and the System program version is System SW version. Don’t care about the COM versions. Reboots the system.

Ex. Serial cable [6] is connected via COM1 to B1 and Destination [5] is set to Local node (or B1, which would be the same). B1 is configured to have E-stop and Redundancy block activated. This will give us the answer: Key: 5 E-Stop: YES Redundancy: YES Module name: B1

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Anybus view The Anybus view shows the status of the I/O transferred over the fieldbus interface of the Anybus card. 1. 2. 3. 4. 5. 6. 7.

Input data to SCS2 via Anybus interface. The index field shows which byte is being viewed and the value field the value of that byte in binary format. Output data from SCS2 via Anybus interface. The index field shows which byte is being viewed and the value field the value of that byte in binary format. Reads all Input data [1] and Output data [2] from Anybus interface. Cancels current operation. Set DeviceNet master in Run mode. This operation can only be done when using a DeviceNet master. Set DeviceNet master in Idle mode. This operation can only be done when using a DeviceNet master. Select node where to Read [3] data from.

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Spreader info view This view is used to administrate the external EEPROM that is mounted on some spreaders. Key = generic name of memory area of EEPROM. 1. 2. 3. 4. 5. 6. 7.

Shows the selected key in the Spreader info field [6]. This field can not be edited. Shows the current value of corresponding Key [1]. Sets the Value [2] for selected Key [1]. Deletes the value for selected Key [1]. The Key [1] can not be deleted, just the value. Updates the entire Spreader info [6] view on the PC. Table of all Keys stored in external EEPROM. Cancels current operation.

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CANopen IO view The CANopen view shows the status of the I/O transferred over the CANopen interface. From this view its also possible to select individual or groups of I/O and override it/them. 1. 2. 3. 4. 5.

Retrieves the CANopen I/Oconfiguration from the system Updates the I/O status Updates system with overridden I/O Dropdown box for selection of which node to show I/O from Enables override for I/O-port if checked. To force a value first check this box, then change the value and finally press SetIO [3] 6. Current value/current overridden value of I/O 7. I/O port identifier 8. Cancels current operation 9. Enable automatic update of values. Triggers read operation [2] with interval determined by the value of: [10] 10. Update interval for Auto [9]

Note. To restore a port to its default value if overridden: Uncheck the corresponding I/O [5] and press SetIO [3]. All forced values are reset if the system is re-started.

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Upload view This view is for Bromma R&D personnel only. It is used to upload memory blocks from the SCS2.

Upload view

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Advanced These six sub views are mainly intended for Bromma’s R&D personnel only.

CAN Tester This view holds the functionally of the CAN Tester. To be able to use the CAN Tester the master node has to be keyed as Test. See the SCS2 manual for information. The main functionality is as follows: • Every node connected to the CAN network is tested. • Each connected node is tested for a pre-selected time at each selected bit rate. • When a node is tested the next node is tested at the same bit-rate and during the pre-selected time. • The test results are sent back to the CAN Tester and are displayed in the list.

1. Selects the bit-rates that are to be tested. 2. Sets the duration time of each test. 3. Shows the additional information that are used when saving the results. 4. Saves the results as a *.csv or a *.txt file. 5. Starts the test. 6. Sows status of the CAN test. 7. Closes dialog. 8. Result field showing which node that is tested. 9. Result field showing what bit-rate the test used. 10. Result field showing the minimum of retransmissions during test. 11. Result field showing the average of retransmissions during test. 12. Result field showing the maximum of retransmissions during test. 13. Result field showing the total number of messages sent during test. 14. Result field showing the total numbers of retransmissions during test. 15. Result field showing the total numbers of bus offs occurred during test. 16. Result field showing the total numbers of messages not answered during test.

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Boot Loader The Boot Loader view is used to download new boot program to connected node. 1. 2. 3. 4. 5.

Selects the file that is to be downloaded (*.s19). Downloads the selected file. Progress bar showing percentage completed. Cancels the download. Closes dialog.

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Asserts The asserts view holds the functionality of reading asserts from the SCS2 . It is used for detecting unexpected system events.

Asserts view

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POM Loader The POM Loader view is used for downloading new power monitoring programs to the SCS2 .

POM Loader view

Bluetooth From this dialog it’s possible to configure and manage Bluetooth settings. Note that the configuration possibilities only works with Bromma Conquip’s own Serial port adapter.

Bluetooth configurator view

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CANopen services From this view it’s possible to perform read and write actions to CANopen slave nodes OD (Object Dictionary). The read and write actions uses the SDO (Service Data Objects) concept of CANopen. For a more detailed description of CANopen and it’s functionality it’s referred to more specific documentation. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Page containing the read functionality Page containing the write functionality Selection of CANopen node to read/write from/to. The SCS2 master node has address 127. Index in OD. (Dec.) Sub index in OD (Dec.) Read value/ value that is to be written Reads/writes value Cancels current command Closes the dialog Status of current command 1 2

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OVERVIEW ...............................................................................................................................................................3 REFERENCES ............................................................................................................................................................3 DICTIONARY AND ABBREVIATIONS ..........................................................................................................................3 DOCUMENT LAYOUT ................................................................................................................................................3

GENERAL .................................................................................................................................................................4 THE NODES ..............................................................................................................................................................5

SOFTWARE ................................................................................................................................................................6 3.1 3.2 3.3

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INTRODUCTION .......................................................................................................................................................4 2.1 2.2

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GENERAL ...................................................................................................................................................................3 1.1 1.2 1.3 1.4

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BOOT PROGRAM .......................................................................................................................................................6 SYSTEM PROGRAM ...................................................................................................................................................6 SPREADER PROGRAM ...............................................................................................................................................6

HARDWARE OVERVIEW........................................................................................................................................7 4.1 I/O LED’S ................................................................................................................................................................7 4.2 DISPLAY ...................................................................................................................................................................7 4.2.1 Event categories.............................................................................................................................................8 4.2.2 Message format..............................................................................................................................................8 4.2.3 Priority of displayed messages ......................................................................................................................9 4.3 GROUND CONNECTION .............................................................................................................................................9 4.4 THE X1 AND X3 CONNECTORS .................................................................................................................................9 4.4.1 X1 I/O connector..........................................................................................................................................10 4.4.2 X3 I/O connector..........................................................................................................................................11 4.5 THE X2 CONNECTOR ..............................................................................................................................................13 4.5.1 Main Supply .................................................................................................................................................13 4.5.2 CAN .............................................................................................................................................................13 4.5.3 Address Key .................................................................................................................................................14 4.5.4 Analogue Inputs ...........................................................................................................................................15 4.5.5 PWM Outputs...............................................................................................................................................15 4.5.6 External Spreader Memory..........................................................................................................................15 4.5.7 RS 485 and SSI.............................................................................................................................................16 4.5.8 Additional Jumper Group ............................................................................................................................16 4.6 THE X4 CONNECTOR .............................................................................................................................................17 4.6.1 AnyBus .........................................................................................................................................................18 4.6.2 Two auxiliary Analogue Inputs ....................................................................................................................18 4.7 THE X5 CONNECTOR .............................................................................................................................................19 4.7.1 RS-232..........................................................................................................................................................19 4.8 THE REDUNDANCY FUNCTION ...............................................................................................................................19 4.9 FIELD BUS CONNECTIONS.......................................................................................................................................20 4.9.1 Mapping of I/O ............................................................................................................................................20 4.10 SPREADER STOP ................................................................................................................................................21 4.11 FAULT FINDING TABLE ......................................................................................................................................22

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SOFTWARE TOOLS................................................................................................................................................23 5.1 5.2 5.3

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OVERVIEW .............................................................................................................................................................23 ABE.......................................................................................................................................................................23 BMS ......................................................................................................................................................................23

MISCELLANEOUS ..................................................................................................................................................24

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DATA SHEET ...........................................................................................................................................................24 DIMENSIONS...........................................................................................................................................................25

APPENDIX A (ERROR MESSAGES) ....................................................................................................................26

1

General 1.1

Overview

This document serves as a user manual and shall be used by the surveillance and maintenance operators of the Bromma SCS2. Software as well as hardware routines and descriptions are covered in this document.

1.2

References

Location where to find the latest revision of this document: http://www.bromma.com/backyard/

1.3

Dictionary and abbreviations

ABE BMS Boot program CAN PWM Spreader Program SCS2 System Program SSI

1.4

Application Builder Environment. A tool for building control logic. See separate manual for details. Bromma Monitoring System. A tool for monitoring the SCS2. See separate manual for details. The part of the software in the SCS2 that is executed at power up. This part is responsible for the loading of the program verifying that the system is set up correctly. Controller Area Network. A two wire serial bus used for high speed, high reliability communication. Pulse Width Modulator. The control logic that controls the functionality of the SCS2. Spreader Control System generation 2. The control system described in this user manual. The system will be referred to as SCS2 in this document. The program that serves as a base for the execution and control of the spreader program. Synchronous Serial Interface – sensor interface

Document layout

Chapter 3, System overview, gives a brief description of the SCS2. Chapter 4, Software, describes how the different software parts correlates. Chapter 5, Hardware overview, describes the hardware in the SCS2. Chapter 6, External interfaces, describes all the external interfaces in the SCS2. Chapter 7, Software tools, describes the supporting tools to the SCS2. Appendix A, Error messages, shows all error messages and their meaning.

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Introduction

The core of the Bromma Smart Spreader is the Spreader Communications System (SCS2). In 1991 when Bromma decided to develop a new and highly advanced communications system a close look at the available bus systems revealed a number of shortcomings, such as temperature range, EMC (Electro Magnetic Compatibility) protection and mechanical roughness. Bromma therefore decided to design a bus system that met the demands made on an electronic system for a tough Spreader application. We decided to develop a modular programmable controller, with a heavy-duty field bus interface that complies with European and international standards for control equipment in this area. The SCS2 solution is a single control product that can be used as I/O, as a PLC, and as distributed control for up to 528 I/O points. SCS2 nodes are simple to install. You can connect up to 11 devices using just a single pair of wires. With its modular and scaleable architecture, intuitive features and unparalleled ease of use, it will help save crane builders and end users time and money. SCS2 includes the following features: A bus system able to handle 528 I/O ports (programmable input or output). Up to four analogue inputs with 12 bit resolution. Four PWM outputs for proportional solenoids. One general purpose RS485 channel OR SSI channel. Communication with the help of a standard spreader cable — no screening, no twisted pair. A system that withstands the repeated shocks and vibrations suffered by spreaders. A system able to operate in tropical heat and arctic cold. Choice of different field bus interfaces (ProfiBus, Interbus-S, Device Net….) Optional duty cycle input

2.1

General

As a universal I/O, SCS2 gives you the freedom to connect to a wide variety of host controllers, including PLC's, DCS and PC-based control systems by way of DeviceNet, Profibus-DP. SCS2 can be networked as a slave to Profibus-DP or you can choose a DeviceNet master module for easy third-party integration. Designed by Bromma engineers for reliable performance in the particularly challenging environment of container handling the system corporate four basic elements: Crane Node1

A device directly interfacing with the crane’s control systems, computer and monitoring screens, providing an optional serial bus interface for programming or diagnostic communications, as well as an interface to the spreader node.

Crane-Spreader Communications Link

A two-wire conventional cable CAN communications between the crane control system and the spreader.

Spreader Node

A device that interfaces directly with the spreader’s sensors, supports discrete signals, and acts as the Master node.

Sensors and Switches

Conventional sensors, switches, and actuators on the spreader.

The system is divided into several hardware units called nodes. The nodes are located on the spreader and in the crane. The nodes are connected to each other via a CAN network, see figure 1. The number of nodes required is based on the 1

For details regarding separate dedicated crane fieldbus gateway, see separate manual

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number of I/O needed. The nodes are all equals, both in software as well as in hardware. This reduces spare parts and enables easy-to-change procedures. The only difference is their identity, id. Depending on their location the nodes have different ids. They are numbered from 0 to 11 where: 0 is the master called B1 1-7 are slave nodes located on the spreader called B2-B8 8-11 are slave nodes located in the crane called A1-A4.

Crane I/O

...

Slave A1

Slave A4

CAN network (BCAN)

B1 Master

I/O

B2 Slave

...

SCS

2

B8 Slave

Spreader Figure 1. The figure shows SCS2 connected to the spreader and the crane via I/O. The nodes are also connected internally via a CAN network.

2.2

The Nodes

The SCS2 is built up of several nodes co-operating in the system. Each node has a specific role, either slave or master. There must be only one master node in the system and the rest are slaves. The master node makes all the calculations and decisions. The slave nodes act as remote I/O to the master, but can also have distributed functions such as regulators.

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Software

The SCS2 software consists of three types of programs; Boot Program, System Program and Spreader Program.

3.1

Boot Program

When the power is applied to the Boot Program starts to run. It will take approximately 5 seconds to boot up the system. During system Program updates it will take longer. The Boot program is responsible for Initialising hardware Checking that all the system Programs match. Checking that the emergency stop and redundancy settings are correct Performing a program downloads.

3.2

System program

After the Boot program is finished, the System program will run, until the system is switched off. The System program is responsible for Executing the Spreader program (only on Master node) Supporting any connected PC via the com-port Monitoring the supply voltage and some internal voltages Handling in the event log Reading and writing I/O

3.3

Spreader Program

The Spreader Program is the program logic that controls the spreader. This program is created in ABE, see chapter 5.2 for a brief description.

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Hardware Overview

Below is a picture of a SCS2 node. The different parts are explained in the following chapter.

X1- I/O Connector

4.1

X2- I/O, bus & supply Connector

X3- I/O Connector

I/O LED 1-48

Bus/AI (X4)

RS232 (X5)

Display & Power LEDS

I/O LED’s

The I/O LED’s indicate the current status of the corresponding I/O module. The LED is powered from the secondary (5V) of the module.

4.2

Display

The display shows three pages of information where each page has a maximum of 8 characters. Each page is shown for 1 second. The pages show the following: Node ID and System program version. Format: . Elapsed time running since power on. Format: DDD HHMM where DDD is the number of days, HH the number of hours and MM the number of minutes. Message page. The message page shows numeric information only, which has to be translated into comprehensive plain text manually. The meaning of this page is explained in the rest of this section. There are also four red LED’s in the bottom of the display window indicating the supply voltage level. Four different levels are indicated and the ideal voltage is when all LED’s are lit. LED1 – 11V, FAIL LED2 – 14V, WARNING 2 LED3 – 17V, WARNING LED4 – 21V, OK It is not recommended to run the system below the OK level though it still seems to work fine. Attached devices may malfunction at lower voltages thus making the system unreliable. The green LED is the “power on” indicator. Manual File: SCS_1

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4.2.1 Event categories There are three categories of information displayed on the event page: information, warning and error. Type Error

Prefix E

Example E102

Note Any error message would shut down the system. All outputs are turned off and the program is halted. Error messages will begin with an E.

Warning

W

W60

Warning shows information about the system status that is of high importance. The system keeps on running. Warning messages will begin with a W.

Information

I

I59

Information shows progress in the system. Examples of information that could qualify to be displayed as information: Program load status (how many percent are completed), version verification info, BMS connected, etc. Informational messages will begin with an I.

Information 4.2.2 Message format The display can show 8 characters. These are used in the following format: LTTTSSSS L = Level type TTT = Message type SSSS = Sub type

Example: E102 => Error in initialising the hardware W61 1 => Warning indicating that a twistlock is indicating locked and unlocked. The sub code indicates that it is corner 1. I59 => Information that the system has started.

Level type The level type can be one of the following: I = Information, W = Warning, E = Error Message type The message type represents the cause of the message. Examples of message types are System started, Wrong system version and I/O error. All these types are described in appendix A. Sub type The sub type is used to specify more detailed information about the message type. The sub types have different meanings for all message types. For example does sub type 14 together with message type 47 mean I/O error on digital port 14 instead of just I/O error. These sub types are described in appendix A.

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4.2.3 Priority of displayed messages Only the latest event is displayed at a time. When the display shows a warning and an event occurs which would show information, the warning has higher priority and is thereby left on the display. The same relationship goes for errorinformation and error-warning. Priority in descending order: Error Warning Information Note that warnings are cleared from the display after at least 10 messages of informational type have passed and the warning message is older than 15 minutes. Error messages are cleared by resetting the system.

4.3

Ground connection

The node chassis must be properly connected to protective earth. A grounding bolt is placed on the right hand side of the node for this purpose.

4.4

The X1 and X3 connectors

There are 48 digital ports on a node. Each port can be configured as either input or output via software. The ports 1 to 44 are joined in groups of 4 resulting in 11 groups. Each group has a “Common” junction. See the connector part for more detailed information. Ports 45 to 48 are single I/O.

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X1 I/O connector

Front view of X1 connector Description Name I/O-1 General purpose input or output / Unlocked_0 I/O-2 General purpose input or output / Unlocked_1 I/O-3 General purpose input or output / Unlocked_2 I/O-4 General purpose input or output / Unlocked_3 Common/Supply 1 Common junction for I/O-1 to I/O-4

X1 pin number 31 41 43 42 44


General purpose input or output / Locked_0 General purpose input or output / Locked_1 General purpose input or output / Locked_2 General purpose input or output / Locked_3 Common junction for I/O-5 to I/O-8

3 2 11 1 21


General purpose input or output General purpose input or output General purpose input or output General purpose input or output Common junction for I/O-9 to I/O-12

26 16 6 7 8



4 5 25 15 35


General purpose input or output / Landed_left_0 General purpose input or output / Landed_left_1 General purpose input or output / Landed_right_0 General purpose input or output / Landed_right_1 Common junction for I/O-17 to I/O-20

10 20 30 40 9


General purpose input or output / Lock_left General purpose input or output / Lock_right General purpose input or output / Unlock_left General purpose input or output / Unlock_right Common junction for I/O-21 to I/O-24

46 47 49 48 50

2

Redundancy remark. I/O signals 21 – 24 are affected by the redundancy safety functionality. See chapter 4.8 Manual File: SCS_1

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To make linking of common supplies easier the X1 connector also has groups if pins linked together to be used basically as jumper bars with the same potential. The following pins are linked together internally for the purpose of feeding switches/valves with common potential. X1 - Pin number 12 13 14 22 23 24 32 33 34 45 4.4.2

Link configuration X1 - Pin number 17 18 19 27 28 29 37 39 38 36

Link configuration

X3 I/O connector

Front view of X3 connector Name I/O-25 I/O-26 I/O-27 I/O-28 Common/Supply 7

Description General purpose input or output General purpose input or output General purpose input or output General purpose input or output Common junction for I/O-25 to I/O-28

X3 pin number 21 31 41 42 11



24 35 44 45 43



5 4 3 2 1

I/O-37 I/O-38 I/O-39 I/O-40

General purpose input or output General purpose input or output General purpose input or output General purpose input or output

6 16 25 26

Manual File: SCS_1

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Name Description Common/Supply 10 Common junction for I/O-37 to I/O-40

X3 pin number 15


49 48 47 46 36



7 8


9 10


50 40


30 20

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To make linking of common supplies easier the X3 connector also has groups if pins linked together to be used basically as jumper bars with the same potential. The following pins are linked together internally for the purpose of feeding switches/valves with common potential. X3 - Pin number 12 13 14 22 23 32 33 34

Manual File: SCS_1

Link configuration X3 - Pin number 17 18 19 27 28 29 37 38 39

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The X2 connector

The X2 connector has a jumper group to be used for supply voltage to the different analogue sensors.


4.5.1 Main Supply 24Volt AC or DC power supply for the node. The signals are doubled in the connector due to the current limit of single pins. DC voltage can be applied either way. Name 24INA 24INA 24INB 24INB

Pin number in connector X2/42 X2/43 X2/45 X2/44

4.5.2 CAN The two CAN nets are placed in the X2 connector. The first net use Bromma CAN (BCAN) voltage levels and the second net use standard CAN voltage levels. The standard CAN net has to be terminated with external resistors. Name CAN High 1 CAN Low 1 CAN High 2 / Reserved3 CAN Low 2 / Reserved3 CAN GND 2/ Reserved3

3

Pin number in connector X2/30 X2/40 X2/50 X2/20 X2/48

CAN channel is std CAN for CAN-Open installations

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4.5.3 Address Key All nodes must have a unique identity. This is read from the Id pins ID0 – ID4 where pins being connected to the ground pin corresponds to ”zeroes” and pins left unconnected are considered ”ones”. Name ID4 ID3 ID2 ID1 ID0 Ground

Pin number in connector X2/49 X2/39 X2/29 X2/19 X2/9 X2/10

Configuration Since all nodes are the same in reference to the software as well as hardware you have to configure them to carry different roles. Setting the address key configures the role of the node. The address key has two other functions as well, enabling Spreader stop and enabling redundancy block. These functions are described in chapters 4.10 and 4.8. The address key setting is described in the following table: Key input

Node name

00000 00001 00010 00011 00100 00101 00110 00111 01000 01001 01010 01011 01100 01101 01110 01111 10000 10001 10010 1001111110 11111

Test A1 A2 A3 A4 B1 B1 B1 B1 B2 B2 B2 B2 B3 B4 B5 B6 B7 B8 Not Used Test

Spreader stop

No No No No Yes Yes No No Yes Yes No No No No No No No No

Redundancy block and Pins to be linked together in override of landing X2 connector pins 10,9,19,29,39,49 No 10,19,29,39,49 No 10,9,29,39,49 No 10,29,39,49 No 10,9,19,39,49 Yes 10,19,39,49 No 10,9,39,49 Yes 10,39,49 No 10,9,19,29,49 Yes 10,19,29,49 No 10,9,29,49 Yes 10,29,49 No 10,9,19,49 No 10,19,49 No 10,9,49 No 10,49 No 10,9,19,29,39 No 10,19,29,39 No 10,9,29,39

Node number identifier when viewing Display and Log 8 9 10 11 0 0 0 0 1 1 1 1 2 3 4 5 6 7

None

Example Here are three examples of how to set the address key: A node with id B1 without redundancy block or emergency stop has the address key 01000. A node with id B2 with both redundancy block and emergency stop has the address key 01001. A node with id A2 (cannot have redundancy block or emergency stop enabled) has the address key 00010. Manual File: SCS_1

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4.5.4 Analogue Inputs There are two analogue inputs on each node via the X2 connector (the other two are via the X4 connector). Each signal has its own 10V-reference voltage output, ground reference and sensor signal that should be connected to the sensor device. Name Analogue in 1 10Vref 1 Signal ground 1

Pin number in connector X2/18 X2/28 X2/8

Analogue in 2 10Vref 2 Signal ground 2

X2/17 X2/27 X2/7

4.5.5 PWM Outputs There are four PWM outputs for driving external loads, for example proportional hydraulic valves. Each output has two connections, one in and one out. The load should be connected between these, since it is a current loop. Name PWM out 1 PWM in 1

Pin number in connector X2/3 X2/4

PWM out 2 PWM in 2

X2/2 X2/1

PWM out 3 PWM in 3

X2/21 X2/11

PWM out 4 PWM in 4

X2/31 X2/41

4.5.6 External Spreader Memory An external EEPROM memory can be mounted on the spreader for spreader id and/or user defined purpose. The memory is connected as below. Name 10V supply Serial data Serial clock Signal ground

Manual File: SCS_1

Pin number in connector X2/36 X2/16 X2/26 X2/6

Cable Red Blue Green Black

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4.5.7 RS 485 and SSI The RS 485 connection can be used for external sensors or user defined purpose. The SSI connection can be used with external sensors with up to 25 bits data length. The hardware and the pins in connector X2 are shared between RS 485 and SSI. Therefore it is only possible to use one of these connections at a time. When used as a RS 485 the following pins are used: Name Pin number in connector Channel A X2/38 Channel B X2/37 When used as SSI the following pins are used: Name Pin number in connector Clock+ X2/38 ClockX2/37 Data+ X2/15 DataX2/25 4.5.8 Additional Jumper Group To make linking of common supplies easier the X2 connector also has groups if pins linked together to be used basically as jumper bars with the same potential. The following pins are linked together internally for the purpose of feeding switches/valves with common potential. X2 - Pin number 22 23 32 33 34

Manual File: SCS_1

Link configuration

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The X4 Connector

The X4 connector can be configured for field bus operation or one of three alternative functions. The alternatives are a RS 232 serial port, two additional analogue inputs or a duty cycle input. The function is selected by connecting different pin headers to connector CN103. To find these pin headers the SCS2 node must be opened. The figure below shows the relative placement of the pin headers. In each pin header the pins are number 1 to 5 or 1 to 10. In the figure a pin with a circle to the left is number one in that header. Field bus operation is selected by connecting the field bus connector on the Anybus card with pin header CN103. The RS 232 serial port is selected by connecting CN100 and CN103. The two additional analogue inputs are selected by connecting CN105 and CN103. Finally the duty cycle input is selected by connecting CN104 with CN103.

Front view of connectors inside node.

Manual File: SCS_1

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4.6.1 AnyBus The AnyBus connector is used to interface any of the fieldbus types used apart from BCAN. Name A-Line B-Line GND-BUS

Pin number in connector X4/2 X4/1 X4/3

4.6.2 Two auxiliary Analogue Inputs These two analogue inputs use the same ground and 10 V reference voltages as the two analogue inputs in connector X2. The input range is either 0 to 10 V or 0 to 20 mA. The 0 to 20 mA range is selected for channel 1 by jumpering pin number 1 and 2 in CN106 and for channel 2 by jumering pin number 4 and 5 in CN106. If no jumpers are added on CN106 the voltage range, 0 to 10 V range is selected as default. In the 0 to 20 mA range a 500 Ohm resistor is used internally and therefore the current being measured must be capable of driving 20 mA at 10 V to utilise the full 0 to 20 mA range. Name GND GND Analogue Input 1 Analogue Reference 10 V Analogue Input 2

Manual File: SCS_1


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The X5 Connector

4.7.1 RS-232 The RS-232 connector, called BMS port, is located to the right of the node and is used only for this purpose. Name TxD RxD RTS CTS GND


4.8

The Redundancy Function

For safety reasons the hardware is designed to override the operator commands in some occasions. This is to prevent the operator from making wrong commands by accident when the spreader is not landed, prohibiting dangerous results.

B

C

D

A E The commands either from a remote node on the network or the local node itself. The CPU and the system software as well as the application specific software (Spreader program). The redundancy block of hardware static logic. The block has two functions, to make sure the twistlocks are energised correctly at boot and to prevent the software from changing between lock and unlock when not landed during operation. At boot the redundancy block checks the sensor status and determines if the twistlock valves are to be energised and in what direction. After a correct landing and a transition between lock/unlock the redundancy block goes passive only preventing the software to change between lock and unlock unless the Spreader is properly landed. In this state the redundancy can be viewed as two relay contacts, where only one contact is closed at a time permitting the twistlock outputs. The only way of overriding the logic of the redundancy block is to energise a specific I/O (landed override) on that particular node. The outputs to the lock/unlock valves The sensor signals from landed, locked and unlocked. To enable the redundancy the address key on B1 or B2 is used, this then automatically means you have to use input 48 as Landed override to be able to override the hardware logic. The landed override signal sets the spreader in landed mode and thereby temporarily disables the redundancy block.

Manual File: SCS_1

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Field bus Connections.

Apart from the parallel I/O of the nodes, each node can be equipped with an AnyBus card used for external buses. This card is fitted into the node on the connector at the right side of the board when the cover is off. By using the AnyBus the crane can utilise the SCS2 as an integrated slave on the PLC network or an AnyBus card can be used as a Master bus for an internal I/O bus on the Spreader. The principal behind the AnyBus is that the interface card translates a number of different bus protocols to a standardised format on the address and data bus of the node. To change between different buses one can then simply change the type of interface card. For details regarding configuration of a specific bus, please view the user manual for that specific card and the electrical documentation for your specific project. The size of the data exchange area between the SCS2 and the Anybus card is configurable up to 64 bytes in and 64 bytes out. The configuration is done via HMS standard files. This interface must be configured in the same way for both the Master and the SCS 2 slave for the bus to work correctly. For each project a document has to be sent to the customer describing the used parts of the interface. When referring to in/out we view it from the SCS2 side, hence input for the SCS2 is an output from the master in the crane.

4.9.1

Mapping of I/O

OUT Byte 0-63 Project specific outputs

IN Byte 0-63 Project specific inputs

Output Segment In the output segment it possible to use a number of bytes for diagnostic information in the form codes. The code sent will be equivalent with the code displayed in the onboard display; hence there will be three levels of this code INFO, WARNING, ERROR. Apart from the code and the byte for indicating the type of code a counter will be incremented each time a code is sent. The counter is a 16bit value and therefore will begin from 0 if the counter overflows. The value of this counter will be sent each time that a new diagnostic message is transmitted.

Byte 0 Byte 1 Byte 2-3 (WORD) Byte 4-5 (WORD) Byte 6-7 (WORD)

Manual File: SCS_1

4.9.1.1 Spreader diagnostic area. => Type of error (info, warning, error) => Node ID (the number of the node from which the message originates) => Diagnostic code => Sub Code for diagnostics => Sequential counter value (message number)

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4.9.1.2 System diagnostic area. This part is named the assert diagnostics and is basically only used to find discrepancies in the SCS2 system. The objective of it is mainly for Bromma Conquip AB’s R&D to identify unforeseen weaknesses in the system. If the customer wishes to implement/decode this it can help Bromma Conquip AB improve its’ equipment further, however the customer might find little or no use in this information on their own behalf. The assert part is configured in the following way. Byte 8 => Node ID Byte 9-10 => Row Number (of source code) Byte 11-16 => Filename (1:st 6 char.) Byte 17-18 => sequential counter The remaining bytes for output will be assigned the interface with the crane and will vary on each project. The assignments here are discrete outputs from the Spreader and current values (pressure etc.) from devices on the Spreader. These assignments shall be are documented in the electrical documentation of the project. Input Segment The entire range of the input area is configurable per project. The assignments here are discrete inputs to the Spreader and set point values for the Spreader. These assignments shall be documented in the electrical documentation of the project.

4.10 Spreader Stop A Spreader stop function can be used in the system. This is performed by enabling Spreader stop using the address key on B1 or B2 and connecting the signal from the spreader stop button to digital port 47 on the corresponding node (B1 or B2). The spreader stop configuration must correspond to the spreader stop setting in the spreader program. This means that if and only if the spreader stop on a node is enabled, digital port 47 must be connected to the Spreader Stop component in the spreader program.

Manual File: SCS_1

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4.11 Fault Finding table Symptom What to do

Comment

Power Supply Node won’t start. No text appears in the display after power-on.

Measure the main supply. The voltage should exceed 17V AC or DC.

The green and all red LED’s in the display should be lit.

Probe TxD and RxD lines with oscilloscope while trying to communicate.

Data lines should show square waves between –10V to +10V relative to GND pin.

RS-232 BMS system can not communicate with the node.

CAN The node can not communicate with the other nodes.

Digital Ports Input signal fault

Output signal fault

Node ID The node stops at start-up with Node Id displayed.

Analogue Inports Analogue input signal appears to be faulty.

PWM Outports PWM output appears to be faulty.

Manual File: SCS_1

Probe bus lines with oscilloscope. CAN high should show square waves pointing downwards and CAN low should be showing square waves pointing upwards.

Check if LED indicator on I/O module responds to sensor signal. Check the Common connection for correct supply. Check if LED indicator on I/O module responds to command. Check the load for proper connection and grounding. Check for broken fuse on the I/O module. Check the Common connection for correct supply.

The LED should be lit when current flows through the module.

Measure the voltage of all ID pins. 5V represent ones and 0V represents zeroes. The measures should indicate the expected id.

This can indicate that the node has wrong id strapped telling the node to participate in the system with wrong role.

Check the reference voltage relative to the GND. Check if the node chassis is properly grounded to the spreader.

There should be exactly 10V difference between them. This is very important in an AC driven system.

The LED should be lit when the circuit is closed. The load should be connected between the modules out pin and ground.

The supply voltage depends on the type of load. 220V,110V,24V or other.

Check the load for errors. Try another load.

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Software tools 5.1

Overview

There are some related tools to the SCS2, which support it in different ways. A brief description of these tools is given below.

5.2

ABE

ABE (Application Builder Environment) is a tool for developing and configuring the spreader program, which controls the logic of the spreader. ABE generates a load file. For more detailed see the separate manual.

5.3

BMS

BMS ultra light (Bromma Monitoring System ultra light) is a tool for monitoring events and reading status of I/O in the SCS2. BMS can also be used to download new programs to the SCS2. For more detailed see the separate manual.

Manual File: SCS_1

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Miscellaneous 6.1

Data sheet

Parameter

Note

Min

Max

Unit

Operating voltage Current consumption Power monitoring

Pin X2 42-44 Depending on number and type of I/O modules Level and quality measurement of voltage. Indicated via LED’s. (faults stored in log) Operating temperature Internal temperature monitoring IP67 In accordance with 89/336/EEC:

17 300

40 800

V AC/DC mA

-40

+85

0

0 0

2,5 10

A V

12

300 230

kHz V AC/DC

Temperature

EMC conformity

Controller Memory

Time PWM current output Analogue inputs SSI I/O 48 programmable

Scan time Serial interfaces

Diagnostics

FB programming

Manual File: SCS_1

C

EN 50081-2: 1993 EN 50082-2: 1995 EN 61000- 4- 6: 1996 EN 61000-4-8:1993 ENV 50204: 1995 EN 61000- 4- 4: 1995 EN 61000- 4- 2: 1995

32bit controller running at 16MHz quartz Program 1.4Mb Log/NVRAM 128kb External EEPROM 256byte 1*realtime clock 4*Current controlled. Short circuit protected. 12 bit resolution voltage/current 10V reference voltage output serial Voltage depending on type of module used. Galvanic isolation. LED indication. SC/OL protected 3A. System scan time Node scan time BCAN – Bromma CAN based bus RS485 – Asynchronous for sensors etc. RS232 – For PC communication Field bus slave to those field buses supplied by HMS. System diagnostics Spreader functionality diagnostics 8 character display for messages & information Power level via LED’s Event and error log Basic binary functions (AND, OR etc.) Basic Analogue functions (compare, add etc.) Basic controller functions(PWM, regulators etc.) Spreader controller functions

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50 5

ms ms


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Dimensions

Figure 1 All dimensions in mm

Manual File: SCS_1

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Appendix A (Error messages)

The error messages, which are generated by the system, can be viewed in the display as well as in the log (using the BMS). It is the same information in both interfaces and is explained in this appendix in the table below. Nu level m.l cod e 0 1 2

Description of code

Description of sub code Consequence

WARNING Failed reading temperature spare 0

Hints

. .

3

spare 1

.

4

spare 2

.

5

spare 3

.

Two different PCs' trying to download to the system

Id of one of the node connected to the PC

7

spare 4

.

8

spare 5

.

9

spare 6

.

10

spare 7

.

11

spare 8

.

12 ERROR

Program memory failure, HW fault

.

System is brought into failsafe mode.

13 ERROR

No response from slave when initialising system

.


14 ERROR

Boot sequence failed

.


15

spare 9

.

16

spare 10

.

17

spare 11

.

18

spare 12

.

19

spare 13

.

20 ERROR

Downloading error, connection . broken

21

spare 14

.

22 ERROR

Memory collides when downloading program

.

23

spare 15

.

6

ERROR

Manual File: SCS_1

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Ensure that only one PC is downloading

Ensure that all slave are powered up & correctly addressed Restart system


reload program


recompile and download program again


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24

spare 16

.

25

spare 17

.

26

spare 18

.

27

spare 19

.

28 WARNING No data in program/system memory 29 spare 20

.

30 WARNING Checksum of memory corrupt

.

31 ERROR

HW fault on memory

.

32

spare 21

.

33

spare 22

.

34 ERROR

System init. Display. This error The error codes during the system boot phase that have caused the code accumalates and displays system to go into failsafe mode the errors ocurred during the system boot, since no reporting is done until the system has started.

35 ERROR

System failed in reading . spreader program from memory


reload and restart

36 ERROR

No spreader program residing in . memory


download program

37 ERROR

System failed to run spreader program

.


reload proram

38 ERROR

Spreader program object instances failed

.


39 ERROR


.


40 ERROR


.


41 ERROR


.


42 ERROR


.


Check spreader program. If problems persist contact Bromma Check spreader program. If problems persist contact Bromma Check spreader program. If problems persist contact Bromma Check spreader. If problems persist contact Bromma Check spreader program. If problems persist contact Bromma

Manual File: SCS_1

System cannot start

Contact Bromma


Contact Bromma if problem persists

.

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43 ERROR

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.

44 WARNING I/O message lost 45 ERROR Memory failure

. .

46 47

spare 23 spare 24

. .

48

spare 25

.

49

spare 26

.

50 ERROR

Failed to configure I/O on node The node ID which has generated the error The node ID which has Duplicate answers on I/O generated the error configuration from the same node when initialising system

51 ERROR

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Check spreader program. If problems persist contact Bromma


Restart system. If problems persist contact Bromma

System is brought into failsafe mode. System is brought into failsafe mode.

restart restart

52 ERROR

System initialising error when configuring nodes I/O

The node ID which has System is brought into generated the error failsafe mode.

restart

53 ERROR

Duplicate answers on I/O configuration from the same node when initialising system


restart

54

spare 27

55 ERROR

Duplicate answers on I/O configuration from the same node when initialising system


restart

56 ERROR

No answer when master . requesting configuration information during intitialisation


57 ERROR



58 ERROR



59 INFO

System started

check connections between nodes. Restart check connections between nodes. Restart check connections between nodes. Restart

.

60 WARNING TWL - No twistlock sensor . inputs active during system start

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Message stored in log and check wiring, displayed on Spreader sensors and connectors or mechanical reasons


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61 WARNING TWL - One twistlock indicating ID no. of the twistlock Message stored in log and check for both locked and unlocked which generated the displayed on Spreader damaged sensors warning and sensor adjustment or mechanical reasons 62 WARNING TWL - timeout locking. Locked ID no. of the twistlock Message stored in log and check sensor, signal has not been received which generated the displayed on Spreader valves and/or after output to valve warning wiring or mechanical reasons ID no. of the twistlock Message stored in log and check for 63 WARNING TWL - Locked sensor lost which generated the during operation. Sensor lost displayed on Spreader damaged sensors without command/output when warning and sensor twistlocks are all locked adjustment or mechanical reasons ID no. of the twistlock Message stored in log and check sensor, 64 WARNING TWL - timeout unlocking. which generated the Unlocked signal has not been displayed on Spreader valves and/or warning received after output to valve wiring or mechanical reasons ID no. of the twistlock Message stored in log and check for 65 WARNING TWL - Unocked sensor lost which generated the during operation. Sensor lost displayed on Spreader damaged sensors without command/output when warning and sensor twistlocks are all unlocked adjustment or mechanical reasons ID no. of the twistlock Message stored in log and check for 66 WARNING TWL - all landed sensors not which generated the received after first landed and displayed on Spreader damaged sensors warning timeout. and sensor adjustment or mechanical reasons 67 WARNING TWL - landed sensor not ID no. of the twistlock Message stored in log and check for released when the other sensors which generated the displayed on Spreader damaged sensors not active and a timer has timed warning and sensor out adjustment or mechanical reasons 68 WARNING TELESCOPE - prox. type. No . Stops the telescope and check for valid sensor found within displays/stores message damaged sensors and sensor timeout limit after output has been activated adjustment or mechanical reasons 69 WARNING TELESCOPE - prox. type. ID no. of the sensor Stops the telescope and check for Wrong sensor in telescoping missing which displays/stores message damaged sensors sequence reached and sensor generated the warning adjustment or mechanical reasons Manual File: SCS_1

29 Printed: 2004-12-08 13:51


Document:

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Project No

SCS2

Manual

Prepared by:

Date:

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2004-12-08 13:51

70 WARNING TELESCOPE - prox. type. The ID no. of the lost position sensor is lost without an sensor output.

Version:

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Message stored in log and displayed on Spreader

71 WARNING TELESCOPE - prox. type. Two ID no.s. of the sensors Message stored in log and check for different position sensors displayed on Spreader damaged sensors indicating simultaneously and sensor adjustment or mechanical reasons 72 ERROR Duplicate answers from one The node ID which has System is brought into restart (check node during boot verification generated the error failsafe mode. address keying) 73 ERROR

Wrong boot version in a node


contact Bromma

74 ERROR

No answer when master requesting boot version.


restart

75 76 77 78

spare 28 spare 29 spare 30 spare 31

.

79

spare 32

.

80 ERROR

Wrong node answered request from master to check if pc was connected No answer after master request to check PC port (RS232)


restart


restart, check connections

82 ERROR

Unable to download program

.


retry

83 ERROR

Unable to download program (checksum failure)

.



84 WARNING Onboard realtime clock time couldn't be read

.

85 WARNING Onboard realtime clock time couldn't be set

.

81 ERROR

86 INFO

87 INFO

88 INFO

Manual File: SCS_1

minimum system CPU cycle time in ms time. Periodically reported every half hour. The counter is reset after reporting. maximum system CPU cycle time in ms time. Periodically reported every half hour. The counter is reset after reporting. average system CPU cycle time. time in ms Periodically reported every half hour. The counter is reset after 30 Printed: 2004-12-08 13:51





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Project No

SCS2

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2004-12-08 13:51

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11

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reporting.

89

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.

90 INFO

The number of the counter

91 92

The number of control loops exceeding 100ms for th last half hour. The counter is reset after reporting spare 34 spare 35

93

spare 36

.

94 ERROR

No operative system in Node

.

95 ERROR

Duplicate answer on The node ID which has System is brought into determining Spreader stop set up generated the error failsafe mode.

check adress key

96 ERROR

No answer on Master request for . "Spreader stop" configuration


check adress key

97 INFO

Spreader stop has been activated/deactivated

0= activated 1=deactivated


98

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.

99

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.

100 ERROR

Spreader program fault

.


System shutdown

contact Bromma


check battery/restart/co ntact Bromma


. . Systems fails to start

contact Bromma

recompile and reload spreader program The first message type Message stored in log and displayed on in the buffer Spreader

101 WARNING CAN message buffer is full

102 ERROR

System failed to initialise HW

.

103

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.

104

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.

105 ERROR

Onboard NV RAM failed memory test

.

106

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.

107 WARNING 10V reference voltage too low

Actual voltage *10

Message stored in log and check supplies displayed on Spreader

108 WARNING 12V internal supply too low

Actual voltage *10


Manual File: SCS_1

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109 ERROR

Battery voltage too low

110 ERROR

The System failed to lock th I/O . on a node during system init.

111

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112

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.

113 114 INFO

spare 44 System is shutting down

. .

115 INFO

.

116

System shutdown has been completed spare 45

117

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.

118 INFO

.

120

Landed override has been activated Landed override has been deactivated spare 47

121

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.

122

spare 49

.

123

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.

124

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.

125

spare 52

.

126

spare 53

.

127

spare 54

.

128

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.

129 ERROR

Spreader program fault or load file has been korrupted

130 ERROR

131 ERROR

119 INFO

Manual File: SCS_1

Project No

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Manual

Actual voltage *10

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Message stored in log and check battery displayed on Spreader System is brought into failsafe mode.

restart

.



.



.


check and recompile spreader program. Reload. /contact Bromma check and recompile spreader program. Reload. /contact Bromma check and recompile spreader program. Reload. /contact Bromma

.

. .

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132

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133

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.

134

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.

135

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.

136 ERROR


.

137

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.

138

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.

139

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.

Version:

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check and recompile spreader program. Reload. /contact Bromma

140 WARNING Unknown CAN message received

The ID type of the message


141 INFO

CAN messages missed. Cyclically reported.

The count of the missed messages


142 ERROR

Two nodes within the system have the same ID/adress

The ID which is duplicate


143 WARNING 10V reference voltage is too high

Voltage * 10

check and correct the adress key Message stored in log and check supplies displayed on Spreader

144 WARNING 12V internal voltage is too high Voltage * 10


145 WARNING Battery voltage is too high


Voltage * 10

146 WARNING User defined Warning. The . user/programmer defines what this fault should indicate within the application program.

Message stored in log and Check specific displayed on Spreader project.



Manual File: SCS_1

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. 148 WARNING User defined Warning. The user/programmer defines what this fault should indicate within the application program.












. 154 WARNING User defined Warning. The user/programmer defines what this fault should indicate within the spreader program.


155 WARNING User defined Warning. The . user/programmer defines what this fault should indicate within the spreader program.


156

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157

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.

158

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.

159

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.

160

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.

161 WARNING CAN error

Manual File: SCS_1

.

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162 WARNING RS232 error

.


163 WARNING Power monitor P1 = sensor supply voltage. Warning 1 = Voltage < 21V

.


164 ERROR

.

check supplies System is taken down into idle mode. Ie if the system voltage comes up again it wakes otherwise is prepared to shut down

.


. Power monitor P2 = internal logic supply voltage. ERROR = Voltage below permissive voltage of system.


167 WARNING Power monitor P3 = PWM supply voltage. Warning 1 = Voltage < 21V

.


168 ERROR

.


Power monitor P1 = sensor supply voltage. ERROR = Voltage below permissive voltage of system.

165 WARNING Power monitor P2 = internal supply voltage. Warning 1 = Voltage < 21V 166 ERROR

Power monitor P3 = PWM supply voltage. ERROR = Voltage below permissive voltage of system.

169 WARNING System failed to read/write to a ID of port: Message stored in log and check supplies displayed on Spreader I/O port Digital=0+port_no, Analogue=100+port_n o, PWM=200+port_no, encoder=300+port_no. 170

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.

171

spare 69

.

172

spare 70

.

173

spare 71

.

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174 ERROR

No answer when on general information request between nodes.

.


175 INFO

TWL - twistlock lock command . received


176 INFO

TWL - twistlock unlock command received

.


177 INFO

TWL - twistlock has been locked

.


178 INFO

TWL - twistlock has been unlocked

.


179 INFO

TELESCOPE - prox. type. Expand command received

.


180 INFO

TELESCOPE - prox. type. Retract command received

.


181 INFO

TELESCOPE - prox. type. Command to go to a speceific position has been received

The ID of the position requested


182 INFO

TELESCOPE - prox. type. The desired position has been reached



183 WARNING TELESCOPE - automatic type. 0 = Desired position The telescope hasn't reached its' not reached within time position within time limit limit. 1 = telescope has not moved more than 1 cm during 3 seconds.

The telescopic motion is stopped until a new command is given. Message stored in log and displayed on Spreader

184 INFO

TELESCOPE - automatic type. . expand command received


185 INFO

TELESCOPE - automatic type. . Retract command received


Manual File: SCS_1

36 Printed: 2004-12-08 13:51

check sensor, pressure,mechan ics. If necessary calibrate system.


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186 INFO

TELESCOPE - automatic type. The ID of the position Command to go to a specific requested position received


187 INFO

TELESCOPE - automatic type. The ID of the position The desired position reached requested


188 INFO

The year has been set

current value (year)


189 INFO

The month has been set

current value (month)


190 INFO

The day/date has been set

current value (date)


191 INFO

The time of day (hour) has been current value (hour) set


192 WARNING Nocontact with the master for 10s

The ID of the node which doesn't have contact

Message stored in log and check displayed on Spreader connections

193 ERROR

Message reported during boot. Unknown role Information request (system boot functionality)

.

restart (check address keying) Message stored in log and displayed on Spreader

195 INFO

Download request active (system boot functionality)

.


196 INFO

Information request received (system boot functionality)

.


197 INFO

set time request received (system boot functionality)

.


198 INFO

Boot version request received. (system boot functionality)

.


199

spare 72

.

194 INFO

Manual File: SCS_1

.

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200 INFO

Download flag request received. . (system boot functionality)

201

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.

202

spare 74

.

203

spare 75

.

204

spare 76

.

205 INFO

Check flash memory request received. (system boot functionality)

.


206 INFO

Restart node request received. (system boot functionality)

.


207 INFO

System start init. (system boot functionality)

.


208 INFO

System look for downloadflag. (system boot functionality)

.


209 INFO

Send datablock request. (system . boot functionality)


210 INFO

Received datablock. (system boot functionality)

.


211 INFO

Download in progress

percentage of downloaded data

progress shown on Spreader display

212 INFO

copy serial information to flash . memory

213

spare 77

.

214

spare 78

.

215 ERROR

No answer when waiting for present nodes response

.


216 INFO

Inforamtion on present nodes has been received

.


217 ERROR

Download timeout

.


218

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.

Manual File: SCS_1

38 Printed: 2004-12-08 13:51



reload


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219 ERROR

220 ERROR 221 ERROR

222 ERROR

223 ERROR

224 ERROR

225 ERROR

226 ERROR

227

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No answers or inconsistent answers from system members during boot The size of received data is to large. Boot message

.


.


No answers or inconsistent answers from system members during boot No answers or inconsistent answers from system members during boot No answers or inconsistent answers from system members during boot No answers or inconsistent answers from system members during boot No answers or inconsistent answers from system members during boot No answers or inconsistent answers from system members during boot spare 80

.


.


.


.


.


.


.

. No answers or inconsistent answers from system members during boot Spreader error and event log has . been cleared


230 ERROR

Failed to set up spreader program correctly

destination of error


231 ERROR

Spreader program download error

.

232 ERROR

Spreader program download error

.

233 INFO

Power monitor P1 = sensor supply voltage. OK

.

234 INFO

Power monitor P2 = internal supply voltage. OK

.

228 ERROR

229 INFO

Manual File: SCS_1

39 Printed: 2004-12-08 13:51

Message stored in log and displayed on Spreader Check spreader program. If problems persist contact Bromma System is brought into Check spreader failsafe mode. program. If problems persist contact Bromma System is brought into Check spreader failsafe mode. program. If problems persist contact Bromma Message stored in log and displayed on Spreader Message stored in log and displayed on Spreader


Document:

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Project No

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11

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235 INFO

Power monitor P3 = PWM supply voltage. OK

.


236 INFO

Reboot (restart) request sent . from master to slaves. Happens when slaves are powered on before master at system start System has been taken down to . idle mode. Ie waiting to wake up.


237 INFO


238

Spare 81

.

239 INFO

System failed to cancel shutdown process

.


240 INFO

No answer when attempting to cancel shutdown process

.


241 INFO

System received timeout when attempting to cancel shutdown process

.


242 INFO

System shutdown aborted

.


243

spare 82

.

244 INFO

TWL - The spreader has been landed

.


245 INFO

TWL - The Spreader has been totally lifted (not landed)

.


246 INFO

FLIPPER - flipper up command . received


247 INFO

FLIPPER - flipper down command received

.


.

AI can start to flicker. Message stored in log and displayed on Spreader

248 WARNING Power monitor P1 = sensor supply voltage. Warning 2 = Voltage < 17V

Manual File: SCS_1

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249 WARNING Power monitor P2 = internal supply voltage. Warning 2 = Voltage <17V

.


250 WARNING Power monitor P3 = PWM supply voltage. Warning 2 = Voltage < 17V

.


251 ERROR

System failed to initialise fielbus . interface


252 ERROR

Duplicate answers when setting . up fieldbus interface


253 ERROR

No answer when configuring fieldbus interface


.

254 WARNING System failed in locking fieldbus interface

.

255 WARNING TWIN195 - twinboxes have failed to get to their upper position within time limit

ID of the twin box failing

Message stored in log and check displayed on Spreader solenoids/mecha nics/sensors

256 WARNING TWIN195 - left hook has failed . to reach its' upper position within time limit


257 WARNING TWIN195 - right hook has failed . to reach its' upper position within time limit


258 WARNING TWIN195 - twin boxes left timed out when expanding to their attach position. Failed to reach switch within time limit

.

check Twin down sequence stopped. Have to return solenoids/mecha nics/sensors Spreaer to twin up position. Message stored in log and displayed on Spreader

259 WARNING TWIN195 - twin boxes right timed out when expanding to their attach position. Failed to reach switch within time limit

.

Twin down sequence check stopped. Have to return solenoids/mecha Spreaer to twin up nics/sensors position. Message stored in log and displayed on Spreader

260 WARNING TWIN195 - left hook has failed . to reach its' lower position (connect) within time limit


Manual File: SCS_1

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261 WARNING TWIN195 - right hook has failed . to reach its' lower position (connect) within time limit


262 WARNING TWIN195 - twinboxes have failed to get to their lower position within time limit



263 WARNING TWIN195 - twin up sensor lost unexpectedly. (not due to output)



264 WARNING TWIN195 - twin up sensor received when twinboxes are down



265 WARNING TWIN195 - left hook down sensor lost unexpectedly.

.


266 WARNING TWIN195 - right hook down sensor lost unexpectedly.

.


267 WARNING TWIN195 - left hook up sensor . lost unexpectedly.


268 WARNING TWIN195 - right hook up sensor . lost unexpectedly.


269 ERROR

System failed to init. RS485

Node ID


restart / contact Bromma

270 ERROR

Duplicate answers in system when setting up RS485

Node ID



271 ERROR

System timed out when trying to . configure RS485



272 INFO

TELESCOPE - automatic type. . Teach in command received


273 INFO

TWINTELESCOPE - expand command received

.


274 INFO

TWINTELESCOPE - retract command received

.


Manual File: SCS_1

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275 INFO

TWINTELESCOPE - left console reached zero gap position

.


276 INFO

TWINTELESCOPE - right console reached zero gap position

.


277 INFO

TWINTELESCOPE - twinlegs expand in motion

.


278 INFO

TWINTELESCOPE - twinlegs retract in motion

.


279 WARNING TWINTELESCOPE - hasn't reached an endstop when in motion within time limit

.

motion is stopped. check Message stored in log and pressure/mechan ics(lubrication)/s displayed on Spreader ensor/valves

280

spare 83

.

281 INFO

TWINMPS - teaching a predefined position

The ID of the position teached


282 INFO

TWINMPS - command to go to The ID of the position a pre-defined position has been requested received


283 INFO

TWINMPS - A command to store a new value for a log position has been received

284 INFO

TWINMPS - A command to The ID of the position return to a log position has been requested received

.

Message stored in log and displayed on Spreader Message stored in log and displayed on Spreader

285 WARNING TWINMPS - the twinlegs haven't reached their requested position within time limit.

.

Motion is stopped. check Message stored in log and pressure/mechan displayed on Spreader ics(lubrication)/s ensor/valves

286 INFO

TWIN195 - twin up command has been received

.


287 INFO

TWIN195 - twin down command has been received

.


Manual File: SCS_1

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288 INFO

TWIN195 - twin boxes have reached their upper position

.


289 INFO

TWIN195 - twin boxes have reached their lower position

.


290 INFO

TTDS - override request received

.


291 INFO

TTDS - override request ended

.


292 WARNING Buffer full transferring serial port info over CAN bus

.


293 WARNING No answer when transferring serial port info over Can bus

.


294 ERROR

Failed to communicate with RS485

.


295

spare 84

.

296

spare 85

.

297

spare 86

.

298 ERROR

Failed reading spreader program.

299

spare 87

300

spare 88



301 WARNING RS485 not functioning as intended

Depending on type of sensor/device


302 WARNING AnyBus not functioning as intended

Depending on type of sensor/device


303 WARNING Error in locking AnyBus setup

Node ID

304 WARNING Timeout when trying to lock AnyBus setup 305 WARNING Wrong node answered when locking AnyBus setup 306 INFO Manual File: SCS_1

Spreader properties

Number of containers 44 Printed: 2004-12-08 13:51

Message stored in log and  2004 Bromma Conquip AB

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loaded/unloaded 307 WARNING AnyBus external bus failure

Version:

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45(55)

displayed on Spreader Message stored in log and displayed on Spreader Message stored in log and displayed on Spreader Message stored in log and displayed on Spreader

308 WARNING AnyBus Status ok 309 WARNING AnyBus external bus ok 310 WARNING Wrong node answered when EEPROM setup 311 ERROR

Timeout when expecting answer from node on EEPROM

312 WARNING Spreader properties 313 WARNING Spreader properties 314 WARNING Spreader properties 315 WARNING Spreader properties 316 WARNING Spreader properties 317 WARNING Spreader properties 318 WARNING Read EEPROM failure 319 WARNING Read NVRAM failure 320 WARNING EEPROM checksum failure 321 INFO

Spreader properties EEPROM set ok 322 WARNING EEPROM set failure 323 INFO

Spreader properties EEPROM attached to new node

324 INFO

RS485 status ok

325 INFO

Gravity point to centre command Gravity point to left side command Gravity point to right side command Gravity point has reached the centre position

326 INFO 327 INFO 328 INFO 329 INFO 330 INFO

Gravity point has reached the left end stop Gravity point has reached the right endstop

. . .

331 WARNING RS485 absolute sensor wrap . around warning. Sensor too near the value where it wraps around and begins from zero again.

Manual File: SCS_1

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. 332 WARNING RS485 absolute sensor has wrapped around. The value has gone from maximum to minimum in one CPU cycle. 333 INFO Added value to NVRAM . successfully 334 WARNING Spreader stop configuration node that reported the problem mismatch 335 WARNING Missed message on bus regarding digital I/O

node from which an answer is expected

336 WARNING Missed message on bus regarding analogue I/O


337 WARNING Missed message on bus regarding encoder data


338 WARNING Missed message on bus regarding AnyBus message


339 WARNING Missed message on bus regarding RS485 data


340 WARNING No contact with the node for 3s. node from which an answer is expected specified by the Sub code 341 ERROR

Error when trying to dowload program Node is missing on the bus during system start.

.

343 ERROR

Inclination sensor initialisation error

node that failed to initialise the sensor

344 ERROR

Timeout when trying to node that failed to initialise the sensor intitialise the inclination sensor

342 ERROR

node that is missing

345 WARNING Missed message on bus regarding inclination sensor


346 INFO

.

347 INFO

Node bus communication ok. BCAN ok BCAN bus status warning.

.

348 WARNING BCAN bus communication off. . 349 ERROR

AnyBus Spreader/systems diagnostic area failed to set up.

350 ERROR

Timeout when trying to set up AnyBus Spreader/system diagnostic area AnyBus Assert diagnostic area failed to set up

351 ERROR 352 ERROR

Manual File: SCS_1



Timeout when trying to set up AnyBus Assert diagnostic area.

46 Printed: 2004-12-08 13:51


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Version:

11

353 INFO

Present nodes shown in sub code bitwise OR for all included nodes. 12bit Value

354 INFO

AnyBus slave card plugged in

357 INFO

AnyBus Input data area size

size of data area (bytes)

358 INFO

AnyBus output data area size

size of data area (bytes)

359 ERROR

Hardware initialisation failed (system prog.)

psu_mon.=1, temp_sens.=2, realtime_clock=3

360 ERROR

NVRAM full. No space left for . Storage NVRAM checksum Error .

Page:

47(55)

node ID holding the card 355 INFO AnyBus Master card plugged in node ID holding the card 356 WARNING AnyBus card missing node ID of the node missing the card

361 ERROR 362 ERROR

365 ERROR

OS code. Operating system fatal error OS subcode.Operating system fatal error OS extra.Operating system fatal error Local regulator (PID) failed.

366 ERROR

Local regulator (PID) timeout

367 ERROR

Error in interpreting the spreader . program. Parameter mismatch between system and ABE file.

363 ERROR 364 ERROR

code from OS

call Bromma

code from OS

call Bromma

code from OS

call Bromma

node ID that failed to initialise the regulator .

restart

368 ERROR

Error in recognising a . component downloaded with the spreader program . 369 WARNING Gravity point haven't reached the requested position within time limit. 370 WARNING Missed message on bus node from which an answer is expected regarding regulator data. 371 ERROR

Error in locking regulator setup .

372 INFO

The Spreader info has been set. The index of the field which is set.

373 INFO

The Spreader info has been set. The value of the field which is set. The logged value is in the range 0-9999. This range limit has nothing

Manual File: SCS_1

47 Printed: 2004-12-08 13:51

retstart Check versions of system and ABE. Check versions of system and ABE.


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11

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to with the actual value set in the Spreader info. 374 INFO

The time of day (minute) has been set

Current value (minute) Message stored in log and displayed on Spreader

375 INFO

Received a change bitrate request. Boot message.

Requested bitrate

376 WARNING TWIN195-Multiple sensor values from left hook


377 WARNING TWIN195-Multiple sensor values from right hook


378 WARNING Codeloading via anybus failed. (start sequence)

node ID that failed to handle start sequence.


379 WARNING Codeloading via anybus failed. (download sequence)

node ID that failed to download.


380 WARNING Codeloading via anybus failed. (finish sequence)

node ID that failed to Message stored in log and displayed on handle finish sequence. Spreader

381 WARNING Disabeling outputs failed.

node ID that failed to disable outputs.

382 WARNING No answer when attempting to disable outputs. 383 WARNING Enabeling outputs faild.

Message stored in log and displayed on Spreader node ID that failed to enabeling outputs.

384 WARNING No answer when attempting to enabeling outputs. 385 INFO

Manual File: SCS_1

AutoTuner stored in NVRAM


Message stored in log and displayed on Spreader Message stored in log and displayed on Spreader

Regulator index.

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386 INFO

Tandem - Teaching a predefined position


387 INFO

Tandem - A command to store a new value for a log position has been received

388 INFO

Tandem - command to go to a pre-defined position has been received



389 INFO

Tandem - A command to return The ID of the position to a log position has been requested received



390 WARNING Tandem - Cylinder position has The ID of the cylinder Message stored in log and displayed on changed more than allowed. Spreader 391 INFO

Tandem – Both landside and waterside spreaders enabled


392 INFO

Tandem – Landside spreader enabled


393 INFO

Tandem – Waterside spreader enabled


394 INFO

TandemPush – A push command received


395 INFO

TandemPush – Inner position reached.


396 INFO

TELESCOPE – Impact detected


397 INFO

TELESCOPE – Telescope is autocorrecting


398 WARNING TELESCOPE – Sensor value is out of range

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399 INFO

TELESCOPE – Bumped out of signal window


400 INFO

TWL – TTDS active


401 WARNING TWL – Lock attempt with TTDS active


402 INFO

Digital I/O configured on an AnybusGateway

Node id on where I/O configured


403 INFO

Analogue I/O configured on an AnybusGateway



404 INFO

PWM configured on an AnybusGateway



405 INFO

ASC – Antisway sytem active


406 INFO

ASC – Antisway sytem ready


407 INFO

ASC – Antisway sytem failed

Message stored in log and displayed on Spreaderi

408

spare 88

409 ERROR

OS extra 2.Operating system fatal error

code from OS

call Bromma

410 INFO

Current hardware version

HW type

Type of hardware version. 5 = SCS2 revision 4 = SCS2 6 = Anybus gateway The PID component found a strange parameter saved in NVRAM. The PID component uses the ABE parameters instead.

411 WARNING Strange parameter saved in NVRAM. (AutoTuner)

Manual File: SCS_1

Parameter No.

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412 WARNING Auto Tuner – Finished but failed Parameter No. to calculate some parameters

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Some parameters could not be calculated. Check sensors etc.

413 ERROR

CANopen – Failed to initialize the software.

414 ERROR

CANopen – Failed to configure PDO

415 ERROR

CANopen - Error in locking CANopen setup

416 INFO

CANopen – Node removed from Node number heartbeat list


417 INFO

CANopen – New node added to Node number heart beat list

Message stored in log and displayed on Spreader. See more specific literature regarding CANopen [DS 301, DS 401]

418 INFO

CANopen – Boot message received from node

Node number


419 INFO

CANopen – Node stopped

Node number


420 INFO

CANopen – Node in operational Node number state


421 INFO

CANopen – Node in preoperational state

Node number


422 WARNING CANopen – Heartbeat failed on Node number node


423 ERROR

CANopen – To many slaves in use

Message stored in log and displayed on Spreader. Check spreader program.

424 ERROR

CANopen – Failed to configure SDO


Manual File: SCS_1

Check spreader program

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425 WARNING CANopen – Failed to send SDO Node number


426 WARNING CANopen – Bus off occured

Message stored in log and displayed on Spreader.

427 ERROR

CANopen – Failed to change the bitrate on CAN interface


428

Spare 89

429

Spare 90

430

Spare 91

431 WARNING CANopen – Emergency object additional byte 1

Contents of byte


Contents of byte


Contents of byte


Contents of byte


Contents of byte

436 INFO

Node number

CANopen – Slave OK

437 WARNING CANopen – Generic error

Manual File: SCS_1

Node number

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Message stored in log and displayed on Spreader. See more specific literature regarding CANopen [DS 301, DS 401] and slave user manual Message stored in log and displayed on Spreader. See more specific literature regarding CANopen [DS 301, DS 401] and slave user manual Message stored in log and displayed on Spreader. See more specific literature regarding CANopen [DS 301, DS 401] and slave user manual Message stored in log and displayed on Spreader. See more specific literature regarding CANopen [DS 301, DS 401] and slave user manual Message stored in log and displayed on Spreader. See more specific literature regarding CANopen [DS 301, DS 401] and slave user manual Message stored in log and displayed on Spreader. See more specific literature regarding CANopen [DS 301, DS 401] and slave user manual Message stored in log and displayed on Spreader. See more specific literature regarding CANopen [DS 301, DS 401] and slave user manual


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438 WARNING CANopen – Current

Node number


439 WARNING CANopen – Current, device input side

Node number


440 WARNING CANopen – Current, inside device

Node number


441 WARNING CANopen – Current, device output side

Node number


442 WARNING CANopen - Voltage

Node number


443 WARNING CANopen – Mains voltage

Node number


444 WARNING CANopen - Voltage inside

Node number


445 WARNING CANopen – Voltage output

Node number


446 WARNING CANopen - Temperature

Node number


447 WARNING CANopen – Temperature ambient

Node number


448 WARNING CANopen – Temperature device Node number


449 WARNING CANopen – Hardware device

Node number


450 WARNING CANopen – Software device

Node number


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451 WARNING CANopen – Software inside

Node number


452 WARNING CANopen – software user

Node number


453 WARNING CANopen – Data set

Node number


454 WARNING CANopen – Additional module Node number


455 WARNING CANopen - Monitoring

Node number


456 WARNING CANopen – CAN overrun

Node number


457 WARNING CANopen – CAN error passive Node number


458 WARNING CANopen – Lifeguard or heartbeat

Node number


459 WARNING CANopen – Recover from bus off

Node number


460 WARNING CANopen - Transmit COB id

Node number


461 WARNING CANopen – General communication

Node number


462 WARNING CANopen – General protocol

Node number


463 WARNING CANopen – PDO not processed Node number


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464 WARNING CANopen – PDO length exceeded

Node number


465 WARNING CANopen – External error

Node number


466 WARNING CANopen – Additional functions

Node number


467 WARNING CANopen – Device specific

Node number

468 WARNING CANopen – Node missing

Node number

Message stored in log and displayed on Spreader. See more specific literature regarding CANopen [DS 301, DS 401] and slave user manual Check CAN connections and spreader program.

469 INFO

Changed to node number


470 WARNING CANopen – Node id chage failed

Node number


471 WARNING TTDS – No sensors

-


Manual File: SCS_1

CANopen – Node id changed

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Spreader Control System 2

2:nd generation

SCS Anybus Gateway

Rev 1.0

05-03-08

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General ......................................................................................................................................................................... 3 1.1 OVERVIEW ............................................................................................................................................................... 3 1.2 DICTIONARY AND ABBREVIATIONS .......................................................................................................................... 3 1.3 DOCUMENT LAYOUT ................................................................................................................................................ 3 Introduction ................................................................................................................................................................. 4 2.1 GENERAL ................................................................................................................................................................. 4 2.2 THE NODES .............................................................................................................................................................. 5 Software........................................................................................................................................................................ 5 3.1 BOOT PROGRAM ...................................................................................................................................................... 5 3.2 SYSTEM PROGRAM ................................................................................................................................................... 5 3.3 SPREADER PROGRAM ............................................................................................................................................... 6 Hardware Overview .................................................................................................................................................... 6 4.1 BCAN - STATUS LEDS ........................................................................................................................................... 6 4.2 THE ANY BUS CARD ................................................................................................................................................. 6 4.3 POWER CONNECTOR ................................................................................................................................................. 6 4.4 BCAN CONNECTOR ................................................................................................................................................. 7 4.5 NODE ADDRESS KEY SWITCHES ................................................................................................................................ 7 4.6 SERIAL PORT CONNECTOR ........................................................................................................................................ 7 4.7 GROUND CONNECTION ............................................................................................................................................. 7 4.8 FIELD BUS CONNECTIONS. ....................................................................................................................................... 8 4.8.1 Mapping of I/O .............................................................................................................................................. 8 4.9 FAULT FINDING TABLE........................................................................................................................................... 10 Software tools............................................................................................................................................................. 10 5.1 OVERVIEW ............................................................................................................................................................. 10 5.2 ABE....................................................................................................................................................................... 10 5.3 BMS ...................................................................................................................................................................... 10 Miscellaneous ............................................................................................................................................................. 11 6.1 DATA SHEET........................................................................................................................................................... 11 6.2 DIMENSIONS .......................................................................................................................................................... 12 Appendix A (Error messages)................................................................................................................................... 13

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© 2005 Bromma Conquip AB

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1 General 1.1

Overview

This document serves as a user manual and shall be used by the those installing and using the Bromma SCS2 Anybus Gateway. Software as well as hardware routines and descriptions are covered in this document.

1.2

Dictionary and abbreviations

ABE BMS Boot program CAN PWM Spreader Program SCS2 System Program Anybus Gateway

1.3

Application Builder Environment. A tool for building control logic. Bromma Monitoring System. A tool for monitoring the SCS2. The part of the software in the SCS2 that is executed at power up. This part is responsible for the loading of the program verifying that the system is set up correctly. Controller Area Network. A two wire serial bus used for high speed, high reliability communication. Pulse Width Modulator. The control logic that controls the functionality of the SCS2. Spreader Control System generation 2. The control system described in this user manual. The system will be referred to as SCS2 in this document. The program that serves as a base for the execution and control of the spreader program. A node that can be used in the Spreader Control System generation 2.

Document layout

Chapter 3, System overview, gives a brief description of the SCS2. Chapter 4, Software, describes how the different software parts correlates. Chapter 5, Hardware overview, describes the hardware in the SCS2. Chapter 6, External interfaces, describes all the external interfaces in the SCS2. Chapter 7, Software tools, describes the supporting tools to the SCS2. Appendix A, Error messages, shows all error messages and their meaning (see main SCS2 manual for details).


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2 Introduction The core of the Bromma Smart Spreader is the Spreader Communications System (SCS2). In 1991 when Bromma decided to develop a new and highly advanced communications system a close look at the available bus systems revealed a number of shortcomings, such as temperature range, EMC (Electro Magnetic Compatibility) protection and mechanical roughness. Bromma therefore decided to design a bus system that met the demands made on an electronic system for a tough Spreader application. We decided to develop a modular programmable controller, with a heavy-duty field bus interface that complies with European and international standards for control equipment in this area. The SCS2 solution is a single control product that can be used as I/O, as a PLC, and as distributed control for up to 528 I/O points. SCS2 nodes are simple to install. You can connect up to 11 devices using just a single pair of wires. With its modular and scaleable architecture, intuitive features and unparalleled ease of use, it will help save crane builders and end users time and money.

2.1

General

As a universal I/O, SCS2 gives you the freedom to connect to a wide variety of host controllers, including PLC's, DCS and PC-based control systems by way of DeviceNet, Profibus-DP. SCS2 can be networked as a slave to Profibus-DP or you can choose a DeviceNet master module for easy third-party integration. Designed by Bromma engineers for reliable performance in the particularly challenging environment of container handling the system corporate four basic elements: Crane Node

A device directly interfacing with the crane’s control systems, computer and monitoring screens, providing an optional serial bus interface for programming or diagnostic communications, as well as an interface to the spreader node.

Crane-Spreader Communications Link

A two-wire conventional cable CAN communications between the crane control system and the spreader.

Spreader Node

A device that interfaces directly with the spreader’s sensorsand actuators. One of the Spreader nodes normally acts as Master. Sensors and Switches Conventional sensors, switches, and actuators on the spreader. The system is divided into several hardware blocks called nodes. The nodes are located on the spreader and in the crane. The nodes are connected to each other via a CAN network, see figure 1. The number of nodes required is based on the number of I/O needed. The only difference is their identity, id. Depending on their location the nodes have different ids. They are numbered from 0 to 11 where: 0 is the master called B1 1-7 are slave nodes located on the spreader called B2-B8 8-11 are slave nodes located in the crane called A1-A4.


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Crane PLC Crane field bus Anybus Gateway A1

CAN network (BCAN)

B1 Master

I/O

B2 Slave

...

SCS2

B8 Slave

Spreader Figure 1. The figure shows SCS2 connected to the spreader and the crane via I/O. The nodes are also connected internally via a CAN network.

2.2

The Nodes

The SCS2 is built up of several nodes co-operating in the system. Each node has a specific role, either slave or master. There must be only one master node in the system and the rest are slaves. The master node makes all the calculations and decisions. The slave nodes act as remote I/O to the master.

3 Sof

tware

The SCS2 software consists of three types of programs; Boot Program, System Program and Spreader Program.

3.1

Boot Program

When the power is applied to the Boot Program starts to run. It will take approximately 5 seconds to boot up the system. During system Program updates it will take longer. The Boot program is responsible for Initialising hardware Verifying that all system versions match. Performing a program download

3.2

System program

After the Boot program is finished, the System will execute until the system is switched off. The System program is responsible for Interpreting the Spreader program (only on Master node) Supporting any connected PC-connection via the RS232 port Monitoring the supply voltage and some internal voltages Logging events in the event log Reading input signals and writing output signals


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Spreader Program

The Spreader Program is the specific application program that controls the spreader. This program is created in ABE, see chapter 5.2 for a brief description.

4 Hardware

Overview

Figure2 is a SCS2 Anybus Gateway node equiped with a Profibus slave card. The different parts are explained in the following chapter. This view shows a Profibus card, this can naturally be exchanged for any other available fieldbus. AnyBus (Profibus) card status LEDS

Status LEDs

AnyBus (Profibus) card address selectors

Power connector BCAN connector

AnyBus (Profibus) card terminator switch

Node address key switches Serial port connector

AnyBus (Profibus) card fieldbus connector

Figure 2. The SCS2 Anybus Gateway node equiped with a Profibus slave card.

4.1

BCAN - Status LEDs

There are three green LEDs for Power, BCAN and Anybus indicating operating status and one red LED indicating error status. Power LED is lit when power is applied and system starts to execute. BCAN LED is lit when the BCAN communication interface is operating normally and flashing when the communication interface is not working as inteded. Anybus LED is flashing when the Anybus interface is not configured and lit when configured and operating normaly. Error LED is unlit when system is running normally and lit when an error has occurred.

4.2

The Any bus card

For details regarding the specific field bus card connection, termination, addressing and status LED’s, please see the separate manual for that specific type of card.

4.3

Power connector

The power connector is a Phoenix Contact 2-pin header (MC1,5/2-G-3,81). Name VCC GND


Description 10 to 28 V DC Ground

Pin number 1 2

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BCAN connector

The BCAN connector is a Phoenix Contact 3-pin header (MC1,5/3-G-3,81). Name CAN H CAN L CAN GND

4.5

Description CAN high CAN low CAN ground, not required by BCAN

Pin number 1 2 3

Node address key switches

There are five switches selecting node address, where the DIP switch 1 corresponds to LSB. The nodes are addressed according to the following table: DIP setting 0=off, 1=on 00000 00001 00010 00011 00100 00101 00110 00111 01000 01001 01010 01011 01100 01101 01110 01111 10000 10001 10010 10011-11110 11111

4.6

Node name Test A1 A2 A3 A4 B1 B1 B1 B1 B2 B2 B2 B2 B3 B4 B5 B6 B7 B8 Not Used Test

Spreader stop

Redundancy block and override of landing pins

No No No No Yes Yes No No Yes Yes No No No No No No No No

No No No No Yes No Yes No Yes No Yes No No No No No No No

Serial port connector

The serial port connector is a standard DSUB 9-PIN female connector. A pin-to-pin cable is needed when connecting the SCS2 Anybus Gateway to a computer serial port. Name Tx Rx Signal GND CTS RTS Not connected

4.7

Description Transmitted data RS-232 Received data RS-232 Ground Clear to send RS-232 Request to send RS-232 Not connected

Pin number 2 3 5 7 8 1, 4, 6, 9

Ground connection

The SCS2 Anybus Gateway chassis must be properly connected to protective earth, for example by mounting the unit on a grounded DIN rail.


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Field bus Connections.

By using the AnyBus the crane can utilise the SCS2 as an integrated slave on the PLC network or an AnyBus card can be used as a Master bus for an internal I/O bus on the Spreader. The principal behind the AnyBus is that the interface card translates a number of different bus protocols to a standardised format on the address and data bus of the node. To change between different buses one can then simply change the type of interface card. For details regarding configuration of a specific bus, please view the user manual for that specific card and the electrical documentation for your specific project. The size of the data exchange area between the SCS2 and the Anybus card is configurable up to 64 bytes in and 64 bytes out. The configuration is done via HMS standard files. This interface must be configured in the same way for both the Master and the SCS 2 slave for the bus to work correctly. For each project a document has to be sent to the customer describing the used parts of the interface. When referring to in/out we view it from the SCS2 side, hence input for the SCS2 is an output from the master in the crane. Hence the crane PLC and the AnyBus card must have corresponding addresses and the nymber of bytes configured for input/output data have to be the same on both sides of the communication link i.e. the crane PLC and the SCS2.

4.8.1

Mapping of I/O

OUT

IN

Byte 0-63 Project specific outputs

Byte 0-63 Project specific inputs

Output Segment In the output segment it possible to use a number of bytes for diagnostic information in the form codes. The code sent will be equivalent with the code displayed in the onboard display, hence there will be three levels of this code INFO, WARNING, ERROR. Apart from the code and the byte for indicating the type of code a counter will be incremented each time a code is sent. The counter is a 16bit value and therefore will begin from 0 if the counter overflows. The value of this counter will be sent each time that a new diagnostic message is transmitted.

Byte 0 Byte 1 Byte 2-3 (WORD) Byte 4-5 (WORD) Byte 6-7 (WORD)

4.8.1.1 Spreader diagnostic area. => Type of error (info, warning, error) => Node ID (the number of the node from which the message originates) => Diagnostic code => Sub Code for diagnostics => Sequential counter value (message number)

4.8.1.2 System diagnostic area. This part is named the assert diagnostics and is basically only used to find discrepancies in the SCS2 system. The objective of it is mainly for Bromma Conquip AB’s R&D to identify unforeseen weaknesses in the system. If the customer wishes to implement/decode this it can help Bromma Conquip AB improve its’ equipment further, however the customer might find little or no use in this information on their own behalf. The assert part is configured in the following way. Byte 8 => Node ID Byte 9-10 => Row Number (of source code) Byte 11-16 => Filename (1:st 6 char.) Byte 17-18 => sequential counter Manual File: SCS2 Anybus Gateway manual

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The remaining bytes for output will be assigned the interface with the crane and will vary on each project. The assignments here are discrete outputs from the Spreader and current values (pressure etc.) from devices on the Spreader. These assignments shall be are documented in the electrical documentation of the project. Input Segment The entire range of the input area is configurable per project. The assignments here are discrete inputs to the Spreader and set point values for the Spreader. These assignments shall be documented in the electrical documentation of the project.


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Fault Finding table

Symptom Power Supply The node won’t start. The power LED is off.

RS-232 BMS system can not communicate with the node.

CAN The node can not communicate with the other nodes.

Node ID The unit stops at start-up.

5 Sof

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What to do

Comment

Measure the main supply. The voltage should exceed 10V DC and be less than 30V DC.

The power LED should be on.

Probe TxD and RxD lines with oscilloscope while trying to communicate. Ensure that connection cables aren’t damaged.

Data lines should show square waves between –10V to +10V relative to GND pin.

Probe bus lines with oscilloscope. CAN high should show square waves pointing downwards and CAN low should be showing square waves pointing upwards.

Check that CAN high and CAN low are not mixed up.

Check selected node ID.

This can indicate that the node has wrong id strapped telling the node to participate in the system with wrong role.

tware tools 5.1

Overview

There are some related tools to the SCS2, which support it in different ways. A brief description of these tools is given below.

5.2

ABE

ABE (Application Builder Environment) is a tool for developing and configuring the spreader program, which controls the logic of the spreader. ABE generates a load file. For more detailed see the separate manual.

5.3

BMS

BMS ultra light (Bromma Monitoring System ultra light) is a tool for monitoring events and reading status of I/O in the SCS2. BMS can also be used to download new programs to the SCS2. For more detailed see the separate manual.


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6 Miscellaneous 6.1

Data sheet

Parameter

Note

Min

Max

Unit

Operating voltage Current consumption Temperature EMC conformity

Power connector Operating voltage 24 V DC Operating temperature In accordance with 89/336/EEC:

10 50 -20

28 200 +85

V DC mA 0 C

EN 61000-6-4:2001 (Emission requirements) EN 55011 (Radiated emission) EN 61000-6-2:2001 (Immunity requirements) EN 61000-4-2 (Immunity: ESD) EN 61000-4-3 (Immunity: RF electromagnetic field) EN 61000-4-4 (Immunity: Fast transients) EN 61000-4-5 (Immunity: Surge) (2)

Controller Memory

32bit controller running at 16MHz quartz Program 1.4Mb Log 128kb Scan time System scan time 50 ms Node scan time 5 ms Serial interfaces BCAN – Bromma CAN based bus RS232 – For PC communication Field bus slave to those field buses supplied by HMS. Diagnostics System diagnostics Spreader functionality diagnostics Event and error log FB programming Basic binary functions (AND, OR etc.) Basic Analogue functions (compare, add etc.) Basic controller functions(PWM, regulators etc.) Spreader controller functions Note 2) For compliance with EN 61000-6-2 the power cable and the serial port cable have to be limited to 10 meters in length


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Dimensions

Figure 3. The SCS2 Anybus Gateway node equiped with a Profibus slave card. All dimensions are in mm.


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Bromma Group Manual

0-1-may 02 rev.00

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Appendix A (Error messages)

The error messages, which are generated by the system, can be viewed in the display as well as in the log (using the BMS). See main system manual for list of codes.


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11 • Fault finding diagnostics Fault finding in hydraulic system NOISY PUMP OR EXCESSIVE HEAT • Check oil level and that filter is clean. • Check that pump is functioning correctly as illustrated in the "system test". • Particularly check that setting of pressure relief valves are correct (as enclosed sheet) and that the pump suction line (inlet) is not blocked. • Pump suction is checked by removing drain line and measuring flow at running pressure of 100 BAR. • Maximum flow should be 1 litre/min. If greater than this, replace the pump. TWISTLOCKS DO NOT OPERATE • Check manual operation of the solenoid valve. • If twistlocks work then check electrical supply & solenoid. NOTE! Blockading pin must be in the "up" position!

IF TWISTLOCKS DO NOT WORK • Check that pump pressure is correct. • Check pressure relief valve. • When valve is operated manually the pressure should remain at working pressure. If it decreases check the seals in the cylinder. • Remove the cylinder and ensure that the twistlocks are free to rotate. • Check directional valve.

BROMMA CONQUIP AB

11 01 ENG rev.

Fault finding in electrical system HYDRAULIC PUMP MOTOR STOPPED Possible cause • 3 phase supply missing. • Motor contactor not functioning. • Feed from crane missing.

Action______________ ____ • Check cable, plug, socket. • Check crane control signal. • Check connection.

HYDRAULIC PUMP MOTOR RUNS BUT KEEPS TRIPPING OUT Possible cause Action________________ __ • Pump pressure too high or pump faulty. • Refer to Hydraulic section. • Pump motor faulty. • Change motor. • Motor supply has one missing phase. • Check to find where supply is connected and repair. TWISTLOCKS WILL NOT LOCK/UNLOCK Possible cause__________________ • Pumps stopped. • Crane spreader is fitted with the safety feature − only work with all four landing switches actuated. • If timer fitted − timer faulty set wrongly. • Check if fault is hydraulic by operating valve by hand. • Check supply to solenoid − if yes. • Check leads and plugs to solenoids. • Check blockading circuit. • Check supply at B and C junction boxes.

FLIPPER WILL NOT OPERATE Possible cause • Pump stopped. • Check if fault is mechanical or hydraulic by operating valve by hand. • Check supply to solenoid − if yes. • Check flipper supplies from crane.

Action________________ __ • Check pump procedure. • Check that the spreader is correctly landed on the container. • Replace or set to 0,5 or 2 sec. • Refer to hydraulic section. • Replace solenoid. • Repair or replace • Check relays, check limit switch and adjust or replace. Check connection. • Check connections. Replace main supply cable.

Action________________ __ • Check pump procedure. • Carry out mechanical hydraulic procedure. • Replace solenoid. • Check crane controls. Check plugs, socket and cable.

BROMMA CONQUIP AB

11 02 ENG rev.

12 • Appendices Units & conversion tables LENGTH 1 ft 1m 1 in 1 mm

= 0,3048 m = 3,2808 ft = 25,4 mm = 0,03937 in

WEIGHT 1 lb 1 kg 1 ton 1 Lt 1 tonne

= 0,4536 kg = 2,2046 lb = 1 t = 2000 lb = 907 kg = 0,893 Lt= 0,907 tonne = 2240 lb = 1016 kg = 1,016 tonne = 1,120 ton = 1 mT = 2204 lb = 1000 kg = 0,9842 Lt = 1,103 ton

VOLUME 1l

= 0,21997 UKgal = 0,26417 USgal

PRESSURE 1 bar

= 10 N/cm2 = 1,02 Kp/cm2 = 14,503 lbf/in2

POWER 1 Hp 1 kW

= 0,746 kW = 1,341 Hp

TORQUE 1 Kpm

= 9,81 Nm = 7,233 lbf

FORCE 1 Kgf = 1 kp = 9,81 N = 2,2046 lbf TEMPERATURE dgr C = 5 • (dgr F-32) 9 A = ampere o C = degrees centigrade c/s = cycles per second o F = degrees Fahrenheit ft = foot gal = gallon Hp = horse power Hz = hertz in = inch kg = kilogramme Kgf = kilopond force

l = litre lb = pound lbf= pound force m = meter min= minute n = newton s = second t = tonne v = volt w = watt µm = micron

BROMMA CONQUIP AB

12 01 ENG rev.

13 • Accessories

BROMMA CONQUIP AB

12 01 ENG rev.

Bromma Group Manual

BGS Accessories H.I.S. Height Indication System

37991 115/230 V AC 37993 24V DC

37992 115/230 V AC PLC 37994 24V DC PLC

8-1- Oct. 02 rev.00

Bromma Conquip

Bromma Group Manual

Description The system is based on ultrasonic sensors and is generally used for indication to the crane pilot that the spreader is approaching a container, or slowing the hoist down as the spreader descends upon a container. Two sensors have been chosen for redundancy and the indicating signal is triggered if either of the sensors detect an object below the spreader. The sensors are of two different models and cannot interfere with each other´s operating frequencies. The range of the system is configurable (0,5-4 m) by setting the sensors at the desired operating range to suit the ramp of the hoist on the current crane. Logic and redundancy can be located in the spreader or crane PLC. In a case were an existing PLC is to be used, Bromma will supply the block logic as a programming guideline. If no PLC is available a heavy-duty controller can be provided for this purpose. The ultrasonic sensors are 24V DC and a power supply is included for 115V AC and 230V AC systems.

Sensor

Main frame

Short distance position

Setting Crane slow speed Crane slow speed: 10% of maximum speed or max 0.3m/s. It is recommended to use the full sensing range of the sensors. This distance can however be reduced based on experience for each specific case.

Long distance position

Setting Switch Points The two sensors are from different manufacturers, therefore the method of setting the switch points is different. Sensor 1.1 (79579) This sensor is provided with a switching output with two programmable switch points. They are set by applying -24V for the long distance position or +24V for the short distance position to the teaching input (pin no. 2 in sensor socket) for at least 1 second. The distance is programmed by holding a 100 mm by 100 mm metal target in front of the sensor at the desired distance and applying the proper voltage to Pin 2. The LED on the top of the sensor indicates that the set point has been properly stored. Bromma Conquip

8-2- Oct. 02 rev.00

LED on top of sensor

Pins in sensor socket (Valid for both types)

Bromma Group Manual

Sensor 2.1 (79580) This sensor is equipped with two controls, P1 and P2. The short distance position is set by P1 and the long distance position by P2. LEDs located on the sensor indicate when the target is detected.

Controls P1 and P2

For both sensors the long distance position should be set to approximately 3 m (depending on crane type). The short distance should be set as short as possible and by all means kept above the bottom of the main frame.

Technical specifications Sensor

79579 (FA)

79580 (SB)

Operating voltage

20-30 V DC

20-30 V DC

< 60mA

< 50mA

Transducer frequency

approx .85 kHz

approx .120 kHz

Detection range

500-4000 mm

400-3000 mm

IP65

IP65

Operating temp. range

-25o C... +70o C

-25o C ... +70o C

Storage temp. range

-40o C... +85o C

-40o C... +85o C

Rated operating current

Protection class to DIN40 050

Spare parts See chapter 6.3 Electrical system

8-3- Oct. 02 rev.00

Bromma Conquip

Bromma Group Manual

Bromma Conquip

8-4- Oct. 02 rev.00

Bromma Group Manual

BGS Accessories Twistlock Counter 70782(230V), 70781(115V), 76140(24V) Application In order to maintain the correct service intervals a twistlock counter can be mounted in the electric cabinet. The counter is mounted directly on a rail. Function The twistlock counter is connected together with the twistlock locked signal. (see chapt. 6.3 Electrical system). When the twistlock locked sensors gives a positve and a negative pulse the counter increments one step. The counter cannot be reset. When it reaches its maximum (9999999 pulses) it restarts from 0.

Technical specifications

Counter Operating Voltage

70782

70781

70873

230V AC

115V AC

24V DC

Numerals

1.5 x 3.5 mm

Voltage tolerance

+ 10 %

Frequency

50 Hz

__

60 Hz

__

Power consumption Protection Ambient temperature

- 20oC to

+70oC

Weight Front

35x45 mm

8-1- Oct. 02 rev.00

Bromma Conquip

Bromma Group Manual

Bromma Conquip

8-2-J Oct. 02 rev.00

Bromma EH5U Eng 00

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