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PAT DS150 - User Manual

PAT DS150
55 pages
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www.patamerica.co
PAT America, Inc.
LOAD MOMENT INDICATOR
DS150
SERVICE MANUAL
P/N 031-300-100-753 REV B 03/08/02
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PAT DS150 Specifications

General IconGeneral
Output Signal4 - 20 mA
Protection ClassIP 65
Operating Temperature50°C
Measurement Range0
Storage Temperature-20 °C

Summary

Notice

Manual Revisions

Details document revision history and changes made.

1 Mechanical Description of the System Components

Pressure Transducer

Converts hydraulic pressure into an electrical analog voltage signal for system use.

Length-Angle Transducer

Measures boom length and angle using a combination of two transducers.

Anti-Two-Block Switch

Monitors load block position relative to boom head to prevent two-blocking.

Console

Displays geometrical data, load information, and provides alarm functions.

Duty Selection Switches

Digital inputs that program the system for specific lifting area configurations.

Basic System Component Layout

Illustrates the physical arrangement of system components on the crane.

Basic Adjustment of the Components

Outlines the procedures for adjusting key system components for proper operation.

2 Mechanical and Electrical Description of the Central Unit

Housing Description

Describes the rugged, waterproof sheet steel housing of the central unit.

Board Description

Details the main board, CPU, and EPROMs within the central unit.

Main Board Components

Lists key components on the main board, including power supply and analog input.

Incoming Signals

Describes signals received from various transducers and their voltage ranges.

Outgoing Signal

Explains the output signal for lever lockout and transducer voltage distribution.

3 Definitions

BOOM LENGTH Definition

The straight line measurement from boom pivot pin to boom point sheave pin.

BOOM ANGLE Definition

The angle between the boom base section centerline and the horizontal plane.

RADIUS OF LOAD Definition

Horizontal distance from rotation axis to hoist line center with rated load.

RATED LOAD Definition

Load value from chart for specific crane configuration, boom, and angle.

ACTUAL LOAD Definition

The weight of the load being lifted plus all additional equipment.

CRANE CONFIGURATION Definition

Physical arrangement of crane for a particular operation.

TWO-BLOCKING Definition

Contact of lower load block with upper load block, boom point, or machinery.

ANALOG Signal Definition

Electrical signals varying proportionally to represented quantities.

DIGITAL Signal Definition

Electrical signals of an on-and-off state representing operation quantity.

4 Drawings

SYSTEM Electrical Diagram

Schematic diagram detailing electrical connections of the system components.

Central Unit Spare Parts List

List of part numbers and descriptions for the Central Unit DS150.

Console Spare Parts List

List of part numbers and descriptions for the Console DS150.

Cable Reel Spare Parts List

List of part numbers and descriptions for the Cable Reel LWG208.

Central Unit Board Layout and Measuring Points

Diagram showing the main board layout and test points for measurements.

5 Procedure

EPROM Replacement in Central Unit

Step-by-step guide for replacing EPROMs in the DS150 central units.

Piston & Rod Pressure Channel Zero Point Adjustment

Procedure to adjust the zero point for pressure transducers.

Length & Angle Adjustments

Steps for calibrating the length and angle potentiometers and sensors.

6 Theory

Main Board Replacement

Instructions for replacing the main board in the central unit.

Anti-Two Block & Shutoff Circuit Theory

Explanation of the circuit operation and its components.

Length Measuring Channel Theory

Description of how the length measuring channel operates and its signals.

Piston Side Pressure Measuring Channel Theory

Details the operation and signal path of the piston side pressure channel.

Rod Side Pressure Measuring Channel Theory

Details the operation and signal path of the rod side pressure channel.

Main Boom Angle Measuring Channel Theory

Explains the function and signal processing for the main boom angle sensor.

Second Angle Measuring Channel Theory

Explains the function and signal processing for the second angle sensor.

7 Troubleshooting Flow Charts

General Flowchart

Provides an overview for diagnosing system problems and directing to specific flowcharts.

Lever Lockout Activated Troubleshooting

Step-by-step guide to troubleshoot lever lockout issues.

Broken Length Cable Troubleshooting

Guide to identify and resolve issues related to a broken or damaged length cable.

No Display Troubleshooting

Steps to diagnose and fix a blank console display issue.

Anti Two Block Problem Troubleshooting

Procedure for diagnosing and resolving Anti-Two-Block system faults.

Bad Data Transfer Troubleshooting

Guide to resolve errors related to data transfer between console and central unit.

Interference Problem Troubleshooting

Steps to identify and fix interference issues affecting the system.

Angle Problem Troubleshooting

Guide to diagnose and resolve incorrect angle readings.

8 Error Code Table

Error Codes E01-E05

Details causes and eliminations for range, zone, and length errors.

Error Codes E06-E08

Details causes and eliminations for range, relay, and anti-two-block errors.

Error Codes E11-E16

Details causes and eliminations for lower limit value errors in measurement channels.

Error Codes E19-E38

Details causes and eliminations for voltage, program, and EPROM mismatch errors.

Error Codes E41-E51

Details causes and eliminations for memory, A/D conversion, and EPROM errors.

Error Codes E91-E94

Details causes and eliminations for data transmission and interference errors.

Addendum A Basic Adjustment and Voltage Checks

Crane Supply Voltage Check

Procedure to measure the crane supply voltage at terminal X1.

Main Board Power Supply Checks

Procedures to check main board power supply voltages against reference values.

Boom Length Voltage Checks

Steps to measure voltage for boom length sensing.

Boom Angle Voltage Checks

Steps to measure voltage for boom angle sensing.

Pressure Transducer Voltage Checks

Procedures to measure voltage for pressure transducer zero points and references.

Addendum B Reference Tables for Measuring Supply and Signal Voltages for Sensor Channels

Signal Voltage Table

Reference table for signal voltages and nominal values for sensor channels.

Amplified Signal Voltage Table

Reference table for amplified signal voltages and test points for sensor channels.

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