Mobilkrane
TECHNICANS MANUAL
SLI-System DS350C
<X>DEMAC.
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S.Weinberger 8333.2 • Technical Training
SLI DS350C
Service Manual
This manual was produced by the technical troining department. lt is designed
for customer service specialists who possess working knowledge of the SLI functions;
for this reason are functional descriptions kept to a minimum.
2nd revised edition 711994
S. Weinberger
r:":mannes;f;ärfn
Dematic
-
Mobile Cranes
Technical Training
NDS350Cl
SLI DS350C
Manual
Table of Contents
lmportant Notes
3
Description of System
Hardware and Interface AC95
Hardware and Interface AC155
Hardware and Interface AC205
5
6
7
Functions -Settings -lnspections
8
Operating/Display Console
LCD, Function of Display Sections
Keyboard
9
13
Keypad A, Push-Button and Indicator Light Function
13
Keypad B, Functions
16
18
View of Keypad A and Keypad B
Setting the Operating Mode
Checks before Starting Work
Troubleshooting
19
20
21
Notes on Programming
Programming the DS350C
22
Transducers
Pressure Transducer - Type DAVS301
23
1st Length/Angle Transducer - LWG220/3
Angle Transducer - Type WG103
24
25
2nd Length Transducer - Type LG152
3rd Length Transducer - Type LG208
26
27
28
Hoist Limit Switch (A-2-B)
Error-Code Chart
Error-Code Numbers and Designations
29
31
Error Code Indication
Glossary
39
Abbreviations and Specialist Terms
AppendixA
AC95, Telescoping Sequences
AC155, Telescoping Sequences
AC205, Telescoping Sequences
Example of a Load Chart
Print-out of Operating Modes
SLI Standard Terminal Diagram
Al
A2
A3
AS
A7
A9
AppendixB Central Unit
Contents
-
System Description
Central Unit with Printed Circuit Boards
Bl
BI
B2
Appendix C - Miscellaneous
Cl
Using the DEMAG-Testadapter
Notes
SLI\.DS350Cl
1140
SLI DS350C
Manual
Important Notes
Description of System
The system DS350C as used by us is made up of
a central microprocessor unit and
an operating/display console, both housed in a sheet metal casing which is built into the
instrument panel
one lengthlangle transducer
one (AC95) or several (AC155/AC205) length transducers
one pressure transducer and
one or more hoist limit switches
The SLI works according to the principle of comparison between
desired value and actual value
The desired value corresponds to the load curve and is preselected on the computer using the
contents ofthe loaddata-EPROM; it changes
when the length or the angle of the boom is altered
when the operating mode is adjusted.
The actual value is determined by force and/or pressure determination.
The microprocessor constantly compares desired value and actual value:
if the actual value is equal to the desired value, the overload cut-off device is actuated,
resulting in all crane movements which increase the Ioad torque being shut down.
Boom length and angle are determined by length and angle transducers.
These are located in cable drums on the side of the basic boom section.
The length of telescopic boom is recorded by the cable which is also used to transmit
signals from hoist limit switch, electrics in main boom head and main boom extension.
Angle of telescopic boom is determined by means of an angle transducer;
angle and length of main boom extension, if fitted, are entered with the code for the
operating mode.
Loading of crane is determined by means of a pressure transducer which measures the
pressure in piston side of luffing cylinder.
When ignition is switched on, the SLI-computer automatically begins a sequence to test its
system; following items are tested:
Contents ofMemory (EPROM) for valid data
Electronic Components
Reference Voltages
Output State of Relays
Limiting Value ofTransducers
An error-code nurnber is displayed if a fault is recognised during test sequence.
SLI\DS350Cl
3/40
SLI DS350C
Manual
lmportant Notes
After successful completion oftest sequence, the operator must enter following on
operating/display console:
operating mode corresponding to operating status;
number of rope falls and
telescoping sequence
If signals given by the crane's electrical system via transducers and controls correspond to
these settings, they are acknowledged by the computer and the system is ready for operation;
otherwise a fault reading will be given.
Figure 1 shows central unit and arrangement of boards
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4/40
._____„
SLI\DS350Cl
SLI DS350C
Manual
lmportant Notes
Hardware and Interface
-
AC 95
Compact SLI DS350C
shared housing for operating/display console and central unit
System Modules in eurocard layout
Connectingboard with six 2 amp fuses, one connecting plug each for transducers and
crane electrics on rear of housing
Power supply board
Analogboard
CPU main board with CPU module, processor 80C537
Display unit Dot-Matrix-LCD, with background illumination
Keyboard module, foil-keyboard with short-stroke keys
Data-EPROM module with one EPROM (256 KB) each for crane data and load data
Connectingboard
Serial interface (=plug) for connecting the programming device
Force Measurement in piston side of luffingcylinder
with pressure transducer 0 - 300 bar, type DAV8 301
Angle Measurementfor telescopic boom
with angle transducer WG103, 0° - 90°, located in length/angle transducer housing
LWG220/3
Length Measurementfor extended boom sections
entire telescopic boom with length transducer located in length/angle transducer housing
LWG220/3;
basic boom length f telescopic boom retracted - with proximity switch B51 l
Slewing Range Measurementfor superstructure
locked over rear with proximity switch B43
Pilot-Pressure 1l'leasurement when extending boom sections
in pilot line, by means of pressure switch B703 - 2.5 bar
Hoist Limit Switch (A-2-B)
for hoist on main boom head and/or main boom extension
3 Relay Outputs
1. Overload
By-pass possible with key-operated switch 8700
2. Hoist Limit Switch (A-2-B)
By-pass possible with key-operated switch 8701
3. Telecylinder Release, dependent on software
By-pass possible with key-operated switch 8703
SLI\DS350Cl
5/40
Manual
SLI DS350C
Important Notes
Hardware and Interface
-
AC 155
Compact SLI DS350C
shared housing for operating/display console and central unit
System Modules in eurocard layout
Connectingboard with six 2 amp fuses, one connecting plug each for transducers and
crane electrics located on rear of housing
Power supply board
Analogboard
CPU main board with CPU module, processor 80C537
Display unit Dot-Matrix-LCD, with background illumination
Keyboard module, foil-keyboard with short-stroke keys
Data-EPROM module with one EPROM (256.KB ) each for crane data and load data
Connectingboard
Serial interface (=plug) for connecting the prograrnming device
Force Measurement in piston side of luffingcylinder
with pressure transducer 0 - 300 bar, type DAVS 301
Angle Measurement for telescopic boom
with angle transducer WG103, 0° - 90°, located in length/angle transducer LWG220/3
Length Measurement for extended boom sections
entire telescopic boom with length transducer located in length/angle transducer
LWG220/3
1 st boom section extended with length transducer LG152
1 st boom section retracted with proximity switch B511
2nd boom section retracted with proximity switch B512
Slewing Range Measurementfor superstructure
locked over rear with proximity switch B43
Pilot-Pressure Measurement when extendingboom sections
in pilot line, by means of pressure S\\<itch B703 - 2.5 bar
Pilot-Pressure Measurement when raisingmain boom with luffingcylinder
for EC acceptance
Hoist Limit Switch (A-2-B)
on main boom head and/or main boom extension
5 Reiay Outputs
1. Overload, by-pass possible with key-operated switch S700
2. Hoist limit switch, by-pass possible with key-operated switch S701
3. 1 st Telecylinder release, and
4. 2nd Telecy/inder release, dependent on software
by-pass of #3. and 4. functions possible with key-operated switch S703
5. Control of telescopic boom, locking Ist telecylinder, dependent on software
6140
SLI'\DS350Cl
Manual
SLI DS350C
lmportant Notes
Hardware and Interface - AC 205
Compact SLI DS350C
shared housing for operating/display console and central unit
System Modules in eurocard layout
Connecting board with six 2 amp fuses, one connecting plug each for signals of
transducers and crane electrics located on rear of housing
Power supply board
Analog board
CPU main board with CPU module, processor 80C537
Display unit Dot-Matrix-LCD, with background illumination
Keyboard module, foil-keyboard with short-stroke keys
Data-EPROM module with one EPROM (256 KB) each for crane data and load data
Connecting board
Serial interface (=plug) for connecting a prograrnming device
Force Measurement in piston side of luffing cylinder
with pressure transducer 0 - 300 bar, type DAVS 301
Angle Measurement for telescopic boom
with angle transducer WG103, 0° - 90°, located in length/angle transducer L WG220/3
Length Measurement for extended boom sections
entire telescopic boom with length transducer in L WG1, B702, type L WG220/3
Ist boom section extended with length transducer 2, B705, type LWG152
1 st boom section retracted with proximity switch B511
2nd boom section axtended with length transducer 3 , 8706, type 208
2nd boom section retracted with proximity switch B512
3rd/4th/5th boom section retracted with proximity switch B513
Slewing Range Measurement for superstructure
locked over rear with proximity switch B43
Piiot Pressure 1vleasurement when extending boom sections
in pilot line, by means of pressure switch 8703 - 2.5 bar
Pilot Pressure Measurement when raising main boom
for EC acceptance
Hoist Limit Switch (A-2-B)
on boom head and/or main boom extension
5 Relay Outputs
1. Overload, by-pass possible with key-operated switch S700
2. Hoist Limit Switch, by-pass possible with key-operated switch 8701
3. Ist Telecylinder Release, and
4. 2nd Telecylinder Release, dependent on software
By-pass of #3. and 4. possible with key-operated switch 8703
5. Control ofTelescopic Boom, locking l st telecylinder, dependent on software
SLI'\DS350Cl
7/40
Manual
SLI DS350C
Functions - Settings - Inspections
Operating/Display Console
with two important tasks:
Input through keypads, for instructions to the system
Display of important information and data on a sectioned LCD and indicator
lights
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Fig. 2 Operating/Display Console DS350C,
LCD in test sequence mode
8/40
SLI\DS350C2
Manual
SLI DS350C
Functions - Settings - Inspections
LCD
with sectioning displaying all necessary information:
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Function of Displp,y Sections
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A
Overload Symbol
red background, flashes when 100% of rated load is
exceeded and if an error occures. '0' appears
simultaneously in section M
B Prewarning Symbol
amber background, flashes when 9 0% of rated load is
reached and if an error occures. 'P' appears
simultaneously in section M
C Hoist Lim it Symbol
appears when a hoist limit switch has been tripped or
when there is a fault in the electrical circuit of the
hoist limit switch. 'H' appears simultaneously in
section :M: and indicator light and audible alarm are
switched on.
SLI\DS350C2
9/40
Manual
SLI DS350C
Functions - Settings - Inspections
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D Grane Data Display
selected data is given in connection with crane symbol
E, or pressure in piston side of luffing cylinder ( 13) or
actual load moment (8): code of desired info is entered
on keypad B and is acknowledged with C
E Grane Sym bol
5
displays crane dimensions which can be selected. The
dimensions are designated with arrows and code
numbers [1,2,3, 4,5, 9 ]; select the desired code on
keypad B and acknowledge with push-button C. Data
is displayed on section D.
The selected dimension is indicated by a flashing
dimensional arrow.
F Load Display
for normal crane operation the total load is displayed;
if tare symbol G appears, net load is displayed
G Tare Sym bol
appears, when the lifting tackle is tared by pressing
tare button 7 on keypad A, in order to have the net
load displayed on F; if radius is changed or ignition is
switched off briefly, this function is erased and F
displays the total load again
Note:
Total load includes weight of hook block, hoist rope
and all lifting tackle
Net load is the load on hook without any lifting tackle;
Display faults may occur due to external factors such
as, for example, wind which affects crane and load
H Load Display
shows rated load (capacity) corresponding to present
operating status
10/40
SLl\DS350C2
Manual
SLI DS350C
Functions - Settings - Inspections
J Load Mom ent Display
(Bargraph display) shows what proportion of the
presently permissible load moment is being exploited.
The load moment fluctuates constantly when the boom
is moved and therefore the load moment display also
fluctuates;
this display is divided into three coloured sections
green, safe working range,0 - 90% of load moment
am ber, prewarning range, 90 - 100% of load
red, overload range, above 100% of load moment
K Operating Mode Display and Sym bol
shows the code of operating mode. This code must
correspond to the number valid for the current
operating status and load curve. Check that this is the
case! These numbers are given in operating mode
table, which is supplied with every central unit.
When an operating mode is automatically altered, e.g.
for various boom lengths, the change is displayed here.
If the computer selects a rigging program, a 9 appears
as second digit and the amber prewarning indicator
light flashes simultaneously.
EEEE appears simultaneously to fault display E04
before acknowledgement is given.
The code to be set can be found in the load chart: Press
function key, enter code and acknowledge pushing C.
L Reeving Display
displays reeving number (= number of rope falls) to
which the SLI is set; to enter: actuate push-button 6 in
section A, enter number of falls on keypad B and
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acknowledge with push-button C
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SLI\DS350C2
M Fault Display
if the system recognises malfunction, an error code
number will be displayed; fault and remedy is given :i.."1
an error-code table
N Text Display
Code number for extension sequence or extension
length in%
11140
Manual
SLI DS350C
Functions - Settings - Inspections
0 Display "On Outriggers" or "On Rubber"
1-h symbol is displayed when operating mode "crane on
outriggers" is selected, r-h symbol is displayed when
operating mode "crane on rubber" is selected.
P we do not use this function.
12/40
SLI\DS350C2
Manual
SLI DS350C
Functions - Settings - Inspections
Keyboard
The keyboard is divided into two sections:
Keypad A, left-hand side: function keys, indicator lights for prewarning, overload, and hois
Keypad B, right-hand side: input of codes and acknowledgement
Always acknowledge operating mode after switching on ignition:
press push-button 5 on pad A, then push-button C on pad B.
Keypad A, Push-Button and Indicator Lights Panel, Function:
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Indicator Light 1, Red: Hoist Limit Switch Alarm
comes on when a hoist limit switch opens or when an error occurs in its electric
circuit, an audible alarm is given at same time and crane movements:
raise hoist, extend telesections and lower boom are cut off
'H' appears as an error display in section M
Indicator Light 2, Amber: Prewarning
comes on when 90% of currently permissible load molllent is reached and
overload situation is imminent;
" P " appears as an error display in section M;
flashes when an erecting program is selected
Indicator Light 3, Red: Overload Alarm
comes on when 100% of currently permissible load moment is exceeded;
Crane movements:
raise hoist, extend telesections and lower boom are shut down.
'0' appears as an error display in section M
SLI'\DS350C2
13/40
an
SLI DS350C
Manual
Functions - Settings - Inspections
Indicator Light 4: no function assigned
Push-Button 5: Clearance for Operating Mode Input
always actuate before entering an operating mode number; lights up when
pressed confi.rming clearance.
Enter operating mode on keypad B. The display comes up in section K of LCD.
The operating mode entered must always correspond to operating status of crane.
Setting the Code
1.
2.
3.
4.
5.
Determine operating status using valid load chart
Assign code for operating status
Actuate push-button 5, keypad A, button lights up
Enter code on keypad B, e.g. 1
Acknowledge with push-button C, keypad B. The light in push-button 5
goes out
Push-Button 6: Clearance for Setting Number of Rope Falls (Rope Reeving
Number)
always actuate before entering number of falls; lights up when pressed
confirming clearance.
Enter number of falls on keypad B. The display comes up in section L of LCD.
The enterediactual number of falls must correspond to that specified for
operating status (exception: special lifts).
Setting Number of Falls:
1.
2.
3.
4.
Determine number of falls for operating status using load chart
Actuate pltsh-button 6, keypad A, button lights up
Enter number of falls on keypad B
Acknowledge with push-button C, keypad B. The light in push-button 6
goes out
Push-Button 7: TARE
for switching on tare function, which deducts weight of lifti..'1.g tackle, hook and
hoist rope from load display:
After push-button has been pressed, load display F is set to zero = tared. The
tare symbol appears in section G of LCD. A flashing "O" appears on load
display F for net load.
If a load is then raised, F flashes the resultant weight. This function is
switched off when the radius is altered or by switching ignition off and on
again.
Push-Button 8: Horn Acknowledge
for switching off audible alarm
14/40
SLI\DS350C2
SLI DS350C
Manual
Functions - Settings - Inspections
Push-Button 9: Input of Wanted Extension Boom Sequence
identical boom lengths can be achieved with different extension sequences of
boom sections :
1. Determine code for extension sequence using load chart
2. Actuate push-button 9, button lights up
3. Enter code on keypad B
4. Acknowledge with push-button C. Button 9 goes out. Subsequently actuate
boom section as detailed in operating manual. The selected boomlength
appears in section M for approx. 2 seconds. lf 100% of boom are extended
MX will be displayed.
Push-Button 10: no Function Assigned
Push-Button 11: no Function Assigned
Push-Button 12: no Function Assigned
SLI\DS350C2
15/40
SLI DS350C
Manual
Functions - Settings - Inspections
Keypad B, Functions:
Tastenfeld B
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Codes for operating mode, rope reeving and extension sequence are entered after
the desired function has been preselected on keypad A.
The functions do not need to be preselected for purposes of displaying crane data.
After inputting and acknowledging with push-button C, section Don LCD
displays the desired information. Codes are explained on crane symbol in section
E and in the followlng table.
Input
Display
1
2
3
Length of main boom
Angle of main boom
Working radius
4
5
8
9
13
Angle of main boom extension
Tip-Height
Current load moment
Length of boom extension
Pressure in luffing cvlinder in bar, piston side
Push-Button ''.Asterix": no function assigned
Push-Button "C": Acknowledge button, used to acknowledge input of crane data,
operating mode, rope reeving and extension sequence
16/40
SLI\DS350C2
SLI DS350C
Manual
Functions - Settings - Inspections
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17/40
-
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_
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__„
Manual
SLI DS350C
Functions - Settings - Inspections
View of Keypad A and Keypad B
Tastenfeld B
Tastenfeld A
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18/40
SLI\DS350C2
Manual
SLI DS350C
Functions - Settings - Inspections
S etti ng Operating Mode
The SLI must always be set corresponding to operating status
ofcrane. The SLI will otherwise neither cut off correctly
nor display correct data.
Codes must always be entered when the operating status of crane has been
altered. Following data is required:
1. Operating Mode
2. Reeving of Hook Block
3. Extension Sequence of Boom Sections
Setting procedure is identical for all functions:
1. Press Preselect Button, this must light up
2. Enter Code Number
3. Acknowledge with Button C,
the p reselect button must then go out, indicating that computer has accepted the setting.
Settin g Operating Mode
1. Press push-button 5 on keypad A, preselect operating mode, button lights up.
The previously selected operating mode is displayed an section K of LCD
2. Enter operating mode (from load chart) on keypad B, checking entry on
section K of LCU
3. Press push-button C to acknowledge setting which has just been entered.
Pre-select button goes out
Always acknowledge operating mode after switching on ignition:
press push-button 5 on keypad A, then push-button C on keypad B
Setting Rope Reeving
1 . Press push-button 6 on keypad A, preselect rope reeving, button lights up.
The previously selected rope reeving arrangement is displayed an section L of LCD
2. Enter rope reeving on keypad Bin accordance with load chart, checking
entry on section L of LCD.
3. Press push-button C to acknowledge setting which has just been entered,
pre-select button goes out.
Setting Extension Sequence
1. Press push-button 9, preselect extension sequence, button lights up.
The previously selected extension sequence is displayed on section N of LCD.
2. Euter code for extension sequence on keypad Bin accordance with load
chart. The desired extension sequence is briefly displayed in% in section N
of LCD, display returns to actual extended length.
3. Press push-button C to acknowledge setting which has just been entered,
pre-select button goes out, SLI is ready for operation.
SLI\DS350C2
19/40
SLI DS350C
Manual
Functions - Settings - Inspections
Checks before starting Work
Hoist Limit Switch (A-2-B)
Position of shift weight:
with even number of rope falls - on dead end of rope
with uneven number of rope falls - on the fall wich moves slowest.
If a main boom extension has been fitted:
hoist limit switch must be removed from main boom head and located on main
boom extension. Cable must be connected and by-pass plug inserted in
terminal box on boom head.
The system does not function if hoist limit switch
and shift weight are not changed over and connected
Hoist Limit Switch Indicator Light and Audible Alarm,
for this purpose, lift shift weight:
Carefully pull hook block up against shift weight. As soon as the hook block lifts
the weight, the alarm must sound, indicator light come on and "raise hoist"
function be shut down. Lower hook block slightly to alleviate this condition.
Next, lower or extend boom to reproduce a hoist limit condition. When the hook
g or telescoping procedure be shut down.
block subsequently raises the shift weight, the alarm must sound, indicator light
come on and luffin
If indicator lamp or alarm do not function as described and crane movements are
not shut down, the system is not in füll working order. Fin d and rectify the fault.
Check:
all Gable Connections for damage
Gable Drum for smooth rotation, pretensioning and correct winding in of
electric cable
Displayed Boom Length must correspond to actual boom length
Displayed Angle must correspond to actual boom angle
Displayed Working Radius must correspond to actual working radius
Pressure Transducer and Connecting Hoses for oil leaks
All faults must be rectified before work with crane is started
20/40
SLI\DS350C2
Manual
SLI DS350C
Functions - Settings - lnspections
Troubleshooting
If the CPU recognises malfunction, the LCD displays an error code number (E .....)
on section M.
All possible code numbers are listed in an error code chart, where reference to the
cause is given. Faults and corresponding remedies are described.
Faults on central unit and transducers must be rectified by specialist qualified
personnel as the system can only be checked thoroughly using a programming
unit. If errors occur, inform our after sales service departement immediately.
Faults due to Operating Mistakes
Faults caused by specified operating ranges being exceeded or by operating
mistakes, (error reading EOl, E02, etc.) can be rectified directly by the crane
operator.
SLI\DS350C2
21140
Manual
SLI DS350C
Notes on Programming
Programming the DS350C
This system is programmed differently to SLI-systems otherwise used by
DEMAG.
The ready fitted telescopic boom is set on a test stand at 2° and weighed in 7 or
11 different sectional lengths (corresponding to standard and special extension
sequences).
A "master" pressure transducer is used to make measurements whilst the
pressure transducer which is subsequently to be fitted on the crane makes
measurements in parallel. This second pressure transducer is adjusted if a
tolerance of 2 bar is exceeded.
Measured values are recorded by a PC and the corresponding program is written
into an EEPROM*.
The ready assembled crane is tested with loads on the test bed.
Any program adjustments which are found to be necessary are then carried out,
including adjustments to basic setting of transducers.
After testing is completed, data are converted from the programmed EEPROM
into an EPROM*, which is placed into the computer.
All program corrections pass through a data logger into the original program,
producing an increasingly accurate data program. This means that fewer
corrections are required with time.
*Info on EEPROM 'and EPROM:
an EEPROM is erased using voltage,
an EPROM using UV light.
22/40
SLI\DS350C3
Manual
SLI DS350C
Transducers
Pressure Transducer
Type DAVS 301
A pressure transducer is used for determination of force. lt measures pressure in
piston side of luffing cylinder.
In a body shaped as a steel pipe is fitted an amplifier from one side and from the
other side there is inserted another steel pipe which is connected to hydraulic
circuit to be measured.
On outside of this second steel pipe there are four strain gauges fitted. These are
connected to a füll bridge circuit and wirde to an amplifier which has been
calibrated by the manufacturer.
The pipe is filled with plastic compound tö protect electronics against moisture,
vibration or shock.
The strain gauge bridge circuit is supplied with a stabilised voltage. When
depressurized, diagonal voltage (signal) equals zero.
When pressure in luffing cylinder builds up, resistance of strain gauges changes
resulting in a voltage which is amplified and fed to central unit.
A transducer must not be fixed with a tight clamp as this leads to incorrect
!
measurements.
Electrical Connection:
-·-·-·-·-·-·-·-·-·-
4-pin cannon plug, double-shielded cable
Hydraulic Connection:
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Inner thread M16 x 1 .5
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Measured Value:
Power Supply :
0 to 300 bar
!101
+/-5.000 V
Signal:
� 0 to -1 .000 V linear
Checks:
release all hydraulic pressure from transducer
unfasten pipes; load moment or pressure
must not be displayed on LCD,
Signal 0.000 V constant, tolerance 20 mV
Balancing:
only possible with software
Important:
always replace if accident damage has occured to the boom.
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SLI\DS350C4
23/40
0
„.
Manual
SLI DS350C
Transducers
lst Length/Angle Transducer
Type LWG 22013
fitted on left-hand side of basic boom section. The upper edge of housing is :flush
with upper edge of basic boom section.
The cable of the reeldrnm is secured to the sheave head. Each extending or
retracting movement of boom drives a lOk0-1 0-turn potentiometer via two
plastic gears; the larger gear wheel slips on the shaft of potentiometer if too
much force occures, thus avoiding any damage.
Pre-Tensioning:
of cable reel drum approx. 5 turns
Zero Setting, Mechanical:
fully retract all boom sections, turn setscrew (=potentiometer shaft) a small
amount to the right and then carefully to the left stop
Voltage Supply:
5.000 V across two protective resistors; interuptions and short circuits in
measuring system can thus be identified.
Balancing:
Connect a digital voltmeter across potentiometer,
balance to 4.000 V
Signal voltage at basic boom length 0.500 V,
if necessary adjust with
trimming potentiometer on PCB
Test: fully extend all boom sections,
compare display with actual length
Fine Balancing:
only possible with software
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24/40
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SLI'-DS350C4
Manual
SLI DS350C
Transducers
Angle Transducer (WG)
Type WG103
fitted inside housing of LWG 220/3, it must be set in a way that its upper edge is
flush with upper edge of basic boom section.
The potentiometer of angle transducer is housed in an aluminium casing which is
filled with liquid silicone to dampen oscillating movements. The axle of
potentiometer is moved by a pendulum.
Potentiometer Range:
5 kQ, 356°
Subarea 90°:
used to measure boom angle;
residual winding is used as series resistance for
monitoring of range.
Voltage Supply:
5.000 V
Signal Voltage:
9 0°
0°
45°
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1 .875 V
3.1 25 V
2.500 V
Fine Balancing:
only possible with software
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SLI\DS350C4
25/40
_J
SLI DS350C
Manual
Transducers
2nd Length Transducer, for AC155 and AC205
TypeLG152
fitted on left-hand side of basic boom section, the length measuring cable is
secured on collar of first boom section and measures its extending/retracting
movements. A 10 kO 1,0-turn potentiometer is driven through turning of reel
drum.
Zero Setting, Mechanical:
Fully retract Ist boom section, turn pot shaft a small amount to the left and
then carefully to the right stop, looked from outside on potentiometer; if
necessary loosen clamping screw of friction coupler.
Pre-Tensioning:
of cable reel drum approx. 5 turns.
Voltage Supply:
5.000 V across two protective resistors; interuptions and short circuits in
measuring system can thus be identified.
Balancing:
Connect a digital voltmeter on potentiometer,
balance to 4.000 V
Signal voltage at basic boom length 0.500 V,
if necessary adjust with
trimming potentiometer on PCB
Control test: fully, extend lst boom section,
Compare display with actual length
s.oov
Fine Balancing:
1
only possible with software
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26/40
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SLI\DS350C4
Manual
SLI DS350C
Transducers
3rd Length Transducer, for AC205
TypeLG208
fitted on left-hand side of basic boom section, the length measuring cable is
secured on 2nd boom section and measures its extending/retracting movements.
A 10 kn 10-turn potentiometer is driven from turning of reel drum.
Zero Setting, Mechanical:
Fully retract first boom section, turn pot shaft a small amount to the right and
then carefully to the left stop, as looked on potentiometer.
Pre-Tensioning:
of the cable reel drum approx. 5 turns
Voltage Supply:
5.000 V across two protective resistors; interuptios and short circuits in
measuring system can thus be identified
Balancing:
Connect a digital voltmeter to the potentiometer,
balance to 4. 000 V
Signal voltage at basic boom length 0.500 V,
if necessary adjust with
trimming potentiometer on PCB
Control test: fully extend lst boom section
Compare display with actual length
Fine Balancing:
only possible witli. software
11 /10 ,„
Jun
rai
SLI\DS350C4
27/40
SLI DS350C
Manual
Transducers
Hoist Limit Switch (A-2-B)
A circuit is wired:
from computer, A700, terminal 23
across transducer B705. 7
Length transducer B702.7, interference PCB
Slip ring E702.2
Length transducer cable, brown
Hoist limit switch X550.6, with two protective resistors 4.7 k.Q and 1 k.Q
connected in parallel
back across
shield
slip ring E702. 1
interference board, length transducer B702.8,
length transducer B705.8
back to computer, A700, terminal 22
A comparator on PCB recognises broken circuit, short circuit or hoist limit switch
open/closed; on terminal 23: 7.1 5 V closed circuit, 4.6 V open circuit.
1.403 kn resistance with closed circuit, hoist limit switch relay picked up;
24 V from terminal 16 to K701/coil;
with open circuit a hoist limit switch-actuated-signal is given.
Hoist limit switch and by-pass plug with 826.Q resistor are connected in series. The hoist limit
switch is always mounted on the boom head currently in use, the by-pass plug is closing open
circuit, otherwise the device will not function.
1 A700
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28/40
SLI\DS350C4
SLI DS350C
Manual
Error Code Chart
Error-Code Numbers and Designations
This table is valid only for cranes with SLI type DS350C
A large proportion of possible faults is diagnosed by the computer and is listed
here. If an error number is displayed which is not given in the table, contact our
Service Department. Please note that an electronics specialist is needed to rectify
mahy of the faults listed.
CodeNumber
0
p
H
EEEE
Error Designation
Overload, 100%, safe working load exceeded
Prewarning at 90% to 100% of safe working load
Hoist limit switch tripped (A-2-B)
Operating Mode not acknowledged, see also E04
EOl
Radius range fallen short/angle range exceeded
E02
E04
Radius range exceeded/angle range fallen short
Operating mode not acknowledged
E05
Illegal length range
E06
Angle range fallen short with luffing fly jib
E07
Nq remote indication from overload relay
E08
No remote indication from limit switch relay(A-2-B)
E09
No remote indication from relay 2
EU
Telescopic boom length: signal below lower limiting value
E12
Luffing cylinder piston side: signal below lower limiting value
E13
Luffing cylinder rod side: signal below lower limiting value
E14
Luffing fly jib force: signal below lower limiting value
E15
Main boom angle: signal below lower limiting value
E16
Luffing fly jib angle: signal below lower limiting value
E17
2nd length input: signal below lower limiting value
E18
E19
New DAT-EPROM (chanel level switch off)
Reference voltage defect
E20
Analog voltages not present
E21
Telescopic boom length: upper limiting value exceeded
Luffing cylinder piston side: upper limiting value exceeded
E22
E24
Luffing cylinder rod side: upper limiting value exceeded
Luffing fly jib force: upper limiting value exceeded
E25
Main boom angle: upper limiting value exceeded
E23
E26
Luffing fly jib angle: upper limiting value exceeded
E27
2nd length input: upper limiting value exceeded
SLI'-DS350C5.DOC
29/40
SLI DS350C
Manual
Error Code Chart
Code Number
Error Designation
E29
E31
E38
E39
E41
E42
E 43
E 45
E 46
E47
E49
Reference voltage defect
Error in system program
Programs in EPROM's not compatible
System program and load chart-EPROM not compatible
Error in internal RAM of CP 80C537
Error in Ist section of external RAM
Error in 2nd section of external RAM
Redundancy error in A/D converter (ADC)
E51
Error in crane data-EPROM or -EEPROM
E52
E56
E57
E58
Error in load chart EPROM
Error in crane data EPROM
Error in serial crane data EPROM
Error in serial EPROM of analog PCB
E72
E73-E77
Error in ADC uPD7004
Buffered RAM disturbed
Wrang data with online operation
Error with relay K2
Error with relays K3 to K7
E83
E84
E86
incorrect telescoping sequence
incorrect operating mode
incorrect percentage for at least one boom section
E88
incorrect main boom angle with luffing fly jib operation
30/40
SLI\DS350C5.DOC
Manual
SLI DS350C
Error Code Chart
Error Code Indication
System Message
0
'Overload', Crane overloaded, 100% exceeded
P
'Prewarning', Prewarning at 90% to 100%
H
a)
Hoist limit switch tripped (A-2-B)
b)
c)
d)
Interuption in hoist limit switch circuit
Short circuit in hoist limit switch circuit
Accidental ground/earth in hoist limit switch circuit
EEEE
Operating mode not acknowledged or not present (see also E04)
Error Messages
Error
EOl
Radius range fallen short
Cause
Remedy
Boom raised to far
Move main boom to radius or
angle corresponding to load
chart
or angle range exceeded
with main boom
operation
E02
Radius range exceeded or
angle range fallen short
with main boom
operation
Boom lowered to far
Move main boom to radius or
angle corresponding to load
chart
E04
Operating mode not
acknow ledged
a) Operating mode not
acknowledged after selftest
of SLI-device
b) SLI adjusted to wrong
operating mode
c) Digital input missing
a) Carry out acknowledging
striking of keys always after
switching on power or
seiftest of SLI resp.
b) Set operating mode
corresponding to crane
status and carry out
acknowledging
c) Check digital inputs for
correct function
SLI\DS350C5. DOC
31/40
SLI DS350C
Manual
Error Code Chart
Error
E05
Illegal length range
Cause
Remedy
a) Boom is extended to far or
not fart enough e.g. with
Operating modes 'on wheels'
where maxim um boom
length is limited or with
Operating modes for luffing
fly jib w here the boom has to
be extended to a certain
length
a) Move boom sections to
length corresponding to
operating mode
b) Retract boom completely
and check initial tension of
reel drum, the cable must be
tight; open housing of length
transducer and adust poti to
basic boom length with
turning shaft with a
srewdriver carefully ccw to
its stop
c) Check coupler or change
b) Adjustment of length-poti
is wrong because cable was
fallen off from reel drum
c) Coupler between drive
and poti defective or gear is
sliding on shaft of poti
d) 5 V supply for
.
E06
Angle range fallen short
with luffing fly jib operation
transducers missing because
of a short in one of the cables
to the transducers
e) Cable defective or loose
from CPU to length
transducer
f) Poti of length transducer
defective
g) Digital input of basic
boom length is switched on
despite boom being extended
gear/0-ring, clean shaft of
poti from oil and adjust basic
boom length as described in
para b)
d) Check all voltages,
if they
are correct change computer;
if voltages are not present or
will break down with a load
of 50 n check cables to
transducers for a short and
replace if required
e) Check cables and plugs
and change them if required
f) Check poti and change it if
required, adjust basic boom
length as described in para
b)
g) Check cable and switch
for digital input and change
if required
Angle of luffing fly jib fallen
short because radius is to
big. Correct radius or angle
Move luffing fly jib in
working range
corresponding with load
is given in load chart of
actual status of crane
chart of actual status of
crane
E07
No remote indication from
overload relay
Blackout of overload relay,
defective or not actuated
Check relay; replace
connecting board if required
EOS
No remote indication from
hoist limit switch relay (A-2-
Blackout of relay, defective
or not actuated
Check relay; replace
connecting board if required
B)
32/40
SLI\DS350C5.DOC
Manual
SLI DS350C
Error Code Chart
Error
E09
EU
No remote indication from
relay 2
Signal i n measuring channel
1 for telescopic boom length
is below lower limit
Remedy
Cause
Blackout of relay 2, defective
or not actuated
Change relay; if no success
change connecting board
a) Cable from central unit to a) Check cable and plug
length transducer defective
or water in plug connector
connector and replace if
b) Lenght-poti defective
b) Check length-poti and
required
if required, adj ust
c) Elektronic component in
change
measuring channel defective
basic boom length
afterwards
El2
Signal i n measuring channel
c) Chanrre analof! PCB
a) Cable from central unit to a) Check cable and plug
connector and replace if
pressure transducer
2 for pressure transducer on
luffing cylinder piston side is
defective or water in plug
below lower limit
connector
b) Check pressure
b) Pressure transducer
transducer and replace if
defective
required
c)
Elektronic component in
measuring channel defective
E13
Signal in measuring channel
3 for pressure transducer on
luffing cylinder rod side is
below lower limit
Change analog PCB
a) Cable from central unit to a) Check cable and plug
connector and replace if
defective or water in plug
required
connector
b) Check pressure
b) Pressure transducer
transducer and replace if
defective
c) Elektronic component in
required
c) Change analog PCB
Signal i n measuring channel
a) Measuring channel open,
a) Connect load cell
below lower limit
e.g. load cell not connected
b) Cable from central unit to
connector and replace
load cell defective or water
required
4 for load on luffing fly jib is
in plug connector
c) Load cell defective
d) Elektronic component in
measuring channel defective
E15
c)
pressure transducer
measuring channel defective
E14
required
Signal i n measuring channel
5 for angle of main boom is
below lower limit
if
c) Check load cell and
replace if required
c) Change analog PCB
a) Cable from central unit to a) Check cable and plug
connector and replace if
length/angle transducer
defective or water in plug
required
connector
b) Check angle transducer
b) Angle transducer
and replace
defective
c) Elektronic component in
measuring- channel defective
SLI\DS350C5. DOC
b) Check cable and plug
33/40
c)
if required
Change analog PCB
E18
New DAT-EPROM (chanel level switch off)
SLI DS350C
Manual
Error Code Chart
Error
E23
Remedy
Cau se
a) Cable from central unit to a) Check cable and plug
Signal in measuring channel
3 for pressure transducer on
pressure transducer
connector and replace if
luffing cylinder rod side
defective or water in plug
required
exceeded upper limit
connector
b) Check pressure
defective
c) Elektronic component in
transducer and replace if
required
c) Change analog PCB
b) Pressure transducer
measurinir channel defective
E24
Signal in measuring channel
4 for load cell on luffing fly
jib exceeded upper limit
e.g. load cell not connected
a) Connect load cell
b) Check cable and plug
load cell defective or water
required
a) Measuring channel open,
b) Cable from central unit to connector and replace
in plug connector
c) Load cell defective
d) Elektronic component in
c)
if
Check load cell and
replace if required
d) Change analog PCB
measurinir channel defective
E25
Signal in measuring channel
a) Cable from central unit to a) Check cable and plug
exceeded upper limit
length/angle transducer
defective or water in plug
5 for angle of main boom
connector
b) Angle transducer
defective
c) Elektronic component in
connector and replace if
required
b) Check angle transducer
and replace if required
c)
Change analog PCB
measuring- channel defective
E26
Signal in measuring channel
6 for angle of luffing fly jib
exceeded uppf(r limit
a) Cable from central unit to a) Check cable and plug
angle transducer defective or connector and replace if
water in plug connector
b) Angle transducer
defective
c) Elektronic component in
required
b) Check angle transducer
and replace if required
c) Change analog PCB
measurinl.? channel defective
E27
Signal in measuring channel
7 for 2nd length input
exceeded upper limit
a) Cable from central unit to a) Check cable and plug
2nd length transducer
defective or water in plug
connector
b) Check 2nd length
defective
required
b) 2nd length transducer
c) Elektronic component in
measuring channel for 2nd
length inout defective
E29
Reference voltage defective
connector and replace if
required
a) Total of supply and
reference voltages on
measuring point (MP) 10 is
>3.3V
b) A/D- Converter (ADC)
defective
transducer and replace if
c)
Change analog PCB
a) Check supply voltages; if
one of this voltages is not
present a short in cable to a
transducer might be the
reason, check cables and
plug connectors, replace if
required
b) Change p ower supply
board with ADC
SLI\DS350C5.DOC
35/40
SLI DS350C
Manual
Error Code Chart
Error
Cause
Remed_y
Replace system programm
EPROM
E31
Data in system programm
Wrong system program
EPROM does not match data EPROM in central unit
in data EPROM
E38
Programs do not match
Wrong EPROM in central
unit
Check version numbers of
EPROM's and insert
EPROM's corresponding to
type of crane and serial
number
E39
System program and load
chart program do not match
Wrong EPROM in central
unit
Check version numbers of
EPROM's and insert
EPROM's corresponding to
type of crane and serial
number
E41
Error in internal RAM o f CP
80C537
E42
Error in Ist section of
external RAM of CP 80C537
E43
Error in 2nd section of
external RAM of CP 80C537
E45
Redundancy error in AJDconverter (ADC)
a) Replace CP 80C537
b) Replace main board with
CPU module
a) Replace CMOS-RAM
b) Replace main board with
CPU module
a) Replace CMOS-RAM
b) Replace main board with
CPU module
•
E46
Error in AJD-converter
(ADC) uPD7004
No remote indication from
ADC
E 47
Buffered RAM disturbed
CRC giving faulty result
E49
Wrong data with online
No valid data in RAM after
operation
programming with online
interface
E51
1
ADC on CPU module and
ADC of CP 80C357 are
giving different results
probably because of a short
in cables to a transducer or
water in plug connector
a) Check supply voltages; if
one of this voltages is not
present a short in cable to a
transducer might be the
reason, check cables and
plug connectors, replace if
required
b) Replace main board with
CPU module
a) Replace power supply
board
b) Replace main board with
CPU module
a) Retract boom completely,
error will possibly be reset
b) Check buffer battery,
replace if required
c) replace main board with
CPU module
Error in crane data EPROM
or E EPROM
a) No valid data in EPROM
b) Jumpers located wrong on
Data EPROM module
c) Data EPROM defective
a) Replace RAM extension
b) Replace online interface
c) Replace main board with
CPU module
a) Load valid data into crane
data EPROM
b) Locate jumpers
corresponding to type of
E PROM
c) Reolace data EPROM
36140
SLI\DS3 50C5.DOC
Manual
SLI DS350C
Error Code Chart
Error
Remed_y
Cause
E52
Error in load chart EPROM
E56
Errar in crane data EPROM
E57
Error in serial crane data
EEPROM
a) No valid data in serial
crane data EEPROM
b) Data EPROM module
defective
a) Copy valid testprogram
data into EEPROM and
restart SLI
b) Replace data EPROM
module
Error in serial EPROM of
a) No valid data in serial
analog board
data EPROM
b) Analog board defective
a) Capy valid testprogram
data into EEPROM and
restart SLI
b) Replace data EPROM
module
E58
E72
Remote indication of relay
K2 gives error-message;
Monitoring contact gives
message 'relay off' despite
relay should have picked up,
or vice versa
E73/
E77
E83
Likewis E 72 but for relays
K3 ta K7
Load chart EPROM defective a) Reset SLI
b) Replace laad chart
EPROM
a) Jumpers wrang located an a) Locate jumpers
corresponding to type of
Data EPROM module
b) Data EPROM defective
EPROM
b) Reolace data EPROM
a) Relay K2 or connecting
board defective
b) Main board defective
a) Check relay and
connecting board, replace if
required
b) Replace main board
see E72
see E72
Incorrect telescoping
a) Telescoping sequence
a) Select valid telescoping
sequence
selected is not in
programmed load chart of
crane
b) Digital inputs da not
correspond with selected
telescooin� seouence
seqence
b) Check digital inputs,
replace switches if required
a) Select valid operating
mode
'
E84
Wrang operating mode
Operating mode selected is
not programmed for this
crane
E86
Incorrect percentage
displayed for at least one
telesection
Displayed percentage
is <-2% or > 106%
E88
\Vrong main boom angle
with luffing fly jib operation
a) Main boom is not in angle
position for luffing fly jib
operation
b) Angle determination of
main boom defective
Check all length
transducers, retract
telescopic boom completely,
error will than be reset
SLI\DS350C5.DOC
37/40
a) Move main boom in angle
position prescribed for
luffing fly jib
b) Check angle transducer
and reolace if reouired
Manual
SLI DS350C
Glossary
Abbreviations and Specialist Terms
AID
Analog/Digital
ADC
Analog/Digital Converter
Basic boom section
Root section of a telescopic boom
B asic length
Length of a fully retracted telescopic boom
CMOS
Complementary Metal-oxide Semiconductor,
high-resistance, medium-fast
CPU
Central Processing Unit, central unit, microprocessor,
arithmetic and control Wlit of a computer
CRC
Cyclic RedWidancy Check, intemal independent test
procedure for data transmission/processing
DAVS
Type designation for pressure transducers used
DMS
Strain gauge
EEPROM
Electric Erasable Read Only Memory, programmable
with voltage eraseable read-only memory
EPROM
Erasable Read Only Memory, programmable,
with UV-light erasable read-only memory
LCD
Liquid Crystal Display
LG
Length transducer
LWG
Length/angle transducer
MP
Measuring Point
PC
Personal Computer
PCB
Printed Circuit Board
Pot, Poti
Potentiometer
RAM
Random Access Memory, read/write memory
can be inscribed and erased as desired
?range exceeded
defined voltage value which indicates incorrect or correct
?range fallen short
defined voltage value which indicates incorrect or correct
SLI
Safe Load Indicator
Transducer
Designation for LG, WG, DAV or load cell
UV
Ultra Violet
WG
Angle transducer
SLI\DS350C6
39/40
=
Load limit device