MAXOUT DX CRANE LOAD LIMITER

Transcription

1 MAXOUT DX CRANE LOAD LIMITER Model MX10x, Version 2+ Model MX10xD Installation and User Manual V1: 31/03/2017 CASWA Pty Ltd 2017 CASWA Pty Ltd Page

2 CONTENTS 1 OVERVIEW SPECIFICATIONS Physical Specifications Electrical Specifications Communication Specifications INSTALLATION DETAILS Prior to Installation Wiring Diagrams Installation with an existing load display Installation with a Dedicated Load Cell (e.g. RCxT) Installation with a 4-20mA Load Output Installation with a 0-10V Load Output Installation with a Q-Link Output (ABUS LIS) Installation with a F-Link Output (ABUS LIS) Setting up Multi-zone Limits COMMISSIONING DETAILS Installing and Launching the FSU Application FSU Program Installation Installing the FSU application Launching the application Connecting to the Device Setting Up Your MaxOut Setting the Hoist ID Setting the Input Voltage Type - New Feature Setting the Load Input Type Calibrating the MaxOut DX Configuring a Single Overload Configuring Multi-Zone Load Limiting Invert Output CASWA Pty Ltd Page

3 4.3.8 Load Summing - New Feature Logging Overloads (Firmware 1.8 onwards) Sending Alerts ROUTINE MAINTENANCE TROUBLESHOOTING APPENDIX A: COMMUNICATION PROTOCOL APPENDIX B: FSU SYSTEM REQUIREMENTS APPENDIX C: MANAGING FIRMWARE CASWA Pty Ltd Page

4 1 OVERVIEW MaxOut DX is an inexpensive electronic load limiter for a single hoist that also wirelessly transmits the load signal using Sole Digital's HoistNet technology. In addition to performing its load limiting function, MaxOut DX is a HoistNet compatible device that can act as a wireless source of load data for displays, data loggers and load summation units. When used in this configuration, only the source MaxOut DX device wired to the load cell needs to be calibrated. MaxOut DX is a drop in replacement for a traditional MaxOut and is wired identically. You can identify a MaxOut DX by either its (a) MaxOut DX sticker (first batches do not have these) or (b) a serial number on a MaxOut sticker that is greater than It is important to note that MaxOutDX units require version 19.5 or higher of the FSU software. This was released in Q Earlier versions of the FSU will not be able to communicate with MaxOutDX units. CASWA Pty Ltd Page

5 2 SPECIFICATIONS 2.1 Physical Specifications Overall length (mm): 115 Overall width (mm): 100 Overall height (mm): 23 Weight (kg): 0.12 Mounting: 30mm DIN Rail Figure 1: Case Dimensions CASWA Pty Ltd Page

6 2.2 Electrical Specifications Parameter Description Min Typ Max Units V in Supply voltage VAC/DC I in Supply current ma L max Maximum voltage on a load sensing pin with respect to device gnd 3.3 V L fs Load pin differential input for full scale reading mv V fault Max voltage for fault output 250 V AC I fault Max current sink by fault output 4 A Pfault Max contactor inrush rating at 48V 200 W Allowable operating temperature Note1 C Note1: Extended operation at maximum temperature will reduce the life the device. 2.3 Communication Specifications Communications between the device and a host is usually via a Bluetooth radio link. The Bluetooth device name will be set to the Crane ID, the PIN is For more details on the communication protocol used to communicate with the MaxOut DX, see Appendix A. CASWA Pty Ltd Page

7 3 INSTALLATION DETAILS 3.1 Prior to Installation Before installing your MaxOut DX device visually inspect the device and check that: (a) the type of input marked on the front of the device is appropriate for your application; (b) the case is not damaged and fits together securely; (c) terminals are secure; (d) terminal numbering is as per the following diagram Figure 2: Terminal Positions NB: As each block of 4 terminals can be removed (for installation) it is important that they be reinstalled in the positions shown. On later models, terminals 1 and 2 have stickers that are are marked N and L respectively. 3.2 Wiring Diagrams Installation with an existing load display The recommended method for connecting a MaxOut DX to an existing load display is to use a 4-20mA output from the display to a 4-20mA configured MaxOut DX or to insert a 4-20mA MaxOut DX into an existing current loop. CASWA Pty Ltd Page

8 3.2.2 Installation with a Dedicated Load Cell (e.g. RCxT) To existing control circuit MAXOUT 13: 14: Load limit 250VAC 4A Red 9: +XCite UP CONTACTOR Green White Black 10: +Sense 11: -Sense 12: -XCite 2: 240VAC V AC 1: 0VAC 0V Figure 3: Connecting a dedicated load cell NB: Output pins (13-14) are Normally Closed and rated for 250V AC 4A. They can be reconfigured to Normally Open using the FSU software. It is very important not to connect pin 15,16 to the chassis earth! Connecting the negative reference The MaxOut DX input circuit is connected to the chassis ground. When installing against an existing load Indicating system, ensure that its inputs are floating. It is important that the voltage on pins 10 and 11 do not exceed 3.3V with respect to pin 12. CASWA Pty Ltd Page

9 3.2.3 Installation with a 4-20mA Load Output To existing control circuit MAXOUT 13: 14: Load limit 250VAC 4A 10: ma IN 4-20mA Signal 12: GND UP CONTACTOR 2: 240VAC V AC 0V 1: 0VAC Figure 4: Connecting a 4-20mA load signal NB: Output pins (13-14) are Normally Closed and rated for 250V AC 4A. They can be reconfigured to Normally Open using the FSU software. CASWA Pty Ltd Page

10 3.2.4 Installation with a 0-10V Load Output To existing control circuit MAXOUT 13: 14: Load limit 250VAC 4A 10: V IN 0-10V Signal 12: GND UP CONTACTOR 2: 240VAC V AC 0V 1: 0VAC Figure 5: Connecting to a 0-10V Load Signal NB: Output pins (13-14) are Normally Closed and rated for 250V AC 4A. They can be reconfigured to Normally Open using the FSU software. CASWA Pty Ltd Page

11 3.2.5 Installation with a Q-Link Output (ABUS LIS) Figure 6: Connection to an ABUS LIS using a Q-Link Q Output NB: Output pins (13-14) are Normally Closed and rated for 250V AC 4A. They can be reconfigured to Normally Open using the FSU software Installation with a F-Link Output (ABUS LIS) Figure 7: Connecting to an ABUS LIS using the Q-Link Frequency (F1/F2) Output NB: Output pins (13-14) are Normally Closed and rated for 250V AC 4A. They can be reconfigured to Normally Open using the FSU software. CASWA Pty Ltd Page

12 3.2.7 Setting up Multi-zone Limits MaxOut DX can be used to implement different load limits in different locations, or in response to external signals. Usually used for altering the maximum allowable load when the crane is moved into specific zones (up to 6 different zones are currently available). These are triggered by zone inputs switches being activated by a set of dry contacts and only for the duration of activation. Figure 8: Wiring up individual zone limits CASWA Pty Ltd Page

13 4 COMMISSIONING DETAILS MaxOut DX is designed to be commissioned using a laptop computer. You will need a CASWA LINK- 2 Bluetooth Modem and the Field Service Utility (FSU) software application, version 19.5 or higher, loaded on a laptop. If your MaxOut has been precalibrated then you can use the TareTool on your android phone to set the load signal to zero. Search for TareTool in the play store... Note: FSU versions prior to 19.5 will not be able to communication with MaxOut DX units. 4.1 Installing and Launching the FSU Application FSU Program Installation Ensure that your computer is switched on, connected to the internet and that the minimum required software versions are installed (see Appendix B for minimum system requirements). Ensure that the LINK-2 modem is installed and that the drivers have loaded Installing the FSU application The latest FSU software can be downloaded from the Downloads tab on the following page: You should check this location periodically for updates Launching the application Double click on the FSU program icon:. CASWA Pty Ltd Page

14 4.2 Connecting to the Device The FSU will scan for Bluetooth enabled devices. This process takes approximately 10 seconds, when complete a list of all Sole Digital devices within range will be displayed. MaxOut DX units are depicted by a icon. If a particular MaxOut DX unit is not found, ensure it is powered up and press the button to repeat the search. Select the MaxOut DX you wish to configure by double clicking on the icon. NB: The Bluetooth link between the Laptop using a Link-2 and a MaxOut DX has a range of approximately 100m. 4.3 Setting Up Your MaxOut All configuration options are now shown on a single screen. CASWA Pty Ltd Page

15 This screen shows the: Hoist ID (see section for configuring this); Current firmware version operating on the device; Load limit history and details of biggest and last overloads; Details of load limits set (single limit, or multi-zone limits if required); Type of Input Voltage powering the device Setting the Hoist ID To set the hoist ID type in the desired identification in the Hoist ID field. This must be 18 characters or less. CASWA Pty Ltd Page

16 4.3.2 Setting the Input Voltage Type - New Feature The MaxOut DX zone select inputs can now work with voltages from V AC or DC. Selecting the matching option: Failure to set the correct input type will result in load zones changing randomly Setting the Load Input Type Make sure that the Input is set to the type of MaxOut DX load input. By default, the mv input will be selected. This is applicable for MaxOut DX devices that have a strain gauge input. The following table provides a list of commonly used input types and how they map onto the options in this FSU selection box. Primary load input coming from: RC3T, RC5T, RC10T rope clamp Other load cell with 4-6 connections Load cell with 2 connections Kone ControlPRO 0-10V ABUS LIS Q-Link (With a load cell connected to the LIS) Serial Output from an existing load display or PLC Stahl Hoist (using our adapter CANBus adapter) Sole Digital X-Scale Wirelessly from a Sole Digital device (e.g. MaxOut, HB200, other Liftlog) Use Input type: mv (4/6 wire cell) mv (4/6 wire cell) ma (2 wire cell) ABUS Q-Link RS232/485 Stahl CANBus X-Scale HoistNet CASWA Pty Ltd Page

17 Using/Removing a HoistNet Input MaxOut DX devices are HoistNet enabled. This means that they can obtain their load signal wirelessly from any other HoistNet enabled device, eliminating the need for long cable runs between the load cell and Load Limiter. For a MaxOut DX, the most likely reason you want to select 'HoistNet' option input is if you already use a HoistNet device to control the load on one or more hoists and you want to use this MaxOut to activate another set of contacts that are located away from the load (e.g. end panel or on a different crane). Note: If you want to add the load from another device to the load input of this MaxOut DX to activate an overall limit connected to this MaxOut, then you do NOT want to select HoistNet mode. Instead, you need to select the option that matches the load type connected to this MaxOut DX and enable load summing. See section for how to set up load summing. To receive a load signal via HoistNet, select the 'HoistNet' option input. The HoistNet controls on the screen will now be enabled. In HoistNet mode, Load Summing is not available, so this box will be disabled. To select a HoistNet source press the button for Link1. A box will appear asking you which HoistNet enabled device you want to connect to: Select the device that has the load signal to be used and press <Bind>. The popup box will close. The name of the bound HoistNet device will be shown on the FSU screen. The connection status will also be shown: CASWA Pty Ltd Page

18 NB: You will need to ensure that the originating HoistNet load signal has been calibrated correctly. If you connect more than one HoistNet input, the load shown and recorded will the combined load from both these sources. To unbind a MaxOut DX from a HoistNet device, or to change the bound device, press the on the Load screen and then select <Unbind> on the popup box. button Note on using a MaxOut DX with an ABUS LIS As the ABUS LIS Q Link output is a digital output, it cannot be calibrated. Therefore, if the load is not showing the expected value, the LIS itself must be recalibrated Calibrating the MaxOut DX If your MaxOut DX device has been preconfigured (an option with Q-Link inputs or by purchasing a pre-calibrated Sole Digital RCxT from CASWA), or if you are using a HoistNet load signal (which is calibrated separately) then you will not need to calibrate the MaxOut DX. You may still need to zero the device. This can also be done with the TareTool on your android device, search TareTool in the play store All other types of MaxOut DX must be calibrated and this process will require test weights Setting the Zero Value This is required for all units, even if they have been pre-calibrated. With no load on the hook (or the crane load display reading 0.00t), click on the <Zero> button. Within a few seconds the display will change to 0.0. CASWA Pty Ltd Page

19 Calibrate If you have not purchased a pre-calibrated MaxOut that was supplied with a Sole Digital RCxT load cell, or if you have changed the load cell or the size of rope, then you will need to calibrate the MaxOut DX using test weights. Lift a load (minimum 80% of rated capacity) and click the <Calibrate> button. Enter the mass shown on the load display when prompted and press <OK>. NB: If the fault output of the MaxOut is used as an overload, you may need to go to the Overload screen and set a large overload limit (e.g. 3000) to allow the load to be lifted. See section for details. Tap the <OK> button and the screen will now display the load on the hook. Note: If calibrated correctly, the load shown will be accurate to within 4% of the maximum rated load (so a MaxOut monitoring load on a 10T crane using a rope clamp at the dead end will be accurate to within 400kg). This error is due to the friction in the crane's pulleys and sheave blocks on a multi fall crane, not in the MaxOut or load cell. For greater accuracy or precision, you must measure the load in the hook itself Configuring a Single Overload Overload limiting is not available for loggers using an ABUS F or Q-Link input (settings will be ignored) Set Overload Limit To set a single overload, enter the desired overload in the Zone 1 input box (in kilograms). The Combined overload is only used in Load Summing mode (see Section 4.5.5). CASWA Pty Ltd Page

20 4.3.6 Configuring Multi-Zone Load Limiting MaxOut DX can be used to set different load limits; this is usually used for altering the maximum allowable load when the crane is moved into specific zones (up to 6 different zones are currently available). These are triggered by input limit switches being activated and are remain set only for the duration of activation. For details on wiring up these zones see Section Note: More complicated zone limiting (including multiple crane/hook arrangements) is possible using one or more MaxOut DX devices. Contact tech@caswa.com to discuss your particular requirements. The crane will be deemed to be operating in Zone 1 (controlled by Limit 1) unless an alternative limit is active. To set the desired zone limits, enter the respective overload(s) in kilograms. The current active zone/limit is shown in black. Inactive zones are greyed out but their limit values can still be changed. CASWA Pty Ltd Page

21 4.3.7 Invert Output The fault output on the MaxOut DX is a pair of normally closed contacts (wired between MaxOut terminals 13 and 14). You can change these to Normally Open by selecting the N/O option in the FSU: Normally Open contacts are may be required if: If there is an interposing relay between the MaxOut DX and the up contactor; You want the MaxOut DX to operate in a fail functional rather than a fail safe mode; You are using the MaxOut DX for slack rope detection Load Summing - New Feature Load Summing is a new feature that enables two-way wireless communication between 2 or 3 HoistNet devices for the purposes of activating limits based on individual AND combined loads. Make sure that hoisting limits are wired in for both Sole Digital devices. To activate Load Summing, check the 'Load Summing' box on ONE of the devices involved in determining the combined load. (Do NOT select 'Load Summing' on the other device.) The HoistNet box will be enabled. Connect to the desired HoistNet source (using the Link1 box first). Make sure that the Combined Load Limit is set correctly: CASWA Pty Ltd Page

22 This Combined limit needs to be set on both devices. The MaxOut DX will now send its load to the linked device. Hoisting will now be disabled on both hoists anytime the combined load exceeds the Combined Load and on a single hoist, or when the limit exceeds the local load in any particular zone. The FSU will display the load from this device in the large box and the combined load in the left hand corner box. CASWA Pty Ltd Page

23 4.4 Logging Overloads (Firmware 1.8 onwards) From version 1.8 of the MaxOut DX firmware the device is able to log overloads. The information that will be logged and is displayed on this screen includes: a) the number of times the load limit has been activated; b) the biggest overload recorded in kg; and c) the size of the most recent overload in kg. These values are calculated from the last time <Reset Count> was pressed Sending Alerts If you have a SiteSentinel on site, the MaxOut DX can be configured to send an or SMS to an Australian mobile phone whenever an overload event occurs. To configure alerts, make sure that the SiteSentinel is switched on when you connect to the MaxOut DX. You should see the following icon in your list of devices when first connecting: CASWA Pty Ltd Page

24 To configure notification enter a single address or a 10 digit mobile phone number in the <Send Alerts to> field: If no Site Sentinel was detected when first connecting to the MaxOut DX, this field not be visible. To send alerts to multiple addresses or to get a logged history of overloads via the web contact tech@caswa.com. CASWA Pty Ltd Page

25 5 ROUTINE MAINTENANCE There is no routine maintenance for this device. CASWA Pty Ltd Page

26 6 TROUBLESHOOTING Fault Cause Fix Load display indicates a fault Load not showing correctly Unable to connect to MaxOut DX from FSU MaxOut DX is affecting load pin voltages Wrong input type selected Load not calibrated or calibration has drifted Check power to the MaxOut. Disconnect pins 10 and 11 to verify that the MaxOut DX is causing the fault. Check MaxOut DX LED is operational (solid red or green). Check that the voltage from pins 11 and 12 is between 4 and 6 volts. If these voltages are out, check the connection between MaxOut DX GND and load pin GND. Select correct load input type using the FSU. Re-zero the MaxOut using the FSU. Recalibrate the MaxOut DX using the FSU and test weights or a known load. Check the load cell for damage. MaxOut DX or FSU are Power cycle the crane. busy Incorrect wiring Check that wiring is as per section 3.2. Check that removable terminals have been reinserted into their correct positions as shown in Figure 2. Pluggable terminals not seating correctly. Replace pluggable terminal and rewire the associated terminals. Adding MaxOut DX to a 4-20mA current loop causes a fault MaxOut DX is pulling the loop to GND Ensure the MaxOut DX is the lowest potential device in the loop or contact CASWA to order a 4-20mA isolator. Load limits not activating Load limits are not set Set the load limits are set with the FSU. Ensure the Voltage type is set correctly with the FSU. Ensure the limits are wired correctly. Load limits cut out prematurely on hoisting Magnetic interference causing MaxOut DX to reset. Check that MaxOut DX is at least 15mm from any large contactor. Load limit set too low. Adjust the load limit using the FSU. MaxOut DX in load summing mode and load from other device is causing the combined load limit to activate. The device is set to Load Summing mode and is actually operating correctly. Reduce the load on one or both hoists. Check that the Combined Load limits are set correctly in both devices. Ensure that the Load Summing check box is only ticked on one device. In load summing mode, connected device is not configured correctly. Reconfigure and recalibrate connected device if necessary. CASWA Pty Ltd Page

27 APPENDIX A: COMMUNICATION PROTOCOL For information about how to communicate with Sole Digital Devices contact Technical Support. APPENDIX B: FSU SYSTEM REQUIREMENTS The minimum requirements for operating CASWA s Field Service Utility (FSU) and Link-2 Bluetooth modem are: Laptop computer running Windows XP SP3 or later; One Spare USB port; Microsoft.NET framework 3.5. APPENDIX C: MANAGING FIRMWARE If you running an older version of the FSU application on your laptop then you should update this before continuing. The process for updating the firmware on your Sole Digital device has changed. Firmware should only be updated if you: a) specifically want a new feature that is only available in later versions; b) are experiencing a problem that has been rectified by a later version; c) are experiencing a problem and need to roll back to an earlier firmware version that didn't cause the problem you are experiencing; or d) have been specifically instructed to do so by your MaxOut DX supplier. To check for new firmware versions or to access old firmware versions, return to the Device Display screen and right click the desired equipment icon. Select 'Manage Firmware'. CASWA Pty Ltd Page

28 A new window will popup and show the FSU software connecting to the device. When this is complete, the window will show the name of the device, its current firmware version and a list of newer firmware that is available for the device. If you need to roll back to an earlier version, check the 'Show old versions' box in the lower left corner of the window. Select a firmware version and then press the <Apply firmware> button that appears in the lower right corner of the window: CASWA Pty Ltd Page

29 The display will change to the following: As the message states, DO NOT switch off the MaxOut DX or the computer running the FSU software, or remove the Link2 modem until you are told to do so. If either device loses power then the MaxOut DX may become unusable and the device will need to be returned to your supplier for repair. When the firmware has finished updating successfully you will see a popup window and also be told to power cycle the device before reconnecting: message in the Close this window, wait for the manage firmware window to close (this may take 20 seconds) and power cycle the device as instructed. You will be returned to the first FSU screen, Manage Connections. Wait a few seconds after power cycling the device and then select the device you wish to connect to by double clicking the device. CASWA Pty Ltd Page