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LMG Marine Crane KL250/200/185/60t GmbH


Year: 1997
Language: english
Author: TTS
Genre: INSTRUCTI0N MANUAL
Publisher: TTS
Format: PDF
Quality: Scanned pages
Number of pages: 151
Description: TTS-LMG Marine Cranes GmbH 7/3063-7/3064 ELECTRICAL EQUIPMENT DISPLAY AND INDICATORS
5.4.1 IN PICA TOR LIGHTS
=M07-H06 "READY FOR OPERATION" is inside the selector switch <START> and lights up when the crane is <READY FOR OPERATIONS i.e. when the main motor is running in the delta circuit and all systems are in order.
During start up procedure this pilot signal blinks until the self adjustment is finished.
=M07-H07 "FAULT" is in the right control desk and lights up as a collective signal when the status monitoring system signals a fault.
This indicator lights are installed additionally to the crane information system on the display, located on the right hand control desk. Normally all relevant fault indications and operation conditions are shown on the display.
Only if the display itself is defective is the main information indicated by these lights.
5.4.2 DISPLA Y OF CRANE IN FORM A TIONS
Normally on the display the operation manual shows the indications of SWL- LOAD ACTUAL LOAD OUTREACH HOOKHEIGHT HEELING ANGLE
By pressing the soft-key button MENUE an additional menu page is called up and CRANE INFORMATION can be selected, the following information is displayed now:
CRANE NUMBER (software identification number)
TEMPERATURE (actual oil temperature)
OPERATION HOURS M01 (elapsed working time of the main motor)
SELECTED CRANE No. (crane 1 is front crane, the highest number is the rearmost crane)
For safety reasons the operational hours should be written down every 2-3 months.
If the PLC system (main processor) becomes defective and must be renewed, the stored operational hour value is lost and must be manually entered into the new PLC.
5.4.3 DIALOGUE MODULE ( OPERATING OBSERVE - AND INPUT PANEL)
A LCD Display with 8 plunger-operated buttons and status LEDs is installed in the right hand control desk of the crane cabin.
The dialogue module communicates via CAN bus with the control system ecomat 100 type R 360 interactively and sends or receives operational status information of the crane. The following information of the dialogue module can be handled at the menu structure
- Fault / Condition messages
- Operating states messages
- Additional messages.
- Service inputs
Operational state messages Under normal conditions, the indications shown by the dialogue module is SWL - LOAD, ACTUAL LOAD, OUTREACH and HOOKHEIGHT to signify normal, trouble-free operation or, if the temperature of the hydraulic oil is below 0 °C," TEMPERATURE < 5° PREHEATING ACTIVE" to show that the booster pump is working in the oil pre-heating mode.
Fault messages are indicated by a separate fault picture with the "FAULT CODE" and the respective cleartext of this fault.
Fault messages have the highest priority and therefore overwrite existing operating conditions or special messages.
A fault message can be cleared by pressing the RESET button F2.
Condition messages are indicated by a separate condition picture with the "CONDITION CODE" and the respective cleartext of this condition, e.g." Condition 2214" with cleartext „LUFFNG OUT PRELIMITATION ", is a typical operating condition message, for instance, and indicates that the luffing direction is approaching the maximum of luffing gear out direction.
Additional messages do not appear on the display during normal operation. They must be called separately.
Additional messages are suppressed when the detailed points are selected over the menu.
Button ,BACK‘ must be pressed to return from the additional message page to the normal mode.
Faults and conditions not eliminated during the menu are selected.
Service inputs could be entered over a separate secured Password area. In this special area e.g. the system values could be reset to default settings, Emergency Codes could be activated or some values could be displayed.
Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.
All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account.
This member of the crew is responsible for explaining the changed situation to the crane operator and must report it to the management of the ship.
Procedure:
. Set MAIN MENU
• Select SECURED AREA (accepted must be entered)
• Select SECURITY CODE must be set and entered ( CODE NUMBER = 257377 )
• Select SET CRANE NUMBER (corresponding crane number must be entered)
now the menu for the secured area modes is opened and the intended mode must be selected
If you want to leave this secured area and especially before you leave the crane:
Switch off the power to de-activate all emergency codes.
(Emergency Operation System = EOS-Codes)

More information

5.5
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5.5.1 GENERAL DEFAULT SETTING
During the first start i.e. when activating the control system for the first time and after replacing the main controller R 360 (located in the control cabinet), the internal memory of the PLC must be formated and paramaterized with the default operational values.
If this default setting is carried out all previous personnel adjustments of the control system will be overwritten.
Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.
All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account.
Procedure:
. Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
. Select SET DEFAULT SETTINGS
follow the instruction displayed
TTS-LMG Marine Cranes GmbH
7/3063-7/3064 ELECTRICAL EQUIPMENT
5.5.2 ADJUSTMENT OF THE CONTROL OIL PRESSURE (BOOSTER
PUMP)
This special mode will have to be activated in order to adjust the control oil pressure without starting the main drive motor - only the motor =M02-M11 for the booster pump (control oil supply pump) will be started / stopped by the <START> switch.
During this special mode possible low-pressure-alarm is suppressed, the technician must take care that there is oil in the system and the pump is running with the right sense of rotation.
On the display is shown the average pressure measured in the hoisting gear circuit.
Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.
All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account.
Procedure:
• Set MAIN MENU
. Select SECURED AREA (KEY-CODE IS ON DEMAND)
. Select CONTROL PRESSURE ADJUSTMENT
press ENTER and SELECTION
to set = TRUE or reset = FALSE this special mode
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5.5.3 SETTING THE LIMIT SWITCHES (BASIC ADJUSTMENT)
Work on the electrical equipment of the crane is to be performed only by well trained personnel.
All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account.
This member of the crew is responsible for explaining the changed situation to the crane operator and must report it to the management of the ship.
The luffing- and hoisting gear travel way is limited by mechanical limit switch contacts and additionally by measurement of the rope length. This rope length measurement is carried out by incremental encoders which are mounted inside the limit switches.
(see also the technical description of the limit switches under item: .DESCRIPTION OF ELECTRICAL COMPONENTS")
At the first start of the crane or after exchange of the limit switch (also when a rope change is not carried out corresponding to the instruction .SPECIAL MODUS FOR ROPE CHANGE".
If another fault is indicated during the limit switch adjustment procedure, the reason for this fault must be eliminated prior to any further action.
ATTENTION: all limit switches are by-passed, the drive will not stop in the limit position, only a command is shown on the display when this position is reached.
ATTENTION: RISK OF DAMAGE. Do not lower the jib below the horizontal line ( 0°). the jib could be damaged, or the wire could unreel completely from the drum.
The following runs have to be done at slow speed.
Start with the adjustment of the luffing gear limit switch.
STEP 1:
Luff the jib in completely in the most upright position (the gap between the jib and rubber buffer should be 5
In this position adjust the limit switch contact for minimum outreach, contact no.1 must open, (seen from the drive shaft).
STEP 3:
Luff out the jib until Step 4 is displayed. If not Step 4 but Step 1 is displayed during this procedure, it is the information that the limit switch contact is not right adjusted correctly - the contact is adjusted on the wrong side of the cam / run out flange. Steps 1 and 2 must be repeated.
Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET LIMIT SWITCHES
• Select LUFFING GEAR or MAIN HOISTING GEAR or AUXILIARY HOISTING GEAR
(follow the instruction displayed
-10 cm). STEP 2:
TTS-LMG Marine Cranes GmbH
7/3063-7/3064 ELECTRICAL EQUIPMENT
STEP 4:
Luff in the jib until the STOP command is displayed. This command is given in the moment when the limit switch contact is opening again.
Now the adjustment of the minimum outreach position is completed and you can drive with the jib to the maximal outreach position. During this procedure the actual outreach (in meters) is shown on the display. The drive will stop automatically at the maximal outreach position with speed slow down the before reaching it.
STEP 5:
In this position adjust the limit switch contact for maximal outreach, contact no.2 must open, (seen from the drive shaft).
STEP 6:
Luff in the jib until Step 7 is displayed. If not Step 7 but Step 5 is displayed during this procedure, it is the information that the limit switch contact is not adjusted correctly - the contact is adjusted on the wrong side of the cam / run out flange. Step 5 must be repeated.
STEP 7:
Luff out again the jib until the STOP command is displayed. This command is given in the moment when the limit switch contact is opening again.
Now the adjustment of the luffing gear limit switch is completed.
Adjustment of the hoisting gear limit switch(es).
Before starting with the hook, the jib must be in the maximal outreach position (this is the reference position for the jib and also the position to adjust the highest hook position).
STEP 1:
Lift the hook into the highest position (the gap between the hook and the jib head should be approx. 1 meter).
STEP 2:
In this position adjust the limit switch contact for highest hook position, contact no.1 must open, (seen from the drive shaft).
STEP 3:
Lower the hook until the Step 4 is displayed. If not Step 4 but Step 1 is displayed during this procedure, it is the information that the limit switch contact is not adjusted correctly - the contact is adjusted on the wrong side of the cam / run out flange. Steps 1 and 2 must be repeated.
STEP 4:
Lift up the hook until the STOP command is displayed. This command is given in the moment when the limit switch contact is opening again.
Now the adjustment of the highest position is completed and you can drive with the hook to the deepest hook position. .During this procedure the actual hook height (below highest position in meters) is shown on the display.
STEP 5:
There is no automatic stop during lowering, The hook should be stopped when the position is approx. 1 meter above the ground. In this position adjust the limit switch contact for deepest position, contact no.2 must open, (seen from the drive shaft).
STEP 6:
Lift up the hook until the step 7 is displayed. If not Step 7 but Step 5 is displayed during this procedure, it is the information that the limit switch contact is not adjusted correctly - the contact is adjusted on the wrong side of the cam / run out flange. Step 5 must be repeated.
STEP 7:
Lower again the hook until the STOP command is displayed. This command is given in the moment when the limit switch contact is opening again and the adjustment of the hoisting gear limit switch is completed.
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5.5.3.1 SETTING LAYER CHANGE POSITION
If the hoisting rope is wheeled up on the winch in 2 layers, the layer change position must be checked or set when this position is not displayed correctly.
Procedure:
. Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
When the indication of counter values is activated on the dialogue module the actual hoisting position counter value and also the layer (1 or 2) is indicated. This layer indication must change from 1 to 2 before the rope will turn in the 2n> layer.
If this layer change indication is not properly adjusted the layer changing position must be set by selection of the setting mode in the secured area.
Turn the winch into the right position before the rope begins to shift over.
Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
. Select SET LAYERCHANGE POSITION
Press ENTER to store the actual position
Now the limit switches are adjusted and the settings stored in the PLC memory. Switch off the controls in order to deactivate the limit switch setting system.
Finally check all limit switch cut-out positions.
TTS-LMG Marine Cranes GmbH
7/3063-7/3064 ELECTRICAL EQUIPMENT
5.5.3.2 RESETTING OF REFERENCE POSITIONS
The rope length measuring system is carried out by means of incremental encoders inside the limit switches. The fault indication F1312 or F2312 will be displayed, if a failure of the rope length measuring system has stopped the corresponding drive.
To reset this alarm and to restore the system, the corresponding drive must be driven into its reference position.
• Jib to the maximum outreach (max. working range)
• Hook / both hooks (if the crane has this equipment) into highest hook position (approx. 1 m below the jib-head or 0,5 m below the chain limiter)
• Jib in max. outreach and hook(s) in highest position is our reference/default position -
Do not activate the emergency system EOS-codes, because these codes will oppress possible system failures. In case EOS-codes had been entered into the PLC before, the power must be switched off to de-activate the emergency codes, and the previous procedure must be repeated. ATTENTION: Now all limit switches are by-passed, the drive will not stop in the limit position, only STOP is displayed, when this position is reached.
ATTENTION: RISK OF DAMAGE. Do not lower the jib below the horizontal line ( 0°). the jib could be damaged, or the wire could unreel completely from the drum.
The following runs have to be done at slow speed.
Restorage luffing gear reference position:
The jib position must be in the normal working area, not beyond the maximum outreach limitation (bypassed with JIB-RESTING switch.
Luff out the jib to the maximum outreach position (maximum working area), the signal STOP will be shown on the display when this position is reached, stop the drive.
Lift up the jib until STOP extinguishes, then lower the jib again, until the signal STOP is shown on the display again.
Restorage main hoisting gear reference position:
Drive the jib to the maximum outreach position (maximum working area),), the signal STOP will be shown on the display. When this position is reached, stop the drive. (The jib should be driven into this position first, it is easier to find the right reference position for the hook, because this is now close to the jib head -approx. 1 m below.)
Lift up the main hook, the signal STOP will be shown on the display when this position is reached, stop the drive. Lower the hook until STOP is deleted.
Lift up the main hook again, the signal STOP will be shown on the display when this position is reached, stop the drive and then lower the hook approx. 2 m.
Restorage auxiliary hoisting gear reference position:
The procedure corresponds to the main hoisting gear, using the aux. hook.
If during this procedure another fault is indicated, the reason for this fault must be eliminated prior to any further action.
Procedure:
• Set MAIN MENU
. Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select RESET OF POSITIONING SYSTEM
. Select RESET OF REFERENCE POSITIONS
YES must be entered
(If this mode is activated the contents of the counter values for luffing and hoisting drive are displayed.)
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5.5.4 SPECIAL MODUS FOR ROPE CHANGE
Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.
All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account.
When a rope has to be exchanged a special mode will support this procedure.
If this special mode is activated the rope length measuring system and also the limit switches are bypassed.
• Drive with the corresponding drive into a definite position (e.g. the jib into the jib resting position, or the hook is touching the deck).
• In this position activate the rope change mode and then remove the limit switch from the winch. (Take
care that the shaft of the limit switch will not be turned.)
• Now the rope can be paid out completely from the winch and the new rope can be installed. (Drive
carefully - no limitation is active.)
• When the new rope is installed and the hook/jib is in the same position Where limit switch has been removed, at this position the limit switch must be fixed to the winch again.
• De-activate the rope change mode.
Procedure:
. Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
. Select ROPE CHANGE MODUS
• Select L_ROPE_CHANGE or H_ROPE_CHANGE or A_ROPE_CHANGE
• Select FALSE or TRUE and ENTER
TTS-LMG Marine Cranes GmbH
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____________CALIBRATION OF LOAD INDICATION
Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.
All procedures described as follows can influence the crane operation system and therefore it is only possible to enter this secured area after activation of a key-code.
Keep the code numbers secret for activating the secured area.
Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override values or messages in the crane computer system and must take the instructions given here into account.
5.5.5.1 AUXILIARY HOIST CALIBRA TION
The crane load will be calculated as a function of the hoisting pressure. The oil pressure in the hoisting circuit consists of the idle running pressure + losses through floating resistances + working pressure. This working pressure always depends on the lifted load.
The default load data for the calculation of the load weight are stored in the memory-module.
These data can be overwritten if the displayed load weight is not similar to the lifted test weight.
Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
. Select LOAD ADJUSTMENT
Lift up the test weight (approx. 60t) with slow speed approx. 1 meter.
When the drive has stopped on the display you can see the measured and calculated load, in the 2nd line the actual value for the load calculation
in the 3rd line you can select a new calculation value (a higher one would increase the load)
by entering this value, the 2nd line actual value for the load calculation and also the displayed load will
change.
If the load displayed corresponds to the lifted weight, you can leave this program.
5.5.5.2 MAIN HOIST CALIBRATION
The crane load will be calculated as a function of the wire rope pull force. This measurement is taken by the load cell =M06-B3.
The default load data for the calculation of the load weight are stored in the memory-module.
These data can be overwritten if the displayed load weight is not similar to the lifted test weight.
Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
. Select LOAD CELL ADJUSTMENT ZERO/MAX
If the load cell adjustment menu is activated, on this page is displayed as follows:
ACTUAL LOAD :
ZERO ADJUST : *—
LOAD_ADJUST :****
At first the ZERO LOAD VALUE (empty hook) must be adjusted.
On the display is shown the ACTUAL LOAD value and the actual (default) ZERO_ADJUST value, the ZERO_ADJUST value must be selected and the displayed value must be overwritten for setting the ACTUAL LOAD value on 000.0
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Then the LOAD_ADJUST value must be calibrated.
Lift up the test weight, this test weight should be close to the maximum lifting capacity of the crane (approx. 200t).
At the display is shown the ACTUAL LOAD (test weight) value and the actual (default) LOAD_ADJUST value, the LOAD_ADJUST value must be selected and the displayed value must be overwritten for setting the ACTUAL LOAD value similar to the test weight.
If the load displayed corresponds to the lifted weight, you can leave this program.
5.5.6 REPORT OF CHANGE
If during the adjustments some PLC-values have been changed, please report the new values to our electrical design department so that we can renew the default data of the PLC program corresponding to these changes.
In case of any spare part delivery the new actual values will be delivered and set automatically, otherwise the personally changed values will be overwritten by the default (old) data.
e-mail: info@tts-lmQ.de
TTS-LMG Marine Cranes GmbH
7/3063-7/3064 ELECTRICAL EQUIPMENT
5.5.7 ZERO-SETTING OF POTENTIOMETERS
The potentiometers of the control levers set the direction and the speed of the corresponding drive.
They are supplied by 24 V DC (not a fixed/regulated voltage) and in neutral position of the control lever the output of this potentiometer shall be 14 of the supply voltage.
If this potentiometer is not exactly adjusted or the potentiometer resistance is non-linear, it is possible to set the potentiometer output level to zero. (Offset value)
(This is only possible when the potentiometer is more or less correctly adjusted, otherwise a fault indication will result.)
Procedure:
. Set MAIN MENU
. Select SECURED AREA (KEY-CODE IS ON DEMAND)
. Select ZERO-SET OF POTENTIOMETERS
PRESS ENTER TO CALIBRATE
"HITS
5.5.8 SETTING OF OPERATION HOURS
When the PLC has been changed and the system has been set back to default data the contents of the operation hours counter is set to zero.
It is possible to override the zero-value with the actual counter value (should be written down every 2-3 months).
Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET OPERATION HOURS
Press ENTER to select and put in the required value
and press TAKE OVER to store this value as actual operation counter value.
5.5.9 ZERO-SETTING OF INCLINOMETER
A feature of the crane control equipment is a heeling monitoring system.
The heeling angle is shown on the display. If the angle exceeds 5° a pre-warning signal is given, and if the angle exceeds 83 the hoisting-, luffing out- and slewing operation is blocked.
At even keel an angle of 0° should be displayed. If this value does not corresponds the output of the inclinometer can be set to zero.
Procedure:
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select ZERO-SETTING OF INCLINOMETER
Select YES and ENTER
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5.6
SPECIAL OPERATION MODES
5.6.1 TEST OPERATION
This special mode allows to check all solenoid valve circuits without running pump motors. Therefore the crane control will be set into operable and all relevant limitations will be by-passed. When the test operation mode is activated it is not possible to start the pump drive motors.
Procedure:
• Set
• Select
• Select
MAIN MENU
SECURED AREA (KEY-CODE IS ON DEMAND)
SET / RESET TEST OPERATION
TEST OPERATION can now be activated = TRUE / deactivated = FALSE by selection and entering
5.6.2 POWER /SPEED REDUCTION
This special mode will limit the speed of all drives at about 50 percent of it’s maximal speed.
This mode can be used to reduce the power consumption of the crane in case of problems with the supply source (shore connection / generator failure), or when the drive speeds shall be reduced to prevent collision conflicts etc.
Procedure:
• Set
• Select
• Select
MAIN MENU
SECURED AREA (KEY-CODE IS ON DEMAND)
SET SPEED REDUCTION
SET / RESET SPEED REDUCTION can now be activated = TRUE / deactivated = FALSE by selection and entering
5.6.3 DISABLE TRIMOT
This special mode will limit the speed of the hoisting drive by switching off the control of the variable displacement motor (TRIMOT).
Procedure:
• Set
• Select
• Select
MAIN MENU
SECURED AREA (KEY-CODE IS ON DEMAND)
DISABLE TRIMOT
T DISABLE: can now be activated = TRUE I deactivated = FALSE by selection and entering
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5.7 TROUBLE SHOOTING
5.7.1 GENERAL REMARKS
The electronic assemblies include ICs in C-MOS Technology, the assemblies should never be extracted or plugged in while the power is connected.
While designing the electrical equipment, great value was attached to providing a status monitoring system that would monitor as many operating criteria as possible and would generate an appropriate message in the event of malfunctions on the display.
If a malfunction occurs, the red collective fault indicator light in the control console lights up.
After the part of the system concerned has been checked and, if necessary, repaired, the crane can be put into operation again by pressing the button < F2 >.
The following text describes the messages given by the status monitoring system in more detail.
The status monitoring system consists of several subsystems handling various criteria.
The first distinction has to be made between fault messages and condition status messages.
"FAULT" signalises malfunctions or faults which interrupt crane operation or certain functions and must be RESET after repair.
"CONDITIONS", in contrast, are intentional interruptions or limits set on the basis of monitoring criteria (e.g. hoisting gear limit switches or excessive hook loads). "CONDITION" displays that a limiting device has responded, but not that there is a fault in the system.
The crane has 2 hoisting gears, the Main- and Auxiliary hoist.
If a FAULT or CONIDTION of a hoisting gear is displayed, the announcement is divided into MAIN or AUX.
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5.7.1.1 POWER SUPPLY AND CONTROL VOLTAGE
The power supply is feed from the ship's mains to the crane main switch across slip ring body.
If the main switch cannot be turned on, check the following points :
1. Is the power feeder from the ship's supply switched on?
2. Is an EMERGENCY OFF button being pressed?
3. Is the breaker =M01-Q1 in the OFF position.
The 24 V DC control voltage is produced by the three-phase rectifier bridge =M01-U1.
The 24 V control voltage is distributed into different circuits which are protected by fuses =M01-F11 to-F18. If one of these fuses is out of order (for instance, blown owing to a short circuit), the fault is indicated by the LED in the fuse terminal.
5.7.1.2 PLC STA TUS INDICA TORS
The main status of the PLC-system is indicated by LED's on the main controller and on the input and output Compact Modules.
When the system is running in good order the green LED is blinking with a 2 Hz signal.
Detailed information about the status indication is given in the hardware description of the PLC components.
The signal status of each input and output on the Compact Modules is also indicated by a LED.
5.7.1.3 ADDITIONAL INDICATIONS
Detailed information about the input- output-status or value will be displayed, if the corresponding indication sheet is selected, e.g.:
DRIVE VALUES potentiometer value, setup value, nominal / actual speed value
SENSOR VALUES digital inputs and outputs (TRUE / FALSE)
analogue inputs (current or voltage) current outputs (PWM value in mA)
COUNTER VALUES position of the drive and drive speed
By calls of this information you are able to check a lot of relevant system data, e.g. it is possible to check the status of an input or a sensor value (output current) will be read into the PLC.
Procedure:
• Set MAIN MENU
• Select INDICATIONS
Choose the required information
TTS-LMG Marine Cranes GmbH
TS
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5.7.2 LIST OF FAULT MESSAGES
and fault identification instructions
F 0010 STATUS FAILURE DELTA CONTACTOR
F 0011 STATUS FAILURE LIMIT SWITCH LUFFING IN
F 0012 STATUS FAILURE LIMIT SWITCH LUFFING OUT
F 0013 STATUS FAILURE LIMIT SWITCH HOISTING
F 0014 STATUS FAILURE LIMIT SWITCH LOWERING
F 0015 STATUS FAILURE PRESS. SWITCH HOISTING
F 0016 STATUS FAILURE PRESS. SWITCH LUFFING
0017 STATUS FAILURE PRESS. SWITCH SLEWING
F 0018 STATUS FAILURE PRESS. SWITCH SLEWING
F 0019 STATUS FAILURE LIMIT SWITCH AUX-HOIST
F 0020 STATUS FAILURE LIMIT SWITCH AUX-LOWER
F 0021 STATUS FAILURE SAFETY LIMIT SWITCH
F 0022 SECURITY FAILURE SAFETY LIMIT CONTROL
The PLC inputs that have some bearing on safety are polled to ensure that their status is correct when the crane control system is switched on. If this message occurs, it means that an extraneous voltage is reaching one of the inputs (possibly due to contact between wires or a creep voltage caused by moisture) or that the corresponding PLC input itself is defective.
The actual input status can be displayed:
. Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Check the contact of the displayed circuit line, e.g. F0015 indicates voltage at input 1X4.01, although the contact of the pressure switch =M07-S10 must be open.
- Eliminate the extraneous voltage, if present.
- Exchange the PLC or the corresponding Compact Module.
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F 0023 SECURITY FAILURE M06 K2S CONTROL
The relay =M06-K2S must be activated only when lowering command of the hoisting drive is given.
This message appears if the control input IX0.37 for relay =M06-K2S has a TRUE signal without activation
of relay =M06-K2S.
The actual input status can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
F 003 MAIN SWITCH CONTROL
Appears if main switch is switched off while pump drive motors are still running. Press <F2> button to eliminate.
The crane shall not be stopped by pressing the emergency stop button.
Remedial action:
- Check the auxiliary contact of the main switch, this contact must be opened when the main switch is ON.
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005
DRIVE CONTACTOR NOT IN DELTA
The motor of the main pumps are switched from the star to the delta circuit by means of timing relays =M02-K4 / -K8. This is intended to happen after about four seconds.
This message appears if the switch-over has not taken place after 10 seconds.
The actual input status can be displayed:
. Set MAIN MENU
. Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Set the switching time on the star/delta timing relay to 4 seconds.
- Replace the timing relay if defective.
- Repair the contactor for the delta circuit if necessary.
- Check the wiring.
- Replace the PLC.
C I 006 ICONTROL LEVER NOT IN NEUTRAL POSITION
The control levers are not to be operated until <READY FOR OPERATION> is displayed.
This is checked by means of the contacts in the control levers.
This message appears if one or more contacts are closed before <READY FOR OPERATION> is displayed.
The actual input status can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Set the control levers to the neutral (zero) position (check the return springs and replace if necessary).
- Check the control lever contacts and replace them if necessary.
- Replace the Cabinet Module in the right control desk.
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HITS
007
OPERATION HOURS COUNTER
Memory contents of the operation hours counter is not correct. This occurs only if the processor module is defective or if the PLC main controller has been changed.
Remedial action:
- Set the operation hours counter back to zero or to the relevant counter value.
. Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET OPERATING HOURS
SET NEW OPERATION HOURS M01:by corresponding data input
0110
CONTROL OIL PRESSURE <15bar
The minimum permissible control pressure for the hydraulic system is 15 bar (normal operating pressure: 26 bar). Fault message F011 appears on the display if the pressure measured by the two pressure sensors (=M07-B10 and -B20) is lower than this value.
The actual sensor output values can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The values of the sensors are displayed in (.lA and bar.
Remedial action:
- Check the hydraulic oil circuit.
(Cf. specification of the hydraulic system.)
- Measure the pressure with a pressure gauge and compare this value with the displayed one.
- Check the power supply DC 24V of the Compact Module.
- Exchange the PLC or the corresponding Compact Module.
0160 OIL OVERTEMPERATURE
The hydraulic oil temperature is monitored by the temperature sensor =M07-B01. Fault message F016 appears on the display if the maximum permissible temperature of 90°C is exceeded.
The actual sensor output value can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in uA and °C.
Remedial action:
- Check the hydraulic oil cooling circuit.
(cf. specification of the hydraulic system.)
- Check temperature sensor =M07-B01.
- Exchange the PLC or the corresponding Compact Module.
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0161 TEMPERATURE SENSOR OUTPUT <4mA
F 0162 TEMPERATURE SENSOR OUTPUT >18mA
This fault message appears if the temperature signal from the temperature sensor =M07-B01. The output current from the temperature measurement must be between 4 and 18 mA (cf. specification of the temperature sensor). Messages are generated if the measured value is outside.
The actual sensor output value can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in pA and °C.
Remedial action:
- Check temperature sensor =M07-B01.
- e.g. connect a pressure sensor to the input of the temperature sensor, if a value of >/= 4 mA is now displayed, then the temperature sensor itself or the connector cable is defective.
- Exchange the PLC or the corresponding Compact Module.
0210
FILTER OVERPRESSURE
This fault message appears if the pressure switch (=M07-S08) of the filter clogging indicator has tripped. The switch trips when the pressure dropped across the filter exceeds 5 bar (cf. specification of the hydraulic system).
The actual input status can be displayed:
. Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs are displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Replace the filter cartridge.
- Check the pressure switch characteristics (the contact must be closed).
- Check the wiring.
- Exchange the PLC or the corresponding Compact Module.
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"ITS
0220
OVERLOAD FEED OIL PUMP
This fault message appears on the display if the motor circuit breaker (MCB) =M02-Q11 for the control oil / booster pump has tripped.
The actual input status can be displayed:
. Set MAIN MENUE
. Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs are displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Reset the MCB.
- Check the power supply for phase failure.
- Compare the current set on the MCB with the specified nominal motor current.
- Measure the motor amperage. If it is too high, the cause must be sought in the booster pump or hydraulic system.
- Check the wiring.
- Replace the PLC.
0230
OVERLOAD OIL COOLER
This fault message appears on the display if the motor circuit breaker (MCB) =M02-Q12 for the hydraulic oil cooler has tripped.
The actual input status can be displayed:
. Set MAIN MENU
. Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Reset the MCB.
- Check the power supply for phase failure.
- Compare the current set on the MCB with the specified nominal motor current.
- Measure the motor amperage. If it is too high, the cause must be sought in the booster pump or hydraulic system.
- Check the wiring.
- Replace the PLC.
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| F | 0240 lOVERLOAD MAIN MOTOR (THERMISTOR)
This fault message appears when the overload protection circuit for the main motor (=M02-M1) trips. The protection circuit consists of a thermistor controlled relay (=M02-F4). The thermistor controlled relay will trip if the pump drive is overloaded or the motor is not being adequately cooled.
The actual input status can be displayed:
. Set MAIN MENU
. Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Check the air circulation in the machinery space (air supply via the crane column, exhaust via the hydraulic oil cooler).
- Check the thermistors in the motor.
- The thermistor resistance is normally 250 to 700 ohms, but exceeds 3.5 kilo ohm if the temperature is too high.
BE CAREFUL WHEN CHECKING THERMISTORS!
They are extremely sensitive and will be destroyed if a voltage exceeding 2 V is applied.
- Check that the thermistor-controlled relay is working properly.
- Check the wiring.
- Replace the PLC.
0251
OVERCURRENT MAIN MOTOR
The current drawn by the main motor is monitored in addition to the winding temperature. This is done by
current sensor =M02-T1 in the motor feeding line. The signal (0 - 20 mA) this transmits to the PLC is
proportional to the current.
Fault message appears if the drawn current exceeds 2.3 times the nominal current.
The actual sensor output value can be displayed:
. Set MAIN MENU
• Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in (iA and the calculated motor amperage A.
(A=|(v1-v2) * 1,73
Remedial action:
- Check the voltage and the current drawn by the motor.
- Check the power supply and output signal of the sensor (about 4 mA output current per 100 A drawn).
- Replace the PLC.
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0252 NO AMPERAGE MAIN MOTOR
The current drawn by the main motor is monitored by the current sensor =M02-T1 in the motor feeding line. The signal (0 - 20 mA) this transmits to the PLC is proportional to the current.
Fault message appears if the current drawn is lower than that normally drawn under no-load conditions (protection against phase failure).
The actual sensor output value can be displayed:
. Set MAIN MENU
• Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in fiA and the calculated motor amperage A.
(A=|(vi-v2). 173
Remedial action:
The sensor works with 220 V, i.e. the crane must be supplied with 220V and the lighting and heating circuit must be switched on via fuse =M03-F34.
Check the voltage and the current drawn by the motor.
Check the power supply and output signal of the sensor (about 4 mA output current per 100 A drawn).
Replace the PLC.
0253 IDLE RUNNING AMPERAGE MAIN MOTOR
The current drawn by the main motor is monitored by the current sensor =M02-T 1 in the motor feeding line. The signal (0 - 20 mA) this transmits to the PLC is proportional to the current.
Fault message appears if the current drawn is higher than that normally drawn under no-load conditions (protection against phase failure).
The actual sensor output value can be displayed:
• Set MAIN MENU
• Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in uA and the calculated motor amperage A.
(A=|M-v2> * 1 73
Remedial action:
- Check the voltage and the current drawn by the motor.
- Check the power supply and output signal of the sensor (about 4 mA output current per 100 A drawn).
- Replace the PLC.
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[HZ 0711 |POWER REDUCTION (MAIN MOTOR AMPERAGE)
The current drawn by the main motor is monitored by the current sensor =M02-T1 in the motor feeding line. The signal (0 - 20 mA) this transmits to the PLC is proportional to the current.
This message appears if the hoisting speed is reduced because current drawn by the main motor is too high.
This can happen if all three crane motions are activated at full speed simultaneously under full load.
If the message appears while working at part load, the power supply to the motor should be checked.
The actual sensor output value can be displayed:
. Set MAIN MENU
. Select INDICATIONS
• Select INPUT I OUTPUT VALUES
. Select ANALOGUE INPUTS
The value of the sensor is displayed in pA and the calculated motor amperage A.
(a=|M-v2) . 1 73
Remedial action:
- Check the voltage and the current drawn by the motor.
- Check the power supply and output signal of the sensor (about 4 mA output current per 100 A drawn).
- Replace the PLC.
0713 SPEED REDUCTION (SPEC. OPERATION MODE)
This message indicates that the speed reduction mode has been activated.
Remedial action:
- De-activate this mode.
• Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select SET SPEED REDUCTION
SET I RESET SPEED REDUCTION can now be activated = TRUE I deactivated = FALSE by selection and entering
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111
1010 HOISTING PRESSURE <7bar
The pressures in the hoisting gear hydraulic circuits are monitored by switches =M07-S10 / -S11. Fault signal appears on the display if the pressure drops below 7 bar.
The actual input status can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Check the hydraulic pressure by measuring it with a pressure gauge. (Cf. specification of the hydraulic system.)
- Measure the characteristics of the switch and replace as necessary.
- Check the wiring.
- Exchange the PLC or the corresponding Compact Module.
- (Status must be <TRUE> when the pump drive is running.)
1020
HOISTING PRESSURE <>15bar
This fault message appears if pressure sensor =M07-B10 / -B11 (hoisting gears) malfunctions.
If the booster pump drive is not active, the sensor must read a pressure value <15 bar.
If the booster pump drive is activated, the sensor must read a pressure value >15 bar.
The output current from the pressure sensor must be about 4.8 mA while the pump is running (cf. specification of the pressure sensor.
The actual sensor output value can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in iiA and bar.
Remedial action:
- Check pressure sensor =M07-B10 / -B11.
- e.g. interchange the hoisting pressure sensor against the luffing pressure sensor, if the failure is now displayed in the luffing circuit, then the pressure sensor itself or the connector cable is defective.
- Exchange the PLC or the corresponding Compact Module.
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1031 HOISTING SENSOR OUTPUT <4mA
F 1032 HOISTING SENSOR OUTPUT >18mA
This fault message appears if pressure sensor =M07-B10 (hoisting gear) malfunctions.
The output current from the pressure sensor must be between 4 and 18 mA (cf. specification of the pressure sensor.
The actual sensor output value can be displayed:
• Set MAIN MENUE
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in nA and bar.
Remedial action:
- Check pressure sensor =M07-B10.
- e.g. interchange the hoisting pressure sensor against the luffing pressure sensor, if the failure is now displayed in the luffing circuit, then the pressure sensor itself or the connector cable is defective.
- Exchange the PLC or the corresponding Compact Module.
F 1033 AUX. HOISTING SENSOR OUTPUT <4mA
F 1034 AUX. HOISTING SENSOR OUTPUT >18mA
The reason for this message corresponds to F 1031 / F.1032; it is created by malfunction of the auxiliary pressure sensor =M07-B11.
1040 HOISTING PRESSURE TEST FAILURE
The hydraulic pump is tested after starting the pumps and every time before a new lifting/lowering cycle is started with a gradually increasing electrical control current for the high-side pressure proportional solenoid valve „B‘ until the pressure reaches 50 bar (or the memorised pressure value from the previous hoisting cycle) with the brakes applied.
The message is generated if the pressure test takes longer than 10 seconds.
The actual sensor output value can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in ^A and bar.
Remedial action:
- Compare the pressure displayed with a measurement carried out by a pressure gauge.
- If no pressure build-up can be noticed, press the emergency button of the solenoid valve directly for functional test of the pump.
- Check pressure sensor =M07-B10.
- e.g. interchange the hoisting pressure sensor against the luffing pressure sensor, if the failure is now displayed in the luffing circuit, then the hoisting pressure sensor itself or the connector cable is defective.
- Exchange the PLC or the corresponding Compact Module.
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1050
HOISTING PRESSURE >40 bar
If the drive is not activated (brake applied), the hydraulic pressure must go down to the idle running (control oil pressure). This message appears if the pressure remains at a level >40 bar.
The actual sensor output value can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in ^A and bar.
Remedial action:
- Compare the pressure displayed with a measurement carried out by a pressure gauge.
- Check the control unit of the hydraulic pump, maybe the pump control unit is not shifting back into neutral position
- (see description of the hydraulic plant).
- Check pressure sensor =M07-B 10.
- e.g. interchange the hoisting pressure sensor against the luffing pressure sensor, if the failure is now displayed in the luffing circuit, then the hoisting pressure sensor itself or the connector cable is defective.
- Exchange the PLC or the corresponding Compact Module.
1060 HOISTING CONTROL LEVER (OFFSET)
The speeds of the various crane motions are controlled by potentiometers in the control levers. The output voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position both directional contacts are open and the output level must be half of the supply value.
Fault message is generated if the output voltage deviates more than 10% of the rated value when the control lever is in the neutral position (before the corresponding control lever contact closes).
The actual control lever conditions can be displayed:
Set MAIN MENU
Select INDICATIONS
Select INPUT / OUTPUT VALUES
Select ANALOGUE INPUTS
Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed in a grade 0 to +/-1000 and the contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.
Remedial action:
- Measure the output voltage of the potentiometer (control lever in neutral position).
- Check the contacts of the control lever.
- Re-adjust the potentiometer.
- Check the wiring.
- Replace the PLC or the Cabinet Module.
- Additional information regarding EOS 1060.
For safety reasons the potentiometer output and also the switching contacts of the control lever are monitored by the PLC.
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If one of the contacts is defective, the drive can be controlled by the potentiometer only, this will be activated by the EOS-code.
Now the drive will be started and stopped by the potentiometer in the control lever without safety control-check.
This is a dangerous condition: if now the potentiometer or the analogue input becomes defective the drive will start without driver command and can be stopped by emergency stop only.
PH- 1070 IHOISTING CONTROL LEVER (SUPPLY)
The speeds of the various crane motions are controlled by potentiometers in the control levers. The output voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position both directional contacts are open and the output level must be half of the supply value.
Fault message is generated if the output voltage deviates more than 90% of the rated value when the control lever is in the neutral position (before the corresponding control lever contact closes).
The actual control lever conditions can be displayed:
Set MAIN MENU
Select INDICATIONS
Select INPUT / OUTPUT VALUES
Select ANALOGUE INPUTS
Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed in a grade 0 to +/-1000 and the contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.
Remedial action:
- Check the wiring and the supply connections of the potentiometer.
- Measure the output voltage of the potentiometer (control lever in neutral position).
- Most of time it is a supply failure or the potentiometer itself is defective.
- Check the contacts of the control lever.
- Replace the PLC or the Cabinet Module.
- Additional information regarding EOS 1070.:
For safety reasons the potentiometer output and also the switching contacts of the control lever are monitored by the PLC. If the potentiometer is defective, the drive can be controlled by the control lever contacts only, this will be activated by the EOS-code.
In normal conditions the contacts of the control lever are connected in parallel, it does not matter in which direction the control lever is actuated. For control with the EOS 1070-code it is necessary to remove the bridge which is connecting the contacts (the bridge on the supply side must remain), and now the contact which will close in lowering direction must be connected to the terminal for the EOS-input (1X5.01).
Now the drive will be started and stopped by the contacts in the control lever without potentiometer speed control. For safety reasons the drive speed is limited to half of its maximum.
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ITS
F 1080 HOISTING PWM-OUTPUT FAILURE =M07-A3
F 1081 HOISTING PWM-OUTPUT FAILURE =M07-A7
The control current for the proportional solenoid vales of the pump is generated in the Compact Module by Pulse Width Modulation. Fault message appears when no control current measurement (actual value) is taken although the corresponding PWM output is activated by the nominal value .
The drive condition can be displayed:
• Set MAIN MENU
• Select INDICATIONS
. Select DRIVE VALUES
Remedial action:
- Check the wiring to the solenoid valve.
- Check the resistance of the solenoid coil, (approx. 24-30Q)
- Replace the PLC or the Cabinet Module.
1210 LIFTING LIMIT (SAFETY LIMIT-SWITCH)
Additional to the electronic limit protection, there are 2 mechanical limit switches installed for collision protection between hook and jib (anti-two-block).
One of these limit switches is actuated.
The actual input status can be displayed:
. Set MAIN MENU
. Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Lower the hook or luff in the jib.
- Check the limit switches, mounted at the jib head.
- Check the wiring to the limit switches.
- Check the relays =M06-K1S, -K2S.
- It is not possible to override this fault by the emergency system.
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| C | 1211 [LIFTING LIMIT (MECHANICAL SWITCH)
The lifting distance of the crane is limited by the hoisting gear limit switch =M06-S16 / -S17.
If this message appears although the hoisting gear is in the "free" range, the following checks should be carried out:
The actual input status can be displayed:
. Set MAIN MENU
. Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action.
Check the mechanism of the limit switch (connection to the hoisting gear drum, limit switch coupling, limit switch gear, cam shaft)
Check the switching contacts.
Check the wiring.
Replace the PLC.
LIFTING LIMIT (ROPE LENGHT)
c 1213 HOOK IS TOO HIGH
The lifting distance of the crane is limited by the hoisting gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S16 / -S17.
If this message appears although the hoisting gear is in the "free" range, the rope length measurement system must be re-adjusted.
Remedial action:
follow up the procedure, described under item .RESET OF REFERENCE POSITIONS"
| C l 1214 ILIFTING PRE-LIMITATION
The lifting distance of the crane is limited by the hoisting gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S16 / -S17.
Before the final limit position is reached the drive speed will be ramped down by the rope length measurement.
If this message appears although the hoisting gear is in the "free" range, the rope length measurement system must be re-adjusted.
Remedial action:
follow up the procedure, described under item .RESET OF REFERENCE POSITIONS”
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1216 ILOWERING LIMIT (MECHANICAL SWITCH)
The lowering distance of the crane is limited by the hoisting gear limit switch =M06-S16 / -S17.
If this message appears although the hoisting gear is in the "free" range, the following checks should be carried out:
The actual input status can be displayed:
. Set MAIN MENU
. Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Check the mechanism of the limit switch (connection to the hoisting gear drum, limit switch coupling, limit switch gear, cam shaft)
- Check the switching contacts.
- Check the wiring.
- Replace the PLC.
1217
LOWERING PRE-LIMITATION
The lowering distance of the crane is limited by the hoisting gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S16 / -S17.
Before the final limit position is reached the drive speed will be ramped down by the rope length measurement.
If this message appears although the hoisting gear is in the "free" range, the rope length measurement system must be re-adjusted.
Remedial action:
follow up the procedure, described under item ,RESET OF REFERENCE POSITIONS”
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PCT
1220
SLACK ROPE
The slack rope monitoring system of the hoisting gear has responded and blocked the motion. Haul the rope taut by cautious operation in the opposite direction.
The actual input status can be displayed:
• Set MAIN MENU
• Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select DIGITAL IMPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action
- Check the contact rail; the contact rail is connected to a 24 V output channel of the PLC. If the lifting gear rope is slack, it will touch the rail, thereby earthing it so that the output voltage will drop down.
In other words, the lifting gear rope must not touch the contact rail, and the contact rail must also be free from any dirt that might cause an earth fault.
- Check the wiring.
- Replace the PLC.
I C | 1221 ILOWERING LIMIT (ROPE LENGTH)
The lowering distance of the crane is limited by the hoisting gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S16 / -S17.
If this message appears although the hoisting gear is in the "free" range, the rope length measurement system must be re-adjusted.
Remedial action:
follow up the procedure, described under item .RESET OF REFERENCE POSITIONS"
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ITS
1301
HOISTING COUNTER EQUALITY FAILURE
This fault is an internal fault in the PLC.
The output pulses from the incremental encoder are counted to ascertain the position of the drive.
For safety reasons, this is done by two separate counters inside PLC and the contents of the counters are compared. It is also necessary to make sure that the correct position information is stored if an emergency cut-out is tripped.
This fault message is generated if the counter contents are not identical.
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
Remedial action:
- follow up the procedure, described under item .RESET OF REFERENCE POSITIONS"
- The fault should have vanished when the plant is switched on again. If it has not, or if the fault occurs often, the PLC must be replaced.
1302 HOISTING COUNTER OUT OF RANGE
The output pulses from the incremental encoder are counted to ascertain the position of the drive.
This position counter value is limited by a minimum and maximum size.
This fault message is generated if the counter contents is not inside its limits.
This could happen if the rope is de-wheeled completely from the drum or the encoder is wrongly installed.
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
The counter values can be displayed:
. Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive w
<COUNTER> displays the actual counter value of the drive <LAYER> displays the quantity of layers wheeled up on the drum <SPEED> displays the speed (rotations per minute) of the drum
Remedial action:
- follow up the procedure, described under item „RESET OF REFERENCE POSITIONS11
- The fault should have vanished when the plant is switched on again. If it has not, or if the fault occurs often, the PLC must be replaced.
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TTS-LMG Marine Cranes GmbH
7/3063-7/3064 ELECTRICAL EQUIPMENT
1303 HOISTING COUNTER MONITORING
The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by electronic measurement of rope length. This fault message is generated when mechanical and electronic limitation of length are not carried out simultaneously (the drive has passed the limit position without opening of the contact).
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
The counter values can be displayed:
. Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive <LAYER> displays the quantity of layers wheeled up on the drum <SPEED> displays the speed (rotations per minute) of the drum
Remedial action:
Check the limit switch contacts (function and adjustment) Check the counter value of the position counter
follow up the procedure, described under item .RESET OF REFERENCE POSITIONS”
1304 HOISTING COUNTER MONITORING
The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by electronic measurement of rope length. This fault message is generated when mechanical and electronic limitation of length are not carried out simultaneously (the contact has opened before the drive has reached the electronic measured limit position).
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
The counter values can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive <LAYER> displays the quantity of layers wheeled up on the drum <SPEED> displays the speed (rotations per minute) of the drum
Remedial action:
Check the limit switch contacts (function and adjustment) Check the counter value of the position counter Replace the PLC.
- follow up the procedure, described under item .RESET OF REFERENCE POSITIONS"
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1306 HOISTING ENCODER OUTPUTS EXCHANGED
The sense of rotation and speed of the winch is monitored by an incremental encoder. The pulses generated by the encoder are phase-shifted with respect to each other (see illustration below).
PULSOR 1
L
PULSOR 2
If this fault message appears (for instance after replacing the encoder), the encoder outputs must changed around.
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
Remedial action:
- interchange the outputs of the encoder
- Replace the encoder
- Replace the PLC.
- follow up the procedure, described under item „RESET OF REFERENCE POSITIONS"
1307 HOISTING NO COUNTING PULSES
The outputs of the incremental encoder are monitored while the winch is running, the signal status at the outputs must constantly change. This fault message is generated if the pulse train fails.
There are two possibilities for activation of this fault:
• The winch does not move although the drive command is given (- the brake is not released; - or the gear of the winch is broken and blocks the drive, - or the hydraulic pump is defective).
• The electrical encoder system fails
When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
Remedial action:
- Check the electrical power of the brake valve (the LED on the valve connector plug should light up).
- Check the hydraulic control pressure for the brake at the respective pressure measuring point.
- Check the hydraulic working pressure of the pump, if the drive is set for lifting run the pressure on the high pressure side of the pump must increase up to 300 bar
- Press the emergency button on the solenoid valve of the pump control unit, the pump must increase up to 300 bar
- Check the encoder power supply.
- Check the encoder installation (coupling) inside the limit switch
- Check the wiring
- Replace the encoder
- Replace the PLC
- follow up the procedure, described under item .RESET OF REFERENCE POSITIONS"
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I~f1 1308 IHOISTING WRONG ROTARY MOTION
The winch monitoring system has indicated that the winch is turning in the paying out direction although the control command calls for the opposite sense of rotation.
If this fault message appears after replacing the encoder, the encoder outputs must changed around. When this fault has been reset, <HOISTING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
Remedial action:
Check the complete drive system to ascertain that the winch moves in accordance with the joystick deflection (direction and speed), interchange the outputs of the encoder Replace the encoder Replace the PLC
I F | 1309 [HOISTING STANDSTILL DRUM MONITORING"
If the drive is not activated (brake applied), the winch monitoring system must not signal any motion.
The actual output status can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select DIGITAL OUTPUTS (select the corresponding output according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
Check the brake concerned.
Check the electrical controls of the brake valves: if necessary, replace the Compact Module.
I F | 1310 IHOISTING OVERSPEED (FULL LOAD)"
The speed of the winch is monitored by an incremental encoder.
This maximum drum speed has been exceeded.
The drive speed can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive <COUNTER> displays the actual counter value of the drive <LAYER> displays the quantity of layers wheeled up on the drum <SPEED> displays the speed (rotations per minute) of the drum
Remedial action:
Check the hydraulic system :
pump delivery limitation system, oil leakage from pump or motor (see specification of the hydraulic system).
Check the electrical power of the TRIMOT control. There must be no output signal when a full load is to be lifted / lowered.
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1311
HOISTING OVERSPEED (EMPTY HOOK)
The speed of the winch is monitored by an incremental encoder.
This maximum drum speed has been exceeded.
The drive speed can be displayed:
. Set MAIN MENU
• Select INDICATIONS
. Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive <COUNTER> displays the actual counter value of the drive <LAYER> displays the quantity of layers wheeled up on the drum <SPEED> displays the speed (rotations per minute) of the drum
Remedial action:
- Check the hydraulic system :
pump delivery limitation system, oil leakage from pump or motor (see specification of the hydraulic system).
- Check the minimum displacement angle of the TRIMOT.
(see specification of the hydraulic system).
1312 HOISTING MUST RUN INTO REF. POSITION
This fault indication appears as a result of a previous failure.
It is necessary to drive into the reference position for reset and confirmation of the counter system.
Remedial action:
- follow up the procedure, described under item „RESET OF REFERENCE POSITIONS"
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TTS-LMG Marine Cranes GmbH
7/3063-7/3064 ELECTRICAL EQUIPMENT
1330 TRIMOT OVERPRESSURE HOISTING
F 1331 TRIMOT OVERPRESSURE LOWERING
This fault message appears when the safety cut-out of the variable displacement hydraulic motor (TRIMOT) for the hoisting gear trips.
This fault could be caused by a driver mistake, when he starts lifting a load with full speed, although the load is not lifted up from the ground (slack rope).
The current output value can be displayed:
. Set MAIN MENU
. Select INDICATIONS
• Select INPUT/OUTPUT VALUES
Select CURRENT OUTPUTS The actual amperage is displayed
The actual sensor output value can be displayed:
• Set MAIN MENU
. Select INDICATIONS
• Select INPUT / OUTPUT VALUES
. Select ANALOGUE INPUTS
The value of the sensor is displayed in pA and bar.
The following action should be taken if this fault occurs frequently :
- Check pressure hoisting pressure on the display and with a gauge.
- Check the current drawn by the solenoid valve.
(Set the controls to the test mode, shift the hoisting gear control lever to maximum deflection. In this state, the current drawn by the solenoid valve should rise from about 200 to about 500 mA within about 4 seconds.)
- If the measured currents are within limits, check the hydraulic controls.
- If the current is outside of the limits, replace the PLC.
- Check the wiring.
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2010
LUFFING PRESSURE <7bar
The pressure in the luffing gear hydraulic circuit is monitored by switch =M07-S20. Fault signal appears on the display if the pressure drops below 7 bar.
The actual input status can be displayed:
. Set MAIN MENU
. Select INDICATIONS
. Select INPUT I OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Check the hydraulic pressure by measuring it with a pressure gauge. (Cf. specification of the hydraulic system.)
- Measure the characteristics of the switch and replace as necessary.
- Check the winng.
- Exchange the PLC or the corresponding Compact Module.
- (Status must be <TRUE> while the pump drive is running.)
2020
LUFFING PRESSURE <>15bar
This fault message appears if pressure sensor =M07-B20 (luffing gear) malfunctions.
If the booster pump drive is not active, the sensor must read a pressure value <15 bar.
If the booster pump drive is actived, the sensor must read a pressure value >15 bar.
The output current from the pressure sensor must be about 4.8 mA while the pump is running (cf. specification of the pressure sensor.
The actual sensor output value can be displayed:
. Set MAIN MENU
. Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in ).iA and bar.
Remedial action:
- Check pressure sensor =M07-B20.
- e.g. interchange the luffing pressure sensor against the hoisting pressure sensor, if the failure is now displayed in the hoisting circuit, then the pressure sensor itself or the connector cable is defective.
- Exchange the PLC or the corresponding Compact Module.
TTS-LMG Marine Cranes GmbH
TITS
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F 2031 LUFFING SENSOR OUTPUT <4mA
F 2032 LUFFING SENSOR OUTPUT >18mA
This fault message appears if pressure sensor =M07-B20 (luffing gear) malfunctions.
The output current from the pressure sensor must be between 4 and 18 mA (cf. specification of the pressure sensor.
The actual sensor output value can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in joA and bar.
Remedial action:
- Check pressure sensor =M07-B 10.
- e.g. interchange the luffing pressure sensor against the hoisting pressure sensor, if the failure is now displayed in the hoisting circuit, then the pressure sensor itself or the connector cable is defective.
- Exchange the PLC or the corresponding Compact Module.
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2040 LUFFING PRESSURE TEST FAILURE
The hydraulic pump is tested after starting the pumps and every time before a new luffing cycle is to be started with a gradually increasing electrical control current for the high-side pressure proportional solenoid valve „B“ until the pressure reaches 50 bar (or the memorised pressure value from the previous luffing cycle) with the brakes applied.
The message is generated if the pressure test takes longer than 10 seconds.
The actual sensor output value can be displayed:
Set MAIN MENU
Select INDICATIONS
Select INPUT / OUTPUT VALUES
Select ANALOGUE INPUTS
The value of the sensor is displayed in nA and bar.
Remedial action:
- Compare the pressure displayed with a measurement carried out by a pressure gauge.
- If no pressure build-up can be noticed, press the emergency button of the solenoid valve directly for functional test of the pump.
- Check pressure sensor =M07-B20.
- e.g. interchange the luffing pressure sensor against the hoisting pressure sensor, if the failure is now displayed in the hoisting circuit, then the pressure sensor itself or the connector cable is defective.
- Exchange the PLC or the corresponding CompactModule.
2050
LUFFING PRESSURE >40 bar
If the drive is not activated (brake applied), the hydraulic pressure must go down to the idle running (control oil pressure). This message appears if the pressure remains at a level >40 bar.
The actual sensor output value can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in mA and bar.
Remedial action:
- Compare the pressure displayed with a measurement carried out by a pressure gauge.
- Check the control unit of the hydraulic pump, maybe the pump control unit is not shifting back into neutral position
- (see description of the hydraulic plant).
- Check pressure sensor =M07-B20.
- e.g. interchange the luffing pressure sensor against the hoisting pressure sensor, if the failure is now displayed in the hoisting circuit, then the pressure sensor itself or the connector cable is defective.
- Exchange the PLC or the corresponding CompactModule.
TTS-LMG Marine Cranes GmbH
TS
7/3063-7/3064 ELECTRICAL EQUIPMENT
2060 LUFFING CONTROL LEVER (OFFSET)
The speeds of the various crane motions are controlled by potentiometers in the control levers. The output voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position both directional contacts are open and the output level must be half of the supply value.
Fault message is generated if the output voltage deviates more than 10% from the rated value when the control lever is in the neutral position (before the corresponding control lever contact closes).
The actual control lever conditions can be displayed:
• Set MAIN MENU
• Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
• Select NEXT I POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed on a scale of 0 to +/-1000 and the contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.
Remedial action:
- Measure the output voltage of the potentiometer (control lever in neutral position).
- Check the contacts of the control lever.
- Re-adjust the potentiometer.
- Check the wiring.
- Replace the PLC or the Cabinet Module.
- Additional information regarding EOS 2060.
For safety reasons the potentiometer output and also the switching contacts of the control lever are monitored by the PLC. If one of the contacts is defective, the drive can be controlled by the potentiometer only, this will be activated by the EOS-code. Now the drive will be started and stopped by the potentiometer in the control lever without safety control-check.
This is a dangerous condition: if the potentiometer or the analogue input now becomes defective the drive will start without driver command and can be stopped by emergency stop only.
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2070 LUFFING CONTROL LEVER (SUPPLY)
The speeds of the various crane motions are controlled by potentiometers in the control levers. The output voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position both directional contacts are open and the output level must be half of the supply value.
Fault message is generated if the output voltage deviates more than 90% of the rated value when the control lever is in the neutral position (before the corresponding control lever contact closes).
The actual control lever conditions can be displayed:
Set MAIN MENU
Select INDICATIONS
Select INPUT / OUTPUT VALUES
Select ANALOGUE INPUTS
Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed on a scale of 0 to +/-1000 and the contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.
Remedial action:
- Check the wiring and the supply connections of the potentiometer.
- Measure the output voltage of the potentiometer (control lever in neutral position).
- Most of time it is a supply failure or the potentiometer itself is defective.
- Check the contacts of the control lever.
- Replace the PLC or the Cabinet Module.
- Additional information regarding EOS 2070.
For safety reasons the potentiometer output and also the switching contacts of the control lever are monitored by the PLC. If the potentiometer is defective, the drive can be controlled by the control lever contacts only, this will be activated by the EOS-code,
In normal conditions the contacts of the control lever are connected in parallel, it does not matter in which direction the control lever is to be actuated. For control with the EOS 2070-code it is necessary to remove the bridge which is connecting the contacts (the bridge on the supply side must remain), and now the contact which will close in luffing out direction must be connected to the terminal for the EOS-input (1X5.01).
Now the drive will be started and stopped by the contacts in the control lever without potentiometer speed control. For safety reasons the drive speed is limited to half of its maximum.
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F 2080 LUFFING PWM-OUTPUT FAILURE =M07-A3
F 2081 LUFFING PWM-OUTPUT FAILURE =M07-A7
The control current for the proportional solenoid values of the pump is generated in the Compact Module by Pulse Width Modulation. A fault message appears when no control current measurement (actual value) is taken although the corresponding PWM output is activated by the nominal value .
The drive condition can be displayed:
. Set MAIN MENU
• Select INDICATIONS
. Select DRIVE VALUES
Remedial action:
- Check the wiring to the solenoid valve.
- Check the resistance of the solenoid coil, (approx. 24-30Q)
- Replace the PLC or the Cabinet Module.
| C | 2210 [LUFF. OUT LIMIT (SAFETY LIMIT-SWITCH)
Additional to the electronic limit protection there are 2 mechanical limit switches installed for collision protection between hook and jib (anti-two-block).
One of these limit switches is actuated.
The actual input status can be displayed:
• Set MAIN MENU
• Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Lower the hook or luff in the jib.
- Check the limit switches, mounted at the jib head.
- Check the wiring to the limit switches.
- Check the relays =M06-K1S, -K2S.
- It is not possible to override this fault by the emergency system.
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2211 |LUFF. OUT LIMIT (MECHANICAL SWITCH)
The maximum outreach of the crane is limited by the luffing gear limit switch =M06-S26.
If this message appears although the luffing gear is in the "free" range, the following checks should be carried out:
The actual input status can be displayed:
. Set MAIN MENU
. Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Check the mechanism of the limit switch (connection to the luffing gear drum, limit switch coupling, limit switch gear, cam shaft)
- Check the switching contacts.
- Check the wiring.
- Replace the PLC.
2212 LUFF. OUT LIMIT (ROPE LENGHT)
The maximum outreach of the crane is limited by the luffing gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26.
If this message appears although the luffing gear is in the "free" range, the rope length measurement system must be re-adjusted.
Remedial action:
follow up the procedure, described under item .RESET OF REFERENCE POSITIONS"
Cl 2214 |LUFF. OUT PRE-LIMITATION
The maximum outreach of the crane is limited by the luffing gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26.
Before the final limit position is reached the drive speed will be ramped down by the rope length measurement.
If this message appears although the luffing gear is in the "free” range, the rope length measurement system must be re-adjusted.
Remedial action:
follow up the procedure, described under item .RESET OF REFERENCE POSITIONS”
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TTS-LMG Marine Cranes GmbH
7/3063-7/3064 ELECTRICAL EQUIPMENT
1 C | 2216 jLUFF. IN LIMIT (MECHANICAL SWITCH)
The minimum outreach of the crane is limited by the luffing gear limit switch =M06-S26.
If this message appears although the luffing gear is in the "free" range, the following checks should be carried out:
The actual input status can be displayed:
. Set MAIN MENU
• Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Check the mechanism of the limit switch (connection to the luffing gear drum, limit switch coupling, limit switch gear, cam shaft)
- Check the switching contacts.
- Check the wiring.
- Replace the PLC.
2217 LUFF. IN PRE-LIMITATION
The minimum outreach of the crane is limited by the luffing gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26.
Before the final limit position is reached the drive speed will be ramped down by the rope length measurement.
If this message appears although the luffing gear is in the "free" range, the rope length measurement system must be re-adjusted.
Remedial action:
follow up the procedure, described under item .RESET OF REFERENCE POSITIONS”
2218 LUFF. IN (ROPE LENGTH)
The minimum outreach of the crane is limited by the luffing gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26.
Before the final limit position is reached the drive speed will be ramped down by the rope length measurement.
If this message appears although the luffing gear is in the "free" range, the rope length measurement system must be re-adjusted.
Remedial action:
follow up the procedure, described under item .RESET OF REFERENCE POSITIONS"
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2219 LUFF. OUT FINAL SAFETY POSITION
The final (maximum) outreach of the crane is limited by the luffing gear rope length measurement system, carried out by means of incremental encoders, mounted inside of the limit switch =M06-S26.
ATTENTION: If this limitation is to be by-passed
RISK OF DAMAGE. Do not lower the iib below the horizontal line (0°). the jib could be damaged, or the wire could unreel completely from the drum.
2301
LUFFING COUNTER EQUALITY FAILURE
This fault is an internal fault in the PLC.
The output pulses from the incremental encoder are counted to ascertain the position of the drive.
For safety reasons, this is done by two separate counters inside PLC and the contents of the counters are compared. It is also necessary to make sure that the correct position information is stored if an emergency cut-out is tripped.
This fault message is generated if the counter contents are not identical.
When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
Remedial action:
- follow up the procedure, described under item „RESET OF REFERENCE POSITIONS"
- The fault should have vanished when the plant is switched on again. If it has not, or if the fault occurs often, the PLC must be replaced.
2302
LUFFING COUNTER OUT OF RANGE
The output pulses from the incremental encoder are counted to ascertain the position of the drive.
This position counter value is limited by a minimum and maximum size.
This fault message is generated if the counter content is not within its limits.
This could happen if the rope is de-wheeled completely from the drum or the encoder is wrongly installed. When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
The counter values can be displayed:
. Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive <COUNTER> displays the actual counter value of the drive <LAYER> displays the quantity of layers wheeled up on the drum <SPEED> displays the speed (rotations per minute) of the drum
Remedial action:
- follow up the procedure, described under item „RESET OF REFERENCE POSITIONS"
- The fault should have vanished when the plant is switched on again. If it has not, or if the fault occurs often, the PLC must be replaced.
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TTS-LMG Marine Cranes GmbH
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En 2303 |LUFFING COUNTER MONITORING
The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by electronic measurement of rope length. This fault message is generated when mechanical and electronic limitation of length are not carried out simultaneously (the drive has passed the limit position without opening of the contact).
When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
The counter values can be displayed:
. Set MAIN MENU
. Select INDICATIONS
. Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive <COUNTER> displays the actual counter value of the drive <LAYER> displays the quantity of layers wheeled up on the drum <SPEED> displays the speed (rotations per minute) of the drum
Remedial action:
Check the limit switch contacts (function and adjustment) Check the counter value of the position counter
follow up the procedure, described under item .RESET OF REFERENCE POSITIONS"
2304 LUFFING COUNTER MONITORING
The limit switch off positions are monitored by the mechanical limit switch contacts and additionally by electronic measurement of rope length. This fault message is generated when mechanical and electronic limitation of length are not carried out simultaneously (the contact has opened before the drive has reached the electronic measured limit position).
When this fault has been reset, <LUFFTING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
The counter values can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive <COUNTER> displays the actual counter value of the drive <LAYER> displays the quantity of layers wheeled up on the drum <SPEED> displays the speed (rotations per minute) of the drum
Remedial action:
Check the limit switch contacts (function and adjustment) Check the counter value of the position counter Replace the PLC.
follow up the procedure, described under item .RESET OF REFERENCE POSITIONS'
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2306
LUFFFING ENCODER OUTPUTS EXCHANGED
The sense of rotation and speed of the winch is monitored by an incremental encoder. The pulses generated by the encoder are phase-shifted with respect to each other (see illustration below).
PULSOR 1
L
PULSOR 2
If this fault message appears (for instance after replacing the encoder), the encoder outputs must changed around.
When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
Remedial action:
- interchange the outputs of the encoder
- Replace the encoder
- Replace the PLC.
- follow up the procedure, described under item „RESET OF REFERENCE POSITIONS-
2307
LUFFING NO COUNTING PULSES
The outputs of the incremental encoder are monitored while the winch is running, the signal status at the outputs must constantly change. This fault message is generated if the pulse train fails.
There are two possibilities for activation of this fault:
• The winch does not move although the drive command is given (- the brake is not released: - or the gear of the winch is broken and blocks the drive, - or the hydraulic pump is defective).
• The electrical encoder system fails
When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
Remedial action:
- Check the electrical power of the brake valve (the LED on the valve connector plug should light up).
- Check the hydraulic control pressure for the brake at the respective pressure measuring point.
- Check the hydraulic working pressure of the pump, if the drive is set for luffing in run the pressure on the high pressure side of the pump must increase up to 300 bar
- Press the emergency button on the solenoid valve of the pump control unit, the pump must increase up to 300 bar
- Check the encoder power supply.
- Check the encoder installation (coupling) inside the limit switch
- Check the wiring
- Replace the encoder
- Replace the PLC
- follow up the procedure, described under item „RESET OF REFERENCE POSITIONS"
"HITS
TTS-LMG Marine Cranes GmbH
7/3063-7/3064 ELECTRICAL EQUIPMENT
2308
LUFFING WRONG ROTARY MOTION
The winch monitoring system has indicated that the winch is turning in the paying out direction although the control command calls for the opposite sense of rotation.
If this fault message appears after replacing the encoder, the encoder outputs must changed around. When this fault has been reset, <LUFFING MUST RUN INTO REF. POSITION> will be displayed automatically, it is necessary to drive into the reference position for reset and confirmation of the counter system.
Remedial action:
Check the complete drive system to ascertain that the winch moves in accordance with the joystick deflection (direction and speed), interchange the outputs of the encoder Replace the encoder Replace the PLC
2309 LUFFING STANDSTILL DRUM MONITORING
If the drive is not activated (brake applied), the winch monitoring system must not signal any motion.
The actual output status can be displayed:
. Set MAIN MENU
• Select INDICATIONS
• Select INPUT/OUTPUT VALUES
• Select DIGITAL OUTPUTS (select the corresponding output according to the circuit diagram)
The status of the inputs is displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
Check the brake concerned.
Check the electrical controls of the brake valves; if necessary, replace the Compact Module.
2310 LUFFING OVERSPEED
The speed of the winch is monitored by an incremental encoder.
This maximum drum speed has been exceeded.
The drive speed can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select SPEED AND COUNTER VALUES
<LIMIT> displays the programmed value for the limitation of the drive
<COUNTER> displays the actual counter value of the drive <LAYER> displays the quantity of layers wheeled up on the drum <SPEED> displays the speed (rotations per minute) of the drum
Remedial action:
- Check the hydraulic system :
pump delivery limitation system, oil leakage from pump or motor (see specification of the hydraulic system).
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inn rv)/r>?u9nn7
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2312 LUFFING MUST RUN INTO REF. POSITION
This fault indication appears as a result of a previous failure.
It is necessary to drive into the reference position for reset and confirmation of the counter system. Remedial action:
- follow up the procedure, described under item „RESET OF REFERENCE POSITIONS"
3010
SLEWING PRESSURE <7bar
The pressure in the slewing gear hydraulic circuit is monitored by switches =M07-S20and -S31. Fault signal appears on the display if the pressure drops below 7 bar.
The actual input status can be displayed:
. Set MAIN MENUE
. Select INDICATIONS
. Select INPUT / OUTPUT VALUES
• Select DIGITAL INPUTS (select the corresponding input according to the circuit diagram)
The status of the inputs are displayed with <TRUE> or <FALSE>.
TRUE = DC 24V, FALSE = no voltage signal
Remedial action:
- Check the hydraulic pressure by measuring it with apressure gauge. (Cf. specification of the hydraulic system.)
- Measure the characteristics of the switches and replace as necessary.
- Check the wiring.
- Exchange the PLC or the corresponding Compact Module.
- (Status must be <TRUE> while the pump drive is running.)
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"ITS
TTS-LMG Marine Cranes GmbH
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3060 SLEWING CONTROL LEVER (OFFSET)
The speeds of the various crane motions are controlled by potentiometers in the control levers. The output voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position both directional contacts are open and the output level must be half of the supply value.
A fault message is generated if the output voltage deviates more than 10% of the rated value when the control lever is in the neutral position (before the corresponding control lever contact closes).
The actual control lever conditions can be displayed:
Set MAIN MENU
Select INDICATIONS
Select INPUT / OUTPUT VALUES
Select ANALOGUE INPUTS
Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed in a grade 0 to +/-1000 and the contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.
Remedial action:
- Measure the output voltage of the potentiometer (control lever in neutral position).
- Check the contacts of the control lever.
- Re-adjust the potentiometer.
- Check the wiring.
- Replace the PLC or the Cabinet Module.
- Additional information regarding EOS 3060.
For safety reasons the potentiometer output and also the switching contacts of the control lever are monitored by the PLC. If one of the contacts is defective, the drive can be controlled by the potentiometer only, this will be activated by the EOS-code. Now the drive will be started and stopped by the potentiometer in the control lever without safety control-check.
This is a dangerous condition: if the potentiometer or the analogue input now become defective the drive will start without driver command and can be stopped by emergency stop only.
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3070 SLEWING CONTROL LEVER (SUPPLY)
The speeds of the various crane motions are controlled by potentiometers in the control levers. The output voltage from the potentiometers varies between 0 and 24V (positive supply voltage), depending on control lever deflection.
The output voltage of the control lever is monitored in the neutral (zero) position. In the neutral position both directional contacts are open and the output level must be half of the supply value.
Fault message is generated if the output voltage deviates more than 90% of the rated value when the control lever is in the neutral position (before the corresponding control lever contact closes).
The actual control lever conditions can be displayed:
Set MAIN MENU
Select INDICATIONS
Select INPUT / OUTPUT VALUES
Select ANALOGUE INPUTS
Select NEXT / POTENTIOMETER CHECK
The values of the control lever potentiometer are displayed on a scale of 0 to +/-1000 and the contact condition is displayed false/true.
The potentiometer value must be below 100 when the contact condition is false.
To check these values move the lever very slowly out of neutral position.
Remedial action:
- Check the wiring and the supply connections of the potentiometer.
- Measure the output voltage of the potentiometer (control lever in neutral position).
- Most of time it is a supply failure or the potentiometer itself is defective.
- Check the contacts of the control lever.
- Replace the PLC or the Cabinet Module.
- Additional information regarding EOS 3070
For safety reasons the potentiometer output and also the switching contacts of the control lever are monitored by the PLC. If the potentiometer is defective, the drive can be controlled by the control lever contacts only. This will be activated by the EOS-code.
In normal condition the contacts of the control lever are connected in parallel, it does not matter in which direction the control lever will be actuated. For control with the EOS 3070-code it is necessary to remove the bridge which is connecting the contacts (the bridge on the supply side must remain), and now the contact which will close in slewing left direction must be connected to the terminal for the EOS-input (1X5.01).
Now the drive will be started and stopped by the contacts in the control lever without potentiometer speed control. For safety reasons the drive speed is limited to half of its maximum.
TTS-LMG Marine Cranes GmbH
TVS
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F 3080 SLEWING PWM-OUTPUT FAILURE =M07-A3
F 3081 SLEWING PWM-OUTPUT FAILURE =M07-A7
The control current for the proportional solenoid values of the pump is generated in the Compact Module by Pulse Width Modulation. Fault message appears when no control current measurement (actual value) is taken although the corresponding PWM output is activated by the nominal value .
The drive condition can be displayed:
. Set MAIN MENU
• Select INDICATIONS
. Select DRIVE VALUES
Remedial action:
- Check the wiring to the solenoid valve.
- Check the resistance of the solenoid coil, (approx. 24-300)
- Replace the PLC or the Cabinet Module.
3218 SLEW. LIMIT (JIB RESTING MODE)
When the jib resting mode has been activated it is not possible to turn the crane tower in any direction without actuation of the key-operated switch <JIB RESTING>.
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HITS
4100
LOAD CELL FAILURE
The Main hoisting drive is protected against overload by measuring the wire rope pull.
The output current from the load cell be about 4 -18 mA corresponding to the lifted load. (cf. specification of the load cell.
If this message appears the measured current is below 3,6 mA.
The actual sensor output value can be displayed:
• Set MAIN MENU
• Select INDICATIONS
• Select INPUT / OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in nA.
Remedial action:
- Check load cell =M07-B3.
- Check the wiring between load cell and PLC-input.
- Exchange the PLC.
4101
OVERLOAD
The crane is protected against overload by a load measuring system.
The lifted load is calculated as a function of the hydraulic pressure (Aux. Hoist) or the load cell value (Main Hoist).
If this message appears, check whether the load being lifted exceeds the maximum allowed load (SWL) for the outreach range currently in use.
The actual sensor output value can be displayed:
. Set MAIN MENU
• Select INDICATIONS
. Select INPUT I OUTPUT VALUES
• Select ANALOGUE INPUTS
The value of the sensor is displayed in pA and bar.
Remedial action:
- Reduce the load or outreach.
- Check the hydraulic oil pressure in the hoisting gear circuits. (Compare the value measured with a pressure gauge with the displayed value given.)
- Replace the hoisting gear pressure sensor (=M07-B10).
- Replace the load cell (=M07-B3).
- Check the wiring.
- Replace the PLC or the corresponding Compact Module.
- If the load indication is different to the lifted load, the load measurement system can be re-calibrated, (see also CALIBRATION OF LOAD INDICATION)
HITS
TTS-LMG Marine Cranes GmbH
7/3063-7/3064 ELECTRICAL EQUIPMENT
[HZ 4103 [OVERLOAD HOOK LASHING'
The pull of the hook is reduced to a level for lashing the hook if the maximum outreach is exceeded by the jib resting mode.
This message indicates that this pull has been reached or exceeded. After the crane controls have been switched on (main switch ON), the hook must first be lowered a little in order to reset the pull limiting system.
Remedial action :
- Briefly operate the hoisting gear in the direction "lowering”.
- Check the hydraulic oil pressure in the hoisting gear circuits. (Compare the value measured with a pressure gauge with the displayed value given.)
- Replace the hoisting gear pressure sensor (=M07-B10).
- Check the wiring.
- Replace the PLC or the corresponding Compact Module.
4203 OVERLOAD JIB RESTING
When the maximum outreach shall be exceeded by activation of the jib resting mode, the crane must not have any load in the hook.
This message appears when the monitoring system has detected a load in the hook.
c 5020 HEELING ANGLE >5°
c 5021 HEELING ANGLE >8°
The heeling angle of the crane is monitored by an inclinometer inside the control cabinet.
The actual heeling value is displayed on the operation menu and when heeling exceeds 5° an additional warning signal is given.
When heeling exceeds 8° the slewing gear, luffing out and lifting, is blocked.
Remedial action:
- Reduce the load or outreach.
- Replace the inclinometer (=M07-A8).
- Check the wiring.
- Replace the PLC.
- Re-adjust the heeling level, see description under item <ZERO-SET OF INCLINOMETER>
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TTS
810 Compact Module DIGITAL not initiated
The compact module =M07-A2 is defective and must be renewed.
820________Compact Module PWM not initiated
The compact module =M07-A3 is defective and must be renewed.
830 Compact Module ANALOG not initiated
The compact module =M07-A4 is defective and must be renewed.
840
Cabinet Module not initiated
The cabinet module =M07-A5 is defective and must be renewed.
850 Compact Module PWM not initiated
The compact module =M07-A7 is defective and must be renewed.
880
Inclinometer not initiated
The Inclinometer =M07-A8 is defective and must be renewed.
Cl CPTOIPAI cm IIDMCMT
TTS-LMG Marine Cranes GmbH
7/3063-7/3064 ELECTRICAL EQUIPMENT
5.8 EMERGENCY OPERATION SYSTEM
Work on the electrical equipment of the crane is to be performed only by fully-trained personnel.
Only a crew member who has been put in charge of the cranes by the management of the ship should be allowed to override messages in the emergency operating mode and must take the instructions given here into account.
This member of the crew is responsible for explaining the changed situation to the crane operator.
The identification and elimination of malfunctions are greatly simplified by the circuit diagrams, units specifications and manufacturer’s documentation, the list of fault status messages and the explanation of the reason for the failures with recommended trouble shooting hints are described under item TROUBLE SHOOTING.
If a fault can not be remedied immediately, for instance because the appropriate spare part is not available, it should be remembered that the causes of many faults can be remedied temporarily by means of an emergency operating system.
ATTENTION!
Before overriding a fault message by means of the emergency operating system, always check that the corresponding monitored criterion, which is intended to protect the machinery against overload and damage, is faulty and that the plant itself has not failed.
The emergency control system only overrides the fault message. It does not eliminate the cause!
The cause of the fault must be identified and eliminated as quickly as possible in order to avoid danger.
The crane is never to be operated by the emergency operating system for normal crane operations.
To de-activate the emergency operation system and set back the control into normal condition the control power must be switched off completely (main switch).
Example 1 :
Status message ______________________________________
' 2211 " |LUFF. OUT LIMIT (MECHANICAL SWITCH]"
blocks the luffing gear in the direction for luffing out. The message is caused by a faulty switch contact in the luffing gear limit switch.
The maximum outreach is limited by the mechanical switch and additionally by the rope length measurement system.
No replacement contact is available, and the status message is therefore overridden by means of the emergency operating system until a replacement has been obtained.
Under these conditions, the luffing range is now restricted to the maximum permissible outreach by the rope length measurement system only so that there is a higher risk of exceeding the maximum outreach and overload.
Example 2:
Fault message
1031 HOISTING SENSOR OUTPUT <4mA
blocks the hoisting gear. The message is caused by a fault in the pressure sensor and is overridden by the emergency operating system until a replacement sensor is available.
This means that the hoisting gear is being used without the hydraulic pressure being checked automatically. In other words, the hydraulic oil is under no pressure when a lifting operation is initiated. Overload protection and tension limiters will not work and must be by-passed, if necessary. The use of the Trimot is blocked. Prolonged operation without pressure checking will lead to damage in the drive systems.
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Example 3 :
Fault message _____________________________
2010 ILUFFING PRESSURE <7bar
blocks the complete crane operation. The message is caused by a faulty pressure switch contact in the luffing gear hydraulic circuit.
No replacement pressure switch is available, and the fault message is therefore overridden by means of the emergency operating system until a replacement has been obtained.
Normally if a hose bursts, the pressure will drop down and the corresponding pressure switch will shut down immediately all drives and the brakes will engage.
Under emergency operation condition, the luffing circuit is no longer controlled against hose bursting, the jib could fall down with the risk of damage and loss of life of personnel.
Overriding fault messages by means of the emergency operating system :
. Set MAIN MENU
• Select SECURED AREA (KEY-CODE IS ON DEMAND)
. Select SET EMERGENCY OPERATION SYSTEM
now the Emergency Operation System CODE can be selected and entered,
the EOS CODE corresponds always to the fault or condition message number,
e.g. F2010 LUFFING PRESSURE <7bar will be overridden by the EOS CODE 2010.
e.g. F1301 HOISTING SENSOR OUTPUT <4mA will be overridden by the EOS CODE
1301.
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TTS-LMG Marine Cranes GmbH
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5.9
SERVICE
5.9.1 MAINTENANCE INFORMATION FOR HYDRAULICAL
The PLC monitors the crane equipment and will report a recommended maintenance instruction on the display. If maintenance works are necessary this information is displayed after switching on the crane control and can be reset by pressing the QUIT - button (F2).
If the maintenance work has been carried out, the maintenance instruction can be reset durable:
. Set MAIN MENU
. Select SECURED AREA (KEY-CODE IS ON DEMAND)
• Select MAINTENANCE
. Select ACKNOWLEDGE
M
901
MAINTENANCE CHECK HYDRAULIC OIL
Every 500 operational hours the hydraulic oil should be checked by taking of an oil sample.
A certain evidencing diagnostics of an oil sample depends decisively on the method of sample taking.
The taking of the sample always has to be made in the same manner. In principle, the oil should be at least hand warm when taking it. If possible the oil to be analysed has to be taken from about the middle of the oil level.
At winch gear where it is not possible to have access to the oil level, the oil to be analysed has to be taken from the oil drain line. About 1-2L oil have to be drained into a container and an oil sample has to be taken from the draining oil.
The access to a good oil level at the slewing gears is also difficult. Here too we recommend having a part of the oil drained by removing the accessible oil draining screw and taking an oil sample from the draining oil.
M 911 MAINTENANCE CHECK MAIN HOISTING GEAR
M 912 MAINTENANCE CHECK AUX. HOISTING GEAR
M 921 MAINTENANCE CHECK LUFFING GEAR
The control system checks that the corresponding drive speed is below 80% of the nominal rated speed. This points to a higher oil leakage in the drive circuit, caused by wear of the pump and/or motor.
For further information, see the hydraulic manuals.
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5.9.2 MAINTENANCE OF ELECTRICAL EQUIPMENT
Safety regulations
All maintenance and repair work is to be carried out exclusively by trained electricians and only after the whole plant is dead. Care must be taken that current labour safety regulations are observed. In addition, all rules and regulations issued by local authorities concerning cranes and accident prevention and works’ regulations are to be followed.
Special care must be taken to ensure that the feeders for auxiliary equipment and deck illumination are switched off (separate feeders).
If the crane has not been used for a considerable time, depending on conditions at the place of use, the wiring, motors and switch gear for the low voltage installations are to be checked for satisfactory insulation, cleaned and, if necessary, dried (condensation).
The whole equipment is always to be kept clean.
The electrical equipment belonging to the plant should be inspected at regular intervals. Defects such as loose terminals or singed cables should be rectified immediately.
Use only fuses from the same manufacturer as the original fuses, and make sure that their ratings are as specified. Switch the plant off immediately if faults develop in the power supply system.
After completion of maintenance work, all covers that have been removed must be replaced and the electrical units closed as specified in the corresponding regulations. The feeders, especially those serving the heating circuits, must be switched on again to prevent condensation when maintenance work has been completed.
Tightness of all terminals
4 weeks after commissioning of the crane the terminals of the power circuits, especially main switch, main contactors, main motor and slipring body must be checked for tight seating and fastened if necessary.
Motors
All motors are fitted with anti-friction bearings. These must be re-greased as specified by the corresponding manufacturers.
The lubricating properties of grease and oil deteriorate during long periods of inactivity. This can lead to rusting in the bearings. The motor should therefore be started for a short period every one or two months.
Slipring body Caution!
Make absolutely sure that all feeders from the ship are switched off before work commences on the slip ring body!
Power may be fed to the slip ring body via several independent feeders from the ship.
TTS-LMG Marine Cranes GmbH
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Safety devices
All monitoring equipment such as limit switches, overload protection devices, pressure switches, etc., should be checked regularly to ensure that they are in perfect working order.
Ail monitoring equipment, and especially safety switches and their actuating mechanisms, must be checked for tight seating whenever they are inspected.
The modification of safety equipment and the installation of other units is permissible only after consultation and after approval has been given by TTS-LMG.
All safety equipment must be tested once again after repairs and after the crane has not been used for a considerable time.
For safety reasons the operational hours should be noted every 2-3 month.
If the PLC system becomes defective and must be renewed the stored operation hours value is lost and must be manually entered into the new PLC.
Annual checks of the entire electrical equipment
Attention is to be paid to the following items:
- Fastening of the units, especially of monitoring equipment, limit switches, etc.
- Conformity to the specified enclosure requirements
- Tightness of all terminals
- Integrity of protective conductor connections
- Replacement of all damaged or worn units and parts (e.g. contacts)
- Firm seating of fuses
- Cleaning of all parts of the plant
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5.9.3 SPARE PARTS
The spare parts documentation of the electrical equipment is located in a separate folder.
This folder is categorised corresponding to the assembly groups.
Additionally in the electrical circuit diagram you can find the part number of the device directly below the electrical identification (mark of the unit).
Example:
-si
«H05/
UOOR
rtt 2302*06
PH 1609376 PN 160e*03
The part number of the main switch -S1 is 2502406
The 3-pole fuse —F1 is divided into 2 part numbers: 1608376 for fuse switch-disconnector
1608405 for fuse cartridge
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