Belden Hirschmann HC4900 User Manual
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Belden Hirschmann HC4900 User Manual

Belden Hirschmann HC4900 User Manual

Load moment indicator
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HC4900 Load Moment Indicator
User Manual
Edition 5 / July, 2014
For Zoomlion RT Crane
With 4-section boom

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Summary of Contents for Belden Hirschmann HC4900

  • Page 1 HC4900 Load Moment Indicator User Manual Edition 5 / July, 2014 For Zoomlion RT Crane With 4-section boom...
  • Page 2 Copyright ©2010 by Hirschmann Electronics（Shanghai）Co., Ltd This document contains propriety information which is protected by copyright law. All rights reserved. The manual may not be copied, reproduced or translated into another language, neither whole nor in part, without advance written authorization from Hirschmann. Edition 5 on July 2014 Reproductions must abide by the copyright law.
  • Page 3 Catalogue 1. GENERAL INFORMATION ................ ‐ 1 ‐  2. WARNING ...................... ‐ 2 ‐  3. SYSTEM CONFIGURATION ................ ‐ 3 ‐  HC4900   ...................  ‐ ‐      ONTROLLER     IC4600   ..................  ‐ ‐      ONSOLE     DAVS   .................  ‐ ‐      RESSURE TRANSDUCER     3.3.1 Technical data ................ ‐ 5 ‐  3.3.2 Installation .................. ‐ 5 ‐  3.4 LWG208 L  ...
  • Page 4 5. OPERATION METHOD ..................  ‐  15 ‐   ................. ‐16‐    5.1F UNCTION ETTING   .....................  ‐ ‐  5.2 OM     SETUP 5.3 R  ..................  ‐ ‐      EEVING ETUP  ............  ‐ ‐  5.4 E EFERENCE ABLE       .................  ‐ ‐ ...
  • Page 5 1. GENERAL INFORMATION HC4900 Load Moment Indicator (LMI) provides effective information to operators, which will assist an operator maintain a machine to work within its design parameters. LMI provides the operator with the information of the length and angle of the boom, tip height, working radius, rated load and the actual load weight and so on.
  • Page 6 2. WARNING The LMI control system is used to assist in the safe operation of the crane by warning crane operator of approaching overload conditions and of over-hoist conditions that could cause damage to equipment and personnel. The device is not, and shall not, be a substitute for good operator judgment, experience and use of accepted safe machine operating procedures.
  • Page 7 3. SYSTEM CONFIGURATION Cable connectio HC4900 LMI System configuration HC4900 LMI system comprises a HC 4900 central unit with an IC 4600 console together with various sensors to record the measured values. The system operates on the principle of reference/real comparison. The actual value is compared with the calculated reference values and evaluated by the system.
  • Page 8 3.1 HC4900 Controller HC4900 controller features high-performance, precise and limiting load moment function in harsh environment. Technical data： System clock: 40MHz Program memory: 16MB Flash Protection class: IP65 Communication interface: 1×CANopen1×RS232 Operating voltage: 12V～30VDC Operating temperature: -20°C～ +70°C Storing temperature:-30°C～+80°C HC4900 controller dimension 3.2 IC4600 Console IC 4600 monochrome console is designed for outdoor construction vehicles...
  • Page 9 3.3 DAVS Pressure transducer DAVS pressure transducers measure high static and dynamic pressure values of liquids or gases in rough operating environment. Measurement precision is maintained even during continuous operation at extremely dynamic pressure. The oil pressure transducer comes with a pressure connector with standardized G1/4 thread or other hydraulic connectors.
  • Page 10 3.4 LWG208 Length/Angle sensor LWG series Length/Angle sensor can be directly installed and can precisely measure the angle and the length of boom with largest measurement length of fifty meters. The sealed housing protects the inside components from water inclusion, humidity etc. 3.4.1 Technical data Operating voltage: 15～30VDC Operating temperature : -25 °C ～...
  • Page 11 Bracket LWG208 Length/angle sensor installation  Length/Angle sensor consists of housing, a spring-loaded cable drum with measuring cable and mounting equipment.  Make the boom horizontal. Make sure the sensor is parallel with the main boom and the bracket is straight before fixing the bracket by bolts. ...
  • Page 12 the cable is parallel with the boom.  The Length/Angle sensor sometimes needs to be adjusted. Press the cable drum line to make the cable drum plane parallel with the boom plane. Rotate the cable drum and observe until the swing get smaller amplitude. If the cable drum swing too much because of the shape distortion and can’t be adjust, please stop the installation and repair or replace the Length/Angle sensor.
  • Page 13 3.5.2 Installation The switch should be installed on the side of boom head where the beginning of the lifting rope is fixed. Make sure the hammer is connected to the lifting rope and is free to actuate the switch. The signal connector and cable must be waterproof and connected correctly. A2B Switch installation diagram - 9 -...
  • Page 14 4．OPERATION AND DISPLAY INTERFACE 1. Data display(background lit) 2. Bar graph(utilization) 3. Indicator light (refer to 4.3) 4. Function keys：Function keys F1-F5 are related to the key symbols which present on the display 5. Numerical keys：They can be used to input values or select function items in accordance with the number on the display.
  • Page 15 Operation notice： 1. OM can only be switched when the boom is fully retracted. 2. Under the load lifting status of the RT crane, the OM switch between 360 lifting and front lifting is automatically done by the LMI based on the rotating field of the boom.
  • Page 16 Data display： 1. Load moment percentage bar graph 2. Load moment percentage displayed value 3. OM code 4. Reeving 5. Rotary angle 6. Outrigger mode 7. Rid pressure 8. Piston pressure 9. Operating height 10. Time (error code will be displayed when defect) 11.
  • Page 17 4.2 Utilization display (bar graph) The Utilization display (bar graph) indicates how much of the admissible load moment (rated moment) is used. As the rated moment changes constantly during load operation, the load moment display also changes constantly. The utilization display is marked with differently colored fields: Green: "Safe”...
  • Page 18 acoustic alarm sounds and load-moment-increasing machine movements are switched off at the same time. An A2B (hoist limit) situation occurs when the hook block comes into contact with the boom head. The danger exists in such situations that the hoist rope will break, causing the load to fall.
  • Page 19 5. Operation method With proper adjustments, the LMI will start to work automatically. The crane operator must be very familiar with the operation of LMI system and correctly adjust it before operating the crane. Below is a diagram of the startup screens. Power On Push Y to continue...
  • Page 20 5.1 Function setting Press F1 key at the main display to enter into Function setup display ： F3： Switch between Metric and Imperial units F4： Switch between English and Chinese language F5：Back to the main interface Numerical key 1：time setting Numerical key 2：CANbus status query Numerical key 3：OM code query...
  • Page 21  Time and date setup Press numerical key 1 at the Function setup display to enter into time and date setup display: F1: Cursor up to select year month date hour and minute items. F2: Cursor down to select year month date hour and minute items.
  • Page 22  OM code query Press numerical key 3 at the Function setup display to enter into OM code information display ( please use the displayed actual data on console ): Operators find code information in accordance with every different crane operating mode, which offer great help for OM setup.
  • Page 23 5.2 OM Setup Since the working conditions of the crane are different, the LMI must be set up to represent the actual configuration of the crane. To do that, the LMI must be configured into a reprentative Operating Mode (OM) code. Before operating the crane, find out the matched OM code according to the crane type and the actual configuration, then enter the appropriate information into the LMI for: A) outrigger configuration, B) parts of line of the hookblock being used and C)
  • Page 24 OM code table to look up proper code to enter for the boom configuration. Outrigger / Tire Configuration Push F1 to scroll through and select appropriate outrigger and tire configurations.  On tires (No need for outriggers) NOTE: F2 must be set for either static lifting or creep, if “On tires” configuration is selected.
  • Page 25 Press F4 key at the main display to enter into Reeving setup display. F3：Confirm Reeving (After confirmation, Current REEV will change to New Reev setting) F4：Reset the Reeving to zero. F5：Back to the main display Reeving setup interface Set Reev interface To change reave setting (parts of line of chosen hookblock), push N (F4 button) to reset.
  • Page 26 5.5 Buzzer stopping The buzzer of HC4900 console will alarm at the following situation:  Actual load exceeds the max. rated load moment  The hook is approaching height limitation (A2B fault) Exceed the operating range of the crane  ...
  • Page 27 6. LMI System functions 6.1 Warning Under any below conditions, HC4900 LMI system will light up and send out alarm for warning.  The crane is overload or exceed operating range  The hook approaching height limitation  Malfunction 6.2 Prohibition If a fault occurs, the LMI system will send alarm warning and all of the following crane’s movements will be prohibited: ...
  • Page 28 7 Daily maintenance and calibrations Please maintain and adjust as follows and contact us if you have any questions. 7.1 Maintenance Maintenance items listed below should be done daily.  Check all components of the LMI system to make sure no cable is damaged or broken.
  • Page 29 7.3 Angle sensor adjustment The angle sensor is installed in the same house with the length sensor. First, retract the boom and make sure the length displayed is equal to the actual. Use the angle instrument to measure if the displayed value is the same when the actual angle is between 0°and 70°...
  • Page 30 7.5 Length cable retract un-smoothly Sometimes when the boom is retracted, the length cable cannot return to the original position naturally or retract not smoothly. This is because that the coil-spring pre-tension is too low or the length cable in the cable reel has fallen off.
  • Page 31 When the outriggers are fully extended, current rated load is not same with performance diagram? Answer: 1) maybe you have forgot to open the switch of outrigger fully extended on operation panel, 2) forgot to confirm the operation of outrigger fully extended during console OM setting of console. Why does the system show E04? Answer：OM setting is wrong, please set OM correctly.
  • Page 32 8. Hints and Trouble Shooting Any improper operation or LMI malfunction will cause an alarm and an error code to be displayed. The errors are caused by operations outside allowable parameters, by incorrect inputs or by other factors. The following codes are displayed on the main screen when the system is in error condition.
  • Page 33 Error Error Cause Solutions code Pressure transducer is Fallen below the Replace pressure defective. PDB lower limit value transducer Setup of variable for analog in the measuring correct PDB value not supported channel variable for analog Electronic component "pressure piston value in DGA6.i.3 in the measuring side"...
  • Page 34 Error Error Cause Solutions code “Rod-side pressure channel” voltage  Refer to E12  Refer to E12 exceed the max. limitation. “Main boom bottom angle sensor  Refer to E15  Refer to E15 channel” voltage exceed the limitation.  +UB System and ...
  • Page 35 Error Error Cause Solutions code  The CRC sign Error in the monitored the monitored  Re-start LMI write/ read memory. write/read memory  Change the The CRC verification is wrong  Buffering of the monitored buffering battery of write/read memory battery is tested no controller ...
  • Page 36 Error Error Cause Solutions code  CAN-bus cable  Check the between controller connecting cable and sensor defective between controller CAN-bus data or unconnected and sensor communication  Controller  Change controller fault CAN-bus port fault  Change Can-bus  CAN-bus cable cable shortcircuit ...
  • Page 37 Error Error Cause Solutions code  Re-start the system  LMI watch dog LMI watch dog open  Connect PC final operated overtime port and observe wrong information  Cable of A2B A2B switch  Change A2B shortcircuit switch shortcircuit switch ...
  • Page 38 9. HC4900 Connecting Diagram - 34 -...
  • Page 39 10. OM List Operating Outrigger Code of Displayed area status setting* code 360° Fully extend 0001 360° Half extend 1001 360° Fully retract 2001 Main boom OM 360° None 3001 Front None 3101 Creep None 4101 360° Fully extend 0002 360°...

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