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Table of Contents
Troubleshooting
Summary of Contents for SkyAzúl qSCALE maestro
- Page 1 Service Manual...
- Page 3 Service Manual NOTICE SkyAzúl makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and/or its fitness for a particular purpose. SkyAzúl will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing, performance, or use of this manual.
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Page 5: Table Of Contents
TABLE OF CONTENTS Safety Instructions ................... 8 Components ...................... 9 Base Kit with vScale D2 (102125) ............. 9 2.1.1 Junction Box, qSCALE maestro (062003) ..........9 2.1.2 Pressure Sensor Kit (102121) .............10 Boom Upgrade (102124) .................10 2.2.1 Sensor Assembly Length Angle WGX/CAN (061185) ......10 Boom Kit, New Cable Reel (102126) ............10... - Page 6 Service Manual Mismatched DA4 ..................38 Maintenance and Repair ................39 Troubleshooting .....................40 Identify the Problem .................40 Initial System Inspection ................42 Indicator Definitions .................43 6.3.1 Indicators on Central Control Unit............43 6.3.2 Indicators on Console ................43 Boom Angle Sensing ................44 Boom Length Sensing ................46 6.5.1...
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Page 7: Safety Instructions
Service Manual 1 Safety Instructions WARNING Imminent threat of personal injury and damage to property due to incorrect sys- tem settings! The correct adjustment of the RCL to the current set-up status is essential for the correct function of the system and of the machine. -
Page 8: Components
SMC, DUMMY PLUG ASSY, 48-PIN 060980 KIT, QSCALE IX, LOAD, PSENS, DAVS, 300 BAR, SAE 6, ID 60/61 102121 Section 2.1.2 2.1.1 Junction Box, qSCALE maestro (062003) Component Name Part Number RELAY, 30A, 12VDC, W/ DIODE, MOUNTING TAB 051355 RELAY, 40A, 24VDC, W/ DIODE, MOUNTING TAB... -
Page 9: Pressure Sensor Kit (102121)
Service Manual 2.1.2 Pressure Sensor Kit (102121) Component Name Part Number SENSOR,PRESS,SINGLE,CAN,ID 60 061091 SENSOR, PRESS TRANS, CAN,ID 61 061092 2.2 Boom Upgrade (102124) Component Name Part Number Notes SENSOR ASSY, LENGTH/ANGLE, WGX/CAN 061185 Section 2.2.1 2.2.1 Sensor Assembly Length Angle WGX/CAN (061185) -
Page 10: Description Of The System
Service Manual 3 Description of the System The maestro system (also referred to as ‘RCL’) is a CAN bus system comprised of a central microprocessor unit, operating console, angle sensor, tilt sensor, load pin, and anti-two block switch. All components and sensors are equipped with CAN bus controllers. -
Page 11: Product Identification
For general system operation, refer to the console Operator’s Manual. 3.3 EC Conformity Declaration The technical design and construction of the qSCALE maestro system corresponds to requirements of the EMC directive 2004/108/EC and therefore carries the CE symbol. The device complies with the following standards: EN 12895:200, EN 13309:2010, EN ISO 14982: 2009 The full conformity declaration is available from the manufacturer on request. -
Page 12: Overview Of Console Elements
Service Manual 3.4 Overview of Console Elements Function Keys F1-F8 Feedback Elements (See Section 3.5) Function Varies by screen Rotary Encoder with Pushbutton Function For Selection and Con- firmation Display with RCL Main Menu "Home" Key (Return to RCL Main Operating Screen) "Set"... -
Page 13: Overview Feedback Elements
Service Manual 3.5 Overview Feedback Elements Light Sensor: Not Used Operating Display: Green While Supply Voltage is Connected USB Data Display: Yellow During Data Exchange via Front USB Port Wireless Indicator: Not Used Multi-Function Light: Flashes Red/White while in error state... -
Page 14: Service Menus
Service Manual 4 Service Menus This chapter contains information, advice, and instructions for navigating and using the service menus. 4.1.1 Password Entry In order to access certain menus it is necessary to enter a password. There are three password levels: User Level Password. - Page 15 Service Manual Password entry is done by the following instructions: Use the rotary knob to select the numbers. Pressing the knob moves to the next digit and selects right arrow. Pressing the right arrow when the curser is to the right of the last number confirms the entry Use the buttons to select the number in the chosen direction.
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Page 16: Obtaining The Daily Password
Service Manual 4.1.2 Obtaining the Daily Password Summary In order to obtain the Daily Password you must find the Daily Password Seed in the Settings Menu and enter it into the excel sheet to be converted into a usable password that will last the entire day. - Page 17 Service Manual HOME SETTINGS SYSTEM SETTINGS Function Keys Choose option to adjust. Adjust chosen option. 4.2.1 4.2.1 (See Section for explanations of (See Section for explanations of each option.) each option.) New Password Entry. (See Section 4.2.2) NOTE A service level password is required to make any changes in the System Settings Screen (See Section 4.2.2)
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Page 18: System Settings Breakdown
Service Manual 4.2.1 System Settings Breakdown Toggling Wind Speed Display Use the keys to select the Wind Speed option. Use the keys to set the Wind Speed display to 0 (off) or 1 (on). Setting the Wind Speed Display to 0 (off) removes the Wind Speed Display from the Information Bar in the Main Operating Screen. - Page 19 Service Manual Toggling Cameras Use the keys to select the Camera option. Use the keys to set the Camera option to 0 (off) or select the number of cameras to activate. Setting the Camera option to 1 or more enables the function key from the Main Operating Screen.
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Page 20: New Password Entry
Service Manual 4.2.2 New Password Entry Summary You can change the active password, for example from a the Daily Password to the Service Password, using the New Password Entry button in the System Settings Screen ... -
Page 21: Sensor Calibration
Service Manual 4.3 Sensor Calibration Summary To calibrate the sensors you must position the machine as directed to set minimum and maximum values. Calibrating the sensors can be accessed through the System Menu. To calibrate sensors an LMI or System Password is required. -
Page 22: Calibrate Angle Sensors
Service Manual 4.3.1 Calibrate Angle Sensors Summary This section describes how to calibrate the boom angle sensor. The machine must be on a level surface to calibrate this sensor. HOME SETTINGS SENSOR ANGLE CALIBRATION SENSOR... - Page 23 Service Manual Enter the Measured Angle of the Boom Use the rotary knob to select the numbers. (See Section for detailed instructions.) Press to confirm the measured boom angle as entered. Angle up the boom a minimum of 5 degrees.
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Page 24: Calibrate Length Sensors
Service Manual 4.3.2 Calibrate Length Sensors Summary This section describes how to calibrate the boom length sensor. The machine must be on a level surface to calibrate this sensor. HOME SETTINGS SENSOR LENGTH CALIBRATION SENSOR... - Page 25 Service Manual Fully extend the boom and press Enter the Measured Length of the Boom Use the rotary knob to select the numbers. (See Section for detailed instructions.) Press to confirm the measured boom length as entered. Calibration is complete.
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Page 26: Luffing Cylinder Tuning
Service Manual 4.3.3 Luffing Cylinder Tuning Description Luffing Cylinder Tuning is not a required step during initial machine setup and should only be performed after all sensors are calibrated and only if the displayed load is inaccurate. Luffing Cylinder Tuning adjusts the lift cylinder rod and piston geometric data to correct system- atic errors in the load display. - Page 27 Service Manual Before beginning perform the following Configure the machine to a main boom operating mode. Fully retract the boom. Remove all weight from the main and auxiliary hoist hooks. Configure the reeving to allow a pick of the largest known load available.
- Page 28 Service Manual Enter the known weight of the load and any rigging added. If the weight of the hook was entered in the previous steps add the weight of the hook to the load entered here. Use the rotary knob to select the numbers. (See Section for detailed instructions.)
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Page 29: Entering Measurements
Service Manual 4.4 Entering Measurements This section describes the process for entering numerical measurements into the dialog box while calibrating sensors. Use the rotary knob to select the numbers. Pressing the knob moves to the next digit and selects right arrow. -
Page 30: Alarm Volume
Service Manual 4.5 Alarm Volume The Alarm Volume can be adjusted in the User Screen. OUTPUT ALARM HOME SETTINGS PREFFERENCES VOLUME Use the rotary knob to adjust the volume. Pressing the knob or to confirm. -
Page 31: Service And Maintenance
Service Manual 5 Service and Maintenance 5.1 Download Application Data The system is able to store multiple Application Files (i.e. machine model and load charts). HOME SETTINGS SYSTEM DOWNLOAD INFORMATION APP DATA Adding machine project file packages to the console... -
Page 32: Reading The Event Recorder
Service Manual 5.2 Reading the Event Recorder The user is able to download the stored event records via the vSCALE console to a USB drive. The USB drive must be for- matted with a fat32 filesystem before downloading can be completed. -
Page 33: Reset Hour Meter
Service Manual 5.3 Reset Hour meter HOME SETTINGS SYSTEM RESET HOUR INFORMATION METER This resets the hours the system has been on to 0. Press to confirm and reset the hour meter. Press to cancel and return to the System Infor-... -
Page 34: Change Date And Time
Service Manual 5.4 Change Date and Time HOME SETTINGS SYSTEM INFORMATION DATE/TIME Adjust the date and time by using to move to the next value. The date and time format is as follows: HH:MM:SS DD-MM-YY Press to confirm the new time and date. -
Page 35: Rotate Display
Service Manual 5.5 Rotate Display HOME SETTINGS SYSTEM ROTATE INFORMATION DISPLAY The display can be rotated 90 degrees at a time by pressing HINT The location of the function keys change as the screen is rotated. When rotating the screen multiple times ensure after each rotation that you are pressing the correct key.. -
Page 36: Screen Capture
Service Manual 5.6 Screen Capture The system has the capability of taking screenshots and saved to either: USB Drive Internal Memory 5.6.1 Taking Screen Captures On any screen: Press and hold the “HOME” function button Press the “SET”... -
Page 37: Mismatched Da4
Service Manual 5.7 Mismatched DA4 One of the following messages may be displayed after an installation error or software corruption. If an installation error is not suspected contact your service representative. To resolve the error the project file must be reinstalled using the procedure described in section 5.1. -
Page 38: Maintenance And Repair
Service Manual 5.8 Maintenance and Repair The qSCALE S6 maestro central control unit and vSCALE D2 maestro console contain no wearing Maintenance parts and therefore cannot be opened. If you notice malfunctions or differences between measured and displayed values, you should switch the device off and have it checked and, if necessary, repaired immediately by an authorized SkyAzul service partner. -
Page 39: Troubleshooting
Service Manual 6 Troubleshooting 6.1 Identify the Problem In most cases, your problem will fall under the following categories: I HAVE AN ERROR CODE INDICATED ON THE CONSOLE Questions: Please go to Section Error Codes Table THE DISPLAYED ANGLE DOES NOT MATCH THE MEASURED BOOM ANGLE... - Page 40 Service Manual THE CONSOLE DISPLAY IS BLANK If the console does not show any sign at all (no lights, no buzzer, and no display), the problem is in the wiring between console and central unit, or the console itself has a problem. Refer to section Console Display for further troubleshooting.
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Page 41: Initial System Inspection
Service Manual 6.2 Initial System Inspection Check all CAN cables for breaks, cuts or damage of any kind. Check connections at sensors and at the CAN Junction Box Check for water across the terminals in the CAN bus or inside the Junction Box Cycle System Power. -
Page 42: Indicator Definitions
Service Manual 6.3 Indicator Definitions Indicators are located on the Central Control Unit and the Console to assist with troubleshooting basic power and software issues. 6.3.1 Indicators on Central Control Unit Visual LED indicators are located on the top of the Central Control Unit. -
Page 43: Boom Angle Sensing
Service Manual 6.4 Boom Angle Sensing The system measures the angle of the main boom of the machine with an angle sensor. The angle sensor is contained within the cable reel, located on the main boom. Basic Start by verifying the measured angle to display the angle at several positions. The CAN Bus is digital Troubleshooting and as such will either transmit the signal correctly or not at all. - Page 44 Service Manual Measure the voltage between pins 3 (GND) and 2 (+) while the angle sensor is still connected to the LGH Board. If the voltage is not within the acceptable range, unplug the sensor and re-measure. If unplugging the sensor resolved the voltage issue, replace the sensor.
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Page 45: Boom Length Sensing
Service Manual 6.5 Boom Length Sensing The system measures the length of the main boom of the machine with a length sensor. The length sensor is contained within the cable reel, located on the left side of the main boom. -
Page 46: Cable Reel Length Cable Replacement Procedure
Service Manual 6.5.1 Cable Reel Length Cable Replacement Procedure Replace the length cable using the following procedure: Fully retract the boom and lock cable reel from rotating. Procedure for Length Cable Replacement Cut old cable at cable drum. -
Page 47: Pressure Sensing
Service Manual 6.6 Pressure Sensing The System measures the pressure of the boom lift cylinder for both rod and piston side. Both sensors communicate on the CAN Bus. Block Diagram Pressure Sensor CAN Bus qSCALE Piston Pressure Sensor The signal runs from the pressure transducer as digital information on the CAN Bus to the central unit. -
Page 48: Load Sensing
Service Manual 6.7 Load Sensing Please note that the load displayed by the RCL is not a direct measurement, but a calculated value that is based on many factors. Factors included that are outside of the measured values include: ... -
Page 49: Anti-Two Block Switch (A2B)
Service Manual 6.8 Anti-Two Block Switch (A2B) The system measures the load block and its relationship to the head of the boom. The A2B switch is located at the tip of the boom. Block Diagram CAN Bus qSCALE... -
Page 50: A2B Problem - Flow Chart
Service Manual 6.8.1 A2B Problem – Flow Chart Use the following flow chart to troubleshoot errors with A2B switch input. Flow Chart SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 51... -
Page 51: No Console Display
Service Manual 6.9 No Console Display If the console never displays an image, check if power is being supplied to the console. Measure the voltage between Pin 1 (+) and Pin 3 (GND). If power is being supplied, the console must be replaced. -
Page 52: Can Bus Communications
Service Manual 6.10 CAN Bus Communications CAN Bus - a serial bus protocol to connect individual systems and sensors as an alternative to con- ventional multi-wire cables. It allows crane components to communicate on a single bus: a dual-wire networked data bus with speed up to 1Mbps. - Page 53 The CAN Bus requires that 120 Ohm resistors be at each end of the CAN bus The resistors in parallel yield 60 Ohms of resistance between the CAN High and CAN Low cables. One of these resistors is located inside the qSCALE maestro S6 Controller. The other is in the WGX angle sensor contained in the Cable Reel.
- Page 54 Service Manual NOTE See Appendix for System Layout You can verify that power is being supplied to the sensor by testing the CAN connectors per this layout: Connector M12, 5 contacts Pin 1 Shield Pin Layout (CiA DR-303-1 7.2)
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Page 55: Troubleshooting Sensors With Display
Service Manual 6.11 Troubleshooting Sensors With Display The status of all inputs and outputs of the system can be checked using several screen displays on the console. 6.11.1 Readings of CAN Bus Sensors To determine whether there is a problem with a sensor, the system has a built in “Analog Input” screen to make trouble-shooting easier. -
Page 56: Readings Of Digital Inputs
Service Manual 6.11.2 Readings of Digital Inputs To determine whether there is a problem with a digital input, the system has a built in “Digital Input” screen to make trouble-shooting easier. HOME SETTINGS MACHINE DIGITAL... -
Page 57: Readings Of Digital Outputs
Service Manual 6.11.3 Readings of Digital Outputs To determine whether there is a problem with a digital output, the system has a built in “Digital Output” screen to make trouble-shooting easier. HOME SETTINGS MACHINE DIGITAL... -
Page 58: Appendix
Service Manual 7 Appendix This appendix contains additional technical information and the full table of error codes. 7.1 Technical Data Operating voltage 9…36 V DC, suitable for 12 and/or 24 V on-board power supply Overvoltage protection overvoltage up to max. 48V DC / 2 minutes... -
Page 59: Version 1 System Drawings
Service Manual 7.1 Version 1 System Drawings The drawings in Section 7.1 are using the legacy design with Junction Box P/N 061179 If your system has a Junction Box with P/N 062003 see Section 7.2 for current system drawings. -
Page 60: Controller To 061179 Junction Box Harness Pinout
Service Manual 7.1.2 Controller to 061179 Junction Box Harness Pinout SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 61... -
Page 61: X1 Controller Plug To 061179 Junction Box Pinout Detail
Service Manual 7.1.3 X1 Controller Plug to 061179 Junction Box Pinout Detail SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 62... -
Page 62: Version 2 System Drawings
Service Manual 7.2 Version 2 System Drawings The drawings in Section 7.2 are using the updated design with Junction Box P/N 062003 If your system has a Junction Box with P/N 061179 see Section 7.1 for legacy system drawings. -
Page 63: System Layout
Service Manual 7.2.1 System Layout (102125) SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 64... -
Page 64: Cable Reel Upgrade (102124)
Service Manual 7.2.2 Cable Reel Upgrade (102124) SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 65... -
Page 65: 062003 Junction Box Wiring Diagram
Service Manual 7.2.3 062003 Junction Box Wiring Diagram SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 66... -
Page 66: Controller To 062003 Junction Box Harness Pinout
Service Manual 7.2.4 Controller to 062003 Junction Box Harness Pinout SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 67... -
Page 67: X1 Controller Plug To 062003 Junction Box Pinout Detail
Service Manual 7.2.5 X1 Controller Plug to 062003 Junction Box Pinout Detail SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 68... -
Page 68: Wind Speed Kit Wiring Detail
Service Manual 7.2.6 Wind Speed Kit Wiring Detail SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 69... -
Page 69: Boom Kit (102126)
Service Manual 7.3 Boom Kit (102126) SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 70... -
Page 70: Boom Kit Wiring Detail (102126)
Service Manual 7.4 Boom Kit Wiring Detail (102126) SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 71... -
Page 71: Cable Reel Wiring Detail
Service Manual 7.5 Cable Reel Wiring Detail SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 72... - Page 72 Service Manual RSCHMANN MCS SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 73...
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Page 73: Vscale D2 Diagram
Service Manual 7.6 vSCALE D2 Diagram SkyAzúl, Equipment Solutions 301-371-6126 www.skyazul.com Page 74... -
Page 74: Error Codes Table
Service Manual 7.7 Error Codes Table The first one or two digits of an error code can determine what type of error is occurring 00xx Other 2xxx Module Error General Error 3xxx Module Error 1Fxx System 01xx Global Cut... - Page 75 Service Manual Error Code Description Solution Limiter Errors 0100 – 05FF E0100 Min radius limit underrun (global cut) Boom down to a valid load-chart radius and angle E0101 Max radius limit exceeded (global cut) Boom up to a valid load-chart radius and angle...
- Page 76 Service Manual Error Code Description Solution Kinematic Errors 0A00 – 0AFF Lay down the load. Only operate within allowed parame- E0A00 Capacity utilization >= 100% ters E0A08 Capacity utilization >= 90% Warning: Operating close to Cut-off Lay down the load. Only operate within allowed parame-...
- Page 77 Service Manual Error Code Description Solution Sensor & I/O Errors 1100 – 1BFF Check the CAN connections and wiring, the sensor calibration, and the E1X00 Sensor Error: IOLength1 CAN configuration. Replace faulty sensor Check the CAN connections and wiring, the sensor calibration, and the...
- Page 78 Service Manual Error Code Description Solution Check the CAN connections and wiring, the sensor calibration, E1X34 Sensor Error: IOWind1 and the CAN configuration. Replace faulty sensor Check the CAN connections and wiring, the sensor calibration, E1X38 Sensor Error: IOIncX1 and the CAN configuration.
- Page 79 Service Manual Error Code Description Solution General Errors E0090 Operating mode changed Not Available The error will clear when the system finishes the E00FC Controller Not Initialized initialization process Turn the Ignition off and on again. Consult Customer...
- Page 82 SkyAzúl, Inc. 16 Walnut Street Middletown, MD 21769 Phone 301-371-6126 Fax 301-371-0029 www.skyazul.com info@skyazul.com SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...
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