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BROSA 0656 FlexLim Operating Manual

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Operating Manual
BROSA 0656 FlexLim Electronics
Manual version: 2.9
Revision: 06/2023
................................................................................................................................................................
................................................................................................................................................................
................................................................................................................................................................
BROSA GmbH
Dr. Klein Straße 1
................................................................................................................................................................
D-88069 Tettnang
................................................................................................................................................................
Phone: +49(0)7542 93 35 0
Fax:
+49(0)7542 93 35 35
info@brosa.net
www.brosa.net
BROSA Pte Ltd
BROSA B.V.
25 Lorong Kilat #02-01
Galliershof 38
Singapore 598126
NL - 5349 BV Oss, Holland
Phone: +65 6795 2324
Phone: +31 412 6146 02
Fax:
+65 6795 2428
Fax:
info.sg@brosa.net
info@brosa.nl
BROSA (Nanjing) Co., Ltd.
Jinma Lu 3, Maqun Scientific Park, Qixia District
210049 Nanjing
Phone: +86 (25)8222 4639
+31 412 6146 86
Fax:
info.cn@brosa.net
© BROSA GmbH, Tettnang, Germany
+86 (25)8222 4639

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  • Page 1 Operating Manual BROSA 0656 FlexLim Electronics Manual version: 2.9 Revision: 06/2023 © BROSA GmbH, Tettnang, Germany ................................................................................................BROSA GmbH BROSA Pte Ltd BROSA B.V. BROSA (Nanjing) Co., Ltd. Dr. Klein Straße 1 25 Lorong Kilat #02-01 Galliershof 38 Jinma Lu 3, Maqun Scientific Park, Qixia District ................................
  • Page 2 BROSA System 0656 FlexLim ............................................................................................................................................................Notes ................................................................ © BROSA GmbH, Tettnang, Germany ................................................................ 2 / 70 ................................

  • Page 3: Table Of Contents

    Scope of delivery ................... 15 Cables ......................17 Display 4.3” / 7” (optional) ................17 Instructions for safe handling of the BROSA electronics 0656 FlexLim ....18 Handling / Transport ..................18 Installation and Commissioning ..............18 Operation and Maintenance ................20 3.3.1...
  • Page 4 BROSA System 0656 FlexLim ................................................................ 4.1.5 Display set-up ..................24 ................................................................ Selection of the “Set-up menu” display ............. 25 4.1.6 ................................4.1.7 Display test ..................... 25 4.1.8 Baud rate selection (conversion) .............. 25 Computer with PuTTY terminal emulation ............25 4.2.1...
  • Page 5 BROSA System 0656 FlexLim ................................................................ 5.4.1.1 Configuration ..................39 ................................................................ 5.4.2 Analog Outputs ..................41 ................................5.4.3 Constants ....................44 5.4.4 Load Spectrum Counter ................45 5.4.5 Comparators ................... 45 5.4.6 Change PIN .................... 47 5.4.7 Service ....................48 5.4.8...
  • Page 6 BROSA System 0656 FlexLim ................................................................ Change history ....................70 ............................................................................................................................................................© BROSA GmbH, Tettnang, Germany ................................................................ 6 / 70 ................................

  • Page 7: Abbreviation

    BROSA System 0656 FlexLim ..............................................................................................................................Abbreviation ................................Abkürzung Benennung BROSA System Configuration Tool BSCT Terminal Program (Freeware) PuTTY Point Of Measurement Location of Sensor Electrically Erasable Programmable Read EEPROM Only Memory Load Spectrum Counter ................................................................ © BROSA GmbH, Tettnang, Germany ................................

  • Page 8: General Information

    BROSA 0656 system. The manual is an integral part of the BROSA 0656 System and the FlexLim Safe firmware from the manufacturer. BROSA GmbH Dr.

  • Page 9: Disclaimer

    We hereby expressly point out that no liability can be assumed for parts or accessories that were not supplied by BROSA or not tested by BROSA to ensure they function correctly with the system. The use of such parts or accessories could adversely affect the overall security of the system.

  • Page 10: Safety Instructions And Warning Symbols

    BROSA System 0656 FlexLim ..............................................................................................1.3 Safety instructions and warning symbols ................................................................ For the sake of clarity and readability, icons are used to alert readers to important information: Warning of imminent danger. Non-observance poses a risk to life and limb.

  • Page 11: Warnings And Important Information

    1.5 Intended Use The BROSA 0656 electronic system is an overload protection and weighing system for crane systems, an important aid for the operation of cranes. The device provides the operating staff with all the information required for safe operation within target values when lifting.

  • Page 12: Reasonably Foreseeable Abuse

    ................................................................ Despite their robust design, BROSA systems must not be used for anything other than the intended purpose. Improper use may endanger the life and limb of the user or third parties and/or damage to the device in which the system is implemented or other property.

  • Page 13: System Description

    CANopen interface (slave) For additional technical details, see chapter 6. Each system can be adapted to the specific needs of a customer using BROSA ’s FlexLim Safe operating system software. As the name implies, FlexLim Safe flexibly allows for the creation of customised load limiting applications.

  • Page 14: System Layout

    BROSA System 0656 FlexLim ................................................................ of these parameters is application-dependent and is explicitly listed in a separate software ................................................................ description................................2.1 System Layout Depending on the configuration level the system may differs but in general the following...

  • Page 15: Topology Of The Canopen Network

    Figure 2: BROSA CAN BUS topology The termination of the can line requires 120 Ohm resitors on both ends. A 120Ω Termination resistor (M12x1) is available at BROSA on request if not scope of supply. Figure 3: CAN Bus Terminaton at both ends...
  • Page 16 BROSA System 0656 FlexLim ............................................................................................................................................................Electronics 0656 Cable Display Sensors FlexLim Pre-wired on mounting CANopen Optionally with Custom designs plate with all modules connection and customer- for interface connection cables specific design communication to the sensors are...

  • Page 17: Cables

    BROSA, we will not be liable for the functionality. 2.5 Display 4.3” / 7” (optional) If requested a grapical Display with a screen of 4,3” or 7” can be supplied by BROSA. The Design can be customized and therefore differs in each project. The Communication between Display and 0656 System Electronics is CANopen based.

  • Page 18: Instructions For Safe Handling Of The Brosa Electronics 0656 Flexlim

    DANGER! The BROSA electronics contain high-quality measurement technology! Pay attention to careful handling! - BROSA electronics are delivered in transport-safe packaging. We recommend that you only remove the electronics from the packaging immediately before installation. Only transport the electronics in the original packaging to avoid damage to the product.
  • Page 19 BROSA System 0656 FlexLim ................................................................ b) Checking the electronics for intactness and function: It must be ensured that the ................................................................ electronics to be installed are free of any kind of damage................................DANGER! Damaged electronics must not be installed!

  • Page 20: Operation And Maintenance

    5. cover or fence off neighboring live parts.) be performed. BROSA electronics emit neither airborne noise nor electromagnetic radiation. The operation of BROSA force measuring sensors is only permitted within the framework of the parameters and properties specified in the technical data sheets and on the type plate.

  • Page 21: Dismantling

    Loosen the mechanical connecting elements such as fastening screws c) Removal of the mechanical securing elements d) Removal of the BROSA electronics 0656 FlexLim DANGER! If the electronics are to be reused, they must not be connected with force at the plug connections! 3.5 Storage...

  • Page 22: Disposal

    If necessary, the electronics must be cleaned. DANGER! BROSA electronics contain traces of environmentally hazardous substances. This also applies to contamination caused by use. Contamination of the environment by these substances must be prevented.

  • Page 23: Access To Service Menu

    ..............................................................................................................................Access to Service menu ................................The 0656 FlexLim electronics offers 2 different methods for calibration and setting of system parameters: • PC with VT100 emulation (e.g. Putty in MS Windows) via the RS232 interface. • External display 0680 The menu structure differs depending on the interface used.

  • Page 24: Making A Menu Selection

    BROSA System 0656 FlexLim ..............................................................................................4.1.3 Making a menu selection ................................................................ Press the “ENTER” key. The menu then scrolls to the “select” option and a “1” is displayed in the first input field. You can change this value to that of the menu to be selected by pressing the corresponding arrow keys (up or down).

  • Page 25: Selection Of The "Set-Up Menu" Display

    BROSA System 0656 FlexLim ..............................................................................................4.1.6 Selection of the “Set-up menu” display ................................................................ Press the “ESC” key and turn on the display. Setup menu : ←: Display test →: Baudrate ↓: Bootloader 4.1.7 Display test Press the left arrow key to scroll through the display test routine. The software version is displayed and the display goes through a test cycle.

  • Page 26: Connection Of A Pc To The 0656 Electronic System

    BROSA System 0656 FlexLim ..............................................................................................4.2.2 Connection of a PC to the 0656 electronic system ................................................................ Connect a serial port of your PC to the 0656, as shown below: Figure 6: Principal connection Note: Most Applications are equipped with a SUB D9 Module for the RS232 Interface.

  • Page 27: Selection Of The Connected Com Port

    BROSA System 0656 FlexLim ................................................................ 4.2.3.1 Selection of the connected COM port ..............................................................................................Set as shown: 1. Select the configuration menu in PuTTY. 2. Open the "Session" tab. 3. Set everything as marked in yellow in Fig. 7 "Com Port Selection".
  • Page 28 BROSA System 0656 FlexLim ............................................................................................................................................................Figure 8: Serial paramters 8. Next, select "Keyboard" in the "Terminal" tab. 9. Set everything as shown in “Fig. 9 VT100 Settings” marked in yellow. Figure 9: VT100 Settings ................................................................

  • Page 29: Using The Service Menu

    3 CANopen inputs, only the inputs actually used by the program will be available for selection (though the BROSA 0656 system supports more channels on the software side). If there is no configuration available for the selected option, the system will indicate this by the “Nothing to select”...
  • Page 30 BROSA System 0656 FlexLim ............................................................................................................................................................Figure 10 :RS232 SUB D Connector (X23) at 0656 System 3. Choose the Parameters in your Ternimal programm as shown in chapter 4.2.3 4. Open the Session via PuTTY 5. Power on the 0656 System Electronics The main display with live values appears at your screen as shown in the example below.

  • Page 31: Navigation

    BROSA System 0656 FlexLim ..............................................................................................5.2 Navigation ................................................................ This chapter contains instructions for navigating through the system structure of the 0656 via the terminal program PuTTY. 5.2.1 Selecting the service menu Press the “ESC” key to open the service menu.

  • Page 32: Error Report

    BROSA System 0656 FlexLim ............................................................................................................................................................5.3.1 Error Report “ESC” and “ENTER” will scroll through the recorded error list. For leaving the Error Report the system needs to be restarted or the combination "1+ <Enter>" must be entered.

  • Page 33: Weighingalgo Info

    BROSA System 0656 FlexLim ..............................................................................................5.3.3 WeighingAlgo Info ................................................................ It shows of the current Weighing Module version and the number of times the password- protected weighing parameters have been accessed. 5.3.4 Reports Select between System Running time and Load Spectrum Counter ( LSC) 5.3.4.1 System Running Time...

  • Page 34: Service

    BROSA System 0656 FlexLim ................................................................ If one or more LSC are implemented in the project, they are visible at this section. A ................................................................ maximum number of four LSC is possible................................The Load Spectrum Counter shows the full load hours and the distribution according to utilization.

  • Page 35: Digital Inputs

    BROSA System 0656 FlexLim ................................................................ By pressing the “ENTER” key the CAN lines 4-6 will be shown. The definition of CAN 1-8 ................................................................ corresponds to the NODE 11-18 of the sensors................................5.3.5.2 Digital Inputs Shows the sensor data displayed on the digital inputs.

  • Page 36: Boot-Up Delay

    BROSA System 0656 FlexLim ................................................................ Each weighing module shows a total of 16 values that are used for linearization and ................................................................ commissioning of sensors................................Note: The entered values must be entered in an ascending order. 5.3.5.5 Boot-up Delay Defines a delayed start of the slave controller if the master PLC requires special startup behaviour (Default is 0 ms).

  • Page 37: Restart System

    BROSA System 0656 FlexLim ..............................................................................................5.3.6 Restart System ................................................................ The system will be reinitialised in 5 seconds (counting back). 5.3.7 Language Select the desired language. 5.3.8 Metrics Notes on the performance of the overload/weighing FlexLim system................................

  • Page 38: Setup Machine (Parameters For Calibration)

    BROSA System 0656 FlexLim ..............................................................................................5.4 Setup Machine (Parameters for Calibration) ................................................................ This section provides possibility adjust paramters while commissioning or recertifications. These paramaters are relevant to the functionality of the 0656 system. Certain menus are protected by a personal identification number. These are safety-critical menus (settings made here have a decisive influence on the safety and functionality of the system!).

  • Page 39: Canopen Inputs

    BROSA System 0656 FlexLim ..............................................................................................5.4.1 CANopen Inputs ................................................................ Select the desired CANopen Input 5.4.1.1 Configuration Configured CANopen sensors can be selected in this screen. If a sensor is selected, status information is displayed and there is the option of assigning the node a new free node ID.
  • Page 40 BROSA System 0656 FlexLim ..............................................................................................................................Active: Yes => A CANopen sensor with the expected settings was found................................Change? : <ENTER> => New node ID can be selected. Important: The node ID must be configured and must not be assigned.

  • Page 41: Analog Outputs

    BROSA System 0656 FlexLim ............................................................................................................................................................5.4.2 Analog Outputs Select the desired analogue output................................................................. © BROSA GmbH, Tettnang, Germany ................................................................ 41 / 70 ................................
  • Page 42 BROSA System 0656 FlexLim ............................................................................................................................................................The minimum and maximum signals that the output channel provides are displayed along with the physical values that represent them. Doubleclick the “ENTER” key to change. To exit entry and return to the previous menu, press the “ESC”...
  • Page 43 BROSA System 0656 FlexLim ................................................................ You can also press “ESC” to skip the entry. The current value then remains unchanged..............................................................................................Enter a new signal value (in this case in mA) and press “OK” to accept the entry or press “ESC”...

  • Page 44: Constants

    BROSA System 0656 FlexLim ..............................................................................................5.4.3 Constants ................................................................ The Constants are the parameters changing the behaviour of the 0656 System Electronics. All Paramteters are individual at every project and could even differ on each machine. Before changing parameters, please note or save the previous values. A loss of them could require a new calibration of the crane.

  • Page 45: Load Spectrum Counter

    BROSA System 0656 FlexLim ............................................................................................................................................................The current value of the constant is displayed. Enter a new value in the specified unit of measure (in this case tonnes) or press “ESC” to leave the value unchanged and return to the previous menu.
  • Page 46 BROSA System 0656 FlexLim ............................................................................................................................................................Select the comparator to be changed Press “OK” to change. To exit entry and return to the previous menu, press the “ESC” key. Enter the new “Min” or “Max” comparator mode (1 or 2) or press “ESC” to leave the mode unchanged and go to the next menu.

  • Page 47: Change Pin

    BROSA System 0656 FlexLim ............................................................................................................................................................The system displays the new comparator parameters. Check that the entry is corr ect and then press “ESC” to return to the comparator selection menu (2.7). 5.4.6 Change PIN The personal identification number for the system can be changed here. Please note that this PIN is essential for accessing the system settings.

  • Page 48: Service

    BROSA System 0656 FlexLim ..............................................................................................5.4.7 Service ................................................................ These service functions require trained staff and are therefore located in the PIN secured section. The Functionalitiy will be explained in Chapter 6.1 5.4.8 Baud rate If there are problems communicating with the external display via the RS 485 interface, the baud rate can be adjusted.

  • Page 49: Weighing Blocks

    ................................................................ This modul is only included in the 0656 FlexLim Weighing. It consists of a total 4 blocks. Each block has its own configuration parameters and linearization values that are separated from each other and saved with a password.
  • Page 50 BROSA System 0656 FlexLim ................................................................ • ................................Result = weighing result * dynamic factor + dynamic offset ................................................................ The measuring range is defined by Min. Capacity and Max. Capacity. The measuring range in parts is defined by Min. Capacity (e) and Max. Capacity (e).

  • Page 51: Bootloader

    BROSA System 0656 FlexLim ..............................................................................................5.4.11 Bootloader ................................................................ The system will enter Bootloader mode in 5 seconds (counting down). As soon as the system is in Bootloader mode, an exclamation mark is sent. Comment: This option has to be used if you would like to upload or download data from the 0656 System Electronics.

  • Page 52: Servicing And Troubleshooting

    BROSA System 0656 FlexLim ..............................................................................................................................Servicing and Troubleshooting ................................6.1 Disfunction of the 0656 System or Error Code on Bus If a critical error occurs, the system is locked and displays a corresponding error code on the display (internal, external or PC).

  • Page 53: Identify And Replace Faulty Load Sensor(S)

    Depending on the system configuration, the sensors in the network are named from Node ID 11-18. The Node ID for BROSA spare parts is 10 by default. This “Basic Node” provides the possibility to change it directly at the 0656 System electronics to the designated NODE ID.
  • Page 54 BROSA System 0656 FlexLim ............................................................................................................................................................4. The menu for “Basic node” is shown below for further configuration. If you change several sensors in a system, please assure to name the Sensors with the right ID according to the sensors position.

  • Page 55: Saftey Backup And Updates

    ................................After a 0656 System has been calibrated it is strongly recommended to save the adjusted parameter as BROSA is only able to deliver the project software with default parameters. To save the parameter files *flash and *FRAM, the download of the parameter files from the 0656 System Electronics can be done with the BROSA Tool “Bootloader Client”...

  • Page 56: Backup Fram File

    BROSA System 0656 FlexLim ................................................................ 2. Click on “Read” ................................................................ 3. Name the file (e.g. “2_Read_Flash.a90”) and save ................................4. The following message will show up 6.3.1.2 Backup FRAM file 1. Select “FRAM” and the right COM Port 2.

  • Page 57: Upload Of Firmware And Software

    BROSA System 0656 FlexLim ............................................................................................................................................................4. The following message will show up 6.3.2 Upload of firmware and software The Upload of the Firmware and the Software must be also done with the Bootloader Client The Upload must be done step by step and in the ranking as shown in this chapter.
  • Page 58 BROSA System 0656 FlexLim ................................................................ 2. Click on “Write” ................................................................ 3. Select the file (e.g. “1_FlexLim.Safe.Firmware.ARM – v1.4.2.a90”) ................................4. Confirm the pop up message and wait until the the message window at the Bootloader client shows “done”...

  • Page 59: Upload Flash File (Indicated With Leading No."2")

    BROSA System 0656 FlexLim ................................................................ 6.3.2.2 Upload FLASH file (indicated with leading No.”2”) ..............................................................................................1. Select “FLASH”, “Data” and the right COM Port 2. Click on “Write” 3. Select the file (e.g. “2_Read_Flash.a90”) 4. The following message will show up 6.3.2.3 Upload FRAM file (indicated with leading No.”3”)

  • Page 60: Upload Slave Firmware (Indicated With Leading No."4")

    BROSA System 0656 FlexLim ................................................................ 2. Click on “Write” ................................................................ 3. Select the file (e.g. “3_Read_FRAM.a90”) ................................4. The following message will show up 6.3.2.4 Upload Slave firmware (indicated with leading No.”4”) 1. Select “Slave Controller” and the right COM Port 2.
  • Page 61 BROSA System 0656 FlexLim ................................................................ 3. Select the file (e.g. “4_FlexLim.Safe.Slave.Firmware.ARM – v1.6.3.a90”) ..............................................................................................4. Confirm the pop up message and wait until the the message window shows “done” ................................................................ © BROSA GmbH, Tettnang, Germany ................................

  • Page 62: Update Confimation

    BROSA System 0656 FlexLim ..............................................................................................6.3.2.5 Update confimation ................................................................ Confirm the success of the Update using the following steps: 1. Close the Programm “Bootloader Client” 2. Open the Terminal Program Session 3. Restart the System with a power curcuit 4 Open the Service menu 5.

  • Page 63: Technical Data Of 0656 Electronic System

    Technical data of 0656 electronic system ................................As the 0656 System Electronics is available in different versions please refer to the article number shown on your System. Technical datas are available at BROSA Example: Designation System electronics type 0656 FlexLim 24V DC (10…30V DC)

  • Page 64: List Of Error Codes And Troubleshooting

    BROSA System 0656 FlexLim ..............................................................................................................................List of error codes and troubleshooting ................................If a critical error occurs, the system is locked and displays a corresponding error code on the display (internal, external or PC). Note: Depending on the configuration, a critical error in the system may cause the communication between higher-level systems and the 0656 electronic system to be interrupted.
  • Page 65 BROSA System 0656 FlexLim ................................................................ Error An SRDO communication (CANopen Safety) error has ................................occurred................................................................. Possible causes 1. Cable between sensor and electronics is damaged or not connected. 2. Electrical faults on the CANopen line. 3. Damage to the sensor itself.

  • Page 66: Curve

    1. Missing or too low supply voltage. 2. Defective DI block on the circuit board. Possible remedy 3. Apply correct power supply. 4. Exchange of the 0656 FlexLim. Error code E 52X (where X is the channel of the DI) Error DI block is overheated Possible causes 1.

  • Page 67: Digital Output

    1. Circuit board failure. 2. Defective DO module / controller. Possible remedy 3. Eliminate the fault. 4. Exchange of the 0656 FlexLim. Error code E 92X (where X is the channel of the DO) Error Communication error between DI module and controller...

  • Page 68: System Errors

    BROSA System 0656 FlexLim ................................................................ Error code E 94X (where X is the channel of the DO) ..............................................................................................Error Undefined error message Possible causes 1. Error from undefined definition of the parameters. Possible remedy 2. Defining the parameters.

  • Page 69: Appendix

    BROSA System 0656 FlexLim ..............................................................................................................................Appendix ..............................................................................................© BROSA GmbH, Tettnang, Germany ................................................................ 69 / 70 ................................
  • Page 70 BROSA System 0656 FlexLim ................................................................ Exemplary wiring diagram of the 0656 FlexLim ..............................................................................................Change history Version Date Changes Name 04.06.05 Temporary edition 14.07.05 Content corrected / extended JO / WZ 09.02.06 Logos, company name adapted 31.05.07 Modification according to FlexLim V2.5.1 15.08.14...

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