MAHA IW 2 LON Technical Handbook

Roller brake tester with iwst circuit board

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IW 2 LON

IW 2 LON ALL-WHEEL

IW 4 S

IW 4/7 LON CLASSIC

IW 4/7 LON COMPETENCE

IW 4/7 LON ALL-WHEEL

Roller Brake Tester

with IWST Circuit Board

Technical Handbook

D1 0223TH1-GB01

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Summary of Contents for MAHA IW 2 LON

Page 1 IW 2 LON IW 2 LON ALL-WHEEL IW 4 S IW 4/7 LON CLASSIC IW 4/7 LON COMPETENCE IW 4/7 LON ALL-WHEEL Roller Brake Tester with IWST Circuit Board Technical Handbook D1 0223TH1-GB01...
Page 2 . KG. All rights reserved. Any reproductions of this document, partial or complete, are only allowed with prior consent of MAHA GmbH & Co. KG. All rights reserved in cases of patent granting or registration of design. The contents of this edition have been checked with great care. However, errors cannot be fully excluded.
Page 3: Table Of Contents
ONTENTS Installation .........................5 Node Overview..........................6 Detailed View ..........................7 Description.........................8 MAH LON IWST..........................8 MAH IW SMC..........................14 MAH LON SMC 5.........................16 LON BP TRK..........................19 LON TRAN 2 HF ..........................24 LON SNT (Power Supply) ......................27 MAH MFA DOT ..........................29 MAH MFA LED..........................31 MAH RECO1 EMPF V 0.10 ......................33 2.10 Remote Control RECO 1......................35 2.11 Commissioning MAH LON IWST ....................37 2.12 Commissioning MAH LON SMC 5 ....................37...
Page 4 D1 0223TH1-GB01...
Page 5: Installation
(Twisted Pair must be at least AWG 24 Standard) Line length - Maximum length according to the specifications of the manufacturer ECHOLON: 500 m. - MAHA factory recommendation: 150 m. - The minimum voltage at the last node must be 20 V. Wiring cross section for patch cable: - for voltage supply at least 0.25 mm...
Page 6: Node Overview
Installation Node Overview D1 0223TH1-GB01...
Page 7: Detailed View
Installation Detailed View Picture 1: Control cabinet Picture 2: BT left Picture 3: BT right D1 0223TH1-GB01...
Page 8: Description
Description Description MAH LON IWST 2.1.1 Circuit Board Overview See following page. D1 0223TH1-GB01...
Page 9 Description D1 0223TH1-GB01...
Page 10 Description 2.1.2 Connector X1, X2 RJ45: LON-Netzwerk Pin Designation Comment LON Data LON Data +24 V DC +24 V DC Looped through between X1 and X2 Looped through between X1 and X2 2.1.3 Connector X3 Phoenix Clamp: LON-Network Pin Designation Comment LON Data LON Data...
Page 11 Description 2.1.7 Connector X7 IR-Eye: The assignment is pre-set by the MAHA Infra-red receiver. The radio receiver simulates the signal from the infra-red receiver. Pin Designation Comment +24 V DC For supply of signal LED Output for signal LED Output for signal LED max. 50mA...
Page 12 Description Pin Designation Comment LED Output 3 + Malfunction VS12 24V / max. 20 mA ⊥ LED Output 4 + Difference too large (orange) VS13 24V / max. 20 mA ⊥ LED Output 5 + Difference too large (red) 24V / max. 20 mA ⊥...
Page 13 Description 2.1.11 Harddip S1 Press Power ON key once -> Motor ON, Motors ON press again -> Motor OFF Danger! If the motors are started in this way, no persons or objects may be in the vicinity of the rotating rollers or the chains. Fix pointer limit Exhibition mode Service technician mode...
Page 14: Mah Iw Smc
Description MAH IW SMC The modular circuit board MAH IW SMC on the MAH LON IWST circuit board is connected via the internal RS485 databus and serves exclusively up to 5 stepping motors. 2.2.1 Circuit Board Overview D1 0223TH1-GB01...
Page 15 Description 2.2.2 Connector X1 to X5 Stepping motors Pin Designation Comment Brown Orange Yellow Smaller measurement range left or double scale (e.g. 4/40 kN) Smaller measurement range right or double scale (e.g. 4/40 kN) Larger measurement range left Larger measurement range right Differential display The stepping motors must be connected to X1 and X2 on test stands with double scales (small and large indicating range).
Page 16: Mah Lon Smc 5
Description MAH LON SMC 5 2.3.1 Circuit Board Overview D1 0223TH1-GB01...
Page 17 Description 2.3.2 Connector X1, X2 RJ45: LON-Network Pin Designation Comment LON Data LON Data +24 V DC +24 V DC Looped through between X1 and X2 Looped through between X1 and X2 2.3.3 Connector X3 Phoenix-clamp: LON-Network Pin Designation Comment LON Data LON Data +24 V DC...
Page 18 Description Pin Designation Comment LED Output 4 + Function: Malfunction 24V / max. 20 mA ⊥ LED Output 5 + Function: Malfunction 24V / max. 20 mA ⊥ LED Output 6 + Function: Malfunction 24V / max. 20 mA ⊥ LED Output 7 + Function: Malfunction 24V / max.
Page 19: Lon Bp Trk
Description LON BP TRK These nodes are installed in the floor assembly of the test stand. Pin Designation Comment Sensor roller RPM + Slip sensor roller GND Signal Slip sensor roller Motor RPM + Slip Motor GND Signal Slip Motor Occupy sensor roller + Occupied GND Signal...
Page 20 Description 2.4.1 Circuit Board Overview D1 0223TH1-GB01...
Page 21 Description 2.4.2 Connector X2 Pin Designation Comment Data line A Twisted pair Data line A Twisted pair +24 V DC 2.4.3 Connector X12 to X31 Measurement gauge and weighing machine 2.4.4 Connector X4 to X8 Proximity switch D1 0223TH1-GB01...
Page 22 Description 2.4.5 Connector X3, X10, X11, Jumper J1 to J3, LED VD1 RS485 for Debugger Input for Temperature or cable pressure sensor Bootloader Service-Pin The jumper J3 is only available for service purposes. If it is set, the PIN number of the neurons can be determined (also serial number).
Page 23 Description 2.4.7 Arrangement and Connection of the Measuring Cells All connectors are needed when connecting a dynamic weighing machine (four meas. cells). With a static weighing machine (two measuring cells) both free inputs must be connected to GND. If the test stand does not have the weighing machine option, no pressure sensors are built into the roller set.
Page 24: Lon Tran 2 Hf
Description LON TRAN 2 HF 2.5.1 Circuit Board Overview 2.5.2 Connector X1, X2 RJ11 connector to connect the LON circuit boards. Pin Designation Comment Data line A Data line B +24 V +24 V Not used Not used 2.5.3 Connector X3 Bayonet-type connector for antenna cable 2.5.4 Connector X4...
Page 25 Description 2.5.5 Connector X5 Phoenix connector: Possible connection of the LON circuit board. Pin Designation Comment Data line A Data line B +24 V 2.5.6 Connector X6 9-pin Sub-D connector, RS232 interface. Internal connection for programming Pin Designation Comment Pins not listed are not used. 2.5.7 Connector X7 Internal application.
Page 26 Description 2.5.9 Connector X9 Power supply voltage and network connection for pit safety. Pin Designation Comment +8 V RS485 A RS485 B Casing ground 2.5.10 Connector X10 Power supply voltage and network connection for pit safety. Pin Designation Comment +8 V RS485 A RS485 B Casing ground...
Page 27: Lon Snt (Power Supply)
Description LON SNT (Power Supply) 2.6.1 Circuit Board Overview 2.6.2 Connector X1 Connection LON circuit board Pin Designation Comment Data line A Data line B +24 V 2.6.3 Connector X2, X3 RJ11 connector for connection of LON circuit board Pin Designation Comment Data line A Data line B...
Page 28 Description 2.6.4 Connector X4 Connection of the power voltage Pin Designation Comment Phase L3 (230 V ~) Zero conductor N 2.6.5 Connector X5 Switch over SCART Pin Designation Comment +12 V Not used Not used 2.6.6 Fuse F1 Fuse 4 A D1 0223TH1-GB01...
Page 29: Mah Mfa Dot
Description MAH MFA DOT 2.7.1 Circuit Board Overview D1 0223TH1-GB01...
Page 30 Description 2.7.2 Connector X1, X2 RS485: Connection to MAH IWST or additional displays Pin Designation Comment +24 V DC –24 V DC Data line A At bus end, bridge with a terminating resistor of 120…130 Ω. Data line B 2.7.3 Connector X3 Internal : Debugger 2.7.4...
Page 31: Mah Mfa Led
Description MAH MFA LED 2.8.1 Circuit Board Overview 2.8.2 Connector X1, X2 RS485: Connection to MAH LON IWST or to other displays Pin Designation Comment +24 V DC –24 V DC Data line A At bus end, bridge with a terminating resistor of 120…130 Ω.
Page 32 Description 2.8.3 Connector X3 Internal: Debugger 2.8.4 Jumper J1, J2 Service pin If the pin is bridged at reset (switch on) an internal self-test is conducted. Hereby all 10 Service pin LEDs and the complete DOT-Matrix are switched on. 2.8.5 LEDs VD42 bis VD45 VD42 VD25...
Page 33: Mah Reco1 Empf V 0.10
Description MAH RECO1 EMPF V 0.10 2.9.1 Circuit Board Overview 2.9.2 Connector X1 Internal 2.9.3 Connector X3 Connection to MAH IWST on X7 Pin Designation Comment +24 V DC Input Impulse signal Output +5 V DC Input 2.9.4 Connector X4 Antenna input D1 0223TH1-GB01...
Page 34 Description 2.9.5 Switch S1 The radio system is operated on a license-free ISM band. Switch position Transmission channel Frequency in MHz HF transmission in ms 868.000 869.850 869.200 868.300 868.200 869.525 868.800 869.800 868.400 868.950 869.000 Do not use! 870.000 868.600 D…F D1 0223TH1-GB01...
Page 35: Remote Control Reco 1
Description 2.10 Remote Control RECO 1 The remote control RECO 1 can only be operated with the MAH RECO1 EMPF circuit board. Motors off Start Motor left Start Motor right Menu point forwards Menu point backwards Confirm 2.10.1 Circuit Board Overview 2.10.2 Battery G1 Model: "CR 2032"...
Page 36 Description 2.10.3 Switch S1 Transmission Frequency DIP switch Transmission Frequency DIP switch channel in MHz position channel in MHz position 868.000 868.800 868.200 869.000 868.400 869.200 868.600 869.800 870.000 869.525 868.300 869.850 Do not use transmis- 868.950 sion channels 8…12! D1 0223TH1-GB01...
Page 37: Commissioning Mah Lon Iwst
Description 2.11 Commissioning MAH LON IWST The pointer on the circuit board must be initialized: 1 Main switch ON. ⇒ The correct mechanical pointer zero point is determined after the switch on. 2 DIP 2 to ON. 3 Loosen the fixing screws of the pointer. 4 Position the pointer to the mechanical limit.
Page 38: Lon Manager
LON Manager Starting the LON Manager Start Lon manager via the Windows start menu : Start Program MAHA LON Manager Before program start check whether: No other programs are started which access the LON network. To make sure that the Lon Manager has not been started several times The LON connection is available.
Page 39: Main Menu
LON Manager Main Menu 1 In the main menu select the button <F5> LON Manager . ⇒ Overview of the connected LON nodes Following single nodes can be selected: <15/16> BPW le and ri= floor assemblies L/R <32> Radio/GSQ = Radio remote control and pit safety <56>...
Page 40 LON Manager Variable inquiry: <F5> Roller set left <F6> Roller set right 3.3.1 Brake Force <F8> Calibrate brake tester brake force <F7> Zero adjustment, complete before mounting the calibration device. Zero adjustment also applies to the weighing machine. 1 Mounting the calibration device left/right 2 Place weights (e.g.
Page 41 LON Manager 3.3.2 Weight 1 Load the floor assembly left/right with known weight, e.g. 1000 kg. 2 Enter the weight value in the left / right entry box in kg . 3 Store with <F7> or <F8>. 3.3.3 Pressure 1 Using the arrow key, switch 2 levels down , then <F5>.
Page 42 LON Manager Edit Variables Buttons: <F5 Import> <F6 Beginning> of the list <F7 End> of the list <F8 Reverse> Test Inputs / Outputs Here the individual outputs, inputs and harddips can be checked. 1 Use switch at the test stand ⇒...
Page 43 LON Manager Adjust Pointer 1 Select point for adjustment: 1 = klMBl, 2 = klBRr, 3 = grMBl, 4 = grMBr, 5 = Difference 2 <F2 Pointer Reset> 3 Change steps - in unit increment U und J - in tenth of a unit increment I und 4 <F3 Store zero point>...
Page 44 LON Manager Set RealTimeClock (RTC) Buttons: <F7PC-time to IWST> Import time from PC <F8 Entry in IWST> Manual entry of time With a new circuit board pay attention: Write RTC first, then read. Create Customer Heading With a new circuit board, the customer heading must be written first, before it can be read.
Page 45 LON Manager 3.3.5 LON SMC Selection between <F5> Edit Variables <1> Test outputs <2> Adjust pointer Edit Variables Buttons: <F5 Import> <F6 Beginning> of the list <F7 End> of the list <F8 Reverse> Test Inputs / Outputs Here the individual outputs, inputs and Harddip-Switches can be checked.
Page 46 LON Manager Adjust Pointer 1 Select pointer to be adjusted: 1 = klMBl, 2 = klBRr, 3 = grMBl, 4 = grMBr, 5 = Difference 2 <F2 REset Pointer> 3 Change Steps - in unit increment U und J - in tenth of a unit increment I und 4 <F3 Store zero point>...
Page 47: Inputs, Outputs, Harddip Switches Of The Mah Lon Iwst
LON Manager Inputs, Outputs, Harddip Switches of the MAH LON IWST Input Designation Press key POWER ON Switch single wheel left Switch single wheel right Switch for weight simulator Pit safety "Ready" signal Motor protection switch (left and right joint) not used not used not used...
Page 48: Manual Programming
LON Manager Manual Programming MAH LON IWST with MAH IW SMC and Printer, MAH MFA DOT (if available). 1 Start LON Manager and select <F5> . 2 <F8> Download and <yes>. 3 <F8> Edit nodes. 4 Enter Node-Id 57 for LON IWST . When working with the LON Manager Harddip 4 on the MAH LON IWST must be at "ON"...
Page 49: Calibration
LON Manager Calibration In the LON Manager menu the following components are available for calibration. Brake tester Shock absorber Side-slip tester IWST IW SMC Call up single nodes in the LON Manager. 3.6.1 Calibration of TRUCK Brake Tester Accuracy of measuring device Accuracy of testing device ±...
Page 50 LON Manager 1 Start LON Manager . 2 Select LON-BPLKW. 3 <F8> Test, calibrate. 4 Place both motor protection switches to position "OFF". 5 Conduct a zero-point adjustment of the brake force with <F9>. 6 Remove the center covers and mount the calibration device. Pay attention that the shackle (A) is in the proper notch of the calibration arm (with extension) (B) for the large and/or small test range..
Page 51 LON Manager 6.4 Place the calibration arm (B) in the shackle (A). 6.5 Put on the counter weight (E) . Use the spirit level (F) for this. 6.6 Balance the calibration device with the counter weight (E). Only when a balanced position is reached no force is acting on the strain gauge of the brake tester.
Page 52 LON Manager Installation of the calibration device for Roller set 2 (IW 4 and IW 7) Installation of the calibration device for Roller set 3 (IW 7) Shackle Spirit level Calibration arm with extension Drive motor Spacer Brake roller Strain gauge (DMS) Weight Counter weight Underlay parts...
Page 53 LON Manager 3.6.2 Starting the Motors Separately Life threatening! If the motors are started in this way attention should be paid that no persons or objects are in the vicinity of the turning rollers or chains. In some countries, e.g. Belgium, the motors must be switched on at calibration. A motor start-up test can also be conducted.
Page 54: Troubleshooting
Troubleshooting Troubleshooting Work on any electrical components of the brake tester (control cabinet, roller set) may only be carried out by qualified electricians or authorized service technicians. The test stand shows an error code when there is a malfunction. The error code is indicated by the pointers of the small measurement range.
Page 55 Troubleshooting Error code Cause Remedy Check sensor for switching clearance Right-side speed sensor defective. and proper contact of connections. Contact service. Exit aid as safety feature disabled! Erroneous zero point adjustment of Drive vehicle off rollers, turn off main pointers. switch and on again.
Page 56 Troubleshooting The roller set starts up automatically when a vehicle is on the roller set with the setting 'Automatic start-up Yes'! A few seconds must pass between switching the test stand on and off so that the test stand can be properly re-started. D1 0223TH1--D01...
Page 57: Spare Parts List
Spare Parts List Spare Parts List Part № Description Designation 52 0242 Thermo printer EPM 203 52 0243 Paper roll for EPM 203 52 0244 Printer cable, serial 52 0245 Printer voltage supply 56 1008 Power supply 53 2497 Fixture for power supply 52 0123 6-key remote control RECO 1...

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