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Hirschmann qSCALE maestro, Service Manual, Page: 14 / 76

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Hirschmann qSCALE maestro Service Manual Download Page 14

 
 
 
 
 
 
 

WIKA Mobile Control LP  

1540 Orchard Drive 
Chambersburg, PA 17201 

 

qSCALE maestro (PLC v01.00.00) Service Manual / Issue E (HMI v1.0.0) 04/2018 / rbm.

 

Service :

 (717) 217-2250 

Parts / Sales :

 (717) 217-2269 

www.wika-mc.com

 
 

14

/76 

 

 

HIRSCHMANN MCS

 

 

 

 

NOTE 

This service manual contains information about the vSCALE D2 / D3 maestro con-

sole, 

 mode selection, operation, sensor calibration and maintenance. 

 

 

 

 

WARNING 

This service manual contains information about the vSCALE D2 / D3 maestro 

console, mode selection, operation, sensor calibration and maintenance. 

Although the system incorporates functions for monitoring adjustable geomet-

rical limit values with visual and audible warnings and a relay output in the event 

of limit values being exceeded, the system cannot be used as an operational limit 

switch. 

The machine driver is responsible for the safe operation of the machine. 

 

 

Summary of Contents for qSCALE maestro

Page 1: ...aestro PLC v01 00 00 Contents Safety instructions 1 Product description 2 Service Menus 3 Service and Maintenance 4 Appendix 5 Service Manual Issue E 04 2018 HMI v01 00 00 This document has the order...

Page 2: ...ght Tower 102127 12 3 Description of the System 13 3 1 Product Identification 15 3 2 General Information 15 3 3 EC Conformity Declaration 15 3 4 Overview of Console Elements 16 3 5 Overview Feedback E...

Page 3: ...on Central Control Unit 45 6 3 2 Indicators on Console 45 6 4 Boom Angle Sensing 46 6 5 Boom Length Sensing 48 6 5 1 Cable Reel Length Cable Replacement Procedure 49 6 6 Pressure Sensing 50 6 7 Load S...

Page 4: ...mc com 4 76 HIRSCHMANN MCS VERSION OVERVIEW Issue Date Description Editor A 11 2017 Initial Release HMI v01 00 00 RBM B 12 2017 Updated Luffing Cylinder Calibration section and Alarm Volume section RB...

Page 5: ...be duplicated repro duced or translated into another language either wholly or partly without the prior written permission of WIKA Mobile Control LP The rendition of common names trade names trademark...

Page 6: ...his service manual WARNING Warning of direct threat of personal injury and damage to property Instructions on precautions to avert the danger CAUTION Warning of dangerous situations Also warns of dama...

Page 7: ...status is essential for the correct function of the system and of the machine The RCL can only operate correctly if all settings are entered correctly according to the current set up status during th...

Page 8: ...608416 1 D3 kit only SMC QSCALE MAESTRO S6 IP66 67 623029 1 JUNCTION BOX QSCALE MAESTRO 061179 1 Section 2 1 1 0985 806 125 10M 90 DEG BEND 900004191 1 ASBSV 4 5 P5 MCS CUSTOM 934637762 1 0935 253 10...

Page 9: ...4N W DIODE 061181 1 EC DIODE 1N4003 200V 1A 000 430 104 003 TERMINAL STRIP ACCY END PLATE PIK 4N 051298 1 TERMINAL STRIP ACCY END BRACKET PIK 4N 051299 2 RELAY SHUTOFF 12V 20 30A 000 304 140 112 1 EC...

Page 10: ...00 093 2 HYDR ADAPTER 9 16 18 UNF 2B 031 300 050 689 2 HYDR FITTING 1 4 NPT MALE TO 031 300 050 750 2 2 2 Boom Upgrade 102124 Component Name Part Number QTY Notes STRAIN RELIEF PG13 5 PG 9 000 214 261...

Page 11: ...CONN ACCY TERMINAL CRIMP EH 051208 5 M4x30mm BOLT 051278 3 HARDWARE LOCKWASHER M4 051177 3 NUT 4mm SELF LOCKING S S 002 060 500 402 3 HARDWARE STANDOFF 3mm x 12 FF 000 212 020 312 3 SCREW 3mm x 10mm...

Page 12: ...v1 0 0 04 2018 rbm Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 12 76 HIRSCHMANN MCS 2 4 Indicator Kit Light Tower 102127 Component Name Part Number QTY INDICATOR LIGHT TOWER 3 COLOR...

Page 13: ...sensor tilt sensor load pin and anti two block switch All components and sensors are equipped with CAN bus controllers When limits are reached an overload warning signal is generated at the operator s...

Page 14: ...tion operation sensor calibration and maintenance WARNING This service manual contains information about the vSCALE D2 D3 maestro console mode selection operation sensor calibration and maintenance Al...

Page 15: ...r type plate for queries about this product 3 2 General Information NOTE Knowledge of how to use a voltmeter to measure both voltage and current is as sumed HINT For general system operation refer to...

Page 16: ...or Selection and Confirmation SET key Selects Settings Silences Alarm HOME key Returns to Main Working Screen ESCAPE key Aborts Function Display with RCL Main Menu Rotary Encoder with Pushbutton Funct...

Page 17: ...mc com 17 76 HIRSCHMANN MCS 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 Po...

Page 18: ...enter a Service Password Daily Password or LMI Password See Section 4 1 2 for information on Obtaining the daily password Password entry is done by the following instructions Use the rotary knob to se...

Page 19: ...he Settings Menu and enter it into the excel sheet to be converted into a usable password that will last the entire day Finding the Daily Password Seed The Daily Password Seed is located in the Settin...

Page 20: ...Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 20 76 HIRSCHMANN MCS 4 2 System Settings HOME SETTINGS SYSTEM SETTINGS Function Keys And Choose option to adjust See Section 4 2 1 for ex...

Page 21: ...option Use the or 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 Operat ing Screen Wind...

Page 22: ...the number of cameras to activate Setting the Camera option to 1 or more enables the function key from the Main Operating Screen Camera s On Camera Off Toggling Camera Full Screen Style Use the or ke...

Page 23: ...rts Sales 717 217 2269 www wika mc com 23 76 HIRSCHMANN MCS 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...

Page 24: ...com 24 76 HIRSCHMANN MCS 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 thr...

Page 25: ...2250 Parts Sales 717 217 2269 www wika mc com 25 76 HIRSCHMANN MCS 4 3 1 Calibrate Angle Sensors Summary This section describes how to calibrate the boom angle sensor The machine must be on a level s...

Page 26: ...c com 26 76 HIRSCHMANN MCS Enter the Measured Angle of the Boom Use the rotary knob to select the numbers See Section 4 4 for detailed instructions Press to confirm the measured boom angle as entered...

Page 27: ...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 CALIBRATION LENGTH...

Page 28: ...2250 Parts Sales 717 217 2269 www wika mc com 28 76 HIRSCHMANN MCS Fully extend the boom and press Enter the Measured Length of the Boom Use the rotary knob to select the numbers See Section 4 4 for...

Page 29: ...ing adjusts the lift cylinder rod and piston geometric data to correct system atic errors in the load display The adjustment computed applies equally to all operating modes at all length and angle poi...

Page 30: ...and fully retract the boom Press the function key to begin setting the Empty Load Weight Allow a few moments for the measurement to complete The measurement will not complete if the piston pressure is...

Page 31: ...nown weight of the load and any rigging added Use the rotary knob to select the numbers See Section 4 4 for detailed instructions Press to confirm the load weight as entered Press the function key to...

Page 32: ...hile calibrating sensors 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 las...

Page 33: ...7 217 2250 Parts Sales 717 217 2269 www wika mc com 33 76 HIRSCHMANN MCS 4 5 Alarm Volume The Alarm Volume can be adjusted in the User Screen An OEM or LMI password must be entered in order to change...

Page 34: ...lication Files i e machine model and load charts HOME SETTINGS SYSTEM INFORMATION DOWNLOAD APP DATA Adding machine project file packages to the console memory is done by the following instructions Ins...

Page 35: ...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 compl...

Page 36: ...0 0 04 2018 rbm Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 36 76 HIRSCHMANN MCS 5 3 Reset Hour meter HOME SETTINGS SYSTEM INFORMATION RESET HOUR METER This resets the hours the syst...

Page 37: ...2018 rbm Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 37 76 HIRSCHMANN MCS 5 4 Change Date and Time HOME SETTINGS SYSTEM INFORMATION SET DATE TIME Adjust the date and time by using a...

Page 38: ...rts Sales 717 217 2269 www wika mc com 38 76 HIRSCHMANN MCS 5 5 Rotate Display HOME SETTINGS SYSTEM INFORMATION ROTATE DISPLAY The display can be rotated 90 degrees at a time by pressing NOTE The loca...

Page 39: ...E and SET function buttons simultaneously o A screen shot of the current screen will be saved 5 6 2 Saving Screen Captures If a USB drive is installed in the console the screen capture will be saved t...

Page 40: ...Parts Sales 717 217 2269 www wika mc com 40 76 HIRSCHMANN MCS 5 7 Mismatched DA4 One of the following messages may be displayed after an installation error or software corruption If an installation er...

Page 41: ...vice may be damaged by the use of high pressure cleaners The device must not be treated with a high pressure cleaner or similarly aggressive method under any circumstances Condensation inside the vSCA...

Page 42: ...s with the boom angle measurement THE DISPLAYED LENGTH DOES NOT MATCH THE MEASURED BOOM LENGTH Start in section 6 5 Boom Length Sensing to troubleshoot possible problems with the boom length measureme...

Page 43: ...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...

Page 44: ...heck 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...

Page 45: ...st of the system SR Is lit solid when the Safety Relay is Active If this light is off it indicates a segmentation fault memory leak or another condition that prevents the system from showing safe work...

Page 46: ...correctly or not at all The scaled value of the sensor can be monitored and should be checked against a digital level outside of the system mounted on the boom If the scaled value varies from the meas...

Page 47: ...ed 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 If the voltage is still ou...

Page 48: ...th cable tension If tension is lacking check the cable reel to ensure it has the proper pretension This varies upon the type of cable reel used The voltage supplied to the length sensor will be throug...

Page 49: ...able from terminal strip 7 Feed new length cable through hole on reel drum through the strain relief on the junction box 8 Rewire terminal strip according to wiring noted in step 4 9 Close junction bo...

Page 50: ...the LMI is not a direct measurement when using pressure transducers rather it is a calculated value Ensure that the hydraulic system is functioning as intended and that sensor values mainly length and...

Page 51: ...ts such as Hook block weight Sling weights etc Tip height length of load line used Boom weights Boom attachments such as Stowed jibs Glass jib telescopic jib etc Before checking the system for a load...

Page 52: ...www wika mc com 52 76 HIRSCHMANN MCS Cable Reel 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 t...

Page 53: ...LE maestro PLC v01 00 00 Service Manual Issue E HMI v1 0 0 04 2018 rbm Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 53 76 HIRSCHMANN MCS 6 8 1 A2B Problem Flow Chart Use the following...

Page 54: ...217 2250 Parts Sales 717 217 2269 www wika mc com 54 76 HIRSCHMANN MCS 6 9 No Console Display If the console never displays an image check if power is being supplied to the console Measure the voltag...

Page 55: ...o communicate on a single bus a dual wire networked data bus with speed up to 1Mbps The use of a CAN Bus design allows for all nodes sensor controller and console signals to be net worked over a commo...

Page 56: ...other is in the WGX angle sensor contained in the Cable Reel The signals are generated by nodes on the CAN BUS The nodes generate consume or both generate and consume data over a CAN Bus The CAN High...

Page 57: ...esting the CAN connectors per this layout Connector M12 5 contacts Pin Layout CiA DR 303 1 7 2 Female Sockets shown Pin 1 Shield Pin 2 Ub Pin 3 Ground Pin 4 CAN High Pin 5 CAN Low Connector M12 5 cont...

Page 58: ...To determine whether there is a problem with a sensor the system has a built in Analog Input screen to make trouble shooting easier This is the place to start if you suspect a problem with a sensor H...

Page 59: ...gital input the system has a built in Digital Input screen to make trouble shooting easier HOME SETTINGS MACHINE INFO DIGITAL INPUTS The Digital Inputs screen shows the current readings from each Digi...

Page 60: ...lem with a digital output the system has a built in Digital Output screen to make trouble shooting easier HOME SETTINGS MACHINE INFO DIGITAL OUTPUTS The Digital Outputs screen shows the current values...

Page 61: ...ity protection up to 48V DC Display 4 3 TFT Color Graphic LCD 480 x 272 Pixel WVGA Or 7 TFT Color Graphic LCD 800 x 480 Pixel WVGA Brightness 400 cd m Contrast 400 1 or 500 1 Illumination LED adjustab...

Page 62: ...540 Orchard Drive Chambersburg PA 17201 qSCALE maestro PLC v01 00 00 Service Manual Issue E HMI v1 0 0 04 2018 rbm Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 62 76 HIRSCHMANN MCS 7...

Page 63: ...Control LP 1540 Orchard Drive Chambersburg PA 17201 qSCALE maestro PLC v01 00 00 Service Manual Issue E HMI v1 0 0 04 2018 rbm Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 63 76 HIRS...

Page 64: ...Control LP 1540 Orchard Drive Chambersburg PA 17201 qSCALE maestro PLC v01 00 00 Service Manual Issue E HMI v1 0 0 04 2018 rbm Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 64 76 HIRS...

Page 65: ...Orchard Drive Chambersburg PA 17201 qSCALE maestro PLC v01 00 00 Service Manual Issue E HMI v1 0 0 04 2018 rbm Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 65 76 HIRSCHMANN MCS 7 3 J...

Page 66: ...1540 Orchard Drive Chambersburg PA 17201 qSCALE maestro PLC v01 00 00 Service Manual Issue E HMI v1 0 0 04 2018 rbm Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 66 76 HIRSCHMANN MCS...

Page 67: ...1540 Orchard Drive Chambersburg PA 17201 qSCALE maestro PLC v01 00 00 Service Manual Issue E HMI v1 0 0 04 2018 rbm Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 67 76 HIRSCHMANN MCS...

Page 68: ...rror is occurring 00xx General Error Other 2xxx Module Error 3xxx Module Error 1Fxx System 01xx Limiter Error Global Cut 02xx Single Cut 03xx Error 04xx Warning 05xx Pre Warning 0Axx Kinematic Error K...

Page 69: ...Range load chart E012D Max length limit exceeded global cut Telescope into the permitted Working Range load chart E0140 Min radius limit underrun global cut Move the Jib down to a valid radius and ang...

Page 70: ...tic Errors 0A00 0AFF E0A00 Capacity utilization 100 Lay down the load Only operate within allowed parameters E0A08 Capacity utilization 90 Warning Operating close to Cut off E0A20 Shutdown due to over...

Page 71: ...configuration Replace faulty sensor E1X1A Sensor Error IOInput3 Check the CAN connections and wiring the sensor calibration and the CAN configuration Replace faulty sensor E1X1B Sensor Error IOInput4...

Page 72: ...ty sensor E1X61 Actuator Error IOCut Check the CAN connections and wiring the sensor calibration and the CAN configuration Replace faulty sensor E1X63 Actuator Error IORigging Check the CAN connection...

Page 73: ...rs again E1F06 Timeout Turn the Ignition off and on again Consult Customer Service if the error occurs again E1F07 Timeout Turn the Ignition off and on again Consult Customer Service if the error occu...

Page 74: ...knowledge to ensure trouble free operation We take the task of continuous improvement and reduction of errors very seriously Your comments and suggestions help us to increase the quality and level of...

Page 75: ...217 2269 www wika mc com 75 76 HIRSCHMANN MCS Suggestions for improvement and additional information General comments Sender Company Department Name Phone Street Zip code City Date Signature Dear user...

Page 76: ...ntrol LP 1540 Orchard Drive Chambersburg PA 17201 qSCALE maestro PLC v01 00 00 Service Manual Issue E HMI v1 0 0 04 2018 rbm Service 717 217 2250 Parts Sales 717 217 2269 www wika mc com 76 76 HIRSCHM...

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