Author: Chad

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Phase Monitoring Relay added

There has been a phase monitoring relay added to Liebherr 81K.1.

It monitors voltage (high and low), frequency (high and low), phase loss and phase order.  The display will show all 3 lines of voltage, and relay status.  If the relay opens it will shut off crane the same as an e stop, and the message on the remote will show E stop pushed.  The display of the relay will flash and an error message will display above the voltage read out.

RL1.PL – Phase loss (one leg is no producing voltage)

RL1.PR – Phase Reverse (Phase order needs changed)

RL1.OV – Over voltage

RL1.UV – Under voltage

RL1.OF – Over frequency

RL1.UF – Under frequency

FLT.INT – Voltage interruption

 

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FM Gru Electrical Schematics

When look at a component in the electrical cabinet or wire, the number indicates what page in the schematics that the component can be found at.  For example, 6U1 is the hoist inverter (VFD) found on page 6.  Wire #1503 is found on page 15 and is wire# 03 in a sequence.

S=Hoist (pg 6)

R=Slew (swing) (pg 9)

C=Trolley (pg 12)

F=Brake

KL= Safety validation for the drives

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FM Gru will not start

Crane will not start with remote control and display shows “Remove Inserted Commands”

A joystick is out of adjustment and not returning to neutral.  Can try and clean connections on the back of joystick, or use app to recalibrate remote.

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T85 starts and immediately shuts off

Crane would start normally, but during start up of drives crane would shut off.  Erection screen was inaccurate, because crane would not start up.  Faults showed 1-213-001, fault with communication with U213X.  U213X had green run and I/O lights.  Unplug H5, H6, and H7 (hoist, slew and trolley).

https://service.rockymtncranes.com/2024/09/09/reeving-impossible-assistance-mode-on-processor-display/

Crane would start and run.  Plugged in hoist cable, restarted crane-it worked.  Plugged in trolley cable, restarted crane-crane would work.  Plugged in slew cable, restarted crane-crane would shut off.  Problem could be slew cable, Canopen card in drive or drive itself.

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Teach In for New Version of Hup

To begin teach in, you must first choose the target (H0, H1, 10, 20) and then you can set the radius.

You must also set the minimum AND the maximum radius.

To set “0” load, you must lower the hook past where the hoist rope is in the middle of the drum; and then you hoist up to where the hoist rope is in the middle of the drum.

You are also required to set the “known” load.

If you do not set the 3 dead turns, an envelope will show in the upper left corner and the message will be that the 3 dead turns has not been set.

The newest version of the CCS manual is here

CCS V1.13-ENU

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FM Gru won’t start

When trying to start crane, the PLC and the load sensor were not turning on.  The top light on this device was flashing red.

This is an electronic circuit break.  Found the short, and corrected.  The red light can be pushed to reset.

 

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Liebherr 81K.1 shutdown and won’t restart

The crane lost eception with the remote and shutoff.  The operator tried to restart and it would not restart.  The operator took a picture of the following code.

The code 0x 0400 means the remote is asked to start (restart), but there is a function being applied at the same time.  The operator was in mid-swing when it lost reception and the operator did not release the joystick when he tried to restart.  The picture shows this.

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Liebherr 81K.1 won’t swing

Customer called and crane won’t swing.   Crane will hoist and trolley, but no swing.  Error code “E 705”.  Slowing gear safety device.  Thaddeus was able to FaceTime with customer and found slew drive circuit breaker was tripped.

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Crane will not hoist

Crane will not hoist up or down.  No fault on CCS, but drive shows “E OC” which means motor overcurrent.

Manually release brake, and fault changes to “E 68″ brake switch malfunction.  This indicates that the drive is seeing an over current fault, and the brake is typically not the culprit.  Verify brake is being released by drive, and verify brake disk adjustment.  With brake manually released, the drum spins freely.

Found contactor K466M (motor heating) was stuck in the activated position.  Could not release the contactor coil (contacts may be welded)  Switched off Q407F, and crane hoists normally.

As drive would send voltage to motor to work, but motor was requiring more voltage than the drive was sending to rotate because it was heating the motor additionally.  Drive would stop due to this ‘over current” sitauation.