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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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De-rating a crane via Potain Connect Access App

Derating is available in Potain Connect thru the Remote Configuration menu. The submenu Crane Performance Limitation will be the menu where you make the adjustment. Toggling the button from off to on is the first step in the process. From there, a popup window will appear asking you to validate your selection. This will reduce both moment and load to 50 percent. Remotely this is the only option for derating the performance. For deactivating the limitation, it is the reverse process.

If the crane is off when you make the limitation selection, the limitation will turn on or off with a few second’s delay. If the crane is turned on, the action of activating or deactivating will not occur until the crane is turned off the next time.
There is no pop-up window on the operators display for limitation when the limitation is done remotely. The operator will see the max pick weight decreased and moment % increase

 

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81K port connection Error – Bad 24V supply and KF2

When the remote shows port connection error it is an indication a Node on the CAN bus is offline.  See (CAN BUS CODES) to access the node tree. 

In this case the KF2 I/O module was bad.

Found the T7 24Volt power supply light was not on. Internal  fuse was blown.

This supply runs the 24V power for the CPU and I/O card.  When the power supply was replaced port connection error was still present. Found that cpu was powered and was registering on the node tree but the rest of the nodes beyond the CPU were offline. 

The start command wasn’t being fed to the F10 safety switch. This command is supplied by the CPU and turns on power to the drives. The electrical Schematic lists +A-Q0 as the main start contactor this is actually contactor +A-K001 in the cabinet.

When the contactor was manually activated the drives would fire up. It was determined the KF2 needed replaced to complete the logic sequence . Once replaced, the remoted connected and the crane started.  

The KF2 is housed along with the KF1. Unbolt the KF1 from the housing  (6- T15 Torx bit screws ) and disconnect the ribbon connector to separate the KF1 from the KF2.

 

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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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81K CAN Bus Codes

E1502 = CPU (=S1+A-KF1)

E1503 = Control Stand Right (=P1+H-S1)

E1504 = ICN_D64 (=S1+A-KF3)

E1505 = Control Stand Left (=P1+DK-S1)

E1506 = ICN_D32 (Manual Mode 125%) (=S1+A-KF4)

E1509 = Radio remote control (=S1+A-KF14)

E1511 = AKS_unigate (Anti Collision) (=S1+A-KF13)

E1513 = EMS Electronic Monitoring System Display (CAB) (=L+A-P0)

E1514 = Display CGM  (=S1 +A -P9)

E1515 = Load Measuring Axle (load Pin) (=F+H-B4)

E1517 = Load Moment Sensor (=A+A-B17)

E1518 = Hook height sensor (=A+H-B5)

E1521 = KAW Sensor Trolley sensor (=C+K-B1)

E1522 = WIW-FC Hoist Frequency Drive (=S1+H-T1)

E1526 = KAW-FC Trolley Frequency Drive (=S1+K-T1)

E1531 = Anemometer (=C+K-B1)

To access CAN Diagnostic  Turn off the power to the crane. Open the panel behind receiver and turn the CAN Diagnostic key to the right. Turn the crane back on and wait for the CAN Bus screen to boot.

Find the node that is causing the error.

Power off the crane, switch the CAN DIAG back to the left, fix the component that isn’t registering.

Any Error 1500-1550 indicates the component is no longer on the Bus.  The CAN bus is not active for some reason it is possible for the error 1514 to be indicated in the Display as the CPU can no longer communicate with the display via the disrupted bus. Even replacing the CGM Display with not correct the problem!