KITO OPERATING AND MAINTENANCE INSTRUCTIONS CONDITION MONITORING UNIT RKT60420150S75GEDO ORIGINAL INSTRUCTIONS 09 February 2022 Document ID: DOCO586074 /1./ en-US ‘Man 9: 0320Internal reference: X727554 en-US / B Contact information Contact the manufacturer's local representative or Konecranes Manufacturing (Jiang Su) Co., Lid No.3, Jiangfang West Road Jingjiang, Jiangsu, China aq OTABLE OF CONTENTS OPERATING AND MAINTENANCE INSTRUCTIONS. Cc TABLE OF CONTENTS 1 7 14 7 1.1.1 How to use this information. 7 4.4.2 Copyright notice. : : 7 1.1.3 Definition of terms. : 7 1.4.4 Symbols used in these instructions. 8 1.1.5 Available technical documents 8 1.2. About this product... 8 1.24 Use of the product. 9 4.22 Conditions of warranty. nn 9 1.2.3 Identification ofthe product... 10 1.24 Standards... 10 128 Directives ar 40 2 HEALTH, SAFETY, AND ENVIRONMENT. 2 24 Safety messages and signals.. C 214 Seal Words 24.2 Hazard symbols. 2.1.3 Mandatory action symbols. 24.4 Prohibited ection symbols. 24.5 — Product safety labels. 2.2 — Responsibilities of the owner.. 2.2.1. Preventing work-related hazards. 7 2.22 — Preventive maintenance... 7 18 2.2.3 Personal protective equioment.. 418 223.1 Fall protection... 7 19 2.2.4 Working in heights... 20 22.5 Incident reporting... 2.3 Conditions of product use. 23.1 Prohibited use... 23.2 Changes to the product. 24 — Emergency sto} 2.5 Main isolation switch. 22 € 26 22 27 23 2.8 Personnel requirements. 24 29 — Environmental information. 24 28.1 Product life-cycle stages. 7 ss 24 2.92 Handling waste material. 7 25 3 PRODUCT DESCRIPTION, 26 BA Technical data. 32 Terminals... 4 at 44 of 42 3 43 32. 32 32 c 44 33. 3166 "Wis abazan ane Tapa one eon ibe mca popary a SWF Won Gr ar opens a ronnl COE wd ema Fa sore Pt alsa cea iboats ches gay oy res wen ae doco ws eee aon CR‘OPERATING AND MAINTENANCE INSTRUCTIONS TABLE OF CONTENTS 4.4.1 Navigation in the menu structure. 33 45 Security and user passwords. 34 4.6.4 Entering a password. 34 5 CONDITION MONITORING ITEMS. seneee 36 5.1. Primary monitoring items. 36 5.11 Starts counter. 36 5.1.2 Running time count a7 5.1.3 Design working period (DWP) counter. 37 5.1.4 Hoisting cycles counter inunnnnnnsnnnn 38 5.1.5 Running time and start counter for alley and bridge... 38 6 DIAGNOSTICS... 38 64 39 62 39 63 Warnings. 42 64 — Measured values.. 4a 7 MAINTENANCE. 7 7A — Safety during maintenance.. 4 7.2 Preparing for maintenance. ry 7.3 Browsing active events... enn 45 7.4 Viewing condition monitoring information. 45 7.5 — Resetting counters. 46 7.8 Checking recent events in the history log. 46 7.7 Finishing maintenance. 47 8 TROUBLESHOOTING. 81 Faults and recovery instructions.. 841.1 F:Control VO 0. 81.2 F:Control V0 1. 8.1.3 F:Control VO 2.. 8.1.4 F:Control VO 4. 8.1.5 F:Control VO 5. @1.6 — F:Cantral UO 6... 81.7 F:Run FB7.. 81.8 F:Control V0 8... . 81.9 FiLoad sensor 15..18 senssnownnrnonrane 8.1.10 F:Calibration 1 8.41.11 F:A10V out 24 8112 FOV out 22. 8.1.13 Filntemal HW 23..... 8.1.14 Flntemal HW 24.26. 8.1.15 Filntemal HW 27...34... 8.1.16 F:ntemal HW 35., 81.17 F:Control VO 37. 8.1.18 F:Multi Hoist 38... 8.1.19 F:CAN 39. 8.1.20 Filnternal HW 40.. 8.1.21. Fiinternal HW 41. 8.1.22 Filnternal HW 42. 8.1.23 Flntemal HW 43. 8.1.24 Flntemal HW 44, : Es 8.1.25 F:CAN45.. 8.1.26 F:Multi TRLY 46. GELTLREB 4188. “hs oman an is epaon oad rah She cae pape of SNF Waco OTOH ea peer plle cra sappy va eos ‘oyreton pecs, dsc othpron veer chew pean ay rater whcsone wen sees We oer SE Hreteso GMD COPE. SMe SiC Yenctauonas hlngas ean‘TABLE OF CONTENTS ot 92 93 94 10 404 10.2 10.3 APPENDIX: FUNCTIONAL SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS 8.1.27 F:TRLY RunFB 47, 56 8.1.28 FICAN 48...rnnnnnnnsnnnnnnnniin 56 81.29 F:Over Speed 4: 57 81.30 F:Speed Diff 50. 37 81.31 FStall 51 37 8.1.32 F:Synchro Pos 52. 37 TRANSPORTATION, STORAGE AND DISMANTLING ‘Transportation of the product. Storing the product... Returning the product to use.. Dismantling the product. PARAMETERS.. Condition monitoring. Intended use... ‘| : Safety data according to EN ISO 13849-1... a i Performance levels of the complete safety functions. 64 Requirements for installation. 1» 85 5168 ‘Tu ceri nib rfc onan ran, bo mune pay TSW Wanaown GAN Sd aes sone Sin anew eae [oyrettevopenn dessa heparne, shew erase enpoyesh ey neh whtvnte ahaa ere wien nar SNF Md GMOH Cy Sedve'snehretecns Gres NsomOPERATING AND MAINTENANCE INSTRUCTIONS TABLE OF CONTENTS. ons See ee ee ee ana TT RT Sahemaueet sean ©INTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS ee 44 Cc 444 NOTE 1.4.3 Cc BOCOSBEGTA INTRODUCTION About this information ‘This information offers guidance to enable safe and efficient operation af the product. ‘Taking the time to read this information helps you to prevent damage to the product, and, most importantly, personnel that are situated close toil. The product is safe when used correctly. However, there are many potentiel hazards thet are associated with incorrect operation and these hazards can be avoided when you know how to recognize and anticipate them. ‘This information also makes you aware of your responsibilities regarding the product and help you to ensure that itis kept in a safe operating condition throughout its lifetime. ‘This information isnot intended as a substitute for proper training but provides recommendations and methods for safe end efficient operation and maintenance. The owner of the product must ensure that operators are propery trained before operation and, aways, comply with all applicable and prevailing safety and other standards, rules, and regulations. How to use this information Every person that is exposed to the equipment ofthe manufacturer must, before operating, servicing and maintaining such products, read and understand the contents of this information and strictly adhere and conform their conduct with and to the information, recommendations, and warnings that are provided inthis document Keep these instructions in a safe, accessible location for future reference by personnel ‘operating the equipment or exposed to the operating equipment. WARNING! IGNORING INSTRUCTIONS HAZARD Failure to follow the given instructions can cause death, serious injury, or property damage. Read and understand this information before operating, servicing, and maintaining the product. ‘The manufacturer makes absolutely no warranty whatsoever regarding the contents of this, document, express or implied, whether arising by operation of law or otherwise, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. Copyright notice ‘This document and the information contained herein, is the exclusive property of SWF Krantechnik GmbH and represents a non-public, confidential and proprietary trade secret that ‘may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner \Whetsoever without the express written consent of SWF Krantechnik GmbH, SWF Krentechnik ‘GmbH © 2022. All rights reserved. Defini All brand names, product names, and trademarks that are used in this manual are registered tracemarks of their respective overs. n of terms: ‘The following terms and definitions may have been used inthis manual: Authorized personnel Persons who the owner authorizes and who have the necessary training to carry out operation or service actions. Calibration ‘A technique to teach the load cell signal to correspond to a certain test load. 7186 Ti Ten US 108 February 2022 ‘Copyright © 2022 SWF Kranlechnik GmbH, All ighs reserved,OPERATING AND MAINTENANCE INSTRUCTIONS INTRODUCTION CE marking The CE matting mdse at product camps wan, the appropriate CE regulations. Condition monitoring Calculation and storage of hoist usage data, DwP Calculated hoisting machinery lifetime that is based either fn the hoist running time or on the number of hoisting cycles. DWPHC% DWP data that is based on hoisting cycles, indicating the effects of cycles and loads on the stee! structure of the hoist. DWPRT% DWP data that is base on running time, indicating the effects of running time and loads on the rotating machinery ‘of the hoist. HIN Hoisting input for a hoist-up request. Hoist ‘A drive mechanism for liting and lowering the load. HouT Hoisting output for a hoist-up contactor. uN Lowering input for @ hoist-down request. Load cell A transducer that is used for creating an electrical signal which magnitude is proportional to the force being measured. Main isolation switch ‘The main isolation switch is the power switch which the service personnel use to turn off the power. Rated capacity ‘The maximum load that the heist is designed to lif Offset correction Offset correction procedure teaches to the condition ‘monitoring unit the voltage level seen in the load call input terminals when there is no load on the hook. Programmable relay A configurable output relay for an additional function, for example, an alarm indication. Qualified personnel A person with the necessary qualifications that are based 6 theoretical and practical knowledge of hoists and cranes, The person must be in a position to assess the safety of the installation regarding the application, Persons with the authority to undertake certain maintenance work on the products of manufacturers include manufacturer service engineers and trained fitters with the corresponding certification. ROUT Programmable relay path. sL3 Hoisting cycle count weighed to power of three of the load. SRT3 Hoist running time weighed to power of three of the load, Strain gauge load cell A load cell based on strain gauge technology. Trolley (for hoisting ‘The hoisting trolley supports the hoisting machinery, and machinery) travels along the main girder or the runway. UKCA marking ‘The UKCA marking indicates that the product complies with the appropriate UKCA regulations, 1.1.4 Symbols used in these instructions Familiarize yourself with the following symbols that are used in this manual. _| Desctiptic ee a Indicates items which require special attention by the reader. There is no obvious risk of injury thet is associated with notes. 8 ‘DOCOEEEGTAT1 Ten US 09 Febuary 2022 Cepyigh © 2022 SWF Krantechnik GmbH, Al igh reservedc ¢ U INTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS. Available technical documents For this equipment, there are technical documents that serve different purposes and audiences. Contact your supplier if you require any of the documents that are listed here. Owner's manual Describes the responsibilties of the owner Includes the functionality, usage, and maintenance of the product. Cortificates Describes that the equipment isin conformity with directives ‘and manufactured according to standards. Also shows testing resuts. ‘Store documents in a safe, dry place where they can be easily located when required. About this product Use of the product ‘The condition monitoring unit is a programmable electronic device for the control and protection of hoist, and for the calculation of the basic condition monitoring values of the hoist. ‘The caleulated condition monitoring values can be read from the control panel display. The parameter settings and callbration of the device are also done by using the control panel, Conditions of warranty ‘The terms under which seller's equipment andlor services are warranted are defined pursuant to the warranty set forth in the contract between seller and customer for seller's products andior services and, if not so set forth, the warranty for seller’s products and/or services is seller's standard warranty In effect at the time of sale, @ copy of which Is available from seller upon request. THE FOREGOING REPRESENTS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY SELLER AND IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A. PARTICULAR PURPOSE, Seller provides no warranties for products manufactured or services provided by parties other than seller (Third Party Products"). Modifying any seller product or incorporating any Third Party Product into any seller product or service without the seller's approval invalidates ‘warranty. Seller does not accept, shall nat have any responsibilty and disclaims any liability for ‘accidents, injury or physical or property damage arising as a consequence of such unauthorized ‘modifications andfor incorporation of Third Party Products, Further, e.g. each ofthe following invalidates any warranty of seller and relieves seller from any responsibilty and liability for accidents, injury or physical or property damage: falure to operate and/or maintain products in accordance with the applicable manuals, instructions, guides, recommendations etc., regardless oftheir form, concerning the maintenance and operation of products that may be communicated from time to time; side-pulling of load; shock loading; excessive jogging; eccentric loading; overloading; accidental occurrence; improper repair, improper handling or storage of products; chemical exposure; abnormel operating conditions not identified to seer in writing prior to selle’s issuance of a quotalion; or any other cause that in seller's sole discretion is not attributable to defects in material and workmanship. The applicable manuals, instructions, guidelines, recommendations etc. may include, for example, Installation and Commissioning Instructions, Owner's Manuals, Operators Manuals, Operating ‘and Maintenance Instructions, User's Guides, UNLESS OTHERWISE REQUIRED BY MANDATORY LAW, SELLER DISCLAIMS ALL WARRANTIES RELATING TO THE CONTENTS OF THIS DOCUMENT, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE, 9166 ‘DOCOSBEOTA 71 en US/09 February 2022 ‘Copyright® 2022 SWF Krantachnik GmbH. All ights reservedOPERATING AND MAINTENANCE INSTRUCTIONS. INTRODUCTION 1.2.3 Identification of the product Nore Example data in the figure is shown for illustration purposes only and does not necessarily match the data on your product. { ee (4 )—-L sepa vonage: 48-220 vac, 60602 | Power consumption: 7A G) (55) [eorictaiage -290\R0, 660 He | Plo coc 80 VAC NA -@ jo: AOU Seco TIMTL IM —4—@) 55203561 €6900005, Gyre ce Tested See ee ey 41, IP class and certifications 6. Relay contact data 2. Product identifier 7. Serial numiver (year (two digits), week (two 3. Control voltage digits), running number (five digits) 4. Supply voltage 8. Tested 5. Power consumption 1.2.4 Standards EN 60204-92 Safety of machinery - Electrical equipment of machines - Part 22: Requirements for hoisting machines EN 60947-4 Low-voltage switchgear and control gear Part 1: General rules EN 61000-6-2 Electromagnetic compatibility (EMC) - Pert 6-2: Generic standards Immunity for industrial environments EN 61000-6-4 Electromagnetic compatiblity (EMC) - Part 6-4: Generic standards = Emission standard for industrial environments EN 14492-2 Cranes - Power driven winches and hoists - Part 2: Power driven hoists EN 42077-2 ‘Cranes safely - Requirements for health and safety - Part 2: Limiting and indicating devices EN ISO 13849-1 ‘Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design EN 62061 ‘Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic control systems EN 61508 Functional safety of electrical/electronic/programmable electronic safety-related systems - All Parts, 1.2.5 Directives and marks for specific countries This product complies with one or more of the following requirements and directives that are described in this section. For more information about which requirements the product meets, see the main sticker that is attached to the device. 0166 ‘DOCOBEEATAT 1 Ten US 109 February 2022 ‘Copyright ©2022 SW Krantechnik GmbH, Al ights reserved, Cc XXCc ALINTRODUCTION OPERATING AND MAINTENANCE INSTRUCTIONS. cE ‘The CE marking certifies that a product has met EU heatth, safety, and environmental requirements, which ensure consumer safety. “The CSA marking means that a product has bean tested and meets applicable standards for safety and/or performance, including the applicable standards written ‘or administered by the American National Standards Insttute (ANSI), Underwriters Laboretories (UL), Canadian Standards Association (CSA), National Sanitation Foundation (NSF), and others. UL ‘The UL marking means that Underwriters Laboratories (UL) has tested representative samples of the product and determined that they mest UL's requirements. These requirements are based primarily on UL's published and nationally recognized Standards for Safety. cece ‘The China Compulsory Certificate mark, commonly known as the CCC Mark, is a compulsory safety mark for various products that are sold on the Chinese market. ‘The CCC mark is required for both domestically manufactured products and products that are imported into China, UKCA ‘The UKCA marking certifies that a product has met UK health, safety, and environmental requirements, which ensure consumer safety. RoHS. ‘The RoHS marking means that 2 product complies with the directive for the restriction of the use of certain hazardous substences in electrical and electronic, ‘equipment. WEEE ‘The WEEE indicates that the product should be disposed of according to the WEEE directive regulations. ‘The condition monitoring unit carries the CE label as a proof of compliance with the Low Voltage Directive (LVD) and the Electro Magnetic Compatlbilly (EMC), 1166 ‘DOCOSBSG7A 71 en-US/09 February 2022 Copyright® 2022 SWF Krantechnk GmbH, Al igs reserved,‘OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY, AND ENVIRONMENT 2 HEALTH, SAFETY, AND ENVIRONMENT 24 Safety messages and signals 24.4 — Signal words ‘The following signal words and symbols are used to identily safety messages in thase instructions, An Indicates an imminently hazardous situation that, if not avoided, will cause deeth or serious injury, Indicates a potentially hazardous situation thet, if not avoided, can ceuse death or serious injury. NOTICE Indicates a potentially hazardous situation that, if not avoided, can cause damage to property or environment 2.1.2 Hazard symbols Hazard symbols are used to indicate the type of the hazard and the potential consequences. Hazard symbols are indicated by a yellow triangle with black symbols and a black triangle band that is surrounded by a yellow border. All personnel working on or in proximity of the machine rust understand and follow the information that is given in all hazard symbols. General hazard symbol AN The general hazard symbol identifies important safety messages in these instructions. When ‘you see this symbol, carefully read and understand the message that follows, and inform other Users when necessary. 216 ‘DOCOSBEOTA7 7 ends 109 Febnvary 2022 ‘Copyright® 2022 SNF Krantechnk GribH, Al ights resend,2 HEALTH, SAFETY, AND ENVIRONMENT ‘OPERATING AND MAINTENANCE INSTRUCTIONS C Mechanical hazard symbols e > > Foot crushing hazard Hand crushing hazard Cutting hazard Entanglement hazard /y EN Ash Falling load hazard Hand entanglement Falling objects hazard Forward or backward hazard tipping hazard A Bb > > 3 c [i > Flying objects hazard Flying objects to face Run over hazard Moving vehicle = sie A EX LX Lr te AN tN te Se TE face hazerd hazard Automated startup Conveyor rail hazard Crushing hazard Hanging load hazard C hazard /N Skin injection hazard Tripping hazard > > Electrical hazard symbols Electrical hazard Overhead power line hazard Cc 366 ‘DOCOEQG7AT en-US 09 February 2022 Copyright® 2022 SWF Keatachik Gre Aight eservedOPERATING AND MAINTENANCE INSTRUCTIONS. 2 HEALTH, SAFETY, AND ENVIRONMENT Material hazard symbols C A Battery leakage “Explosion hazard Environment pollution Harmful substance hazard hazard hazard A A High pressure hazard Ignition hazard ——-Oxidizing substance —_—Preseurized gas > hazard hazard /. /\ C SD) fan Hazardous or Explosive Biohazard Corrosive chemical poisonous material atmosphere hazard Substance hazard hazard. ‘Hot liquid hazard ‘Thermal hazard symbols ; Hot surface hazard Slippery when frozen hezard Noise hazard symbols (\ Noise hazard ares ‘DOCOEBEQ7#7 7 TenS/ 09 Febriany 2022 Conyright® 2022 SWF Kranteohnik GmbH, Al ights reserved.2 HEALTH, SAFETY, AND ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS Cc Radiation hazard symbols Radioactive hazard Laser hazard Light hazard Strong magnetic flekd hazard Ergonomic hazard symbols Lifting hazard Cc 48168 "DOCO58GO74 1 en-US 709 Februmry 2022 ‘Copyright © 2022 SWF Krantechaik GmbH. Al ight reserved.‘OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY, AND ENVIRONMENT 2.4.3 Mandatory action symbols Mandatory action symbols specify actions to be taken to avoid a hazard. Mandatory actions are indicated by white symbols on a blue background. All personne! working on or in proximity of the machine must understand and follow the information that is given in all mandatory action symbols. Se @ 2 Wear approved safety _ Wear approved Wear pproved Wear approved safety gloves hearing protectors _protective clothing shoes °@ © © Wear approved safety Wear approved hard Wear approved high Wear approved eye hamess hat visibilty clothing protector o Disconnect ‘Apply indicator for Use jack Alarm hom equipment from in-hole leak test power source ‘Switch off and lock- Two persons for Use wakway ‘Wash hands out equipment handling Read manual Wear approved Use seat belt respirator oo C ‘Conyright ©2022 SWF Krantachnk GmbH. Al ights reserved, ‘DOCOBSEOTAT 1 Fen US 708 February 2022C Cc 2 HEALTH, SAFETY, AND ENVIRONMENT 241.4 241.5 NOTE 2.2 2.24 (OPERATING AND MAINTENANCE INSTRUCTIONS: Prohibited action symbols Prohibited action symbols indicate actions that are prohibited in order to avoid a hazard. Prohibited actions are indicated by a red circle with a red diagonal line across the circle. The action that is prohibited is always in black. All personnel working on or in proximity of the ‘machine must understand and follow the information that is given in all prohibited action symbols. OQ @®@ ® ® General prohibition Access prohibited Do not climb Do not remove guard Do nat smoke Donot modify Donottestforleak Do not touch with hands Pacemaker not Do not weld No opan tre Restrict access allowed Product safety labels ‘The product safety labels communicate the following + Level of risk that is based on the signal word Danger, Warning, or Notice + Type of hazard, such as cutting parts, hanging load, hot surface, live parts + Consequence cf hazard, such a8 cutting, injection, crushing, bum, electric shock + Hove to avoid the hazard Always keep safety labels visible. Check the condition of safety labels daily. Before operating the machine, replace safety labels and instructions that are damaged, have come loose, or that do not meet the legibility requirements for safe viewing distance. Responsibilities of the owner Preventing work-related hazards ‘The owner of the product must ensure that the operators have a sufficient knowledge of the woricrelated hazards and of the ways to avoid the hazards. ‘The operator must always perform a locat risk assessment before every work phase or shift. The assessment ensures that the operator stops and thinks about what to do before stating to ‘work + Identify potential hazards that could affect you, your colleagues, the environment, your product, or work method while you are performing the task + Assess the risks and implement the actions that are needed to eliminate or reduce the risks 176 ‘DOCOSBEITA 7 1 /enUS/09 February 2022 ‘Copyright® 2022 SWF Krantecmik GmbH, Al ighis reserved.OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY, AND ENVIRONMENT 2.2.2 /\ ‘Only competent persons are allowed to carry out operation and other tasks. The responsibilty of the owner is to: + Provide training and orientation + Validate training methods + Verify competence and skills + Monitor and evaluate user performance regularly Preventive maintenance ‘Scheduled inspections and preventive maintenance are essential for keeping the product in ssale working condition, Here are some general guidelines for preventive maintenance. + Itis the product owner's responsibility to organize proper regular inspections maintenance to ensure long-term safely, reliabilly, durebilly, operability, and warranty for the product. + Owner must keep a record (log book) of all maintenance activities and usage relating to the product + Different maintenance actions must be carried out at different intervals and by different persons who are qualified and authorized to perform these checks. + Daily checks and minor lubrication must be carried out by operators or maintenance personnel. These checks are important for catching small faults before they become major faults. + Maintenance actions, excluding the daily actions that are performed by operators, must be done by service personnel who are authorized by the owner of the product, + Owner shall ensure that replacement parts and materials meet the specifications that are defined by the product manufacturer. + Keep this information in a safe, accessible location during the whole lifetime of the product. WARNING! MACHINE MALFUNCTION HAZARD Failure to regularly and properly maintain the product can cause death, serious injury, oF property damage. Do not allow the product to be used if itis not in proper condition or if it has not been maintained correctly. Contact a service agent that is authorized by the manufacturer or manufacturer's representative immediately in case of doubt. RISK OF PROPERTY DAMAGE. PWehilatay Only use genuine spare parts, materials, and lubricants that are approved by the 2.2.3 NOTE product manufacturer ar manufacturer's representative. Far mare information, see the Product spare part catalog. Personal protective equipment This section proposes personal protective equipment to ensure the operator's safety. Follow the local regulations and requirements of the working environment. Use only approved and accepted personal protective equipment. For safety, the operator or others near the product are required to wear personal protective ‘equipment (PPE). Various types of PPE are available as isted below and must be selected ‘according to the requirements of the working environment. + Hard hat + Eye-protector + Hearing protectors + Safety shoes + Respirator + Safety gloves ‘DOCOSSSI747 4 /en US 08 February 2022 ‘Copyright ©2022 SWF Krantechnik Gib, Al ights reserved,C Cc 2 HEALTH, SAFETY, AND ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS. 2.2.3.1 + Protective clothing + Safety hamess when working at heights + High-visibilty clothing Do not weer loose clothing or jewelry that can get caught on controls or pulled into moving parts of the product Tie back long hair, Long hair can get entangled. Select the appropriate clothing for each task, for example: + Wear fire-resistant clothing when welding, flame cutting, or using an angle grinder + Tear-resistant clothing must resist damage from sharp edges in the steel structure + Wear anti-static clothing when working on electrical circuits so that components do not get damaged by a discharge of static electricity + When working with lubricants, clothing must prevent direct skin contact with the lubricant + Choose the clothing with consideration to the temperature at the working site + For work on explosion-proof products, clothing and equipment must be suitable for the hazardous area. Fall protection ‘While personnel are doing installation, inspection, or maintenance work at heights, they must {ollow fall protection procedures as required by local regulations. Fall prevention practices and fall protection equipment aim at protecting personnel working on or around the equipment from exposure to falls. IF the equipment does not have a service platform or guardrail, personnel must use a properly fitted safety harness. The safety harness is attached to the dedicated fixing points on a building ‘or equipment in order to prevent falls. Ifthe product does not have dedicated fixing points for fall protection, itis the owner's responsibility to make sure that suitable and secure fixing points are available or provide an ‘appropriate manlift, If ladders must be used, personnel must practice setting and securing the ladders before using them for actual work, Fall protection system has four components: + Safety harness: Safety hamess helps to prevent employees to get hurtin a fall. + Lanyard belt: Lanyard belt is connected fa the anchar point and is attached to the safety hamess. Lanyard belts are shock absorbing, which means that they slow down and eventually stop a fall + Snap hook: Snep hooks connect the D-ring to the safety harness. Snap hooks must be double locking. The basic rule is: connect only one snap hook to one D-ring + Anchorage point: Anchorage point is the point fo which personal fall protection equipment is attached, The point must be capable of supporting at least 2.268 kg (5,000 Ib) per employee. Ifthere is any doubt about the strength of the attachment point, find an alternative point that ‘can support the worker, Atypical fall protection program may include: + Documented and established site policies and procedures + Conducting site assessments for fall hazards + Selection of the proper fall protection system and equipment + Training on fall protection procedures end the proper use of fall protection systems + Inspection and proper maintenance of fall protection equipment + Measures to prevent falling objects + Rescue plans necessary, contact your supplier or service organization for assistance with designing your fall protection program. 9166 ‘DOCOSBEI7A T+ Ven-IS 709 February 2022 ‘Copyright® 2022 SWF Krantochnik GribH. All ights reserved‘OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY, AND ENVIRONMENT 2.2.4 2.2.5 2.3 2.3.4 AN 2.3.2 Working in heights Maintenance and inspection work, repairs and on call services at heights must be carried out in ‘a safe working environment. If the equipment does not have a service platform, all control points for maintenance must be ‘accessed in a safe manner by using aerial work platforms. WARNING! FALLING HAZARD Lifting personnel with an aerial work platform includes a risk of falling from heights, which can cause death or serious personal injury. Each person on the aerial work platform must always wear a safety harness and be attached to the platform. The following requirements and safety precautions must be observed when using an aerial work platform: + All control points for maintenance must be safely reached from the aerial work platform. + The service area must be free of obstacas and suitable for the use of the aerial work platform, + The operating and safety instructions for the aerial work platform must be followed. + The fall protection procedures must be followed, + Unintended movements of the equipment must be prevented by necessary means, for example, by using lockout-tagout-tryout procedures. Incident reporting Product safety issues that you must report are events in which the manufacturer's product has been involved in an accident or near-miss incident. Contact your local manufacturer's, representative immediately to report any safety-related feedback, such as unauthorized ‘modifications, missing instructions and safety labels, neglected maintenance, or misuse. Reporting is mandatory to ensure safe working conditions for employees, to provide Information for the risk assessment process, and to initiate product and work procedure improvements. Conditions of product use Prohibited use WARNING! PRODUCT MALFUNCTION HAZARD Using the product outside the limits of its duty class or operating conditions could ‘cause malfunction of the product and could lead to death, severe injury, or property damage. Do not use the product outside the limits of its duty class or operating conditions. In case of doubt, contact the manufacturer or the manufacturer's representative. Changes to the product MACHINE MALFUNCTION HAZARD Unauthorized changes or modifications to the product could lead to death, severe injury or property damage. Always contact the manufacturer to get advance written approval for any product change or modification. 20166 DOCOSBEOTA 71 /en-US/ 09 February 2022 (Copyright® 2022 SWF Krantechnik GmbH, Allrights reserved.Ce 2 HEALTH, SAFETY, AND ENVIRONMENT 24 OPERATING AND MAINTENANCE INSTRUCTIONS All modifications and corrections not authorized in the product manuals or which may affect the maintenance, operation, safety, and availability of the product need to be approved in writing by the manufacturer before implementation. Approval requires risk assessment taking into consideration any new risks that the changes and modifications may bring, Changes and modifications without proper risk assessment, elimination or reduction of risk and \without appropriate sefety measures may lead to death, serious personel injuries or damage to property or environment. Unauthorized modifications will also void the warranty, If a modification or correction as described above has been implemented without the manufacturer's permission, its effect on warranty liabilty will be considered case-by-case. Thus, the warranty application may be rejected altogether. Should you consider a modification or alteration necessary, you must contact the organization that manufactured and designed the product. No modification is permitted unless you first obtain the written approval of the manufacturer, Emergency stop NOTE UNCONTROLLED MOVEMENT HAZARD Using the emergency stop can cause the machine to move or operate In an uncontrolled manner. This can cause death, serious injury, or property damage. Only use the emergency stop button in an emergency situation, In case of machine malfunction o other emergency situations, you can stop ell motions immediately by pressing the red emergency stop button. in normal operation, do not use the ‘emergency stop button. Instead, use the direction controls. Routinely using the emergency stop button increases wear on the product. Do not operate the machine unless you know the location of the emergency stop button. ‘There are two main types of emergency stop buttons: + Emergency stop button with a twist-release mechanism which latches in the activated position + Emergency stop button with 2 push-pull mechanism which remains pushed in To reset the latching type of an emergency stop button, twist the button in the direction of an arrow in the mushroom head. The rotating movement releases the latch and allows the button ‘a spring aut to the normal reset position. Ss Carre Figure 1. Emergency stop button with twist-release mechanism “To reset the push-pull type of emergency stop button (without a rotalion arrow on the button, head), pull the button manually outwards to the normal reset position. Figure 2. Emergency stop buiton with push-pull mechanism 21166 ‘DOCOSE6074 7 11 en-US 109 February 2022 Copyright© 2022 SWF Krantechaik GmbH, All ighs esened,OPERATING AND MAINTENANCE INSTRUCTIONS 2 HEALTH, SAFETY, AND ENVIRONMENT Restarting the machine and the operation controls is possible only after the emergency stop Cc button has been reset to the normal reset position. 25 Main isolation switch You can only operate the product when power is turned on. The owner must identify and document the location and function of the main isolation switch and communicate this Information to all operators. NOTE — Do not operate the product unless you know the location of the main isolation switch. WARNING! ELECTRIC SHOCK HAZARD Even though one switch is turned off, there may still be voltage present in some parts of the product. This could result in exposure to electric shocks, which could [ead to death or serious injury. Be aware of the main isolation switch functionality. WARNING! SWINGING LOAD HAZARD. ‘Turning off the main isolation switch causes sudden loss of power. The sudden loss of ‘ Power could cause the load to swing, which could lead to death, serious injury, or C damage to the product or load. Avoid turning off the main isolation switch during load movement. 2.6 Lockout-tagout-tryout procedure Before installation, inspection, and maintenance, the power sources must be de-energized, isolated, locked out, and tagged out, Lockout-tagout-tryout procedures are primarily intended to protect personnel by preventing accidental starting of the machinery or exposure to electric shocks. Follow the lockout-tagouttryout procedures in accordance with the local regulations and the documented site fockout-tagout-tryout policy. The owner must ensure that the operators are fully aware of the applicable lockout-tagout-tryout practices. ‘The following items are normally included in the documented lockout-tagouttryout policy: + Communication requirements: who to inform before using lockout-tagout + When the use of lockout-iagout is permitted + Identification of each of the switches, controls, valves, and other energy isolating devices present al the site, Role of each device should also be explained. + Lockout tagout sequences to be followed before, during, and after maintenance + Safely and operational considerations regarding other products on the same runway or on adjacent runways STORED ENERGY HAZARD. When the product is switched off, there may still be stored energy in the electrical, hydraulic, or pneumatic systems, rotating parts, linearly moving parts, or in the load. Unintended release of energy can cause death, serious injury, or property damage. Prevent the unintended release of energy by following the approved lockout-tagout- ‘tryout procedures. 22186 ‘DOCOESEOT#7 1 Ter-US/ 09 February 2022 ‘Copyright® 2022 SWF Kranlechnk GmbH, All ights reserved,2 HEALTH, SAFETY, AND ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS MACHINE MALFUNCTION HAZARD Operating the product while it is under installation or maintenance can cause death, serious injury, of property damage. Never attempt to operate a control, switch, valve, or other device when it is locked out ‘or tagged out. To lock out, tag out, and try out the product: ‘Tum off the product and disconnect power. Place @ personal lock and tag on controls to prevent their use until you remove the lock. ‘While performing the work, always keep the key to the lock with you. If more than one person locks out the same machine, use individual locks and approved mult-lock devices. Verify the absence of voltage with approved voltage test equipment. Verify the isolation of other forms of energy with an approved method. 7. Attempt to operate the product using normal controls. If properly isolated or immobilized, ie no equipment or system starts nor any part activates or moves, 8. Release energy (pneumatic or hydraulic pressure or other stored energy) that may cause danger during the work in a safe way. 9. After completing the work, remove all locks and tags. Rene oe 2.7 Fire safety Ignition sources like smoking, open flames, welding work, and sparks, together with combustible materials, such as fuel, can cause fire and, if not avoided, can cause death ocean, Ignition sources are prohibited near the machine, During maintenance, follow appropriate fire prevention and protection measures, ‘including but not limited to trained personnel, proper fire extinguishing equipment, and agents, Before starting any maintenance or repairs that require ignition sources, such as. Cc casing craame ing! cory ots eperiet sosessssrts comral ie fai + Smoking and open fire are prohibited near the product. + Access to all fire-fighting equipment must be granted at all times, especially during maintenance and repair works. All fire-fighting equipment must be inspected and serviced regularly, according to local regulations, Damaged firesighting equipment and used fire extinguishers must be replaced immediately. Know the various types of fires and the appropriate fire-fighting methods, Various fires must not be extinguished with water. In most eases special extinguishing agents, dry powders or deoxygenating agents are required, Al personnel must be trained regulary in fire-fighting methods, in cooperation with focal authorities and rescue organizations. If there is a fire, the fire alarm must be activated and all available personne! must help with fire-fighting according to the predetermined fire plan of the workplace, For explosion-proof products, the owner decides whether work can be performed safely. Usually the owner issues a specific work permit, that is required for welding and ther spark- ‘emitting work that causes dangers to arise. The permit epplies also to associated tools such as electric drs, © se ‘DOGOSSEGTA 7 1 /enUS/ 00 February 2022 ‘Copyright ©2022 SWF Krantectonk Gr, Al ights reserved,OPERATING AND MAINTENANCE INSTRUCTIONS. 2 HEALTH, SAFETY, AND ENVIRONMENT 28 Personnel requirements C |SPECIALIST SKILLS REQUIRED JN Incompetent operation and maintenance procedures can cause death or serious injury. ‘Operation and maintenance procedures require professional skills and special training regarding the tasks and working methods. Do not operate the machine or do any maintenance tasks without proper training. Always follow the instructions, Use appropriate personal protective equipment, depending on the task. ‘To avoid hazardous situations and dangerous consequences, leave all operation and maintenance work to professionals, Tasks mentioned here below are examples of tasks which. ate allowed only for trained personnel, More details on the risks related to the tasks and instructions for carrying out these tasks safely can be found in the chapters where the procedures are instructed. Tasks that require special technical skills and training include, but are nt limited to: C 1. Hydraulic system maintenance 2. Pheumatic system maintenance 3. Electric system maintenance 4. Battery maintenance 5. Tire maintenance 29 Environmental information Environmental impacts have been taken into account in designing and manufacturing this product. To prevent environmental risks curing use, follow the instructions and local regulations for disposal of waste material. Proper use and maintenance improve the environmental performance ofthis product. 2.9.1 Product life-cycle stages Product life-cycle stages include: + Production of materials and components + Equipment manufacturing and assembly + Use phase, including maintenance and modernization C + Dismanting and recycling of waste materials, + Deliveries between each stage Figure 3, Product Ife-cycle stages Cc 24166 'DOGOSBSO7#7 4 en-US 09 February 2022 ‘Copyright ©2022 SWF Krantachnk GmbH. All ighs reserved,2 HEALTH, SAFETY, AND ENVIRONMENT OPERATING AND MAINTENANCE INSTRUCTIONS. 2.9.2 Handling waste material Handle and dispose of the waste material from installation, maintenance, or dismanting according to local regulations. From the sustainability point of view, the preferred waste handling methods are reuse, recycle as material, energy recovery and, as a final resort, safe disposal. ‘As waste regulations and types of recovery and disposal methods vary regionally, no common, detailed guidance can be given. The following list provides proposals for adequate waste handling methods. NOTE Always use licensed recycling companies. Table 1. Waste handling methods ‘Material jastohanding method Metals Recycle the metals. Electronics and iG elecvomeshenical components ‘Some electrical parts may be treated as hazardous waste. Collect and recycle the electronics and electromechanical components, separately, Batteries Batieries and other energy storage components may contain hazardous substances. Collect these items separately and recycle according to local regulations. Plastics Recycle plastic as material, use it for energy recovery, or deliver it to a landiil site, ‘Chemicals: ‘Never spill chemicals, such as oll, grease, and other liquids, onto the ‘ground, soil, or sewage. Store waste oll and grease in containers that {are indicated for the purpose. More detailed information on chemical handling as waste can be found in the chemical's safety data sheet that is available from the manufacturer of the chemical, Packing materials Cc Reuse or recycle packing materials, such 2s plastics, woad, and cardboard. Rubber Recycle rubber according to local regulations. ‘Whenever possible, return the used rubber ties to the tire supplier for recycling. Cc ‘DOG0686074 11 Fen US) 08 February 2022 25168 ‘Copyright® 2022 SWF Kraniechnk GmbH, All ighis reserved,‘OPERATING AND MAINTENANCE INSTRUCTIONS 3 PRODUCT DESCRIPTION 3 PRODUCT DESCRIPTION C ‘The congition monitoring unit is an electronic device that is designed to supervise and protect the hoist. It monitors the use of the hoist and prevents lifting or lowering in @ potentially ‘dangerous situation. The condition monitoring unit also records the use of the hoist and calculates the remaining design working period (DWP) according to FEM and ISO standards. ‘The condition monitoring unit is designed to ft a wide variety of hoists and motor drives. It can bbe used with both variable speed control drives and two-speed drives. It contains hardware and software that are especially designed for crane use. With the display, the unit can be programmed and calibrated, and stored values can be read. 1 Contains display, push buttons, and LED lights, 2 | Green LED light _ | indication of OX and running state 3 [Red LED light | Indication of waming and fault 4 | Connector x1 | Terminals 1-18 for AC power signals (high voltage) 5. | DIP selector Selector switch 1 for CAN termination resistor switches Selector switch 2 not in use 6 [Ethernet port | For example, for PC software (optional), modem, or PLC system 7 | Connector x2 _| Terminals 19 -36 for DC measurement signals (low voltage) 26166 'DOCOSBSO7#7 1 /enUS/ 08 February 2022 ‘Copyright ©2022 SWF Kranteohnik GribH, All igh reserved,3 PRODUCT DESCRIPTION 3.4 Technical data ‘OPERATING AND MAINTENANCE INSTRUCTIONS Figure 5. Dimensions of the condition monitoring unit Supply voltage range ‘48-230 VAC 410% 50/60 Hz Control voltage range 48-230 VAC #10% 50/60 Hz Power consumption 7A ‘Safe operating temperature range -20°C..A60°C-4°F..+140°F Storage temperature -40°C...480°C-40°F,..176"F Humidity (0%-80% RH, no condensation Lifetime Minimum 10 years at operating temperature Vibration EN 6068-26 ‘3mm at 2-9 Hz, 0.5.9 ato 200 He ‘Shock EN 60088-2-27 109-11 ms Degrees of protection IP code EN 60529 (P20 EMC. EN 61000-6-2 Immunity for industrial environment EN 61000-6-4 Emission for industrial environment 10-VDC supply for load cell and amplifier 10 VDC #3%, Imax=80 mA ‘Two analog inputs for load signal (0-10 VDC, >150 ka 42-VDC output for encoder 11-15 VDC, Imax=50 mA (galvanic isolated) ‘DOCOBREO7ET 1 en-US 108 February 2022 27168 ‘Copyright © 2022 SWF Krantechnik GmbH. Al ights reserved.‘OPERATING AND MAINTENANCE INSTRUCTIONS 3 PRODUCT DESCRIPTION Encoder input Max 10 kHz, ‘Two temperature sensor inputs Bismetal & PTC (tip 36 KO, reset 1.8 KO) and NTC (30 kA at 25°C or 32,762 kA at 25°C) Analog output 0-10 VDC, Rmin=1 ko CAN ‘CANopen (galvanic isolated) Ethemet 100BASE-TX Relay output rating (HOUT, LOUT, FOUT) [230 VAC 2A Relay output rating (ROUT1, ROUT2) 230VAC 1A Dimensions: Height (H) 472in. With (W) arin. Depth (D) 4280. Conductor diameter 0.2-2.5 mm?, AWG 2412 Stripping length 0.39 in, Connection terminal ‘Spring connection with push wire feature 3.2 Terminals [Beséription — E ua + fo ‘Supply voltage for condition monitoring unit, line 2 [oN ‘Supply voltage for condition monitaring unit, neutral or ‘Supply for MF1O_1, MFIO_2 and MFIO_3 relay outputs 4 | MFI6 (HIN) Hoisting request 20168 ‘DOCOEESOTA 1 en-US 109 February 2002, Copyright ©2022 SWF Krantechnkk GmbH. All rights reserved‘3 PRODUCT DESCRIPTION OPERATING AND MAINTENANCE INSTRUCTIONS Table 2. Connector X1 terminals (Continued) [ Teaninal’ | Name = [Besctation ee Provides the control voltage to hoist up contactor 5 | MFIC_1 (HOUT) {two-step control), hoist up request (frequency Converter) or operates as TDU slowdown limit input 6 [MFI (LIN) Lowering request Provides the control vollage to lower down contactor 7 |MFI0_2 (LouT) {(wo-step control), lower down request (frequency Converter) or operates as TDU slowdown limit input. | MFIB (FIN) Fast speed request or run feedback Provides the control voltage to fast speed contactor 9 |MFIo_s (FouT) {two-step control) or fast stop control (stop limit or fault in frequency converter. 10 [RIN Supply for relay output MFIO_4 1 [MFIO_4 (ROUT) Reley output 1 (orogrammable) 12 [RIN2 Supply for relay output MFIO_5 13 | MFIO_5 (ROUT2) Relay output 2 (programmable) 14‘ Melt “Multfunction input 1 (progremmable) 15 | MFI2 Multifunction input 2 (progremmable) 16 | MFIs “Multifunction input 8 (programmable) 7 MFI4 Multifunction input 4 (programmable) 18 [MFIs Multifunction input 6 (programmable) Table 3. Connector X2 terminals [Terminal | 19 20 Thermistor input 1 a [TP 22 | TP2+ ‘Thermistor input 2 23 | TP. 24 [vst Load cell supply, 10 VDC 25 [GND Load cel! supply, OV. 26 [ANI ‘Analog input 1 27 AIN2 ‘Analog input 2 28 |AOUT ‘Analog output 29 [GND ‘Analog output, ground 30 | ENC_vs 12. VDC for encoder 31 [ENC_GND (0V for encoder ‘DOCOSBEGTA 17 en-US 09 February 2022 729966 Copyrign © 2022 SW Krartechnk GmbH. Agha reserved‘OPERATING AND MAINTENANCE INSTRUCTIONS 8 PRODUCT DESCRIPTION Table 3. Connector X2 terminals (Continued) Terminal | Name _ |Description: 32 JENCA Encoder, input A 33 [ENC Encoder, input B 34 | CANH CAN bus, high 35 [CANL CAN bus, low 36 | CAN_GND CAN bus, neutral ores 'DOCOSS60747 7 Fen-US 109 Febroary 2022, Copyright® 2022 SWF Krenlechnik GmbH. All ights reserved, C4USER INTERFACE C4 OPERATING AND MAINTENANCE INSTRUCTIONS: USER INTERFACE 44 Control panel ‘The condition monitoring unit hes an integrated control panel which consists of the following items, + Display + Four push buttons «ESC «= ¥ (DOWN) + a UP) < ENT + Two status LED lights (red and green) 4. Red LED light 5, DOWN button 2. Green LED light 6. UP button 3. Display 7. ENT button 4, ESC button 42 LED lights ‘The condition monitoring unit has two status LED lights (red and green) in the top-left comer of the control panel. The status of the device and the corresponding condition of each LED (ON, OFF, or blinking) are listed in the following table. vice statu GreenkeED q Power on oN Power on, hoist running Blinking ‘Alarm or warning active oN Blinking Fault active ON ON Power off OFF OFF 6 DOCOEREOTAT 17 eS 708 February 2022 ‘Copyright © 2022 SWF Kraniechnik GmbH. Al ights reseed.‘OPERATING AND MAINTENANCE INSTRUCTIONS AUSER INTERFACE ‘When a condition monitoring value exceeds the design value, an alarm or warning is raised. Running the hoist is possible, but safe operation cannot be guaranteed. ‘A aultis triggered when one (or more) of the supervised safety feature values exceeds the limit. Running the hoist is restricted. For RUN or fault supervision, itis possible to connect an external indication device such NOTE asan alarm horn or lamp to elther relay output. The relay output must be programmed as function Ready. 43 Display information 4.3.1 Menu mode Pressing the ENT button shifts the display into the menu mode. A password is required to proceed, Pressing the ESC button retums the display to the home screen, 4.3.2 Status mode {In addition to the actual load information, the display on the condition monitoring unit can also show various messages. These messages indicate, for example, alarms, warnings, and actions needed, Power-on indication \When the condition monitoring unit is powered up, and the hoist is running, the display shows the actual load in tons. 3.0t - the display shows the Hoisting works load of the solo hoist. I here are more than normally, ‘one hoists (mult-hoisting), the display shows the sum load of al the hoists in the crane. Ifthere is only one hoi This display is also called home screen, which you see first when you power on the device, NOTE A non-calibrated condition monitoring unit may prevent hoisting upward Display message ‘Alarm message Hoisting is ied ‘The letter A denotes an alarm, and is followed 1O.9t [Preven by the alarm name, A: Overload ‘The condition monitoring unit indicates an alarm below the actual load on the display. The alarm is shown immediately when an alarm situation occurs. The alarm disappears from the display when the situation returns to normal. 22166 ‘DOCOSEEOTA 1 /encUS 08 February 2022 ‘Copyright © 2022 SWF Krantechnik GmbH. ll igh reserved,4 USER INTERFACE OPERATING AND MAINTENANCE INSTRUCTIONS Description laa Displaymessage [Hoisting oe Eee _| operations. Fault message Hoisting is +0.20t prevented. F:Load sensor 18 ‘The letter F denotes a fault, and is followed by the fault name or its code. The condition monitoring unit indicates 2 fault by showing its identification number and name cn the displey below the actual load. A fault is indicated immediately when the situation ‘occurs. The fault indication disappears from the display when the situation retuins to normal, or when the problem is corrected. Only the most recent fault is shown on the display. If several faults are active, you can browse them with arrow buttons, Design limit warning message Hoisting is C 3.0t possible. The letter W denotes a warning, and is ururadnes followed by the design mit name. ‘The condition monitoring unit has preprogrammed design limk parameters, for ‘example, for the maximum number of brakings. if one of these limits is exceeded, the device displays @ warning. ‘Not Authorized message Hoisting works 7 normally. You tried to access a menu at wrong password | Not Authorized level 44 Menu structure The user interface consists of the following menus. 4 | Condition Monitoring —_| Hoist usage data read-only parameters (for example the ‘number of starts) 2 _ | Diagnostics Fault and alarm history and count logs 3 [Monitor Information about the status ofthe concition monitoring unit (for example, the actual load, signal value ofthe load coll, and lO signal status). 44. Navigation in the menu structure Use the navigation buttons to view, select, edit, or adjust the parameter values. (sez) oom] Le] Loom) BOO o Cc 33166 ‘DOCOSRGO7A 11 /ensUS/08 February 2022, “Copyright® 2022 SWF Krantechrik GmbH Alights esacved.OPERATING AND MAINTENANCE INSTRUCTIONS 4.USER INTERFACE + To activate the menu, press the ENT button + Move in the menus and menu items with the & (=UP) end ¥ (=DOWN) buttons. + To activate a parameter for editing, press the ENT button. + Increase or decrease a value in the activated field, or change a selection or value with the a. (UP) and ¥ (=DOWN) buttons. + To seve the edited value, press the ENT button. + To move left and right in the value field, use the ESC and ENT buttons respectively. + To confirm a selection or value change, press the ENT button. + To cancel editing and retum to the previous display, press the ESC button once. + To retum to the home screen, press the ESC button repeatedly. 45 Security and user passwords ‘Security in the condition monitoring unit is implemented with a user password. The password is (0000 and cannot be changed. The password gives access to the following menus. + 1.Condition monitoring + 2 Diagnostics + 3Monitor 45.1 Entering a password 1. When the home screen is visible (the actual load is displayed), press the ENT button, ‘The text ENTER PASSW/ORD appears together with four zeros in the top-right corner. The ccursor blinks on the first zero. 3.0t oa Eo0e ENTER 7 PASSWORD 2. Use the & (UP) and ¥ (DOWN) buttons to change the value of each digit. Press ENT after entering each digit to confirm and to move to the next digit. If you must cancel a selection, press the ESC button. the password. “ goo ENTER PassuoRD Press ENT after entering the last digit to confirm 3.» Ifthe entered password Is correct, the display shows 1 Condition Monitoring. You can now navigate in the menu structure, ‘To exit the menu structure, press the ESC button repeatedly until the device returns to the home screen. CONDITION > MONITORING 24066 'DOCO58507477 Ten US) 09 February 2022 ‘Copyright ©2022 SWF Krantechnik GmbH, All ights reserved, ©Cc GUSER INTERFACE OPERATING AND MAINTENANCE INSTRUCTIONS > Ifthe password entered is incorrect, the display shows text WRONG PASSWORD and retums to the home screen. Verify your password and restart from step 1. For more: Information, see section "User interface” URONG PASSWORD sve ‘DOGOSE607A 4 Fen. 708 February 2022 Copyright® 2022 SWF Krantecink GmbH. Allighs reserved.‘OPERATING AND MAINTENANCE INSTRUCTIONS 5 CONDITION MONITORING TEMS. 5 NOTE NOTE 54 CONDITION MONITORING ITEMS. ‘To read the monitoring items and to program the unit, the condition monitoring unit is equipped with a display. The monitoring iterns consist of variable read-only values. The monitoring iterns ate useful for maintenance, preventive repairs, troubleshooting, and general overhauls. In addition, the monitoring values accurately show the usage of the hoist ‘The values are stored in the memory of the condition monitoring unit. The stored values remain also during power-off situations. After a power-off situation, the previously stored values are taken into account when new values are calculated, The condition monitoring unit does not prevent running the hoist when a counter reaches the design limit value. Instead, it raises a warning, which indicates that safe usage of the hoist is no longer guaranteed. The condition monitoring items can only be read after a correct password has been given. The manufacturer provides a personal password with each delivery that has been ‘acquired with this option. Primary monitoring items ‘The primary monitoring items according to the FEM and ISO regulations are the following. + Hoist design working period counter (DWP%) + Starts counter + Running time counter Depending on the hoist duty class, the hoist Is given an initial design working period (DWP). DWP counts down according to a calculation, which includes the running time with a certain load. The total running time (independent of the load) and the number of starts are directly related to the duty class and theoretical lifetime of the hoist. Table 4. Relation between the hoist duty class and the primary monitoring items sin A 7.600 (64,000 ‘3.200 160.008, 6.200 ‘378.000 72.500) 750,000 ? a Priary maniteng tems are ease-specic or cependent on the hoisting machinery. For more informatio, 320 the holst documontation, 36085 Starts counter “The starts counter counts the number of instants the hoist is started. A start is counted when the run command output (either liting or lowering) is activated, and the run feedback becomes active, If only a run command input is activated, a start is not counted. The maximum allowed number of stars is directly related to the theoretical Iifetime of the hoist. When the starts counter reaches the design limit value, an adequate overhaul must be performed, For mare information, see the hoist documentation 'DOCOEBEO747 1 en-US/09 February 2022 Conyright ©2022 SWF Kraniedink GmbH. Al ights reserved, C5 CONDITION MONITORING ITEMS OPERATING AND MAINTENANCE INSTRUCTIONS: © s12 Running time counter ‘The running time counter records the total number of hours that the hoist has been running, either upwards or downwards. The running time counter is not load-dependent. ‘The maximum allowed running time is directly related to the theoretical Ifetime of the hoist. ‘When the running time counter reaches the design limit value, an adequate overhaul must be performed. For more information, see the hoist documentation. 5.1.3 Design working period (DWP) counter The theoretical lifetime of the hoist is presented as design working period (DWP). The DWP is based on a calculation which includes the running hours, the hoisting cycles, and the load. ‘The condition monitoring unit displays the DWP as a percentage of the initial value, A new hoist is given a DWP value of 100%. The value corresponds to the value of either the initial DWP hours or intial DWP hoisting cycles, according to the hoist duty class. When the DWP counter reaches zero, a general overhaul must be performed, after which the hoist is given a new DWP. For more information, see the hoist documentation. Cc ‘The condition monitoring unit does not prevent running the hoist when the DWP reaches zero, Instead, itraises a warming, which indicates that safe usage of the hoist is no longer ‘guaranteed. 3 ott Ats; load SRT3 n= 2 [s« : a a | Pt 3 EI loads SL3n1= 2 nom.load (D_SRT3— SRT), DSRS wpRT%= 100% DWP =min (DUIERTI, DIIPHOX) SRTS Load sum with hoist running time, third power. Parameter 1.2.8. ' Time period number (Time period is 0.1 s.) Atti Running time in fast speed with load tsi Running time in slow speed with load. SR Speed ratio Two-speed systems —_—_Slow-fast (for example 6) Frequency converter Always 1 load ‘Actual load in period 1 C 1168 ‘BOCO5B6O7A 1 Fen-US/ 09 February 2022 ‘Copyright ©2022 SWF Kreniechrik GmbH, Al rights reserved.‘OPERATING AND MAINTENANCE INSTRUCTIONS: 5 CONDITION MONITORING ITEMS NOTE 5.1.4 5.1.5 seuss nomload_| Rated capacity of the holst. Parameter 8.1.1 sis Load sum with hoisting cycles, the third power, Parameter 1.2.10. loadk “The load difference between the maximum load and the inital load within the hoisting cycles k k ‘Number of hoisting cycles DWPRT% | DWP% value that is calculated with hoist running time. Parameter 1.2.9. D_SRT3__| Designed running hours, the third power. Parameter 6.2.6. DWPHC% | DWP% value calculated with hoisting cycles, Parameter 1.2.11 D_SL3__| Designed constraint for hoisting cycles, the third power. Parameter 8.2.9. DwP% | Remaining design working period of the hoist as percentage, starting from 100%, Parameter 1.1.3. DWP% is calculated when parameter 1.2.8 SRT3 and parameter 1.2.10 SL3 are known. For example, parameter 1.2.8 SRT3 is 163 h, parameter 1.2.10 SL3 is 3780, and hoist duty class is M4, (800-163) WERTH X 100% = 79.6% (24000-3780) = 24000 S780) 100% = 04.25% wee = 2 DWP% «min (DWPRTS., BWRHCS When DWP% is known, parameter 1.2.8 SRT3 and parameter 1.2.10 SL3 can be calculated. Hoisting cycles counter The hoisting cycles counter shows the total number of hoisting cycles, The value increases by cone when the hoist is started to DOWN direction, ifthe load difference is more than 10% of the rated capacity between the maximum load and the intial load within the last hoisting motion. Running time and start counter for trolley and bridge In addition to the hoist running time and starts counter, the condition monitoring unit can be programmed to count the total running time and starts of the trolley and bridge travel motion. ‘When this option is activated, a complete overview of the usage of the crane is recorded. ‘DOCOEBEOT47 1 /en US 09 February 2022 ‘Copyright® 2022 SWF Krantechnik GribH, Al ight servedDIAGNOSTICS OPERATING AND MAINTENANCE INSTRUCTIONS 6 6.1 6.2 DIAGNOSTICS Alarms Alarms indicate that a limit is reached during an operation. The system usually allows operation to continue after recovery from an alarm situation, for example, when the temperature decreases below the alarm fevel, or when the load is lowered afler attempted lifting of overload. [Alarm codeonthedisplay [Description eee A:Overload 0. Single hoist overload is detected. Gaeeeats Bip oveoed dete (um oad hos eededthe A:Hoist OT 2. Hoist overtemperature. TP1 is configured to detect it. AHoist OT 3 Holst overtemperature. TP2 is configured to detect i A:Slack Rope 4 Slack rope detected. Aitrolley O17 Trolley overtemperature, TP' is configured to detect ATrolley OT 8 ‘Trolley overtemperature. TP2 is configured to detect it. A:HOSTUP 9 Hoist has reached the stop limit in direction UP. A:HOSTDOWN 10 Hoist has reached the stop limit in direction DOWN. ATRLY ST1 11 Trolley has reached the stop limit towards rection 1. ACTRLY ST2 12 Trolley has reached the stop limit towards direction 2. ACTRLY SD1 13 Trolley has reached the slowdown limit towards direction 1. ACTRLY SD2 14 ‘Trolley has reached the slowdown limit towards direction 2, ATACST 18 Trolley ant-colision stop limit is activated ACTACSD 16 Trolley anti-collision slowdown limit is activated. AVHOSDUP 17 Hoist has reached the slowdown limit in direction UP. ACHOSDDOWN 18° Hoist has reached the slawdawn limit in direction DOWN. Geet External sop in ront ofthe condition monitoring unit prevents hoisting. No voltage in the OLIN input terminal. aes ru 29 eee eas Faults. A fault occurs when the condition monitoring unit detects a situation that prevents the hoist or trolley from running. The condition monitoring unit stops the motion, shows the fault code on the display, and illuminates the red LED continuously on both the unit and the display. Depending ‘on the detected situation and parameter settings, the condition monitoring unit allows only fiting, lowering, or traveling, or prevents running the hoist or trolley. ‘The fault code disappears from the display automatically when the fault situation is cleared. It is also possible to clear the fault and retum to the original display by pressing the ENT button. However, 2s long as the fault is active, the red LED lights are illuminated and the fault code can be read from the display in status mode. 39166 ‘BOCOEBEG?A 71 Ven US/00 February 2022 ‘Copyright® 2022 SWF Krartechrik GmbH, Allighs reserves,OPERATING AND MAINTENANCE INSTRUCTIONS 6 DIAGNOSTICS: NOTE For'more information about each fault, see chapter “Troubleshooting” > "Faults and C. recovery instructions”. Fault code on the display — Running: Unexpected feedback from the intemal Lifting and lowering F:Control VO 0 | relay KS in the condition monitoring unt. | prevented F:Control VO {| intemal fault inside the unt. Traveling prevented NO F:Control VO 2_ | intemal faut inside the unt “Traveling prevented NO Unexpected feedback from the internal F:Control V0.4 | relay KH in the condition monitoring unit, or pavertat lowering No voltage in MFIO_1 when KH is open. Unexpected feedback from the internal Lifting and lowering F:Control VO 5. | relay KL in the concition monitoring uni, or No voltage in MFIO_2 when KL is open. Peer Unexpected feedback from the internal ; F:Cortrol YO 6 | relay KF in the condition monitoring unit, or | Ling end lowering No C voltage in MFIO_ when KF is open, mr Lifing and lowering FiRun FB7 | Unexpected hoist run feedback-signal, | FINNO ane No Feedback from the intemal relay KS is F:Control VO 8. | active when itis expected tobe inactive. | RNG and lowering Yes For example, the contact of KS is welded, | Preventes Feedback from the intemal relay KH is F:Contro! HO 12 | active when itis expected to be inactive. | Lifing end lowering Yes For example, the contact of KH is welded, |” Feedback from the intemal relay KL is F-Contro! 10 13 | active when itis expected to be inactive. | Lfing end lowering Yes For exemple, the contact of KLis welded. |! Feedback from the intemal relay KF is ; F Control HO 14 | active when itis expected to be inactive. | Ling end lowering YES For example, the contact of KF is welded. | > C AINT voltage is at its maximum. Ina F:Load sensor | configuration where AIN2 is also used for | Lifting prevented, lowering | 49 15 load measurement, this fault is active also | allowed when AIN2 voltage is at its maximum, AINT voltage is at its minimum, Ina F:Load sensor | configuration where AIN2 is also used for | Lifting prevented, lowering | xo, 16 load measurement, this faults active also | allowed when AIN2 voltage is at its minimum. FiLoad sensor | Load difference between internal safety _| Lifting prevented, lowering 7 chennels is too large. allowed A FiLoad sensor Lifting prevented, towering | nay 18 Load is too small (below zero). be Lifting prevented, lowering | yoy F:Calibration 19 | Load measurement calibration has failed. | <1 Cc 40s 'D0CO5850747% Jen US 00 February 2022 ‘Copyright® 2022 SWF Krantechnik GmbH, Alvights reserved,Cc 6 DIAGNOSTICS. OPERATING AND MAINTENANCE INSTRUCTIONS Fault code on Lifting prevented, lowering FlgV out 21 | VSt is above the upper imi. - : : Ling prevented, lowering FA0Vout22 | VS1 is below the lower limit a No : Parameters related to functional safety are |, Syrterme!HW | corrupted in the internal memory ofthe | rns end lowering Yes condition monitoring unt ee Fntemel HW | Communicetion between internal safely | Liting and lowering aa 24 channels has falled prevented Enteral HW | Gommunicetion between internal safely | Lifting and lowering a 25 channels has felled. prevented Filntemal HW | Communication between internal safely | Lifting and lowe a 2% channels has failed. prevented Eintemal HW _ | Intemal safety channels do not see Lifting and lowering No 27 identical input coming into MFI. prevented Filntemal HW | Iniemal safety channels do not see Lifting and lowering Ne 28 identical input coming into MFI7. prevented Fulnternal HW | Internal safety channels do not see Lifting and lowering Ne 29 identical input coming into MIB, prevented Fiinternal HW — | Intetnal safety channels do not sea Liting and lowering aa 30 identical input coming into MFI prevented Fintemal HW _| intemal safety channels do not see iting and lowering a 3t identical input coming into MFI2. prevented Filnteral HW | Intemal safety channels do not see Lifting and lowering No 2 identical input coming into MFIS. prevented Filntemal HW _ | Intemal safety channels do not ses Lifting and lowering i 33 ‘identical input coming into MFI prevented Fulnteral HW _ | Intemal safety channels do not ses Ling and lowering ao 34 identical input coming into MFIS. prevented Finteral HW | Internal safety channels failed to share the | Lifting and lowering a 38 parameters at startup. prevented : Both MFG (HIN) and MFIZ (LIN) are active | Lifting end lowering F:Control VO 37 | simultaneously. prevented ae Mullchoisting supervision has detected | Lifting and lowering FeMulti Hoist 38 | unexpected behavicr. prevented No Faully CAN communication between F:CAN39 | condition monitoring units, or incorrect CAN | Uting and lowering No emia prevented guration. Fiintemal HW _ | Difference in MFIO1 signal between the | Lifting and lowering a 40 two internal safety channels, prevented Fiintemal HW | Difference in MFIO2 signal between the | Liting and lowering No “1 two internal safety channels. prevented 41158 DOCDSEGG7AT I /eUS/5 February 2022 ‘Copyright® 2022 SWF Krantechrik GmbH. All ight reservedOPERATING AND MAINTENANCE INSTRUCTIONS @ DIAGNOSTICS. Fault code on ating fee en eae meg Filntemel HW | Difference in MFIO3 signal between the | Lifting and lowering na 2 two internal safety channels. prevented Filntemal HW | Difference in MFIO4 signal between the _| Lifting and lowering ie 43 two internal safety channels prevented Fiintermal HW | Difference in MFIOS signal between the __ | Lifting end lowering 44 ‘we intemal safety channels. prevented Faulty CAN communication between the FICAN 45 condition monitoring unit and the traveling | Traveling prevented No frequency converter (TDU) of the trolley Supervision of trolley multttraveling has F:Multi TRLY 46 | Suberusion of tly ua Traveling prevented No FITRLY RunFB | Supervision of troley traveling has 47 detected unexpected behavior. aera pec No Faulty CAN communication between the | ig, ‘ F:CAN 48 condition monitoring unt andthe hoisting | Ling and lowering No frequency converter (TDU) ofthe trlley._| Prever F.Over Speed Lifting and lowering ue ‘Overspeed situation detected. aria YES : Lifting and lowering F:Speed Diff 50 | Speed difference situation detected. oad YES ‘Speed sensor frequency during running is _| Lifting and lowering Peat not detected, prevented ae F:Synchro Pos. | The calculated position difference between | Lifting snd lowering ig 82 synchronized hoists exceeds the limit. prevented 63 Warnings ‘Warnings indicate that a calculated cor n monitoring value has exceeded the corresponding design value of the hoist. An active waming is indicated with a warning cade an the display and a blinking red LED. The warning code appears on the display until the waming is cleared. come ‘The number of actual control actions has exceeded the design limit. WeBrakings ‘The calculated value for the brake DWP% is less than zero. wDWP ‘The calculated relative DWP% Is less than zara. Wen ‘The actual numberof ist ehare has exceeded the design \WeRunning time ‘The actual value for the hoist running time has exceeded the design value. NOTE ifawarning is active, the hoist still runs normally, but safe use is not guaranteed. NOTE 42166 ‘DOCOBEGO7ET J en-US /09 February 2022 When a warning appears, check actions from the general overhaul instructions of the. hoist, or contact the manufacturer. Copyright ©2022 SWF Krantechrik GmbH, All Aghts reserved.6 DIAGNOSTICS OPERATING AND MAINTENANCE INSTRUCTIONS Measured values ‘The measured values allow maintenance analysis, The parameters for the measured values are In the Monitor menu, No. “The measured actual load value of the solo hoist that is. aa a eee ne connected to the unit. ‘Measured voltage at analog input AIN1. Voltage across bead pi woneao itt | Mae terminals 26-25, VDC. 33 ‘SPARE ‘Net single hoist lead or net sur load, depending on the 34 Net load Tons selection of the AOUT functionality (net load = gross load ~ tare load). Incicates the status of the outputs MFIt ... MFI8. "1" means Cael teri-meie | Forexample, | thatthe inputs active, "O" means thatthe input is inactive. 00000101 For example, 00000101 represents a situation where MFI6 and MFI8 are acive, and all ther MFls are inactive. For example, | indicates the status of the outputs MFIO1, MFIO2, MFIO3, hae MFIO1 -MFIOS | sqi09 MFIO4, MFIOS, 1" means active, "0" means inactive, 37 ‘SPARE 38 SPARE 38 SPARE Encoder frequency as seen on the ENC terminals. 340 JENG Freq i ‘A negative frequency means direction DOWN, and a positive frequency means direction UP. 341 |SWversion | Numeral Software version of the unit. ‘Motor rotation frequency mullipied by pole pair number. 342 ENC Motor Freq | He ‘Annegative frequency means direction DOWN, and a Cc postive fequency means drecton UP. Frequency reference sent to hoist frequency converter ata [HoistFrea |p through CAN bus. Reference A negative frequency means direction DOWN, and a positive frequency means direction UP. Measured hook position. 3.14 |Hook Position | Meters ‘A negative value from upper stop limit. Upper stop limit sets the postion o zero, Synchro Pos ; ‘Current position error ofthe hoist when compared to the 348 | Efror Milimeters | synchronization reference position. ‘DOCOSBSOTA [1 Fer-US 09 Fabry 2022 43166 Copyright® 2022 SWF Kraniecanik GmbH, Al ights reserved‘OPERATING AND MAINTENANCE INSTRUCTIONS: ‘7 MAINTENANCE MAINTENANCE Cc Safety during maintenance AS ELECTRIC SHOCK HAZARD. Even if the main isolation switch is off, electrical components can have stored electrical energy. Contact with the electrical energy could cause death, serious injury, or property damage. [Wait 15 min before opening electrical cubicles or working on electrical components. MACHINE MALFUNCTION HAZARD Using unsuitable spare parts, materials, and lubricants can result in malfunctions that could cause death, serious injury, or property damage. Use only original spare parts, materials, and lubricants that are approved by the Cc manufacturer or representative of the manufacturer. NOTE NOTE 7.2 acs ‘Mechanical and electrical maintenance work requires special skills and tools to ensure the safe and reliable operation of the product. Maintenance work must be done by service personnel who are authorized by the manufacturer or representative of the ‘manufacturer. ‘Some maintenance tasks require two people. General guidelines for safety: + Observe local safety regulations. + Make sure that you have all the appropriate personal protective equipment. Use them when required. + Follow the fall protection procedures. + Prevent access to the area from unauthorized persons and bystanders. + Ensure that the secured area is spacious enough to prevent injuries thet could occur if ‘components or tools fal. + Follow lockout-tagouttryout procedure. * Use hand tines that are securely attached to the building structure to if and lower materials ‘and tools. When you work in high places, use safety equipment to make sure that objects do not fall + Ensure that safety devices work property so that they provide protection against human error. + Beware of hot components. Some components, such as motors, can become hot in use. ‘Check that components are cool before you perform maintenance, + Do not disassemble components further than instructed. Preparing for maintenance 1, Familiarize yourself with the product and its user instructions. 2, Find out the location of the main isolation switch and the emergency stop buttons. 3. Choose a safe working focation. Move the product to a location where it causes the least disturbance and where you can access it easily. 4, Inform that the product is under maintenance and that itis notin operation. 5. Make sure that there is no load on the hook. If there is any chance that you open the hoisting brake during maintenance, lower the hook on the floor. 6. If applicable,check the parameters of the condition monitoring unit before you switch off the power supply. C (DOCOBEEO7#7 1 Fen-US 09 February 2022 Copyright© 2022 SWF Kranlechnik GmbH. Al ights reserved,‘7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS: 7.3 7.4 WARNING! UNEXPECTED MOVEMENT HAZARD Unexpected movement when you are on the service platform or manlift could cause death or severe injury. When you enter the service platform or use manlift to check the parameters, take precautions, Take the radio controller with you or make sure that the pendant controller is held by service personnel ‘Turn off all controllers and main Isolation switches before you start maintenance work, 8. Lock out and tag out the product power sourcs if necessary, in accordance with local regulations. For more information, see "Lockout-tagout-tryout procedure" 9. To make sure that power is disconnected, measure between the pheses and between each phase to ground. 10, Make sure that personnel or body parts cannot be struck, crushed, or compressed by the product when it moves: * Secure the area so that service personnel ara not at risk from the movements of machines, automatic doors, or adjacent cranes atthe site. + Make sure that the product cannot start up accidentally and cannot move during maintenance + To prevent entrapment, use guards to shield parts that move. + Be prepared in case the equipment moves in the wrong direction during tests. Browsing active events 1. The home screen shows the most recent active event (fault, alarm, or warning) along with the load information. If there are multiple active events, the display shows the most recent one, -0.20t F:Load sensor 48 2. Use the arrow buttons to browse possible other active events. Viewing condition monitoring information 1. Enter the four-digit password (Level 1 password). os foo ENTER i PASSWORD Press ENT. 3, Use the A, V, and ENT butions to access menu 1 Condition Monitoring. 4 CONDITION » MONITORING 4, Toaccess the content in the menu, press ENT. Use the arrow buttons to browse the menu content. 45186 (BOCO5B6O7A 71 FerUS 709 February 2022, ‘Copyright® 2022 SWF Krantechnik GmbH. Alrights reservedOPERATING AND MAINTENANCE INSTRUCTIONS ‘7 MAINTENANCE Starts 2 5. Toexit the menu, press the ESC button repeatedly until the device returns to the home screen, 3.0t 7.5 Resetting counters ‘When the hoisting brake or any of the contactors on the hoist is replaced, resat the corresponding counters. 1. When the hoisting brake is replaced, set parameter 9.10 Brakings value to 0. 2, When the contactors on the hoist are replaced, reset the value of parameters 9.7 Controls up, 8.8 Controls down, and 9.9 Controls fast to 0. 7.6 Checking recent events in the history log “The history log shows the 20 latest events 1. Enter the four-digit password (Level 1 password) and press ENT. os ooo ENTER > PASSWORD 2. Use the a, ¥, and ENT buttons to access menu 2 Diagnostics and parameter 2.1 History log. a History log » 3, Press ENT to access the parameter content and use arrow buttons to browse the most recent faults and alarms. ‘The display always shows the Starts value at which a fault or alarm occurred, together with, the fault or alarm name, aan 1 F:10U out 21 ‘You may compare the displayed Starts value to the most recent Starts value shown in parameter 1.1.1 Starts. 46166 "DOCOESEO7AT 4 Fer-US 109 February 2022 ‘Copyright ® 2022 SWF Krantechnic GmbH lights reserved.7 MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS C 17 Finishing maintenance Make sure that you leave the site in a safe condition. 4, Make sure that the work area is clean. 2. Remove all locks and tags from switches, 3. Restore safety devices to operational status. If you have bypassed safety devices for test purposes, restore them to full operational status before you allow the product to be used for normal operation. 4. Test that the product functions normally. 5. Inform the site responsible that you have finished the work. ce ares ‘DOCOEBEITA 71 Jen US 09 February 2022 ‘Copyright ® 2022 SWF Krantechnik GmbH. Alvights rasarved,‘OPERATING AND MAINTENANCE INSTRUCTIONS 8 TROUBLESHOOTING 8.1 8.1.1 F:Control 1/0 0 Faults and recovery instructions S TROUBLESHOOTING Faull deception || | Possible cause : Unexpected feedback from th internal relay KS in the condition ‘monitoring unit. + No voltage in the OLIN input terminal because of a loose or incorrect electrical connection. + KS does not get closed or the feedback circuit of the relay is broken. ‘Check that there is a voltage in the OLIN input terminal, 8.1.2 F:Control /0 1 Internal fault inside the unit. Missing control voltage on RIN input, ‘Check the RIN‘ input and MFIO4 ‘output connections in the candition ‘monitoring unit 8.1.3. F:Control VO 2 Incorrect wiring ‘Check the RIN‘ input and MFIO4 ‘output connections in the condition monitoring unit. 8.1.4 F:Control /0 4 ‘ossible cause Unexpected feedback from the internal relay KH in the condition ‘monitoring unit, + There is voltage in MFIO_1 when KHis open. + KH does not get closed or the feedback circuit of the relay is broken. Cheek thet there is no voltage In MFIO_1 when the condition monitoring unit is powered on and the hoist is not running. internal relay KL in the condition ‘monitoring unit, or voltage in MFIO_2 when KL is open. 8.1.5 F:Control /0 5 Fault description: — [Possiblecause Solution. 2 Unexpected feedback from the | + There is voltage in MFIO_2 when | Check that there is no voltage in KL is open. + KL does not get closed or the feedback circuit of the relay is broken. MFIO_2 when the condition ‘monitaring unit is powered on and the hoist is not running. 43185, ‘DOCOSBEDI 74 Ten US/ 09 February 2022 Copyright ® 2022 SWF Krantochnik GmbH, Al ights reserved.© 8 TROUBLESHOOTING Cc 8.1.6 F:Control 1/0 6 ‘OPERATING AND MAINTENANCE INSTRUCTIONS Fault description: [Solution ere Unexpected feedback from the interrat relay KF in the condition ‘monitoring unit, + There is voltage in MFIO_3 when KF is open. + KF does not get closed or the feedback circuit ofthe relay is broken, ‘Check that there is no voltage in MFIO_3 when the condition ‘monitoring unit fs powered on and the hoist is not running two-speed hoist) is unexpected. 8.1.7 F:RunFB7 Faultdesctiption _ | Possible cause: — | | Solution i i The run feedback signal (for Two-speed control, MIS Measure the vokage coming into example, brake contactor state ina | configured for un feedba MIS, When no ling or lowering * Incorrect electrical connection so that the run feedback is ‘constantly active in MFIS + Incorrect or loose electrical ‘connection so that the run feedback signal does not ‘connect into MFIS terminal + Internal fault inside the unit + Hoist has reached upper or lower limit request is active, the voltege should be zero. When lifting (or lowering) is requested and nothing prevents lifting (or lowering), the voltage should equal the control voltage, except when the hoist hes reached the upper or lower limit This fault is very common in the typical usage of @ hoist or a multi- hoist crane, Therefore this fault is not stored in the fault history log (214... 2.4.80) ‘DOGDSBETAT 11 en-tiS/ 09 February 2022 49166 ‘Copyright ® 2022 SWF Krantechnk GmbH. Allighs reserved.OPERATING AND MAINTENANCE INSTRUCTIONS. 8.18 F:Control I/O 8...14 ‘8 TROUBLESHOOTING Fault description Possiblecause Sotion ee Internal diagnostics inside the condition monitoring unit indicate that there is a voltage after the relay contact even though the relay Is open, There is a unique fault for each internal relay, The relay contact is welded, but because of the fault detection mechanism, the reason can also be an incorrect electrical connection. ‘Two-speed: Measure the voltage from outputs MFIO1, MFIO2, and MFIO3 when the hoist is not moving. Voltage should be zero. ‘When you activate hoisting up at low speed, only MFIO_1 should have control voltage. When you activate lowering at low speed, only MFIO_2 should have control voltage. ‘When you activate hoisting up at fast speed and MFIO_tand MFIO_3 have control voltage, MFIO_2 should not have control voltage. Inverter: Measure the voltage from outputs MFIO1 and MFIO2, when the hoist is not moving. Voltage should be zero. ‘When you activate hoisting up, only MFIO_1 should have control voltage. When you activate lowering at low speed, only MPIQ_2 should have control voltage. 8.1.9 F:Load sensor 15. Fai + There is a short circuit between *+ Check the electrical connections in AINt, VS1, and GND. Measure the voltage between St and GND using a multi- meter. Voltage should be 10.0- 12.0. + When there is no load on the hook, check the voltage of the AIN1 from the Monitor menu. ‘The value should be roughly 2.0 v. + When there is 2 load on the hook, the voltage in AIN’ must be greater than 2,0V, The voltage in AIN1 must never be 0 or 10V. + Ifthe voltage in AIN1 behaves as described, perform load calibration using zero load and the test load. + Ifthe problem persists, replace the condition monitoring unit. F:Load sensor | AIN voltage is at 5 maximum. IN‘ and the load cell amplifier supply voltage VS1. FiLoad sensor | AIN voltage is at |- No signal is connected to AIN( 6 ‘minimum. (open circuit) + There is a short circuit between AIN1 and GND. FiLoad sensor | Load difference |- Wrong load measurement 7 between interal| parameters between internal safety channels | safety chennels. Is too large, Fiload sensor [Loadistoo | + Wrong load measurement 18 small (below parameters between internal zet0). safety channels. + Load signal coming from the load cell amplifier has drited downwards. orn (9000586074771 en-US /09 February 2022 ‘Copyright ©2022 SWF Krantechnik GmibH, Allrighs roserved,8 TROUBLESHOOTING 8.1.10 F:Calibration 19 ‘OPERATING AND MAINTENANCE INSTRUCTIONS ‘Fault description [Possible cause Solution = Load measurement calibration has failed, Calibration load voltage (for zero or test load) is out of valid range. + Check the electrical connections in AIN1, VS1, and GND. Measure the voltage between \VS1 and GND using @ multi meter. Voltage should be 10.0— 120V. When there is no load on the hook, check the voltage of the AINt from the Monitor menu. The value should be roughly 2.0, v. When there is @ load on the hook, the voltage in AIN1 must be greater than 2.0 V. The voltage in AIN1 must never be 0 or 10V. + If the voltage in AIN1 behaves as described, perform load calibration using zero load and the test load, + Ifthe problem persists, replace the condition monitoring unit. + With a test load on the hook, check that the voltage on AINT is at least 0.3 V higher than the voltage without load. + With a test load on the hook, check that the voltage on AINt is not too close to 10 V. The unit must be able to measure a 140% load based on the input voltage. 8.1.11 F:10V out 24 \VS1 is above the upper limit, Internal fault in the condition monitoring unit. Measure the voltage between VS1 ‘and GND using e mutti-meter. Voltage should be 10.0-12.0 V. 8.1.12 F:10V out 22 Fault decsato \VS1 is below the lower limit + Short circuit in the VS1 terminal, + Internal fault in the condition monitoring unit. Measure the voltage between VS1 and GND using a multimeter. Voltage should be 10.0-12.0V, ‘DOCOEBENT#7 1 /en-US 79 February 2022 sis ‘Copyright® 2022 SWF Krantechnik GmbH, Al ights reserved.OPERATING AND MAINTENANCE INSTRUCTIONS 8.1.13 F:Internal HW 23 8 TROUBLESHOOTING Fault descri Possible cau: | Solutio Parameters relaied to functional safety are corrupted in the internal memory of the condition ‘monitoring unit. Internal fault in the condition ‘monitoring unit, Rewrite the parameters using, for exemple, APT. Power off and ower on the unit. Ifthe problem persists, replace the condition monitoring unit. 8.1.14 F:Internal HW 24...26 hia Possible cause Solution e ‘Communication between intemal safety channels has failed, + Excessive electromagnetic interference. + Internal fault in the condition ‘monitoring unit, * Update the software In the unit using, for exemple, APT. + Power off and power on the unit. Ifthe problem persists, replace the condition monitoring unit. 8.1.15 F:Internal HW 27... Fault description Internal safety channels do not see identical input coming into mutti- function inputs. + Excessive electromagnetic interference. + Internal fault in the condition ‘monitoring unit. using, for exemple, APT. + Power off and power on the unit. Ifthe problem persists, replace the condition monitoring unit 8.1.16 F:Internal HW 35. ssible cause share the parameters at startup. + Excessive electromagnetic interference. + Internal fault in the condition ‘monitoring unit. + Software versions between internal safety channels are not compatible. + Rewrite the parameters using, for example, APT. + Update the software in the unit using, for example, APT. + Power off and power on the unit. Ifthe problem persists, replace the condition monitoring unit 8.1.17 F:Control /O 37 Fault description Possible cause. _ [Solution i ‘Both MFI6 (HIN) and MFI7 (LIN) are active simultaneously. + Incorrect electrical connections. + Internal fault in the condition ‘monitoring unit ‘Check the electrical connections. MFIG is active when the UP button is held down on the pendantiradio. MFI7 is active when the DOWN button is held down. Power off and power on the unit. If the problem persists, replace the condition monitoring unit. 66 ‘DOCOSBSOTAT 1 en-US 109 February 2022 Copyright ®2022 SWF Krantechnik GoibH, All ights reserved,Cc S TROUBLESHOOTING 8.1.18 F:Multi Hoist 38 (OPERATING AND MAINTENANCE INSTRUCTIONS Fault description Possible cause Solution - Mult-hoisting supervision has detected unexpected behavior. + Hoist selection (for example, a rotary switch on the pendant) is changed on while hoists are running. This could be part of a normal process. + Incorrect electrical connections. This fault is very common in the typical usage of @ hoist or a mut hoist crane. Therefore this fault is not stored in the fault history log (2A... 24.30). 8.1.19 F:CAN 39 ‘one of the condition monitoring units + CAN_H of CAN_H signal is not connected to one of the condition ‘monitoring units + Too many terminating resistors are connected between CAN_H and CAN_L. + Too few terminating resistors are connected between CAN_H and CANL. Incorrect CAN configuration: + Hoist count (parameter 6,101) is. ‘not equal in every condition ‘monitoring unit + There are more condition monitoring units on the CAN bus than the hoist count (hoist count must be identical in each unit), + More than one condition monitoring units are configured to use the same hoist name (parameter 8.1.4). Each unit in the crane must have @ unique hoist name. There are gaps in naming the condition monitoring units, for example, if parameter 6.10.1 Hoist count value is 3, and the units are named A. B, and D. In this case, D is not allowed, the name must be C. All condition monitoring units on the CAN bus are not powered on. + Check that each condition (7 [Possibiecause = [Solution : Faulty CAN communication Incorrect electrical connections: |» Measure that the resistance between condition monitoring + CAN H and CAN_L signals are | between CAN_H and CAN_L is units, connected towrong terminals in | 600. ‘monitoring unit gets the control voltage into input OL. ‘DOCOSEGOTAT 1 en-US 109 February 2022 53166 ‘Copyright® 2022 SWF Krantochrk GmbH, Al ight resend,OPERATING AND MAINTENANCE INSTRUCTIONS 8.1.20 F:Internal HW 40 S TROUBLESHOOTING Fault description Difference in MFIO1 signal between the two intemal safety channels. + Excessive electromagnetic interference. + Internal fault in the condition ‘monitoring unit. + Update the software in the unit using, for example, APT. + Power off and power on the unit. Ifthe problem persists, replace the condition monitoring unit. 8.1.21 F:Internal HW 41 [ Fault deseript Difference in MFIO2 signal between the two internal safety channels. + Excessive electromagnetic interference. + Internal fault in the condition monitoring unit + Update the software in the unit using, for exemple, APT, + Power off and power on the unit, Ifthe problem persists, replace the condition monitoring unit 8.1.22 F:lnternal HW 42 Possible caus Difference in MFIO3 signal between the two internal safety channels. + Excessive electromagnetic interference, + Internal fault in the condition ‘monitoring unit, + Update the software in the unit using, for example, APT. + Power off and power on the unit. Ifthe problem persists, replace the condition monitoring unit, 8.1.23 F:Internal HW 43. Difference in MFIO4 signal between the two internal safety channels. + Excessive electromagnetic interference. + Internal fault in the condition monitoring unit. + Update the software in the unit using, for exemple, APT. + Power off and power on the unit. lf the problem persists, replace the condition monitoring unit. 8.1.24 F:lnternal HW 44 [Possible cause Difference in MFIOS signal between the two internal safety channels. + Excessive electromagnetic. Interference, + Internal faull in the condition ‘monitoring unit. + Update the software in the unit using, for example, APT. + Power off and power on the unit, Ifthe problem persists, replace the condition monitoring unit, 54r6s ‘DOCOEBGO747 1 /en-US 109 February 2022, ‘Copyright © 2022 SWF Krantochnik GmbH, Allrighs reserved. Cc@ TROUBLESHOOTING OPERATING AND MAINTENANCE INSTRUCTIONS c 8.1.25 F:CAN 45 Fault description e Possiblecause Solution ae Watchdog byte is not updated on the PDOs from the trolley travel frequency converter (TDU). Incomect electrical connections: + CAN_H and CAN_L signals are connected to wrong terminals in ‘one of the condition monitoring units or frequenay converters CAN_H or CAN_H signal is not connected to one of the condition ‘monitoring units or frequency converters: ‘Too many terminating resistors are connected between CAN_H and CAN_L. ‘Too few terminating resistors are connected between CAN_H and CAN. Incorrect CAN configuration in the ‘frequency converter: + The CAN bus speed must be the same in the condition monitoring Unit and in the frequency converter. + CANOpen Node-1D in the frequency converter does not match the NodesD thet the ‘condition monitoring unit expects, * Condition monitoring unit A is connected to the frequency converter with node ID 65 * Condition monitoring unit B is connected to the frequency converter with node ID 68, + Process data configuration of the frequency converter is incarcect, + Measure that the resistance between CAN_H and CAN_Lis 600. + Check that each condition ‘monitoring unit gets the control voltage into input OL. + TOU parameter 06-04 Process data 2 must be set to value 9 (FaultWatchdog). Check that value 9 is not used by any other process data then process data a 8.1.26 F:Multi TRLY 46 * Incorrect configuration of the traveling frequency converter. Fault description “| Solution ‘Supervision of trolley multi- + Trolley selection switch is This fault is common in the typical traveling has detected unexpected | changed while a trolley (or usage of a multitrolley crane. behavior. trolleys) is running. Therefore this fault is not stored in the fault history log (parameters 24. 1.30). Cc 56 ‘BOCOSSEO7A 11 /en.US/ 08 February 2022 ‘Copyright © 2022 SW Krantechnik GmbH, Al ighs reservedOPERATING AND MAINTENANCE INSTRUCTIONS s TROUBLESHOOTING 8.1.27 F:TRLY RunFB 47 Faas a pee aa + The trolley does not move when it should. + The trolley starts or stops moving unexpectedly, Incorrect configuration of the TDU traveling frequency converter. Cheek that the parameters in TOU are configured correctly. This fault is not stored in the fault history log (parameters 2.4.4..2.4.30). 8.1.28 F:CAN 48 [Fauttdescription Possible cause Faulty CAN communication between the condition monitoring unit and the hoisting frequency converter (TDU). Incorrect electrical connections: + CAN_H and CAN_L signals are connected to wrong terminals in ‘one of the condition monitoring Units or frequency converters CAN_H or CAN_H signal is not ‘connected to one of the condition monitoring units or frequency ‘converters ‘Too many termineting resistors are connected between CAN_H and CAN_L. Too few terminating resistors are connected between GAN_H and CAN. Incorrect CAN configuration in the frequency converter: + The CAN bus speed must be the same in the condition monitoring unit and in the frequency converter. + CANOpen NodetD in the ‘frequency converter does not ‘match the Node that the condition monitoring unit expects. + Condition monitoring unit A is ‘connected to the frequency ‘converter with node ID 49, + Condition monitoring unit B is ‘connected to the frequency ‘converter with node ID 50. + Process data configuration of the frequency converter is incorrect. + Measure that the resistance between CAN_H and CAN_L is 600. + Check that each condition monitoring unit gets the control voltage into input OL. + TDU parameter 06-04 Process data 2 must be set to value 9 (FaultWatchdog). Check that value 9 is not used by any other process data than process data 2 sere ‘DOCOSEEO7AT 1 en-US 109 February 2022 Copyright ©2022 SWF Krantechnik GmbH, All ights reserved ©‘8 TROUBLESHOOTING OPERATING AND MAINTENANCE INSTRUCTIONS. 8.1.29 F:Over Speed 49 Fault description. | Possible cause. ioe Solution Overspeed situation detected. * Interference in speed sensor failure, for example, inthe gear. Value of parameter 8.9.5 Max Freq in ECU is not the same as in the corresponding parameter in Tou, + Incorrect value of parameter 8.3.12 ENC pulse number. + Check the grounding of the speed sensor cable shield + Check and, if necessary, replace the speed sensor. + Check hoist operation without load. + Check the parameter values. + Check the value of parameters 3.10 ENC Freq and 3.12 ENC Motor Freq. 8.1.30 F:Speed Diff 50 oll leeqtie at ssible cailse ‘Speed difference situation + Interference or missing speed | + Check the grounding of the detected. sensor signal, speed sensor cable shield. + Load measured too low in ESR |+ Check and, if necessary, replace use the speed sensor. + Mechanical failure, for example, | + Check the load measurement in the gear. operation and calibration. + Speed sensor channels + Check hoist operation without incorrectly connected. load. + Value of parameter 8.3.6 Max | + Swap the connections between Freq in ECU is not the same es | speed sensor channels. in the comesponding parameter | + Check the parameter values. in TOU. + Check the value of parameters + Incorrect value of parameter 3.40 ENC Freq and 3.12 ENC 8.3.12 ENC pulse number. Motor Freq. 8.1.31 F:Stall 51 [Fault description ‘Speed sensor frequency during running is not detected. + Motor does not run + Mechanical failure for examole, in the gear. + Missing signal in speed sensor channels. + Motor brake Is not opening. + Check the motor brake operation. + Check, and if necessary, replace the speed sensor and wiring. + Check the hoist operation without load. + Check the value of parameters 3.40 ENC Freq and 3.12 ENC Motor Freq. 8.1.32 F:Synchro Pos 52 Fault description [posible ‘The caloulated position difference between the synchronized hoists is ‘more than the value given in parameter 6.10.5 Synchro Pos Error Limit, * Highly unbalanced load between the hoists, + Possible measurement drift when the upper stop limit is reached, by driving them individually. + Reattach the load on the hooks ina more balanced manner. DOCOSBEOTAT en-US 109 February 2022 ar Cong © 2022 SWF Krantechak GmbH. A ighs ervEd‘OPERATING AND MAINTENANCE INSTRUCTIONS. 9 TRANSPORTATION, STORAGE AND DISMANTLING 9 9.41 NOTE 9.2 NOTE 9.3 9.4 58166 (00005880741 TRANSPORTATION, STORAGE AND DISMANTLING Transportation of the product When transporting the product or its components, take the following precautions: + Load and transport the product with caution and using appropriate methods, meking proper preparations and taking appropriate caution. + Do not load or transport products if your alertness or working ability is impaired, for example, by medication, illness, of injury. Hf transported improperly, essential parts of the product can become damaged. Defects or faults which are due to improper transportation are not covered by the product warranty. Storing the product ‘When storing the product or its components, take the following precautions: Store the product at room temperature Store the product the same side up as during normal operation Protect the product from dust and humidity stored outdoors, protect the product from adverse weather conditions if stored improperly, essential parts of the product can become damaged. Defects or faults which are due to improper storage are not covered by the product warranty. Returning the product to use Store the product correctly. For more information, see “Storing the product.” ‘When taking the product into use after a long period, proper commissioning must be done according to chapter "Commissioning": Dismantling the product If the product must be dismentied, follow these safety instructions: + Follow the safety precautions for dismantling the product. For example, when working at heights, follow the fall protection procedures. Only experienced service personnel are permitted to dismantle the product. + Owner shall nominate a person responsible for the dismantling process. This person shall give instructions and monitor the process. + All controls must be placed in the OFF. position, safety switches must be opened, and the main isolator switch must be tured off. The product must be electrically isolated before dismantling starts. + Make sure that ail personnel involved are aware that the product willbe dismantled before dismantling starts. + Owner must prevent unauthorized persons and bystanders from walking on or below the work site. Ensure that the secured area is spacious enough to prevent injuries which could occur as a result of falling components or tools. + Only use safe tools and machinery for dismantling, + Make sure that removed fastenings and components will not fall. + Pay attention to the environmental conditions. For example, do not disassemble the product it the prevailing weather could compromise safety. + Disassembly sequence is completed in the reverse order to the assembly sequence. Refer to installation and assembly instructions for correct sequence. + After the product has been dismantled, the owner or person responsible for dismantling can return the working area back to normal use. Ifyou need more detailed dismantling instructions, contact the manufacturer of the product. 77 TenUS 109 February 2022 ‘Copyright ©2022 SWF Krantechnic GmbH. Al rights reserved,10 PARAMETERS © 40 10.1 PARAMETERS Condition monitoring ‘OPERATING AND MAINTENANCE INSTRUCTIONS Read-only menu for condition monitoring values and measured values. Accessible with the user's password. Table 5. Parameters in Condition monitoring > Condition monitoring 1 menu Condition , 14 eile Condition monitoring 4 menu “Toial numberof starts of the hoist in ether up or down 141 | stants Numeral ane 44.2 [Running time _ | Houre “Total running ime ofthe heitin hours. C Remaining design working period of the hoist as. a ee paca = percentage, starting from 100%. When the DWP counter at descends to 0% (or even negative) a general overhaul must be carried out. a eaeeeeS eae eee Remaining ifetime of contactors and brake control : components. Remaining design working period ofthe brake in 14.5 — |BrakeDwP% |% percentage. The DWP for the brake is calculated according to the number of Starts and E-tops. Total number of hoisting eyeles. The number increases by 1.4.6 | Hoisting cycles | Numeral cone, when aload value increase of more than 10% of the rated capacity is ited. 447 __ [SPARE Total number of emergency stop incidents (control voltage eee enon purer switched off when running), Over “Total numberof over temperature incidents in the hoisting Co [8 [emperatures [NUM ctor 4440 [Overloads | Numeral Total number of overload incidents. Table 6. Parameters in Condition monitoring > Condition monitoring 2 menu 12 monitoring 2 Condition monitoring 2 menu 424 Controls up | Numeral Total number of starts in up direction, 422 Controls down | Numeral Total number of starts in down direction. Total number of starts to fast speed (counts in two-speed 1.23 Controls fast | Numeral control only). 4.24 Brakings Numeral Total number of brakings. ‘DOCOSBEGTA 7 1 /enUS/08 February 2022 9188 ‘Copyright ©2022 SAF Kraetechnik GmBH.Alight reserved.OPERATING AND MAINTENANCE INSTRUCTIONS 20 PARAMETERS. Table 6. Paremeters in Condition monitoring > Condition monitoring 2 menu (Continued) ‘Total number of brake stops from fast speed. 4.2.5 |Faststoos | Numeral 126 | Runningtime | srours Total running time at slow speed. 127 {Running time | jours Total running time at fast speed 428 [SRT Hours Load cum with hoist running time, third power. 129 [DWPRT% — |% DWP% value thatis calculated with heist unning time. 1240 [Sis Numeral Load sum with hoisting cycles, thied power. 12m [oweHce | % DWP% value calculated with hoisting oycles. 1.242 | SPARE 1.2.43 [SPARE Bridge tata | Bree, Numeral “otal number of bridge overload incidents. Rated ED ‘Counts the hours when the ED value has exceeded the 12.48 | exceeded(min) | Numeral nominal ED value, 1.2.46 | SPARE 1.2.47 [Powerontime | Hous Total power-on time of the unit 12.18 |Poweron Numeral ‘Total number of times that the untt is powered on. 1.2.19 | SPARE 1.220 | SPARE 1.2.21 | SPARE Table 7. Parameters in MFI counters menu 13 MFI counters MFI counters menu MFI1 Running 134 ane Hours ‘Total hours of running time when MFI1 input is closed. Can bbe used to monitor the total running time of other machinery (for example, the trolley drive). Active only if parameter 5.3.1 is set fo "STIRT" and the MFI input is connected, 13.2 MFH Stats | Numeral ‘Total number of starts when MFI input i closed. Gan be used fo monitor the total number of starts of other machinery (for example, the trolley drive). Active only if parameter 5.3.1 is set fo "STIRT" and the MFI input is connected. sores ‘DOCOSSEO7A 71 /enUS/09 February 2022 Copyright® 2022 SWF Krantechnik GmbH, All ighs reserved20 PARAMETERS OPERATING AND MAINTENANCE INSTRUCTIONS Cable 7. Paremetors in ME! counters menu (Continued) shown ae Description. MFt2 Running | Houre ‘Total hours of running time when MFI2 input is closed, Can be used to monitor the total running time of other machinery time (for example, the trolley drive). Active only if parameter 5.4.1 is set to "STIRT” and the MFI2 input is connected ‘Total number of sterts when MFI2 input is closed. Can be used to monitor the total number of starts of other 134 |MFI2Starts | Numeral machinery (for example, the trolley drive). Active only if parameter 5.4.1 is set to "ST/RT" and the MFI2 input is connected. iat MFIS Running | oye “Total hours of running time when MFI3 input is closed. Can be used to monitor the total running time of other machinery time (for example, the trolley drive). Active only if parameter 5.5.1 is set to"ST/RT” and the MFI3 input is connected. C ‘Total number of starts when MFI3 input is closed, Can be used to moniter the total number of starts of other 136 MFI3Stats | Numeral machinery (for example, the trolley drive), Active only if parameter 5.5.1 is set to "ST/RT” and the MFI3 input is connected. a MFI4 Running time ae ‘Total hours of running time when MFI input is closed. Can bbe used to monitor the total running time of other machinery (for example, the trolley drive). Active only if parameter 5.6.1 is set to "ST/RT" and the MFI4 input is connected. ‘Total number of starts when MFI4 input is closed. Can be sed fo monitor the total number of starts of other 1.38 |MFI4Starts | Numeral ‘machinery (for example, the trolley drive). Active only if parameter 5.6.1 is setto "ST/RT" and the MFI4 input is connected. ase) MFI5 Running time Hours Total hours of running tine when MFIS input is closed. Can be used to monitor the total running time of other machinery (for example, the trolley drive). Active only if parameter Cc 57-1 fs sat to "STIRT” and the MFIS input is connected. Total number of starts when MFIS input is closed, Can be used to monitor the total number of starts of other 1.3.10 | MFIs Starts | Numeral machinery (for example, the trolley drive). Active only if parameter 5.7.1 is set to "ST/RT" and the MFIS input is connected. (DOCOSGEITATT eS 100 February 2022 ete “Copyright® 2022 SWF Krantechnik GmbH. Al rights reserved,OPERATING AND MAINTENANCE INSTRUCTIONS 10 PARAMETERS 10.2 Diagnostics C Table 8. Parameters in Diagnostics > History log menu | Name Description ae 2A History loo History log menu, Srp “The latest faul. The fault name and the actual number of aaa Numeral starts atthe moment when the fault was detected. For more name Seat information, see chapter "Faults. “The second latest fault. The faut name and the actual aig |Fautorslarm | Numeral number of starts at the moment when the fault was alas detected, For more information, 68 chaptar "Faults. “The history log shows the latest 30 fauts. The faut name Fauttoralarm | mera and the actusl number of stats atthe moment when the name fault was detected, For mare information, see chapter “Raut. C ; Clears the history log (parameters 2.1.1 .. 2.1.80). To clear past [Reset Histor’ | Numeral the log, hold down the ENT button continuously for at least @ 3 seconds. 22 ‘Count log Count log menu. ‘Sensor channel aaa — | Sener crerne! | Numerat Total number of sensor channel faults. Control IO Fauit eee cee Numeral Total number of control IO faults 22a Mere ey | Numeral Total number of internal hardware faults. 2.24 | RURFBF aut | Numeral Total number of run feedback faults. rou 22s | Muli holst Foul | wumeral The total number of muli hoisting faut. Clears the count log (parameters 2.2.4 ..2,2.6) To clear C 226 — | Reset Count leg the log, hold down the ENT button continuously for at least 3 seconds, 10.3 Monitor Table 9. Parameters in Monitor menu “The measured actual load value ofthe solo host that i a pera ere ee [sere connected to the unt. Measured voltage at analog input AIN1, Voltage across i AIN( voltage | Volts terminals 26-25, VOC. 33 SPARE sass Cc ‘DOCOSSGO74) 7 en-US 109 February 2022 Copyright ©2022 SWF Krontechnix GmbH. Allights reserved,10 PARAMETERS OPERATING AND MAINTENANCE INSTRUCTIONS. Cable 9 Parameters in Monitor menu (Continued) — | Value shown : = ae a es : Net single hoist load or net sum load, depending on the Tons selection of the AUT functionality (net load = gross load ~ tare load). Indicates the status of the outputs MFI... MFIB, "t" means ay murie-meig | Forexemple, | thet the input is active, "o" means thatthe input is inactive. 0000101 For example, 00000101 represenis a situation where MFI and MFI8 are active, and all other MFis are inactive. For example, _| Indicates the status of the outputs MFIO1, MFIO2, MFIO3, bed MFION-MFIOS | so109 MFIO4, MFIOS. "1" means active, °O" means inactive a7, SPARE 38 ‘SPARE Cc is ‘SPARE Encoder frequency as seen on the ENC terminals, 340 ENC Freq ‘ Anegative frequency means direction DOWN, and a positive frequency means direction UP. 3a ‘SWversion | Numeral Software version ofthe unit, Motor rotation frequency multiplied by pole pair number. 3.42 ENC Motor Freq | Hz A negative frequency means direction DOWN, and a positive frequeney means direction UP. Frequency reference sent to hoist frequency converter a Holst Freq a through CAN bus. Reference ‘Annegative frequency means direction DOWN, and postive frequency means direction UP. Measured hook position. Se tee | Hock oetion | er ‘Annegetive value from upper stop limit, Upper stop limit sets Cc the position to zero. ‘Synchro Pos : ‘Current position error ofthe hoist when compared to the 3.45 Error Mane ‘synchronization reference position Cc ‘BOCOSEEG7A 11 en-US 708 February 2022 6216s “Copyright © 2022 SW Krantechnik GribH. All righs esarved,‘OPERATING AND MAINTENANCE INSTRUCTIONS APPENDIX: FUNCTIONAL SAFETY APPENDIX: FUNCTIONAL SAFETY The product may only be used by strictly following the safety instructions specified in this document. Intended use + The condition monitoring unit is a safety-related part of the hoist control system. + All the environmental conditions that are specified in chapter "Conditions of product use" must ‘be observed when operating the condition + The condition monitoring unit can be used PL c in accordance with EN ISO 13849-1 ‘monitoring unit. in safety-related circuits for up to performance level + Performance ievel evaluation must be done at the system level, including sensors and actuators. The maximum attainable performance level is PL c, when the safety function contains an element that consists of a category 1 subsystem (for example, a single contactor on output). + The condition monitoring unit is designed to fit a wide variety of hoists and drives. It can be used with both variable speed control drives and two-speed systems + Ifthe condition monitoring unit that is supplied by the manufacturer is integrated into the overall control, the product standards for the hoists and the technical specification regarding the functionality and principal circuits must be taken into account. System designer and supplier are responsible for the overall system, Safety data according to EN ISO 13849-1 NOTE Condition monitoring unit + PL according to EN ISO 13849: Max. PL d + PFHD: 365-7 + MTTFd: HIGH + DC: LOW >=80%) + Category 2 (Input circuits) + Category 3 (Logie and output) These values apply fora system where the input side is implemented without redundancy as a single channel solution (a single sensor using a single input of the condi The output relays are normally open. The n monitoring unit). status of the relays is tested and verified internally by the condition monitoring unit on device startup and during operation when relays are switched. Performance levels of the complete safety functions The safety functions that can currently be imalemented with the condition monitoring unit are 64166 shown in the following table. ‘Safety function Hoist overload protection Hoist intermediate load limit PLe Bridge overload protection (sum load) PLe Bridge intermediate load lit (sum ad) PLe Multihoisting supervision PLe (DOCOSBSOTAT T /enUS 109 February 2022 ‘Copyright ©2072 SWF Krantachnic GmbH, All ighs reserved, c ©APPENDIX: FUNCTIONAL SAFETY OPERATING AND MAINTENANCE INSTRUCTIONS C Safety function Performance level according to EN ISO 13849-4 Trolley mult-traveling supervision PLe Hoist Overspeed Supervision (TDU only) | PLe. Hoist stop limits (TDU only) PLe Requirements for installation Inthe safety-related circuits, the logic device (condition monitoring unit) and its connected sensors and actuators must all meet the safety requirements and achieve the specified performance level. Cc ‘DOGOS8EO7A TT Fen US) 08 February 2022 e566 ‘Copyright® 2022 SWF Krantechnik GmbH, All ighis reserved,‘OPERATING AND MAINTENANCE INSTRUCTIONS Co 6616s ‘DOCOSBGO7#7 1 en-US 108 February 2022 Copyright ® 2022 SWF Krantechnik GribH, All ighs reserved,‘This document and the information contained herein, is the exclusive property of SWF Krantechnik GmbH and represents a non-public, confidential and proprietary trade secret that may nat be reproduced, disclosed to third eres alsrad or otherwee employed in any manner vhatsoever witout the express writen consent of SWE Krantechnik GmbH. Copyright 2022 @ SWF Krantechnik GmbH. All rights reserved,