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OPERATING INSTRUCTIONS - ENGLISH Grade-Controller COMBI GRADE G 176 MS

MOBA Mobile Automation AG Kapellenstr. 15 D-65555 Limburg www.moba.de Article number: 10-02-00541 Edition 03/2006

MOBA Mobil Automation GmbH Vor den Eichen 4 - 65604 Elz Telefon 06431/9577-0 - Telefax 06431/9577-77

Index
1.
1.1 1.2 1.3

General information ____________________________________ 3
Rights to changes ______________________________________________ 3 Packaging and storage __________________________________________ 3 Safety measures _______________________________________________ 3

2.
2.1

Introduction ___________________________________________ 6
Advantages and specials ________________________________________ 6

3.
3.1 3.2 3.3 3.4
3.4.1 3.4.2 3.4.3

Mounting _____________________________________________ 7
Dimensions of the device ________________________________________ 7 Mounting of the G 176 MS ________________________________________ 8 Attaching the connecting cable ___________________________________ 8 Attaching the system components ________________________________ 9
Attaching the sensing tube to the sensor arm _______________________________ 9 Attaching the sensing ski to the sensor arm ________________________________ 9 Attaching the sensor arm to the controller _________________________________ 9

4.
4.1 4.2
4.2.1 4.2.2

Operation, working examples and start-up _______________ 10
The control elements ___________________________________________ 10 Mechanical sensing ____________________________________________ 11
Sensing of a stringline _________________________________________________ 11 Sensing of a surface ___________________________________________________ 11

4.3
4.3.1 4.3.2

Ultrasonic sensing _____________________________________________ 12
Sensing of a stringline _________________________________________________ 12 Sensing of a surface ___________________________________________________ 12

4.4
4.4.1 4.4.2

The Handset __________________________________________________ 13
Attaching the handset _________________________________________________ 13 Operation of the handset _______________________________________________ 13

4.5

Start-up ______________________________________________________ 14

5.
5.1 5.2

Maintenance _________________________________________ 15
General information ____________________________________________ 15 Periodic maintenance __________________________________________ 15

6.
6.1 6.2 6.3 6.4 6.5

Connecting plan, specifications and troubleshooting ______ 16
Pin connections _______________________________________________ 16 Block diagram ________________________________________________ 16 Specifications _________________________________________________ 17 Sensitivity tables ______________________________________________ 17 List of failures and troubleshooting _______________________________ 18

7.

Declaration of conformance ____________________________ 20

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contact your MOBA supplier. The equipment must be protected against humidity and dirt if it is not to be used immediately.3 Safety measures Warning: Before assembly. losses or damages caused thereby. and the sensors.1. 1. however. Safety precautions: The safety precautions recommended here correspond to basic regulations regarding operation of electrical systems. Assembly: Only original MOBA cables may be used. without prior warning. do not correspond to the information given here. They can be applied for all applications in conjunction with MOBA equipment. Should questions arise. 1. Page 3 . Plugs and sockets must not be removed from the cable as they are protected against humidity and removing them would destroy their protection. to make changes to the product and to its operation which. it might be necessary. Should there be signs of damage the equipment must not be operated !!! Damaged cables and connectors are also a safety risk and must not be used !!! In the event of damage contact your MOBA supplier. In order to maintain our technical leadership. 1. Ensure that the safety screw fasteners sit securely on the connectors . under circumstances. setting up and operating the equipment read the operating instructions carefully and fully. can be found in the data sheets attached or in these operating instructions. We accept no liability for disturbances.1 General information Rights to changes We try to ensure that these operationg instructions are correct and up to date.2 Packaging and storage The product is carefully packed to ensure sufficient protection during shipment. On receipt the packaging and the contents should be inspected for possible damage. Further information about the assembly of the equipment.

voltage transients and overvoltages of short duration. The connecting terminals or connectors must be fitted with a suitable fuse. all connections must be made in accordance with VDE regulations or regulations of the area in which the equipment is used. Connect screened leads to earth at one end only (equipment end) Do not supply other equipment directly from the supply terminals Do not use unused terminals as connections for other equipment Maximum voltages: Do not exceed the maximum voltages. microprocessor technology requires careful installation. Safety in the event of disturbances: This equipment has been developed and tested for industrial environments. or between any isolated circuit and earth is. control and signal cables in separate channels where possible Suppress contactor and relay coils Prerequisite for a disturbing sure mode is a good electrical connection between the machine chassis and housing chassis of the units. The maximum voltage between any two circuits isolated from one another. can lead to disturbances during the operation later: Pay attention to the correct polarity of the connections Do not exceed (neither too high nor too low) the specified voltage supply range Protect the equipment with a suitable supply fuse Use cables of adequate current and voltage ratings Use the shortest possible cable paths. if not heeded to. Configuration: Page 4 . All supply cables and terminals must be sized according to the current taken. The voltages specified in the technical data may not be exceeded.Wiring and cabling: The wiring and cabling must be correctly carried out in accordance with these instructions. (Avoid loops) Lay out load. unless otherwise stated. Nevertheless. limited to its highest input voltage or the supply voltage. Further. We would therefore like to point out the following which. Fuses: The equipment is fitted with electronic fuses which protect it against wrong polarity.

it is advisable. Defective equipment should be tested in an area which has been especially built for this purpose. to use an independent alarm unit. Ask for help Ask your MOBA supplier if you have questions concerning the operation and assembly of the equipment. In many cases the use of an alarm from within the controller itself does not. It is the responsibility of the user to reconfigure according to the operating conditions of the system. offer adequate protection. Alarm supervision In complex systems. Page 5 . in which a fault could endanger operating personnel or damage to the system. An independent alarm unit provides protection and shut-down of the system in the event of an alarm. Any attempt to remove faults from equipment that is still installed can be dangerous to personnel and to the system itself.The equipment can be configured by the user. Damages caused by such negligence are not covered by the manufacturer's guarantee. Before removing or replacing sensors make sure that the voltage supply has been disconnected. because of its dependence on the system. Fault clearance Before starting to clear faults make sure that all voltages have been disconnected. Failure to observe the above safety measures can cause breakdown of the equipment or of the system. Explosive areas The equipment is not designed for use in explosive areas.

The MOBA levelling system is most commonly used to control the screed position of the finisher. Increasing costs for material and operating time call for precise working at an according capacity per day. With the MOBA grade controller G 176 MS you made the right choice. All advantages at a glance: Easy handling Safe to false polarity and voltage peaks Supply voltage 10 . The reliable automatic levelling system of MOBA for the control of your road construction machines. bulldozers and other construction machines.2. 2.40 V DC Both mechanical and contact-free sensing by ultrasonics Page 6 . concrete pavers. but also works successfully on milling machines. The smallest fraction of a centimer during the laying of asphalt. direction and cross slope. or superfluous extension of the operating time may represent for you the limit between profit and loss.1 Introduction Advantages and specials The Combi-Grade G 176 MS and the Slope-Controller S 276 M are two fully independently working units which can be run separately but also together as a whole system for the automatic control of level.

3.1 Mounting Dimensions of the device The dimensions of the G 176 MS Page 7 . 3.

2 Mounting of the G 176 MS Fastening tube with crank handle The level controller G 176 MS can be mounted easily and rapidly with simple tools. For this purpouse a fastening tube with a crank handle should be mounted as an extension of the control unit (actuator). Locking screws 1.3 Attaching the connecting cable Set the valve switch to the “STANDBY” position. Lock the controller’s centering pivot to the fastening tube with the according locking screws. Set the valve switch to the “STANDBY” position. 3. 5. Centering pivot Mounting of the G 176 MS 3. 2. To the machine To the controller Attaching of the connecting cable Page 8 . Insert the round centering pivot that is on top of the controller’s housing vertically into the fastening tube. Turn the controller’s housing so that the operator can see the lamps (front panel of the device against the direction of travel). Loosen the locking screws of the fastening tube. 4. Connect the 10 pole socket of the connecting cable to the 10 pole device plug of the machine. Connect the 7 pole socket of the connecting cable to the 7 pole plug of the controller.3.

Push the sensor arm on the shaft. The sensing tube is used for sensing the stringline.4. Attaching of the sensing ski to the sensor arm 3.4. Loosen the locking screw of the sensor arm.4. Insert the fastening ring of the sensor arm into the fastener of the ski. Locking screw Attaching of the sensor arm to the controller Page 9 . The sensing ski is used for sensing the ground.3 Attaching the sensor arm to the controller Turn the flat part of the shaft towards the front of the controller. Attaching of the sensing tube to the sensor arm 3. 3. Push the pin through the fastener of the ski and the fastening ring of the sensor arm.3. Lock the sensor arm with the locking screw.2 Attaching the sensing ski to the sensor arm Remove the locking pin from the pin of the sensing ski. Lock the pin with the locking pin.4 Attaching the system components The system has two different sensors for sensing the reference. remove the pin.1 Attaching the sensing tube to the sensor arm Unscrew the nut at the end of the sensing tube. Lock the sensing tube with the nut. Insert the end of the sensing tube into the fastening ring of the sensor arm.

4.1 Operation. 4. working examples and start-up The control elements Control lamp Valve switch Control lamp Selector switch Sensitivity adjustment Description of the control elements Page 10 .

2 4. For this purpose. The sensing ski must be attached to the sensor arm.1 Mechanical sensing Sensing of a stringline Switch the selector on the module to the “GRADE” position. the counterweight has to be set in such a way that the sensor arm presses the sensing tube from below against the stingline when the controller is set to zero. Set the valve switch to the “STANDBY” position.2.2 Sensing of a surface Switch the selector on the module to the “GRADE” position.2.4. The zero setting is achieved by positioning the controller by means of the crank handle until the two control lamps go out. Set the counterweight of the sensor arm in such a way that the sensor Direction of travel arm presses the sensing ski onto the reference when the controller is set to zero. Set the counterweight of the sensor arm in such a way that the sensor arm presses the sensing tube onto the reference when the controller is set to zero. The sensing tube must be attached to the sensor arm. When attaching the sensor arm take care that the flat side of the shaft is oriented towards the front side of the controller and that the fastening screw of the sensor arm rests on the flat part of the shaft. it is possible to guide the sensing tube beneath the stringline. When attaching the sensor arm take care that the flat side of the shaft is oriented towards the front side of the controller and that the fastening screw of the sensor arm rests on the flat part of the shaft. 4. Set the valve switch to the “STANDBY” position. Sensing of a surface Page 11 . The zero setting is achieved by positioning the controller by means of the crank handle until the two control lamps go out. Stringline Direction of travel Sensing of the stringline Direction of travel Sensing with the tube gliding under the stringline Note: If the tension of the stringline used as reference is too low.

Stringline Sensing of a stringline with ultrasonics 4. It must be ensured that the sound lobe touches the stringline.3. Sensing of a surface with ultrasonics Page 12 . The zero setting is achieved by positioning the controller by means of the crank handle until the two control lamps go out.3. the sensor arm should not be attached to the controller in order to avoid potential damages. The stringline's diameter has to be at least 3 mm to be indentified as a reference clearly. When operating with the ultrasonic mode. Set the valve switch to the “STANDBY” position.2 Sensing of a surface Switch the selector on the module to the “SONIC” position.3 4. For sensing the stringline the Combi Grade must be positioned at the vertical of the stringline. The working point is about 30 cm below the sensor head. At this distance the sound lobe has a width of approx. When operating in the ultrasonic mode. The working point is about 30 cm below the sensor head. the sensor arm should not be attached to the controller in order to avoid potential damages. 5 cm. Set the valve switch to the “STANDBY” position. The zero setting is achieved by positioning the controller by means of the crank handle until the two control lamps go out.1 Ultrasonic sensing Sensing of a stringline Switch the selector on the module to the “SONIC” position.4.

Connect the 5 pole plug of the connecting cable to the 5 pole device socket of the Combi Grade.5 cm in the “SONIC” mode. However the working point should not be adjusted by more than +/ . in order to avoid damaging the mechanism and the ultrasonic sensor.4.4. Turn the knob on the Handset to the mid position. Attaching of the Handset 4.2 cm when operating with mechanical sensing.4.4 4. Turning the knob allows the working point to be ajusted by +/. Position the controller by means of the crank handle in such a way that both control lamps are out.2 Operation of the handset The Handset is workind as soon as it is connected to the controller.1 The Handset Attaching the handset The Handset has a 6 m long connecting cable.4 cm. In the “GRADE” mode the working point can be adjusted by +/. The Handset Page 13 .

temperatures etc. Sensitivity adjustment The sensitivity adjustment (loosen the locking ring and adjust by turning the button). No further adjustment should be needed if the readjustment had been done under working conditions. The variation of the working level (adjustment of the working point) has to be done with the Handset. Note: A clockwise rotation of the sensitivity adjustment increases the sensitivity of the controller. turn the adjuster slowly counterclockwise until the hydraulic system quiets down.5 Start-up Turning the valve switch to the position “ON” connects the output of the controller with the according valve. he has to carry out this adjustment by means of the crank handle. When this is the case. The Handset The crank handle Page 14 . A counterclockwise rotation decreases the sensitivity. The automatic system is activated.4. If the user does not have a Handset. A minor readjustment of the device may be necessary after the first operation of the machine because vibrations. influence the control circuit. Valve switch The valve switch Turn the sensitivity button clockwise until the hydraulic system starts to swing.

Note: Keep the thread of the plug-connections and of the cable connectors free of any dirt. asphalt or concrete in order to avoid a bad contact. The electronic components are mounted in a solid case in order to avoid any mechanical damage. 5. grease. Page 15 .5. Remove any asphalt or concrete sticking to the sensor arm by means of an appropriate agent and oil the bearing afterwards. The power supply cables should also be checked regularly in order to detect any damage and dirt. 5.2 Periodic maintenance Normal repair procedures carried out in the open consist in replacing burned-out lamps and other spare parts that have been located with the troubleshooting.1 Maintenance General information The level controller has been designed for high working safety so that the maintenance needs a minimum of procedures only.

1 Connecting plan. (+) E: Pot.6. specifications and troubleshooting Pin connections 1) 7 pole device plug: for the connection to the machine Allocation: A: + supply B: Controller output DOWN C: . (-) 1) 2) 2) Connections on the level controller 6.supply D: Pot.supply D: Controller output UP E: free F: free G: free 5 pole device socket: for the connection of the Handset Allocation: A: + supply B: Setpoint C: . 6.2 Block diagram Sensor head Amplifier Ref. Transmitter Machine Transmitter lower raise Output The block diagram of the G 176 MS Page 16 .

0 0 m m + /.2 .5 m m Sensi ti vi ty 1 2 3 4 5 6 7 8 9 10 Sonic D eadband + /.0 .0 m m 0 .5 m m 7 .0 m m 1 6 .0 m m 1 6 . Grade Sensi ti vi ty 1 2 3 4 5 6 7 8 9 10 D eadband + /. +/.25 mm level difference measured at the sensor arm 1 mm level difference Adjustable from overswinging up to a dead range of 5 mm -10 °C to +70 °C -25 °C to +75 °C up to 4g.0 m m 3 .0 0 m m + /.1 .0 m m 1 9 .0 0 m m + /.2 .0 m m < 1 .0 m m Page 17 .0 m m 11 . (current limited) ON/OFF with pulse width modulation (*NPN) 3 Hz approx.5 0 m m + /.3 Specifications 10-40 V DC 0.1 .1 .5 m m 1 3 . Those actually reached also depend from the construction and type of the machine respectively used and of the operating conditions.7 5 m m + /.5 m m < 0 .2 .2 5 m m + /. 6.3 .7 5 m m + /.2 5 m m + /.5 m m 3 .0 .2 . (without valves) 3 amp.5 m m 2 3 .5 amp.2 5 m m < + /.5 m m 5 .0 .6 kg IP 54 Power supply: Operating current: Current load: Output signal: Frequency: Operating range: Setting range (with Handset): Resolution (synchro-transmitter) Resolution (ultrasonic) Sensitivity: Working temperature range: Storage temperature range: Vibration: Weight: Protection type: The values given for accuracy and resolution are purely electrical values of the controller. The deadband is given as complete band.2 .2 5 m m + /.2 5 m m + /. 10-100 Hz 2.6.0 .2 .1 .0 m m 1 . +/.80 mm level difference approx.3 .2 5 m m + /.0 m m 9 .2 5 m m Pulse range 2 4 .50 mm level difference 0.0 .5 0 m m + /.1 .2 5 m m + /.0 m m 1 4 . 0 m m 7 .0 0 m m + /. approx.7 5 m m + /.0 0 m m + /.2 . the pulse range follows in both directions.0 m m 1 9 .2 5 m m + /.4 Sensitivity tables This is a comparison of the adjustable sensitivity levels with the values for the deadband and the pulse range. approx.0 . hidden behind it.0 0 m m Pulse range 2 0 .

It also describes their reasons and the actions to be done in order to eliminate them.5 List of failures and troubleshooting The list of failures and troubleshooting indicates all the failures that are the most likely to occur during the operation of the system. Controller does not actuate the valves Possible reasons: No voltage avilable for the controller Controller module faulty Wiring within housing of the controller faulty Lamps work but controller does not actuate the valves Controller module faulty Current cable to the controller faulty Cable damaged Action: Check the wiring to the machine Replace the module Check the wiring Replace the module Replace the cable Check the cable with the ohmmeter Check the wiring Replace the lamps Replace the module Replace the module Replace the sensor Replace the lamp Wiring within the housing faulty Lamps are not on but controller actuates the valves Lamps are burned-out Controller module faulty Hydraulic system works on only one side. One lamp is on (indicates the direction of the movement) Hydraulic system works but only one lampe is on Hydraulic system works but both lamps remain on Sensitivity of the controller cannot be set Zero offset of the controller Controller module faulty Sensor is faulty Lamps are faulty Controller module faulty Replace the module Controller module faulty Replace the module Fastening screws of the sensor bearing got loose Controller module faulty Sensor is faulty Reset the sensor and tighten the screws Replace the module Replace the sensor Page 18 . Symptoms: Lamps are not on.6.

ultrasonic sensor does not work Possible reasons: Ultrasonic sensor faulty Interface faulty Wiring within housing of the controller faulty Action: Replace the ultrasonic sensor Replace the interface Check the wiring Ultrasonic sensing works. mechanical sensing does not work.Symptoms: Mechanical sensing works. Shaft encoder faulty Replace the shaft encoder Wiring within housing of the controller faulty Chek the wiring Any control or measurement on the controller should be executed by educated personnel only which has been specially trained for such work. Page 19 .

73 EN 55011 . 1995 Dipl.7. VDE 0847 part 4-4 criterion B Performance criteria according to EN 50082 T/2 Additional information: The products meet the EMC-requirements of 89/336/EEC. VDE0847 part 4-2 criterion B ENV50141 (1993). that the machine in which this shall be installed is conform to the Council Directive. IEC 1000-4-4:1995. Declaration of conformance Declaration of conformance to ISO/EC Guide 22 and EN 45014 standards Name of manufacturer: Address of manufacture: MOBA Mobile Automation MOBA Mobile Automation Vor den Eichen 4 D-65604 Elz The manufacturer declares that the products: Product types: G176 M Combi Grade-System G176 MS 04-15-0001X 04-15-2001X Model numbers of the components which were tested in a typical system: G176 MS Handset MS 04-15-2001X 04-15-2101X are designed and manufactured to meet the following standards: Saftey: EMC: DIN VDE 411. class B ENV 50140 . E DIN VDE 0843 T6:12/93 EN61000-4-4:1995. E IEC 1000-4-6.DIN VDE 847 T3 (1993) criterion A ENV 50140 . part 1. The products were tested in typical configurations.DIN VDE 847 (1993). IEC 1000-4-2 (1995). Elz. 0001/10.DIN VDE 0875 T11 (1992). IEC 65A/77B (Sec) 145/110 criterion A EN61000-4-2 (1995). Markus Wendel Quality manager Page 20 . It is not permitted to take the appliances into service if it is not clarified. January 11th.-Ing.