Training - Gruas Portico

Richard Galviz
Electrical
Training Manual
For
LIEBHERR
AC Cranes
Electrical Training Manual
DISCLAIMER
Maintenance should only be carried out by competent, authorized personnel

working with proper tools and equipment in a safe manner.
Cranes by their nature are dangerous machines and every care should be taken
to ensure the safety of everyone who has to work on or near it.
This document is intended only as a guide and is not intended as a replacement
for manufacturer’s literature. Consult the relevant manual before undertaking any
work.
No modifications should be carried out without prior consent of Liebherr
Container Cranes Ltd.
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Table of Contents
TABLE OF CONTENTS............................................................................................................ 3
SECTION 1............................................................................................................................... 5
READING DRAWINGS............................................................................................................. 5
LAYOUT OF THE CRANE........................................................................................................ 6
DRAWINGS.............................................................................................................................. 7
KEY TO READING LIEBHERR DRAWING'S / SYMBOLS.......................................................7
SCHEMATIC DRAWINGS LAYOUT......................................................................................... 8
SCHEMATIC DRAWINGS LAYOUT CONTINUED...................................................................9
ELECTRICAL CONNECTION BOXES...................................................................................10
SYMBOLS.............................................................................................................................. 11
ELECTRONIC SYMBOLS...................................................................................................... 13
LAYOUT OF THE HOUSE...................................................................................................... 14
ELECTRICAL PANELS................................................................................................................. 14
SECTION 2............................................................................................................................. 15
HOIST LIMITS........................................................................................................................ 16
TROLLEY............................................................................................................................... 17
TROLLEY LIMITS........................................................................................................................ 17
BOOM..................................................................................................................................... 18
BOOM LIMITS............................................................................................................................ 18
A FRAME LIMIT SWITCHES.................................................................................................. 19
CABLE REEL DRUM.............................................................................................................. 20
TRAVEL LIMITS..................................................................................................................... 22
SECTION 3............................................................................................................................. 22
PLC / INTERBUS.................................................................................................................... 22
CODESYS PLC...................................................................................................................... 23
OVERVIEW................................................................................................................................ 23
BASIC LOGIC......................................................................................................................... 24
PLC LOGIC GATES AND ELECTRICAL EQUIVALENT CIRCUITS.......................................................28
LOGIC AND POU STRUCTURE............................................................................................32
GOING ONLINE TO CPLC..................................................................................................... 33
CROSS REFERENCING........................................................................................................ 34
GLOBAL SEARCH.................................................................................................................. 36
WATCH AND RECIPE MANAGER......................................................................................... 37
CODESYS HELP.................................................................................................................... 37
INTERBUS SYSTEM.............................................................................................................. 39
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SECTION 4 AC DRIVES........................................................................................................ 45
INFORMATION....................................................................................................................... 48
LCP......................................................................................................................................... 49
LCP MAIN MENU................................................................................................................... 51
LCP - ALARMS....................................................................................................................... 53
LCP COMMUNICATION PARAMETERS...............................................................................56
LCP DIP SWITCHES.............................................................................................................. 57
DRIVE SIGNALS.................................................................................................................... 58
LCP COPY PARAMETERS.................................................................................................... 59
RS 232-485 CONVERTER..................................................................................................... 60
VLT MCT 10........................................................................................................................... 60
MCT 10 OPENING A PARAMETER FILE..............................................................................61
MCT 10 MAIN WINDOW........................................................................................................ 62
MCT 10 NETWORK AND PROJECT......................................................................................62
MCT 10 DOWNLOADING FROM PC TO A DRIVE................................................................64
MCT 10 UPLOADING FROM DRIVE TO PC..........................................................................65
MCT 10 COMPARING PARAMETERS..................................................................................66
MCT 10 SCOPE FUNCTION.................................................................................................. 69
PLC TERMS AND DEFINITIONS........................................................................................... 94
ABBRIEVATIONS................................................................................................................... 96
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Section 1
Reading Drawings
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Layout of the Crane
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DRAWINGS
KEY TO READING LIEBHERR DRAWING'S / SYMBOLS
For identification of electrical equipment, LIEBHERR use a code that is made up of letters and
numbers. This code can be broken up to show the location of equipment, the drive it is
associated to, the type of device and its component number.
An example of a code is S1HK10 and this can be broken up as shown;
From the lists below, it can be seen that S1 is the Electrical House, H relates to the Hoist, the
type of device is a contactor and the component No. is 10.
Location Associated Drive
S1 = Electrical House A= General Control

S2 = Switchgear Panel Trolley Cabin E= Boom/Derrick
S5 = Filter Panel F= Travel/Gantry
R1 = Electronics’ Panel (Hoist 1&2,Overload) H= Hoist
P1 = Chair Control Station K= Trolley
P2 = Spreader Indicator Lamps in Cabin N= Cable Reeling Drum
P10= Boom Station R= Heating & Lighting
P20= Travel Station (crane entry) S= Spreader
T= Trim/List/Skew
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Type of Device
C= Capacitor's
F= Protective device's i.e.: fuses, MCB’s etc
H= Indicating equipment i.e.: indicator lamps
K= Relays, contactors
M= Motor's
Q= High current switches
R= Resistors
S= Switches
T= Transformer
X= Terminals, plug's, socket's
Y= Electrically actuated mechanical devices i.e.: solenoid valves
Z= Filter's
Schematic Drawings Layout
For convenient tracing of components and equipment, the schematic diagrams are sub-
divided into diagram segments numbered 1 to 8 as shown below.
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In the drawings, components are labelled with an identification code. If the component has
auxiliary contacts on it that are used in other places in the circuit or drawings, then these
contacts will have a number beside them, for example /57.3. This number gives the page
number followed by the segment number where these contacts are actuated. Lines of
potential or power supply lines use the same numbering to show where their supply is coming
from.
Where a relay or contactor’s coil is shown, a list of its contacts will be shown underneath it
and the page and segment number will be beside it.
/57.3 is page 57, segment 3. If the number is just shown as for example, .2, then its contact is
on the same page in segment 2.
Schematic Drawings Layout Continued

At the bottom right hand corner of each set of drawings is a box like the one above showing a
location where the drawings are belonging to, the Drive it is related to and the page no. of that
particular drawing.
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Electrical Connection Boxes
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Connection Box Location
X1 Electrical House
X2 Trolley Cabin Switchgear Panel
X5 Operators Chair (Underneath Chair)
X6 Back of Crane (Festoon connection box)
X7 Top of Trolley Cabin (Festoon & Spreader cable)
X9 Top of A frame
X11 Travel Motor's 1 + 2
X15 Storm-anchors / Rail-brakes (Seaside)
X16 Storm-anchors / Rail-brakes (Landside)
X23 Pulley Frame (Spreader Cable Connection Box)
X31 Trim / List / Skew
X40 Floodlight control on main beam
X41 Link box between main beam and boom
X42 Link box between main beam and boom
X51 Repair winch / Re-reeve unit
Symbols
Normally open Normally Closed Delay to Open

Contact Contact Contact
Pushbutton with
Delay to Close Pushbutton Latch
Contact
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Proximity Switch
Cam Switch Cam Switch
N/O Contact
N/O Contact N/C Contact
Proximity Switch
N/C Switch Indicating Lamp Access Light
Floodlight Heater Thermal Switch
Symbols Continued
PTC Thermistor Current Transformer Choke
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Joystick Transducer AC/DC Rectifier Fuse
Fuse with Monitor Coil Delay ON

Timer
Delay OFF Latching Coil PLC Input

Timer
3 Phase Motor
PLC Output
Electronic Symbols
Resistor Potentiometer Capacitor
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Diode Thyristor OP Amp
Layout of the House
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Electrical Panels
Panel Description
1. Travel Drive
2. Hoist Drive 1 Master
3. Hoist Drive 1 Slave
4. AFE Slave Left
5. AFE Master
6. AFE Slave Right
7. Hoist Drive 2 Master
8. Hoist Drive 2 Slave
9. Trolley / Boom drive
10. Hoist general control / Overload
11. PLC / PC
12. Heating and Lighting
13. Main Supply, Travel LC filter
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Section 2
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Hoist Limits
The limits used for the hoist, except the emergency stop limit switch, are located at the end of
the hoist drum. They are cam type switches and are normally closed, therefore lose of a
signal gives a limit indication. The emergency stop limit switch is located on the trolley and it
uses a weight suspended from a lever type limit switch and will activate should the spreader
hit the weight and lift it off the limit switch. Again, this is normally closed type switch.
The 50% pre-limit switch hoist down is only used when the trolley is over land for slow down.
The hoist down limit switch is activated when there is 3 turns of rope left on hoist drum. These
switches are normally closed so that they are fail-safe, therefore, if the cable to the limit
switch is broken, the limit will be activated and the hoist will slow down. If the limit switches
were the normally open type and the cable broke, the slow down limit would never activate
and the hoist would not stop in time and cause damage.
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TROLLEY
Trolley Limits
Limit switches are fitted to the trolley to provide slow down zones, stop positions, emergency
stops and trolley parked indication. Two types of switches are used for trolley limits;
1. Lever type which activate upon physical contact with a striker bar and are used for
the stop limits and emergency stop limit.
2. Magnetic type which are non contact and are used for slow down speed zones, stop
limit when the boom is up, trolley parked indication and heavy lift zone indication.
Layout of trolley limits
An encoder is also fitted to the trolley to provide trolley position indication on the EMS display
and on the WinCC / Crane Visualisation display and also for slow down when auto parking
the trolley. The encoder is fitted to the output shaft of gearbox number 1.
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BOOM
Boom Limits
The Boom up and down operations are automatic and so it is important that the limit switches
operate and are set correctly.
The boom down and the locking zone limit switches are cam type and are fitted to the boom
drum. All other limit switches are located at the top of the A frame. The locking zone limit
switch is used to keep the boom in slow speed while it is locking or unlocking. When the
boom enters the locking zone, it is slowed down and when it leaves the locking zone it speeds
up to full speed (providing that fast speed has been selected).
If the boom is locking, when it reaches the boom up limit, the hook closes and the boom is
lowered into it and it keeps lowering until the slackrope limit switches are activated. This
ensures that the weight of the boom is on the hook and not on the ropes.
If the boom is unlocking, the boom is first raised to take up the slackrope and the weight.
When it reaches boom up limit, it begins to lower in slow speed until it passes the locking
zone limit switch where it can speed up. The hook is also held open until the boom has left
the locking zone.
The boom down limit switch is set to operate just as the weight of the boom goes on to the
holding arms. This limit switch slows the boom down to pre-limit speed and the boom drum
continues to pay out rope until the slack-rope limit switches are activated and for a time after
this to ensure that there is enough slack-rope payed out to ensure that the weight of the boom
is on the holding arms when the trolley is on the boom and not on the boom ropes.
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A Frame Limit Switches
The following limit switches are fitted to the A frame lock to determine when the boom is up,
locked and also protection against the boom over-travelling ( E stop up). The thruster to open
the hook is also fitted with limit switches to show if it is open or closed.
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Cable Reel Drum
The cable reel drum uses a stalled torque motor with a wound rotor for torque control and it is
a brake type motor. The motor can run at full torque with no rotation for long periods of time.
The motor torque always acts in one direction, winding on. To wind off, the torque is reduced
and the cable is pulled off under tension as the crane travels.
The motor is a combination of an electric motor and a spring-loaded brake in a common
enclosure. The rotor is cone shaped and this causes the rotor to be pulled into the stator and
releases the brake when power is applied to the stator. This axial movement is limited by the
spring, which applies the brake again when power is removed. The brake disc also acts as
the cooling fan.
Brake Motor
As the cable reel drum motor is always winding on, the torque in the motor must be changed
depending on how much cable is on the reeling drum and whether or not the cable is being
wound on or pulled off against the torque direction of the motor. Changing the amount of
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resistance in the rotor circuit varies the torque in the motor. As the amount of cable is -
reduced on the drum, the torque is reduced and as it increases the torque increases. When
the cable is winding off, the torque is reduced so the cable can be pulled off under tension.
This keeps the cable tight on the drum and this prevents excessive cable from being wound
off. If the diverting arm falls straight down because the cable has gone slack, an extra torque
step is brought in for acceleration to pick up this slack cable. A limit switch set over the pit
prevents this acceleration step from coming on when the cable is directly over the pit when
the diverting arm is pointing straight down as this extra torque could pull the cable out of the
pit.
Torque Steps
Limit Switch Wind On Wind Off
2/3 to Full NK7M NK4M
1/3 to 2/3 NK6M NK3M
Empty to 1/3 NK5M Star Point
Typical rotor resistance circuit
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Travel Limits
The travel limit switches are located on the cable reeling drum and are cam type similar to the
hoist limit switches. The travel limits are set to activate at the end of crane travel or when the
cable reel drum is empty (3 turns of cable left on the drum). When the crane travels to the left,
the travel right limit switches will become activated when the drum turns as both left and right
limits are activated as the crane travels away from the pit connection with the drum paying out
cable. To overcome this, when traveling left, the travel right limit switches are bridged out by
diverting unit direction limit switches – payout direction A and when traveling right, the travel
left limit switches are bridged out by payout direction B.
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Trim / List / Skew

For rope adjustment of the spreader in the trim, list or skew directions, an electro – hydraulic
system is fitted to the back of the crane. Four hydraulic cylinders act upon the four hoist
rope’s, each cylinder is connected to a lever acting on a sheave of a corresponding rope.
Rope adjustment is initiated by the operator, using a joystick in the driver’s cabin. The
operator selects the motion and the amount of adjustment, the rest of the control is done by
the plc. The hydraulic system uses proportional valves to adjust the amount of movement of
the hydraulic cylinder. A potentiometer fitted to each lever gives position feedback to the plc.
This also allows the plc control the speed of the rams extending or retracting so that they all
move at the same speed. Limits are also set using this position feedback and this can be
used to view the status of spreaders trim, list and skew on EMS display.
A center position is also stored in the plc and this is activated by pressing the ‘Zero’ button on
top of the T/L/S joystick. This brings the cylinders back to whatever position they were at
when the position was stored.
The hydraulic cylinders can be manually adjusted from the T/L/S platform using a selector
switch for selecting a cylinder and retract and expand buttons. The crane must be turned on
from S1 (Electrical house) and the Rope Adjustment switch turned on. Turning off this key
switch stores the position of the selected cylinder as the center position. This must be done
for each cylinder.
Ram out shortens rope and ram in lengthens rope.
Ram 1 Ram 2 Ram 3 Ram 4

Trim Left In In Out Out
Trim Right Out Out In In
List Forward In Out Out In
List Reverse Out In In Out
Skew Left In Out In Out
Skew Right Out In Out In
Table showing the action of each ram for each T/L/S movement
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Basic Hydraulic Diagram
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Section 3
PLC / Interbus
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CoDeSys PLC
Overview
CoDeSys is the software on the PC for programming and monitoring the Crane program
which is loaded on the PLC. CoDeSys automatically starts, on power up of the PC. Once the
program is downloaded to the PLC the program will run on the PLC without the PC, i.e. the
PC does not control the crane. The PC is only used for changing the program on the PLC and
diagnostics.
Starting CoDeSys and Visualisation

When you power up the PC both CoDeSys and the Visualisation Program should start
automatically. If they both don’t start then double click the icons on the PC desktop. It is
advised to start the CoDeSys a minute before the Visualisation. If the Visualisation has
started and the CoDeSys has not, then go to the Tools menu and click the option to start
CPLC.
When CoDeSys has started the screen shown on the following page will appear.
DECLARATION SECTION
OBJECT
ORGANISER
Main Section
POUs – Program Organisation Units
MESSAGE WINDOW
CoDeSys Layout
As shown above the CoDeSys screen is divided into four sections.
 Object Organiser Section. (This is located on the left of the screen)
 Declaration Section (This is located at the top of the screen)
 Logic or main Section(This is in the middle of the screen)
 The message section(This is located at the bottom of the screen)
The Object organiser screen is affectively a menu screen. This screen is divided into 4
screens which can be reached by the tabs at the bottom. The four tabs are:
 POUs (Contains Logic)
 Data Types (This can be ignored)
 Visualisation (Different from main visualisation program)
 Resources (Inputs and Outputs are located in here)
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All the Logic on the CPLC is in the POU tab and is divided into folders here. The main folders
are Crane Functionality and System Functionality. System Functionality can be ignored.
Crane Functionality is subdivided into more folders for the different drives and parts of the
Crane. These subfolders are further divided into Program blocks called POUs. The Logic is
contained inside the POUs. The other tabs will be talked about later.
The declaration screen is where all the variables for that POU are declared. If you want to
introduce a new variable to the Logic you must first give it a name and declare to the PLC
what data type it is i.e. BOOL or Integer etc, otherwise the PLC will not recognise it. Variables
declared in the declaration screen are known as LOCAL variables and can only be used in
that particular POU. A GLOBAL VARIABLE is declared elsewhere and can be used in any
POU.
The Logic or Main Screen is where the Logic within the POU is displayed. This is done by
double clicking the POU in the Object organiser. The Logic within the POU is divided into
Networks. Each Network has a comment on the Top describing what the logic in that network
is doing. Note: When you open a POU it stays open until you close it. Opening another POU
just opens it over the other one. You should not open more than Ten windows at a time. You
can use the Window drop down menu to jump between open POUs.
The message window gives you messages about the status of the system. If you try and
download changes to the CPLC and it won’t work the reason why will be displayed here in
RED. The message window can also be used to show you cross references of variables.
Naming of Variables
In general the following rules are used for naming variables
 All digital inputs to the CPLC start with i
 All digital outputs from the CPLC start with q
 All internal variables in the CPLC start with b
BASIC LOGIC
AND Gate
An AND gate has an infinite number if inputs and a single Output. The output of an AND gate
is TRUE (i.e. = 1) only if all the inputs are TRUE. If any of the Inputs are FALSE (i.e. =0) then
the output is FALSE.
TRUTH TABLE
INPUTS OUTPUT
Test1 Test2 Q3
0 0 0
0 1 0
1 0 0
1 1 1
An AND gate is the equivalent of a series circuit in Relay Logic, with the Inputs the series
contacts and the Output the Coil.
OR Gate
An OR gate has an infinite number of Inputs and a single Output. The Output of an OR gate is
TRUE if any of the inputs are TRUE. If all the Inputs are FALSE then the Output is FALSE
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TRUTH TABLE
INPUTS OUTPUT
Test1 Test2 Q4
0 0 0
0 1 1
1 0 1
1 1 1
An OR gate is the equivalent of a parallel circuit in Relay Logic, with the Inputs as the
contacts and the Output as the coil.
On Delay Timer
An On Delay Timer delays the Output from being TRUE for time delay PT when the Input is
TRUE. If the Input should go FALSE before the time has elapsed the Output will not come
On. If the Output is On and the input goes Off then the Output will go Off immediately. Note
that the time has to be written in the format T#5ms for a 5 milli second delay or T#5s for 5
second delay or T#5m for a five minute delay. A timer has to be declared and given a variable
name at the start. The output can be used in the program by using this name with .Q after it,
OnDelayTimer.Q in the example shown. OnDelayTimer.Q is the same value as OnTimer in
our example below.
Off Delay Timer

An OFF Delay Timer delays the output from going OFF for time delay PT when the Input goes
OFF. When the Input comes On the Output comes On immediately. The time is written in the
same format as a TON.
Pulse Timer
The Output of a Pulse Timer is TRUE if the Input is TRUE. The Output remains on for Time
PT regardless of the Input. When PT has elapsed the Output returns to FALSE as long as the
Input is OFF.
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RS Latch
An RS Latch is the equivalent of a Flip Flop in relay logic. The Output of the Latch comes on
when the SET is ON. The output remains ON even if the SET Input goes OFF. When the
RESET Input is on the Output Goes OFF. An RS Latch is Reset Dominant i.e. if both the SET
and RESET Input are on at the same time the RESET Input gets dominance and the Latch is
Reset and the Output goes OFF. A Latch has to be declared and given a variable name at the
start. The output can be used in the program by using this name with .Q after it, RSLatch.Q in
the example shown. RSLatch.Q is the same value as RSLatchForTest in our example below.
SR Latch
An SR Latch is identical to a RS Latch except that in this case the SET Input has dominance.
That is if both The SET and RESET Inputs are ON then the SET gets dominance and the
Output is ON.
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Inverter
An Inverter simply inverts the Input. If the input is TRUE then the Output is FALSE and vice
versa. An Inverter appears as a small circle on the Input of a Gate as shown below.
Rising Edge Trigger

An R_Trig block detects a rising edge on the Input. That is when the Input switches from
FALSE to TRUE the Output becomes true momentarily and then returns to FALSE.
Falling Edge Trigger

An F_Trig block detects a falling edge on the Input. That is when the Input switches from
TRUE to FALSE the Output becomes true momentarily and then returns to FALSE.
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PLC Logic Gates and Electrical Equivalent Circuits
AND Gate and

equivalent circuirt.
NAND Gate and

equivalent circuit
OR Gate and
equivalent
Circuit
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NOR Gate and

equivalent
Circuit
Examples of Combinations of AND & OR Gates
Combination of AND and OR gates and equivalent circuits
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Combination of Gates using a negated or inverted input
AND Gate with a negated or

Inverted input
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SET / RESET
A Set / Reset operates as a latch. When there is an input at the SET, the output turns on and
latches on even when the input is removed from the SET input. When there is an input at the
RESET input, the output is turned off and remains off until it is SET again.
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Comparison between a PLC timer and a hard wired timer
Logic and POU Structure.

Drive Folders
All the Logic for the CPLC can be reached from the Object Organiser Screen. As already
shown the Logic is divided into Folders i.e. each drive has its own folder.
The folders are then divided into POUs. Each POU contains numerous Logic circuits.
For the Drive Folders the main POUs are the Drive_General and Drive Commands:
Drive_General POU
The Drive_General POU (e.g. Hoist_21_General) contains the Logic which Turns the
particular drive ON. The main Logic is
 Drive Safety Chain(Must be ON for Drive to Be On)
 Drive On/Off commands including restart if drive goes off
 Monitoring of Brakes
 Various Interlocks to Drive Regulators
 Drive Over speeds
 Hoist Brake Command
Drive Commands POU

The Drive_Commands POU (e.g. Hoist_22_Commands) contains all the motion commands
and speed commands to the Drive. The main Logic is:
 Various Interlocks to Drive Regulator
 Hoisting/Lowering commands
 Positioning Mode
 Creep Speed command
 Delay Full speed after slack rope and deposits.
 10%/25%/50%/Full Speed Commands
 Hoist Joystick
 Hyperbolic Calculator (Corrects speed ref depending on load)
 Set Value Reference for Hoist.
The other POUs in the drive folder can for the most part be ignored.
Note: The Trolley Folder has two extra POU which contain the Logic for the Autopark of the
Trolley and the Locking of the Trolley Gates.
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Crane Control Folder

This Folder contains the Logic for turning the entire crane on. If the crane will not turn on look
in the Crane General POU. This contains the following:
 General Safety Chain (Must be on for crane On)
 Interlock on Drives if Over temp in switch boxes
 Interlock when changing Boom/Trolley parameters
 Crane On/Off from S1, P1, P20, P10.
 Delay Restart after switch off
 Crane On Lamps P1, P10, P20
 Main-contactor Close command
 Signal Horn Logic
 Wind Level Logic
 Buzzer and Lamps
 Hour meter Digital outputs
The other POUs in this Folder contain the Logic for the Reset lamps on various reset buttons
and the loading of the Trolley/Boom Paramaters.
Logic for other parts of crane i.e. Storm Anchors or Cable Drum can be found in other folders.
Going Online To CPLC.

The logic that appears on the main window when you open CoDeSys is the logic that is
stored on the PC. The Logic is also stored on the CPLC at two different locations. In the
CPLC RAM (Random Access Memory) and on the CPLC Hard drive.
To view the logic that is on the CPLC you have to go ONLINE. To do this, do the following:
 Click On the Online Drop down menu
 Click the Login option
The Logout of the PLC simply do the following

 Click On the Online Drop down menu
 Click the Logout option
Alternatively you can use the shortcut keys shown below which appear on the toolbar
The Key on the left is Login and the right is Logout (with the x).
If the Logic on the PLC and the PC are different, you will be asked if you want to download
the changes. Ensure you know what the differences are before saying yes.
When you have logged in you can see the status of the Logic on the CPLC.
A value that is TRUE will be shown in Blue and values that are FALSE appear in Black
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Cross Referencing
Referencing a variable where you already know one location

The cross referencing function is used to search for variables within the program. If you are
looking at a variable and you want to see where else it is used do the following:
1. Logout of the CPLC

2. Highlight the variable you want to search for.
3. Go to the Project drop down menu and click Show Cross Reference
4. A box appears with the variable name in it. Click Get References
5. A list where it is used appears. (Ignore ones that say Implicit Access)
6. The List also shows whether it is read or write access i.e. whether it is written to
at that location or just read at that location.
7. To go to that location highlight the place on the left hand side of the list and press
GO To. The POU automatically opens at the location where the variable is used.
8. Alternatively you can send the reference list to the message window where you
can flick through all of them by clicking To Message Window and F4 to jump
between places.
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Referencing When you Know Variable Name But Not Any Location
Simply repeat the steps above but write the name into the Cross Reference pop up box.
Reference An Input/Output From The Wiring Drawings

To reference an input of output that you have found on the wiring drawings and want to see
where it is used in the CPLC do the following:
1. Get the Module No and terminal number from the wiring drawings
2. Go to the Resources Tab in the Object Organiser screen. All the values which
are communicated to the PLC over the Interbus and Can bus networks are
located in here i.e. Inputs and Outputs.
3. Go to the following location Global Variables/Interbus/IO.
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4. Here you will find a list of all the Interbus modules that are on the crane. Select
the one that your input is on and double click on it.
5. All the inputs in that module are displayed here. Highlight the Input you want to
reference and Do a cross reference as in 5.1 above.
Note: If cross referencing a timer or latch make sure you do not have .Q in the name for the
cross reference.
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Global Search
Some variables are stored in structures or databases and cannot be found using the Cross
Reference function. In general you will notice these variables as having a dot or square
brackets in the name (see the hardware errors in the safety chains for example). The Global
Search function has to be used for these. To do a Global Search do the following:
1. Highlight the variable you are searching for

2. Go to the Project drop down menu and select Global Search. Then select to
search in entire project.
3. The following window will appear
4. You can either Click Find Next which will automatically go to the next location
of that variable (keep doing this until you find location you are looking for) or
click to Message Window where a list of all the locations will be displayed in
the message window. You can use F4 to jump through the list.
Note: You can also use the shortcut key located in the toolbar. Make sure you use the
button on the left of the screen as there are three buttons which look very similar.
Watch and Recipe Manager

This is another useful function of CoDeSys. With this function you can make up list of
variables and watch them Online. This allows you to see all the variables for a particular
crane function on the one screen i.e. all the trolley limit switches. We have already made
numerous watch lists. They can be found in the Resources Tab. Click Watch and Recipe
manager. The screen shown below appears. All the lists are located on the column on the left
with the members of the list located on the main pane. To switch between lists simple double
click the list on the left. To add a new list right click in the column on the left and select new
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watch list. Give the list a name. You can then add the variables by simply typing in their
name or copying and pasting them in. Note you must include a dot before the name.
CoDeSys Help
CoDeSys has a comprehensive Help Menu. This can be accessed from the Help drop down
menu or by simply pressing F1. The help menu gives a description of how to carry out all the
functions in CoDeSys. It also gives a description of All the Gates and Timers etc. used in
CoDeSys. A quick way of getting these is to select say an AND gate at random in the program
and press F1. The Help screen will appear on the AND gate description screen.
Tracing Signals from the Wiring Diagram to the PLC Program
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1 2 In CoDeSys, select Project / Global Search…
3 Double-click the result line to jump to the POU directly.
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Tracing Signals from the PLC to the Diagram
Highlight desired signal: Open to Phoenix Bus Structure

1 3 Diagram in S1:
2 Press Shift-F2. The module reference is shown:
Module # Connection #
4 5
INTERBUS System
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For the purpose of relaying all input and output information to the PLC, a Bus system
(INTERBUS) is used. This dramatically reduces the amount of cabling to the PLC and within
the switchbox. A single 5 core cable is used to transmit all input / output data within the
switchbox and also to the trolley. Below is a typical INTERBUS layout for a crane. The EMS
display is normally the last item on the INTERBUS.
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INTERBUS Layout
Bus Terminal module
1.1 1.2 1.3 1.4 1.5 1.y
1.0
2.1 2.2
CONTROLLER
2.0 Local Bus
Modules
3.1 3.2 3.3 3.4 3.5 3.6
3.0
Remote Bus
Cable
x.0
INTERBUS Controller Stat-up Sequence

This can be seen on the front of the PLC (SMA Enduro)
LOAD
INTERBUS
CONFIGURATION
(DEFINED BY
PLC PROGRAM)
TEST
EPROM
TEST
RAM
TEST
PARAM
MEMORY
CTRLR
READY 
INTERBUS
ACTIVE
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INTERBUS Errors
Example 1 – Remote Bus Error
“Remote Bus error”
1.1 1.2 1.3 1.4 1.5
1.0
2.1 2.2
2.0 ?
3.1 3.2 3.3 3.4 3.5 3.6
3.0
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Example 2 – Local Bus Error
“Local Bus error”
1.1 1.2
1.0
2.1 2.2 2.3 2.4 2.5
2.0 ?
3.1 3.2 3.3
3.0
Faulty local bus module!
Example 3 – Output Error
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“An error occurred at the outgoing remote bus

interface of the indicated bus segment”
1.1 1.2 1.3 1.4 1.5
1.0
2.1 2.2
2.0
3.1 3.2 3.3 3.4 3.5 3.6
3.0
Cable faulty, or disconnected

from ‘OUT’ connector of bus
terminal module 3.0
Crane Interbus Layout
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Interbus Layout
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Section 4
AC Drives
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Danfoss FC302 Drives
FU1 Travel Drive

HU1 Hoist Drive 1 Master
HU2 Hoist Drive 1 Slave
AU1 AFE Slave Left
AU2 AFE Master
AU3 AFE Slave Right
HU11 Hoist Drive 2 Master
HU12 Hoist Drive 2 Slave
KU1 Trolley / Boom Drive
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Electrical Layout of the Drives
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MCT10
This is a software tool from Danfoss for programming drives, reading parameters, writing
parameters and changing parameter values. There are also useful tools for comparing
parameter within the drive to parameters stored on the PC and a scope function for reading
values live from the drive like speed, current, frequency etc
Double click on the MCT10 icon to start the program or double click on the
parameter file. Parameter files have a file extension .ssp
Information
• The Danfoss Manuals are an invaluable source of information.

– FC300 Service Manual
• Information about hardware fault finding and repair
– FC300 Programming Guide
• Information about all parameters
– FC300 Operating Instructions
• Information about alarms, warnings and trouble-shooting
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LCP Panel
LCP
• Functions
– Displays the drive / motor status
– Allows the user to view and change parameters
– Displays alarms and warnings
– Can store parameters in internal memory.
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LCP - Status
LCP Main Menu
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LCP Main Menu
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LCP Main Menu
LCP Main Menu
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LCP Main Menu
LCP - Alarms
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LCP Alarms
LCP Alarms
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LCP Communication Parameters
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LCP DIP Switches
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Drive Signals
LCP Copy Parameters
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RS 232-485 Converter
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VLT MCT 10
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MCT 10 Opening a Parameter File
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MCT 10 Main Window
MCT 10 Network and Project
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MCT 10 Network and Project
MCT10 – Viewing Project Parameters
• Project parameters arranged for each drive.

– AFE
– Hoist 1
– Hoist 2
– Travel
– Trolley / Boom
• Each drive is possible of changing between 4 different sets of parameters
called Setups.
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MCT 10 Downloading from PC to a Drive
MCT 10 Uploading from Drive to PC
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MCT 10 Comparing Parameters
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MCT 10 Scope Function
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Drive Connections:
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Bit Switches:
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AFE Connections:
Relay 1 Soft charge ready (24VDC) (iAFE_SoftChargeReady)

Relay 2 DC-link on ref (24VDC) (iAFE_DcLinkOnReference)
Terminal 18 Start (24VDC) (qAFE_Run)
Terminal 19 Spare
Terminal 20 L24V-
Terminal 29 DC-link on ref (24VDC) -> Drives Terminal 27 = Coast Inverse
Terminal 68/69 RS485
Terminal 91/92/93 L1/L2/L3 (630VAC)

Terminal 94 PE
Terminal 117/118 DC-/DC+ (975VDC) (DC Bus)
Fan Supply L1/L2/L3

Soft Charge Supply L1/L2/L3
MDCIC Supply L1/L2/L3 (Mains Synchronise)
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Hoist 1 Connections:
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Relay 1 Mech brake ctrl (Master-Slave & Slave-Single1) (24VDC)

Relay 2 Drive ready/rem ctrl (24VDC) (iHoist1FC_Ready)
Terminal 18 Start (24VDC) (HK2 Hoisting)
Terminal 19 Start reversing (24VDC) (HK3 Lowering)
Terminal 20 L24V-
Terminal 27 Coast Inverse (24VDC) <- AFE Terminal 29 = DC-link on ref
Terminal 32 Set-up select bit 0 (24VDC) (qHoistParameter2)
Terminal 37 Safe Stop (24VDC) (IGBT Release HK5)
Terminal 39/42 Torque Reference (0/4-20mA) -> Hoist 2
Terminal 53/55 Speed Reference (0/4-20mA) (Master-Slave & Slave-Single1)
(nSetvalueHoist1)
Terminal 96/97/98 L1/L2/L3 (690VAC) (Motor)

Terminal 94 PE
Fan Supply L1/L2/L3

S201 ON Speed Reference (0/4-20mA)
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Hoist 2 Connections:
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Relay 1 Drive ready (Master-Slave) / Mech brake ctrl (Slave-Single2) (24VDC)

Relay 2 Drive ready/rem ctrl (24VDC) (iHoist2FC_Ready)
Terminal 18 Start (24VDC) (HK2 Hoisting)
Terminal 19 Start reversing (24VDC) (HK3 Lowering)
Terminal 20 L24V-
Terminal 37 Safe Stop (24VDC) (IGBT Release HK5)
Terminal 53/55 Speed Reference (0/4-20mA) (Slave-Single2) (nSetvalueHoist2)
Terminal 54/55 Torque Reference (0/4-20mA) <- Hoist 1

Terminal 94 PE
Fan Supply L1/L2/L3

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Travel Connections:
Relay 1 Mech brake ctrl (24VDC)

Relay 2 Drive ready/rem ctrl (24VDC) (iTravelFC_Ready)
Terminal 18 Start (24VDC) (FK2 Right)
Terminal 19 Start reversing (24VDC) (FK3 Left)
Terminal 20 L24V-
Terminal 37 Safe Stop (24VDC) (qReleaseIGBT_Travel)
Terminal 53/55 Speed Reference (0/4-20mA) (nSetvalueTravel)

Terminal 94 PE
Fan Supply L1/L2/L3

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Trolley / Boom Connections:
Relay 1 Mech brake ctrl (24VDC)

Relay 2 Drive ready/rem ctrl (24VDC) (iTrolleyBoomFC_Ready)
Terminal 18 Start (24VDC) (qTrolleyBoomDir1) (Forward/Up)
Terminal 19 Start reversing (24VDC) (qTrolleyBoomDir2) (Reverse/Down)
Terminal 20 L24V-
Terminal 29 Ramp Bit 0 (24VDC) (qLongIntegratorTrolley)
Terminal 32 Set-up select bit 0 (24VDC) (qTrolleyBoomParameter2)
Terminal 37 Safe Stop (24VDC) (qReleaseIGBT_TrolleyBoom)
Terminal 53/55 Speed Reference (0/4-20mA) (nSetvalueTravel)

Terminal 94 PE
Fan Supply L1/L2/L3

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Encoder Connections / Switching:
Switchover Control – Hardwired loop from Trolley/Boom drive terminal 32, (Set-up select bit
0 / qTrolleyBoomParameter2)
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Encoder Connections to the Drive
CW rotation channel A pulses lead channel B pulses by 90 degrees, CCW rotation channel A
pulses lag channel B pulses by 90 degrees.
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Drive Internal Layout and Components:
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LCP (Local Control Panel):
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 Removable Keypad/Display – operator interface.

 Parameter change / upload / download.
 EEPROM - data storage including during power down.
 Display parameter values, drive signals, status, alarms etc.
Control Card:
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 Logic Control – microprocessor which supervises and controls all drive functions.
 PROMs – contain parameters for programmable options.
 EEPROM - data storage including during power down.
 PWM IC – pulse width modulation waveform for Power card.
 Control Terminals – programmable function I/O, analog and digital.
 Serial Link communications.
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Power Card:
 Low level logic – high level power signal isolation

 Monitoring DC bus voltage, line voltage, output current etc.
 Gate drive firing signals.
 Scaling of current / voltage feedback signals.
 Fault processing for output short circuit and ground fault conditions.
 Switch mode power supplies.
Plug Connections
FK100 Relay Output (N/O & N/C)

FK101 Relay Output (N/O & N/C)
FK102 External Brake Temperature Switch
FK103 Auxiliary Fan
MK100 SCR Gate Driver
MK101 Connection to Control Card
MK104 Test Connector
MK105(A) DC Link supply +DC
MK105(B) DC Link supply -DC
MK106 Line Power (R,S,T)
MK107 Fans
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MK109 Gate Drive Card

MK400 DC Link Out
Gate Driver Card:
 Isolation / buffering of gate drive signals.
Plug Connections
MK102 Signal to IGBT U Phase

MK103 Signal to IGBT V Phase
MK104 Signal to IGBT W Phase
MK105 Signal to Brake Chopper IGBT
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Block Diagrams
Mains – side FC converter configuration
Motor – side FC converter configuration
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PWM – voltage output
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PWM - output
Torque – Speed Characteristic
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4-Quadrant Operation
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Torque – Power ranges
Load / Speed Curve
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PLC Terms and Definitions

Address Identifier for a memory cell, operand (e.g., input, output).
Analogue Continuous representation of values and states by the

corresponding physical quantity.
AND operation A logic operation equivalent to connecting contacts in series.
Baud Unit used in serial transmission of data.
Baud Rate Transmission speed of serial transmission of binary numbers.

This is measured in Bits per second (Bits/s).
Binary Numbers, data and information which are exclusively expressed

using the two values 0 and 1 (e.g. 1 = current, 0 = no current)
Bit The unit for a single binary digit.
Boolean Algebra Mathematical rules for binary variables and conditions. For
Boolean equations the following signs are used:
logical AND operation: AND or &
logical OR operation: OR or >=1
logical Negation: NOT or 0
Bus system The path for the transfer of information and data.
Byte Unit of information comprised of 8 bits. A byte can assume a

value between 0 and 255.
Control system flow In CSF, the control task is represented diagrammatically

Chart (CSF) using generally understood symbols according to the German
standard DIN 40700/40719
CPU The central processing unit of the programmable controller that

contains the control and arithmetic units.
Cycle Time The time required for a program to run through once.
Cyclic Scanning The processor of the programmable controller executes control

statements one after the other. After execution of the last of the
last statement, it begins at the beginning again.
Digital Representation of an instantaneous value in digits.
Editor Utility program for creating and changing programs.
EPROM Erasable Programmable Read Only Memory, read only memory

erasable by ultraviolet light and electrically programmable. With
this type of memory, the contents remain intact in the event of a
power failure.
EEPROM Electrically Erasable Programmable Read Only Memory, this

type of memory is electrically erasable and programmable. With
this type of memory, the contents remain intact in the event of a
power failure.
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Ladder diagram (lad) The diagrammatic representation of controller functions in a form

resembling relay circuit diagrams.
Module Component of a programmable controller.
Offline Operational method of a programming device without the PLC

attached.
Online Operational method in which the programming device (PC) is

connected to the PLC, thereby enabling programs and data to be
read or changed.
Operand Contains the information required for the execution of an

operation as part of a control statement (e.g., input, output).
Operation A part of the control statement. It describes the function to be

executed by the CPU.
OR operation A logical operation that is equivalent to the connections of

contacts in parallel.
PLC Programmable Logic Controller. It consists of a power supply,

processor, program memory and input and output modules.
RAM Random-access memory. Electrically erasable and

programmable read and write memory. Without battery backup,
the contents of the memory are lost in the case of a power
failure.
ROM Read only memory
Scan time The time required in cyclic scanning to execute all the statements
of a program once.
Software The generic term for all programs belonging to a computer

system regardless of whether they originate from the
manufacturer (system software) or the user (user software).
Statement list (STL) Representation of the automation task as a list of individual

program steps using the signs and symbols standardized in DIN
19239.
User program A program in the PLC that describes the control task of the user.
Watchdog Internal supervisory unit in PLC’s used to recognize system and

memory errors.
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ABBRIEVATIONS
AFE Active Front End

AWC Automatic Wear Compensator
ASCII American Standard Code for Information Interchange
BS British Standard
CoDeSys Controller Development System
CMS Crane Management System
CPU Central Processing Unit
CRD Cable Reeling Drum
CSF Control Statement Flowchart
CSV Comma Separated Value
DIN German Industrial Standard
DINT Double Integer
EMC Electro-Magnetic Compatibility
EMI Electro-Magnetic Interference
EMS Electronic Monitoring System
FB Function Block
FC Frequency Converter
GPS Global Positioning System
HIPAC High Intelligence Pendulum Automatic Control
HMI Human Machine Interface
HT High Tension or High Voltage
IEC International Electrical Commission
IL Instruction List
INT Integer
IP Ingress Protection or Internet Protocol
ISO International Standards Organisation
LAD Ladder
LCP Local Control Panel
MCB Miniature Circuit Breaker
MDB Microsoft Data Base
MMI Man Machine Interface
OLE Object Linking and Embedding
OPC OLE for Process Control
PB Program Block
PLC Programmable Logic Controller
PF Power Factor
PE Protective Earth
POU Program Organisation Unit
RMG Rail Mounted Gantry
RTG Rubber Tyred Gantry
SDB Symbolic Data Base
SFC Sequential Flow Chart
SINT Short Integer
STL Statement List
SWL Safe Working Load
TEU Twenty foot Equivalent Unit
TOD Time of Day
TTDS Twin Twenty Detection System
UDINT Unsigned Double Integer
UINT Unsigned Integer
UPS Uninterruptible Power Supply
USINT Unsigned Short Integer
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VDE German Industrial Standard

WinCC Windows Control Centre
YMS Yard Management System
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Training - Gruas Portico

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Richard Galviz

Maintenance should only be carried out by competent, authorized personnel

Layout of the Crane

KEY TO READING LIEBHERR DRAWING'S / SYMBOLS

Location Associated Drive

S1 = Electrical House A= General Control

Schematic Drawings Layout

Schematic Drawings Layout Continued

Electrical Connection Boxes

Connection Box Location

Normally open Normally Closed Delay to Open

Floodlight Heater Thermal Switch

PTC Thermistor Current Transformer Choke

Joystick Transducer AC/DC Rectifier Fuse

Fuse with Monitor Coil Delay ON

Delay OFF Latching Coil PLC Input

Resistor Potentiometer Capacitor

Diode Thyristor OP Amp

Layout of the House

Layout of trolley limits

A Frame Limit Switches

Cable Reel Drum

Typical rotor resistance circuit

Trim / List / Skew

Ram out shortens rope and ram in lengthens rope.

Ram 1 Ram 2 Ram 3 Ram 4

Basic Hydraulic Diagram

Starting CoDeSys and Visualisation

POUs – Program Organisation Units

Off Delay Timer

Rising Edge Trigger

Falling Edge Trigger

PLC Logic Gates and Electrical Equivalent Circuits

AND Gate and

NAND Gate and

NOR Gate and

Examples of Combinations of AND & OR Gates

Combination of AND and OR gates and equivalent circuits

Combination of Gates using a negated or inverted input

AND Gate with a negated or

Comparison between a PLC timer and a hard wired timer

Logic and POU Structure.

Drive Commands POU

Crane Control Folder

Going Online To CPLC.

The Logout of the PLC simply do the following

Referencing a variable where you already know one location

1. Logout of the CPLC

Reference An Input/Output From The Wiring Drawings

1. Highlight the variable you are searching for

Watch and Recipe Manager

Tracing Signals from the Wiring Diagram to the PLC Program

1 2 In CoDeSys, select Project / Global Search…

3 Double-click the result line to jump to the POU directly.

Tracing Signals from the PLC to the Diagram

Highlight desired signal: Open to Phoenix Bus Structure

2 Press Shift-F2. The module reference is shown:

Bus Terminal module

1.1 1.2 1.3 1.4 1.5 1.y

INTERBUS Controller Stat-up Sequence

“Remote Bus error”

1.1 1.2 1.3 1.4 1.5