9.

2 ELECTRIC SYSTEM - 24 VOLT

9.2 Electric System - 24 Volt Signal Terminal Circuit Notes

available no. breaker
For organizational reasons, the documentation for 12V 1
the electric system - 24 volt is attached to the Direct battery 2 -1F22
spare parts list. max. 6A
This way the diagrams match to the individual ma- 12V 3 -1F23
chine. Direct battery 4 -1F24
max. 6A
24V 5 -1F25
9.2.1 Overview of switch cabinets Key switch 6 -1F26 Before
max. 15A battery
main
The machine includes the following switch cabi-
switch.
nets:
 X1 cabinet, underneath the operator’s cabinet
Power supply for the 2way Radio is supplied in the
 X10 cabinet, behind the hydraulic tank
Operator‘s Console. 2pin plug direct Battery +.
 X30 LH drive controller cabinet
 X40 RH drive controller cabinet
 X3 Terminal box hydraulic tank 9.2.2 Electrical documentation
 X24 Terminal box servo valve block
This section introduces the scope and content of
the electrical documentation and how to use it in
daily operation.

The electrical documentation includes 5 sections:

 Circuit diagram (current flow diagram)

 Layout drawing

 Connection tables - terminal strips

 Connection tables - plug connections

 Electrical components and extras

(bill of material)

 Wiring harness
Fig. 1 Switch cabinets - 642888

Customer connection points Always refer to the documentation,

which is relevant to the specific ma-
Customer connections are available on the X2 chine-serial-number.
terminal in the X1 cabinet to install customer
equipment such as 2 way radio, fire fighting sys-
tem.

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9.2 ELECTRIC SYSTEM - 24 VOLT

9.2.2.1 Naming of electrical components
The components of the machine are grouped as
follows:
 Group number 1: Parts not connected to any
controller. These are parts like the key switch,
battery, main switches and working lights.
Based on these groups, the electrical components
are coded in the electrical documentation and in
the spare parts list. This code consists of:
 Group number
 Letter according to DIN 40 719

 Group number 2: Components connected to  Identifying number

the Servo controller / ICN-V.
Example: -2K1
 Group number 3: Components connected to
the drive controller LH. 2: Component connected to the Servo control-
ler / ICN-V
 Group number 4: Components connected to K: Relays, cabinets
the drive controller RH. 1: Identifier

 Group number 5: Components connected to The following table shows an excerpt of the DIN
the auxiliary controller. 40 719 standard.

 Group number 6: Parts related to the BCS

tower. These are parts like the BCS screen
and the FM Radio.

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9.2 ELECTRIC SYSTEM - 24 VOLT

Letter Designation Examples

A Assembly group, parts of groups Amplifiers, magnetic amplifiers, combinations of
devices
B Transformation from non-electrical into Metering transformers, thermo sensors, thermo
electrical magnitudes (and vice versa) cells, photo-electric cells, dynamometers, quartz
crystals, magnetic field sensors, inclinometers
C Capacitors ----
D Time-lags, accumulators, binary elements Coupling links, bi-stable elements,
monostable elements
E Miscellaneous Lights, heaters
F Safety devices Fuses, overload guards, interlocks, circuit break-
ers, safety relays, releases
G Generators, electrical supplies Rotary generators, rotary frequency converters,
batteries, power supplies, oscillators
H Monitors Optical and acoustic monitors
I ---- ----
K Relays, contactors Power contactors, auxiliary contactors,
auxiliary relays, blinker relays, time-lag
relays
L Inductive devices Throttle coils
M Motors ----
P Meters, testers Indicating, recording and metering instruments,
impulse initiators, clocks
Q High-voltage switch relays Circuit breakers, main switches, isolators,
motor isolators (thermistors), automatic
cut-outs, fused circuit breakers
R Resistance Adjustable resistances, potentiometers,
shunts
S Switches, selectors Buttons, limit switches, control switches,
signal emitters
T Transformers Transformers, converters
U Modulators, converters Frequency converters, converters, inverters,
transverters, demodulators, reversing
converters
V Diodes Cancelling diodes for solenoid valves
W Conductive paths, hollow conductors Switch lines, cables, busbars
X Terminals, plugs, sockets Isolating plugs/sockets, test sockets, terminal
strips, solder strips
Y Electrically actuated mechanical devices Brakes, couplings, valves
Z End points, compensating devices, filters, Cable duplications
limiters, Y-terminals
Table 1

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9.2 ELECTRIC SYSTEM - 24 VOLT

9.2.2.2 Layout drawing The key includes the columns:

1: Device designation
The layout drawing is a detailed illustration in ei- 2: Amount
ther 3D or schematic form. It shows the location of 3: Function / Description
the most important electrical components. The 4: Description
components are indicated by schematic symbols 5: Schematics
according to DIN standard, see section “Naming 6: Location
electrical components”. Their unique identifier is 7: Group
their respective part codes. 8: S/N Nr.

The line highlighted in yellow indicates the infor-

mation on relay -2K1, one of the examples for en-
tries in the list of electrical components that is ex-
plained below.

1 Device designation

The unique identifier of the electrical component

that is the schematic symbols according to DIN
standard, see section “Naming electrical compo-
nents”.
Fig. 2 Layout drawing - 642889

Example
9.2.3 List of electrical components
Relay -2K1, see the line highlighted in yellow in
the figure.
The key to electrical components in the circuit dia-
gram is a systematically arranged list accomplish-
ing the circuit diagram. Its purpose is to locate
components both in the circuit diagrams and on 2 Amount
the machine itself. It also contains the components’
part numbers (Part No.). The number of particular component parts on the
machine.

Example

-2K1 is included once in the machine.

3 Function / description

Function of the component.

Example

 -2K1: “RELAY”
 -2B10: “SENSOR – HYD. OIL MIN.”

Fig. 3 Layout drawing - 642631

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9.2 ELECTRIC SYSTEM - 24 VOLT

4 Description 8 S/Nr. or Part-No.

Additional information on the component. This is the Part-No. for ordering spare parts. If no
Part No. is given, the part in question is associated
with the electrical system but is part of another
Example
assembly group.
The Part No. must then be determined using the
 “RELAY” for the relay relevant spare parts sheets. For example the part
 “FLOAT SWITCH” and “PLUG” for the sen- numbers for solenoid valves are to be found in the
sor “HYD. OIL MIN.” hydraulic systems.

5 Schematics
Example:
Current path number that appears at the bottom
-2Y1 PROPORTIONAL VALVE
edge of each circuit diagram sheet, see section
“Circuit diagram”. The current path number helps
to locate electrical components in the circuit dia-
grams.

Example

-2K1 is located on sheet 50, column 5 in the cir-

cuit diagram matching to the list of electrical
components shown in the figure above.

6 Location

The location is the approximate position on the

machine in which the electrical component is in-
stalled. Fig. 4 Figure spare parts list - 642898

Example:

The relay -2K1 is located in the switch cabinet.

Fig. 5 Data spare parts list - 642899

7 Group

The group number of the component might be

used as cross reference to the spare parts list if
the part in question is associated with the electrical
system but is part of another assembly group.

Example:

For the valve -2Y1, the group number is 23.217

in the figure below.

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9.2 ELECTRIC SYSTEM - 24 VOLT

IMPORTANT: The arrow indicates a reference to a

9.2.4 Circuit diagram different page of the circuit diagram. Physically on
the machine, the shown connection of the refer-
The circuit diagram (current flow diagram) is a ence might be a cable of 5 cm length.
representation of the electrical circuits of the ma-
chine in all their details.
The diagram shows for all electrical supplies and
components:

 The function
 The way they are connected

The circuit diagram comprises several DIN A4

sheets arranged in function groups.
All components are shown in the de-energized
state (i.e. no current flowing) and without any actu-
ating elements acting.

The electrical supplies and components are identi-

fied by the spare parts number and indicated by
symbols according to the DIN standards 40 700,
40 703, 40 708 and 40 711 to 40 716. Fig. 7 References - 642645

Each page is divided into 0 – 9 columns or current The information included in the reference is:
paths with a description below each current path
(2).

Each page has a page number or “Blatt Sheet”

located in the bottom right corner (3). On the bot-
tom left corner is the machine model to which the
electrical drawing applies (1).

Fig. 8 Reference information - 642646

Fig. 6 Circuit diagram - 642652

If electric connections are separated on two differ-

ent pages references will be used.
The reference is indicated by the arrow in the fig-
ure.

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9.2 ELECTRIC SYSTEM - 24 VOLT

Current path

The current paths run from positive to negative.

The numbers given at the right-hand side, along-
side the main horizontal paths, stand for:

Fig. 11 Relays in the circuit diagram - 642892

The location of the contact is stated below the coil

at the bottom of the page.

Fig. 9 Current path - 642653

1 30: Positive (unswitched)

2 15: Positive (key switched)
3 VIQ: Positive (deenergized by use of
Emergency stop) Fig. 12 Location of the contact - 642650
4 31: Negative (unswitched)
The location of the coil is indicated directly below
the relay contact.
Relays

Basically, the two relay types (1) and (2) are used.

Fig. 13 Location of the coil - 642649

Numbers on the contact points of relays or switch

Fig. 10 Relay types - 642651
In general, the coil and the contact of the relay are
placed on different pages of the circuit diagram.
contacts are exactly as to be found on the actual
component.
Relays that have closer, opener or changer con-
tacts in other current paths have an indication (un-
der the current path for the energizing coil) as to
the current path in which the contacts are to be
found.

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9.2 ELECTRIC SYSTEM - 24 VOLT

9.2.5 Connection tables - terminal

Collector terminal points strips
Collector terminal points (open circles) are coded
with the identification of the relevant terminal strip The "Connection tables - terminal strips" show the
or plug connection. See section "Connection table connections between electrical components. They
terminal strips" and section "Connection table - are exact illustrations of the terminal strips as fitted
plug connections". in the machine. The key to the circuit diagram
gives the exact location of the various terminal
strips.
The connection tables make it possible to locate
Example: the cable connections of a particular component
without checking the continuity.
The line has a discon-
necting point on termi- The following figures show
nal strip -X1, terminal  a part of the X1 terminal strip in the X1 switch
No.6 cabinet
 the related excerpt of the X1 switch cabinet
layout
Cable cross section  the related connection table

Figures alongside current paths indicate the cable

cross section.

Example:

Cable cross section =

10 mm²

Cable colour coding Fig. 14 X1 terminal strip - 642882

Combinations of letters alongside the current path

indicate the cable colour coding according to DIN
or ISO.

Example:

bl or BL = blue
br or BN = brown
ge or YE = yellow
gn or GN = green
gr or GY = grey
rt or RD = red sw
sw or BK = black
vi or VT = violet
ws or WH = white

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9.2 ELECTRIC SYSTEM - 24 VOLT

The table includes the following items:

 End points (targets)

 Bridges (jumpers)

 Terminal No.

 Type of terminal

 Cable cross section

 Potential

 End points (targets)

End point

The end point numbers serve in the location of the

contact point of a specific terminal. They state the
receiver and actual connection point.
End point 1 is always located at the bottom side or
where the locking bracket is (see arrow).

Fig. 15 X1 layout - 642883

Fig. 17 End point numbers - 642900

Example:

In the connection table shown in the figure, end

point number 3 of terminal No. 61 indicates that
this line from terminal No. 61 is related to the cou-
pling relay -4K4.

The cables have tagged sleeves with the appropri-

ate end point number.

Fig. 16 X1 connection table - 643140

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9.2 ELECTRIC SYSTEM - 24 VOLT

Bridges

If terminal points need to be extended, the relevant

terminals are interconnected with bridges (jump-
ers). Bridges are indicated by a yellow jumper bar.

Fig. 18 Tagged sleeves - 642884

This makes re-connection easy (and accurate) if

several cables have been disconnected at the
same time (e.g. during trouble-shooting).

Two types of terminal strips with red indicator LED Fig. 21 Bridges - 642887
are used.

 Type 1: The LED is lighting if the signal is Terminal No.

+24V.
All terminals on a particular strip are listed here.
The numbers are also to be found on the strip (in
switch box).

Type of terminal

This column contains the terminal coding as used

by the manufacturer.

Cable cross section

This column indicates the cross section of the in-

Fig. 19 High in Signal = +24 V - 642885
coming/outgoing cable.

Type 2: The LED is lighting if the signal is 0V. Potential

This column indicates the voltage potential of the

relevant terminal point. No entry means that the
potential is 24 Volt.

Fig. 20 High in Signal = +0 V - 642886

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9.2 ELECTRIC SYSTEM - 24 VOLT

Cross section of cable (mm²)

9.2.6 Connection tables – plug con- Here the cross section of the incoming /outgoing
nections cable is indicated in mm².

The "Connection table - plug connections" gives

the pin and sleeve connections of multi-pole plug No.
connections.
This number is that of the relevant pin or sleeve
The table includes the following items: connection. The numbers are stamped into the
plug housing.
 End point - sleeve connections

 Cross section of cable (mm²) End point

 No. of pin or sleeve End point No. of the plug (pin connections).

 End point - pin connections

 Code

Fig. 22 Plug connections - 642893

End point (target)

This is the number of the end point of the sockets

(sleeve connections).

Code

The code indicates the specific position in the plug

connection.

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9.2 ELECTRIC SYSTEM - 24 VOLT

9.2.7 Schematic symbols

Fig. 23 Schematic symbols 1 - 642894

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9.2 ELECTRIC SYSTEM - 24 VOLT

Fig. 24 Schematic symbols 2 - 642895

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9.2 ELECTRIC SYSTEM - 24 VOLT

Fig. 25 Schematic symbols 3 - 642896

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