PDC Service Manual - E

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e-mail PAT.Service@pat-group.de
The contents of this manual is subject to change without prior notice. PAT does not make any warranty of any kind for this
documentation, including, but not limited to implied warranties of merchantability or fitness for a specific purpose. PAT does
not accept any liabilities for errors in this manual or for incidental or consequential damages arising out of furnishing or use of
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PDC SERVICE MANUAL_E.DOC 23.08.01HF 1

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Table of Contents
1. Description of the System
2. Systemlayout
3. CPU – Board 22 020 10 0100
4. LMB – Board 22 020 10 0007/ 0009
5. Digital Input Board (Basis) 22 020 30 0051 / 0052
6. Digital Input Board (Piggy) 22 020 30 0055 / 0058
7. Digital Output Board (Piggy) 22 020 30 0065
8. Analogue Input Board 22 020 30 0030
9. Analogue Output board (Basis) 22 020 30 0022
10. Analogue Output board (Piggy) 22 020 30 0025 / 0026
11. Profi Bus Board 22 020 30 0006
12. Optical Transmitter 22 020 30 0070
13. Optical Receiver 22 020 30 0070
14. Power Supply 22 020 30 0180
Supplement: Wiring Diagram, I/O Description

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1. Description of the System
The PAT PDC System has been constructed in 19“ technology. The 19“ rack houses all re-
quired components.
Interfacing to Profibus, several CPUs can communicate if required.
Profibus also integrates couplers known from the ECIS system.
The various modules available for the specific applications will be described in this manual.
The systems complexity may vary from a pure LMB to a complex control unit according to
configuration. Complexity also defines the number of required components. Since control
processes are programmed by crane manufacturers, the manufacturers´ information on con-
trol functions are to be obeyed.
A pure LMB function and also LMB programs are encoded and processed in an individual
module.
There are two types of display consoles available now. (See System layout)

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2. SYSTEMLAYOUT
Netzteil
Power Supply
Analogausgang
Analogue Output
Console 0–1A
Analogeingang
Analogue Input
4 – 20 mA
Profibusankopplung
Profi Bus Interface
Digital Ein/Ausgänge
Digital In/Output

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General instructions on working with computer components
In the following sections the basic components of the modular "Pat Dynamics Control
- PDC" are described which fulfil (or will fulfil in the future) various control, monitoring
and visualisation tasks in the machines AC 100, AC 120, AC 300, AC 500-1, AC 650,
CC 2800, and CC 2500.
Some basic rules which are valid for the operation of electronic machines must be fol-
lowed during maintenance and repair work to this system. These rules, relating to the
relevant components, are listed in the following and the terms used are explained.
General Rule
Boards or components may only be plugged in or removed while off circuit! The wires and
coding switches/ jumpers may only be modified and fuses may only be changed while off
circuit!
E-PROM electric programmable read-only memory

Memory chip which can be written electrically using suitable programming units and
which can be read only during normal operation. These chips must be erased by ex-
tensive UV radiation in order to be written again. This is therefore called non-volatile
memory.
In order for the UV rays to reach the actual chip, there is a window in the E-PROM.
This window is sealed off after programming using a sticker, sealing off all light, so
that nothing is accidentally erased by extensive sunlight, for example.
This sticker may therefore only be removed when erasing the E-PROM.
E-PROMs are electrostatically endangered components. You must make sure you
are not electrostatically charged before touching an E-PROM. Ideally, this is done us-
ing special earthing wristbands, electrostatic mats and tools and similar items. If these
aids are not available, at least equipotential bonding between the PDC and the opera-
tor should be established; this is done by touching a metal component of the PDC
(e.g. housing), before touching the E-PROM.
An E-PROM is removed from its socket by pulling the E-PROM out on both sides at
the same time using a pair of IC pull-out pliers. A small screwdriver may be used as
an aid with which one lifts the E-PROM out of the socket alternatively on both front
sides. This is the only way to avoid bending the E-PROM pins. A removed E-PROM
can be used again, and must be returned to department 8315.1. Department
8315.1 must always be informed when the E-PROMs have been exchanged!
An E-PROM is inserted into its socket by first setting all pins into the bases. Possibly
bent pins must be straightened carefully (!). When all pins are in the bases, the E-
PROM is pressed into the socket evenly on both sides and without any mis-
alignment. You must check afterwards if all pins fit into the socket correctly or if
any pins were bent outward or inward (hard to see!).
EEPROM electric erasable programmable read-only memory
In principle an E-PROM; however, it is not erased by UV rays but by electrical means.
This is why an EE-PROM does not have a window. An EE-PROM can be erased and
programmed again in the machine which means that in many cases it is not neces-
sary to exchange these components.

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RAM random access memory

In the general sense: memory with free access to the current contents. During opera-
tion, this memory represents the memory of the crane. All programs and data (e.g.
the current crane configuration) which are required during crane operation are filed in
this memory. This memory loses all data it contained as soon as the power supply is
cut off. RAM is therefore a volatile memory in contrast to the E-PROM and EE-PROM.
This is why all data which is to be stored permanently (e.g. customer settings) are
filed in a non-volatile memory.
Ribbon cable
Often ribbon cables are used in computers to connect contact rows with up to 68
strands. These ribbon cables are either welded directly into a board or are closed off
using plugs / couplings. These plugs / couplings are usually fitted with cutting con-
tacts. The ribbon cable is laid into the contact body and pressed into the cutting con-
tact using a plastic strip. This means that the plastic strip is locked into the contact
body. This type of fitting is relatively highly loadable in a mechanical sense; however,
the ribbon cable may never be pulled in order to loosen a plugged connection.
You may only pull the plastic bodies when loosening a plugged connection; a possibly
stuck plugged connection can be loosened carefully (!) using a small screwdriver.
In order to avoid a polarity reversal of the ribbon cable at least the strand / contact is
marked with the number "1" at the connecting points of the ribbon cable (i.e. on the
board). The ribbon cable itself has strands of different colours or a marking for the
strand with the number "1". It is normal at this point to see a grey ribbon cable with a
red strand as number "1", for example.
Furthermore, the plugs / couplings are coded mechanically using lugs or slots and
can only be inserted easily in the correct direction.
Coding switch
So-called coding switches are used to carry out single settings on a board. They are
small rotary switches with 10 or 16 positions, for example. The coding switch is set
carefully (!) using a small screwdriver. The position of the coding switch is indi-
cated, for example, by a small arrow. The different positions of the coding switch may
lock into place only weakly, which means that the exact setting of the switch position
is the responsibility of the operator.

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Coding jumper
Another way of making settings on a board is to use coding jumpers. During this pro-
cedure two contact pins are connected with each other so that they are conductive
using a small plug-in connector. The plug-in connectors (coding jumpers) must be
plugged in carefully and only in the indicated direction. Surplus plug-in connec-
tors may not be plugged into free contact pins.
Trimming potentiometer
There are small trimming potentiometers on some boards for continuously variable
settings. These trimming potentiometers must be rotated carefully using a suitable
screwdriver. Avoid rotating past the mechanical stop as a defective potentiometer
means that the whole board must be exchanged. The current position of the potenti-
ometer is usually indicated with a small marking (arrow point, line). If this is not the
case, the correct position must be set by first rotating the potentiometer to both final
stops in order to determine the rotating area and then rotating it into the correct posi-
tion.

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2. Assignment of the plug-in boards in the computer
The plug-in boards described in the following chapters can exist in various places and
in different numbers, depending on the type of machine and the technical equipment.
You can have the current configuration of the PDC, i.e. the type and position of the
plug-in boards, displayed by the operating console. The following figure shows the
screen display as an example for a lattice boom crane.
Basic digital
Profibus interface board input boards
Basic analog
LLD board Video board Analog input boards output board
CPU board
State
fields
Piggy digital Piggy analog Mains board

Info menus input boards output boards
Profibus with profibus Piggy digital

participants output boards
Legend:
Status overview ECIS bus participants

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The following figure shows the relevant screen display as an example for a tele-
scopic crane crane. The fundamental layout of plug-in boards remains the same;
however, number and labelling changes. Legend: Status overview
ECIS I/O boards
Basic digital
Profibus interface board input board
Basic output
LLD board Video board Analog input boards board
CPU board
Status
fields
Piggy digital Piggy analog Mains board

Info menus input boards output boards
Profibus with Piggy digital

participants output boards

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The CPU, LLD, Profibus and video boards are always in the first four positions (as
shown here).
The digital input and output boards are in the following plug-in positions; the basic
board is always plugged in first and then the piggy boards.
After that are the analog input and output boards. First the basic boards and then the
piggy boards are plugged in here as well.
The plug-in board with mains supply for the entire computer is always in the outer
right-hand position.
The state fields (in this example: ) give information on the status of the basic plug-
in boards and / or bus participants. But in this case "OK" only means that the relevant
component group is functioning and that the connection to the connected piggy
boards and / or bus participants is in order. However, "OK" does not means that all
piggy boards are also supplying correct input and output values or that all input and
outputs of a bus participant are functioning correctly!
The indicated symbols are explained by selecting the info menus.

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3.1 Layout of the CPU board
The CPU board is the actual heart of the PDC system. It contains the processor, the
memory chips as well as all peripheral components required for operation. Only the
E-PROM components are important for a software change. They are arranged as fol-
lows:
Data E-PROM 22
System E-PROM
RAM components
System E-PROM 11
Data E-PROM 21
The bottom number on each E-PROM indicates the plug-in station on the board. The
E-PROMs in plug-in stations -11- and -12- contain the operating system software.
The E-PROMs in plug-in stations -21- and -22- contain all control programs (SPS),
data components, graphics, applications and configurations. The EE-PROM is on the
bottom layer and cannot be exchanged without taking the CPU apart. It usually is not
necessary to exchange the EE-PROM.
The following descriptions with the following meanings are on the E-PROM.

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ECIS General description for the operat-

TFT1 ing system E-PROM
M2 Not relating to the machine, sys- B1 System E-PROM no. -11-

tem E-PROM B2 System E-PROM no. -12-
03.35 Running index, continuous with

each new program version
2CF3 4-digit HEX number, inspection

sum
-11- Plug-in station number
39 Machine recognition, here e.g. AC C1 Application software,

300 E-PROM no. -21-
C2 Application software,
01.08 Running index, continuous with E-PROM no. -22-
each new program version
XX Machine description in plain Eng-

XXX lish
46DD
4-digit HEX number, inspection
sum
-21-
Plug-in station number
The 4-digit HEX number represents the last 4 digits of the inspection sum of the entire
binary content of the E-PROM. When creating a new E-PROM or when duplicating
make sure the inspection sum is correct!

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The following connections and display elements are on the front plate of the CPU
board:
Switch and LED "Reset": System reset, cold start
Switch and LED "Abort": Hot start
Switch and LED "F1": Service button "F1" and display "F1"
7-segment display: Status and fault display
Switch and LED "F2": Service button "F2" and display "F2"
Interface "1", RS 232: Download interface for Etool
Interface "2", RS 232: Debug and modem interface
Interface "3", RS 422: Reserved for console control

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3.2 Layout of the LMI board
The LMI board must be viewed as an independent processor board. It is responsible

for the tasks and calculations necessary for the load limit device. Only the E-PROM
components are important for a software change here as well. They are arranged as
follows:
Loads E-PROM LC
Data E-PROM DAT
System E-PROM 0
The bottom number on each E-PROM indicates the plug-in station on the board. The
System E-PROM -0- contains the operating system software with all calculations. The
Data E-PROM DAT contains the crane-specific data and benchmark figures. The
Loads E-PROM WC contains the actual loads. The same rules apply for the inspec-
tion sums as listed for the CPU.

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The following connections and display elements are on the front plate of the LLD
board:
LEDs "RES", "INT",

"1", "2", "3", "4": Service lamps for PAT,
not relevant for servicing
LED "Load": Display for overload
LED "A2B": Hoist limit switch display
Interface "RS 232": Programming and parameterising interface for LMB
"Digital I/O X2": I/O plug X2, see circuit diagram for machine
"Keyswitch X3": I/O plug X3, see circuit diagram for machine

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3.3 Layout of the analog input board

The analog input boards read in the measured values of the different sensors, each
board containing 7 inputs. There are several boards with an identical layout in the
system, however, the computer must be able to differentiate between them. This is
why each board has a clear address, which is set using the address coding switch;
see figure. The addresses are counted up from "0" up to maximum "F", which means
there are 16 possible addresses. Each address for this type of board may be in the
system only once!
When exchanging a defective board, the substitute board must be set to the same
address which was set on the defective board. If two boards are exchanged (e.g. for
testing), then the addresses of the boards must be exchanged, too.
The address coding switch must be rotated carefully (!) using a suitable screwdriver.
If the correct address is not known for a board, the details for the address and plug-in
station can be obtained from the documents of the company Terex / Demag.
Address coding switch 0-F

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3.4 Layout of the analog basic output board
The analog basic board creates variable electric control signals, which are distributed
via so-called piggy boards. In the basic board, a maximum of eight signals are cre-
ated for this purpose, which are then passed on to a maximum of four piggy boards;
i.e. each piggy board has two channels. The analog signals are passed on to the
piggy boards via four connecting plugs and via ribbon cables.
As is the case with the analog input board, each analog basic output board contains
an address coding switch with which each board receives an address, which in turn
may be in the system only once for this type of board. When exchanging a defective
board in this unit the same address must be set on the substitute board as on the de-
fective board as well. If two boards are exchanged (e.g. for testing), the addresses of
the boards must be exchanged, too.
station can be obtained from the documents of the company Dematic. Usually the ad-
dress is "0", as there is only one analog basic output board in the system.
Furthermore, there is a coding jumper on the analog basic output board which can be
plugged into six different positions. This jumper sets the ripple frequency which is su-
perimposed over the control signal of the proportional hydraulic valves. The six posi-
tions correspond to the following frequencies, from left to right: 160 Hz, 80 HZ, 40 HZ,
20 Hz, 10 Hz, 5 Hz. The ripple frequency is set to 80 Hz in the following figure.
4 × connecting plugs for piggy boards
Coding jumpers, 6 different positions

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3.5 Layout of the analog piggy output board
The analog piggy board receives two input signals from the basic board using a rib-
bon cable; the piggy board reinforces the signals and passes them on to two con-
sumers (e.g. proportional valves). The ribbon cable is connected to a relevant con-
necting plug. The maximum output current is 1 Ampere for each channel.
There is no address coding switch on the analog piggy output board. The address is
determined by the fact that each board receives its signals from the analog basic out-
put board via its own output or its own ribbon cable. This means that when the ribbon
cables of the piggy boards are exchanged the connecting leads must be exchanged,
too.
Furthermore, there is a fuse on the board which protects the output levels against
short circuiting. There is also a trimming potentiometer which sets the ripple ampli-
tude of the output board. This potentiometer always remains in the central position if
not expressly fixed otherwise.
Connecting plug for the cable of the basic board

Trimming potentiometer
Fuse

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3.6 Layout of the digital basic input board
The digital basic input board reads in the measured values of 16 binary sensors, i.e.
"0" or "1" values. Furthermore, up to four digital piggy boards are addressed using
this board; these can be either input or output boards. These boards are connected
using ribbon cables; a ribbon cable with connecting coupling is guided from the first
piggy board to the basic board and is plugged into the connecting plug there. There is
another connecting plug on the piggy board, to which the next piggy board can be
connected with its ribbon cable, etc.; a maximum of four piggy boards can be con-
nected one after the other. There is a fuse on the board which protects all connected
piggy boards. If this fuse is defective, none of the piggy boards will work, even if con-
trol indicates differently.
This board also receives a clear address which is set using the address coding
switch, see figure. The addresses are counted up from "0" (via ...8-9-A-B...) up to
maximum "F", i.e. there are 16 possible addresses. Each address of this type of
board may only be in the system once!
When exchanging a defective board, the substitute board must be set to the same
address which was set on the defective board. If two boards are exchanged (e.g. for
testing), then the addresses of the boards must be exchanged, too.
station can be obtained from the documents of the company Terex / Demag. There
can be up to three digital basic input boards in the system.

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Connecting plug for ribbon cables

Fuse

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3.7 Layout of the digital piggy input board
The digital piggy input boards also read in the measured values of 16 binary sensors.
However, the boards are not independent but are addressed via the digital basic input
board. As previously described, they are connected to the basic input board using a
ribbon cable with connecting coupling. The connecting coupling at the end of the rib-
bon cable is not shown here. The connecting plug for the next piggy board is next to
the ribbon cable.
The digital piggy boards receive their addresses by plugging them into a certain place
behind the basic input board, they do not have a coding switch. In other words, they
will automatically receive the addresses "0" to "3" if there is a maximum of four piggy
boards behind the basic input board. This means that the function of the digital piggy
input boards is dependent on their plug-in station. If therefore two boards are ex-
changed for testing, the connections to their front plates must also be exchanged. If
this is not done, the digital input signals will be on the wrong channels!
Connecting plug for ribbon cable

Ribbon cable with plug

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3.8 Layout of the digital piggy output board
The digital piggy output boards have 16 potential-free relay outputs with NO contacts.
These boards are not independent either and are addressed via the digital basic input
board. They are connected to the basic input board as described for the digital piggy
input boards using a ribbon cable with connecting coupling.
These boards receive their addresses, too, by plugging them into a certain place be-
hind the basic input board, they do not have a coding switch, either. This is why the
function of the digital piggy output boards depends on their plug-in station as well. If
therefore two boards are exchanged for testing, the connections to their front plates
must also be exchanged. If this is not done, the digital output signals will be applied to
the wrong consumers!
Each relay output is protected by a time-delayed fine fuse with 2 A. The fuses are
plugged in and are fixed mechanically using two screwed-in plastic strips. In order to
change a fuse, the relevant strip must be removed and then fitted again afterwards.
There are two substitute fuses on the board for emergencies.
16 × fuses for output relays

16 × output relays 2 × substitute fuses
Connecting plug for ribbon cables
Ribbon cables with plug

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4.0 Changing the software
The software in the modular PDC is linked in various memory media.

- E-PROM area
- EE-PROM area
- battery-buffered RAM
- operating RAM (no buffer)
In the E-PROM area there are:

- operating system software (separate E-PROMs)
- control programs (SPS programs)
- control data components (for first operation)
- graphics
- applications (rapid calculations, keyboard entries, optional functions, etc.)
- telescoping help
- system configuration (definition of hoists in the PDC)
- I/O configuration (definition of hoists outside of PDC)
In the EE-PROM area there are:

- control data components (works settings)
- application data (operating modes, state variables, etc.)
In the buffered RAM there are:

- possibly control programs (test and intermediate versions)
- control data components (individual settings)
- application data, retentive flags, etc.
In the operating RAM there are:

- the currently processed control program
- all volatile flags
- all other volatile data
When creating the software setting it was determined that all data required for crane
control is stored in the E-PROM. This means that to change the software only means
to change the E-PROMs. The appendix offers software help for transmitting relevant
information from the E-PROM into the corresponding memory areas.
The software helps are implemented in the PDC-Tool of the operating system soft-
ware.

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Hertzstraße 32-34 SERVICE MANUAL