Logicontrol - V1.6 Reach Stacker

Logicontrol - V 1.
6x
LOGICONTROL SYSTEM
EdgeVision
Version 1.6 xxx

2419.315.0009
OPERATOR MANUAL
STACKER CS45/50 RS50/60/70
Index
1. Introduction...................................................................................................... 2
2. Front panel description .................................................................................... 3
3. Main page description ..................................................................................... 3
4. Monitoring page description............................................................................ 4
5. Safeties............................................................................................................. 5
6. Safeties Bypass ................................................................................................ 6
7. Operator messages ........................................................................................... 7
8. Basic functions of Logicontrol system ............................................................ 9
8.1 Automatic height selection (Vertical Movements) ..............................................................9
8.2 Dynamic overload control..................................................................................................10
8.3 Engine shut off control.......................................................................................................11
8.4 High boom speed control ...................................................................................................11
8.5 Gear shift and cylinder valve control .................................................................................11
1
Logicontrol - V 1.6x
1. Introduction
This manual describes Logicontrol System in the new version (2001-2002 production).
All old and new functions are anyway revised, and this manual can be used as unique manual for all
Logicontrol versions.
The manual is divided into 2 sections: operator and assistance.
It is recommended to keep a copy of the operator manual in the operator cab, in order to allow a
quick reference in case of problems or questions.
Assistance manual must never be kept in the operator cab and must be available only for Service,
because wrong operations can compromise machine safety.
Logicontrol has following features:
• Measurement and visualization of operator’s most important machine parameters for normal
machine handling.
• Boom movements interlock in case of overload or other dangerous conditions.
• Malfunction black box: all sensors malfunctions, overloads and bypass use are stored in a
permanent memory
• Operative black box: all information of containers moved is stored into a permanent memory
• Test of all signals connected to the system.
• Monitoring of the most important machine parameters for a correct system working
2
2. Front panel description
1 5
3 6
2
4
1. Keys for system interface

2. Yellow led for pre-alarm conditions
3. Red led for alarm conditions
4. Key to bypass movements interlock in case of overload condition
5. LCD contrast adjust
6. Connector for RS232 serial communication
3. Main page description
9
1 2
3
7
8
4 5 6
10
1. Weight lifted, in tons or pounds

2. Weight maximum allowed, in tons or pounds
3. Unbalanced load indicator
4. Load center distance (from front wheel to spreader center) in meters or feet
5. Twist Lock height to ground, in meters or feet
6. Twist Lock status (locked, unlocked)
7. Spreader landed status sensors (4 corner blocks)
8. Container size (20-40) or tool type (PB: piggy back, H: hook)
9. Machine stability histogram (full means overload)
10. Alarm and warning messages to operator
3
4. Monitoring page description
1 6
2 7
3 8
4 9
5 10
1. Cooling water temperature: degrees or status (OK, ALARM)

2. Engine oil temperature: degrees or status (OK, ALARM)
3. Transmission oil temperature: degrees or status (OK, ALARM)
4. Engine RPM
5. Machine speed
6. Boom angle in degrees
7. Boom length in meters or feet
8. Stabilizers lifted/lowered (if installed)
9. Hour meter engine on
10. Container lifted number (historical)
Some Logicontrol versions can have different information on this screen page.
It is possible to switch between main page and monitoring page pressing keys OK or ENTER.
4
5. Safeties
Attivazione quando… Effetto Messaggio Bypass

Sicurezza
sul display
Lift and retraction
Minimum distance Distance wheels-load center negative Minimum distance Code
locked
Sideshift and rotation
Unbalanced load Container loaded on one side Unblanaced load Code
locked
Lowering and Boom lowering
Lowering locked Spreader is landed on a container Code
retraction locked locked
All movements except
Overload Actual weight is over maximum allowed Overload Key or code
retraction locked
Sensor … fault or One or more sensor used for stability All movements except
Sensor … falult Key or code
not connected control are fault or not connected retraction locked
Spreader height is too low (only for
Height control Lowering legs locked Minimum Height Code
piggy back machines)
Spreader too far (for empty loaders All movements except
Maximum distance None Key or code
stackers) retraction locked
Liftinf stabilizers
Stabilizers control Macchine unstable without stabilizers Stabilizers control Code
locked
Alarm from engine/transmission Engine shut down (20-
Engine shut down Engine shut off Code
sensors 40 sec)
Boom locked close to its physical limit Single movement
Boom limits None Code
(to prevent hydraulical shocks) locked
Machine speed is over 9km/h and All movements except High Speed: boom
High speed control Code
spreader is far (4 mt) or high (8mt) retraction locked locked
Speed 4 disabled or
Stability over 70% or spreader high Medium Stab:
Speed 4 control speed limited Code
(8mt) o far (4 mt) Speed Limit 1
(medium speed)
Speed 3 and 4
Overload or Stability over 65% and Low Stab: Speed
Speed 3-4 control disabled or speed Code
spreader high (8mt) o far (4 mt) Limit 2
limited (low speed)
5
6. Safeties Bypass
The operator is the only responsible of safeties bypass use.

Without safeties, machine handling can be very dangerous.
Supervisors must communicate bypass codes only if stricly necessary.
All safeties above described can be bypassed using BYP key and a 4 digits code (one different for
each safety).
All bypass use are stored in the black box.
To remove the bypass, insert again the same code or restart the machine.
Following bypass are available:
• Overload control
• Load cells control (unbalanced load and lowering control)
• Engine shut off control
• Speed limit control
• Boom control (movements limits, minimum distance, boom lock for high speed)
• All safeties at the same time
• Alarm buzzer
6
7. Operator messages
Cod Message Description

0 Boom Angle Sensor Fault Boom angle sensor (inclinometer) is fault or not connected
1 Boom Length Sensor Fault Boom length sensor (cable reel) is fault or not connected
2 Load Cell 1 (Right) Fault Load cell right is fault or not connected
3 Load Cell 2 (Left) Fault Load cell left is fault or not connected
5 Water Temp.Sensor Fault Water temperature sensor is fault or not connected
6 Tras.Oil Temp.Sensor Fault Transmission oil temperature sensor is fault or not connected
7 Eng.Oil Temp.Sensor Fault Engine oil temperature sensor is fault or not connected
9 Bypass All Safeties The bypass code to override all machine safeties has been
inserted
10 Bypass Overload Control The bypass code to override overload control has been inserted
11 Bypass Boom Controls The bypass code to override boom controls has been inserted
(movements limit switches, minimum distance, boom lock for high
speed and piggy back height control safety)
12 Bypass Load Cells Controls The bypass code to override load cells controls has been inserted
(unbalanced load and lowering lock)
13 Bypass Engine Control The bypass code to override engine shut off control has been
inserted
14 Bypass Transmission Safety The bypass code to override speed limit control has been inserted
15 OVERLOAD Overload control active (weight lifted is bigger than maximum
allowed): all movements except retraction are locked
16 Minimum Distance Safety Minimum distance safety active
17 Boom Lowering Locked Spreader is pressed on container (no seated light active): boom
lowering locked
18 Unbalanced Load Load is too unbalanced on one side: side shift to wrong side and
rotation are locked
19 Stabilizers Control Machine could be unstable without stabilizers: stabilizers lifting is
locked
20 Engine Shut Off Control Engine shut off control activated
21 Piggy Back Minimum Height Minimum piggy back height safety activated: lowering legs is
locked
22 High Speed: Boom Locked Machine has overtaken 9Km/h. All movements except retraction
are locked
23 Medium Stab: Speed Limit 1 Machine is in medium stability conditions: maximum speed is set
at 12 km/h or speed 4 is disabled
24 Low Stab: Speed Limit 2 Machine is in low stability conditions: maximum speed is set at 8
km/h or speed 3 and 4 are disabled
7
Cod Message Description

26 Calibration Angle Boom angle calibration is lost. Follow instructions on assistance
manual
27 Calibration Length Boom length calibration is lost. Follow instructions on assistance
manual
28 Calibration Load The load is not calibrated or the calibration is lost. Follow
instructions on assistance manual.
30 Vertical Control Activated Automatic height selection has been activated
31 Container 9 6’ “container high cube” option for automatic height selection has
been selected
32 Minimum Height Selected The boom is moving to the minimum height possible
33 Maximum Height Selected The boom is moving to the maximum height possible
34 High Boom Speed Disabled High boom speed electro valve is not activated
35 Low Cooling Water Level Low cooling water level alarm activated
36 Low Engine Oil Pressure Low engine oil pressure alarm activated
37 Low Fuel Level Low fuel level alarm activated (< 5 %)
45 High Water Temperature High cooling water temperature alarm activated (> 105 °C)
46 High Transmission Oil Temp High transmission oil temperature alarm activated (> 120 °C)
47 High Engine Oil Temp. High engine oil temperature alarm activated (> 120 °C)
8
8. Basic functions of Logicontrol system
8.1 Automatic height selection (Vertical Movements)
Pressing keys from H = 2 to H= 5 without touching the joystick, the system moves automatically
the boom up to the selected standard height maintaining the distance constant.
If the container stack is made of high cube containers, press first key 9 to inform the system of the
different stack height.
Grab the joystick (dead man sensor) or emergency stop button to stop immediately automatic
movements.
Pressing key 1 the machine moves the boom to the minimum possible height (1 container); pressing
key 8 the boom goes to maximum possible height considering its capability (boom dimensions).
Accuracy on the vertical line is about ± 30 cm.
Any overload or error from stability sensors stops automatic movements.
Machine
Description Notes
movements
Combination of boom
lifting and extension
Vertical Lift
so that d is always
constant
d
Combination of boom
Vertical lowering and
Lowering retraction so that d is
always constant
d
9
8.2 Dynamic overload control
Logicontrol has sensors to check constantly boom angle, length and the weight lifted. From this, the
system calculates container height and distance. All these parameters are shown on display.
The system then compares the actual configuration with the machine capacity chart (supplied by
manufacturer).
Finally, if the actual weight is bigger than maximum allowed, these are the actions:
• Boom lifting, lowering and extension are locked

• An alarm buzzer turns on
• Stability factor reaches 100% and a message appears
• If overload condition lasts for over 1 second, it is stored in the system black box.
It is possible to bypass this safety using a key (not stored in black box) or a code (stored in the black
box).
The weight calculation is performed using two load cells.

These are the conditions to get a good weight accuracy:
• Engine must be on
• Spreader has to be centered
• Boom has to be still
• Auto float control (if present) has to be off
Never lift a container with boom fully extended.

If the container is full, Logicontrol can detect the overload
when it is too late and back wheels can lift up.
10
8.3 Engine shut off control
If there is an alarm from engine or transmission, Logicontrol shows the alarm, and after about 30
seconds it shuts the engine off.
These are the alarms:
• · Low engine oil pressure

• · High engine oil temperature (over 120°C)
• · High cooling water temperature (over 110°C)
• · High transmission oil temperature (over 120°C)
• · Low cooling water level
• · Low fuel level
On some special versions, the number and type of events that shut engine off may be different.
8.4 High boom speed control
On the following conditions an additional electro valve used to increase boom lifting and lowering
speed is activated:
• Load center distance below 4,5 meters

• Load height over 3,5 meters, during lowering movement and with a load hooked up
• Engine rpm over 1.400
• Weight below 7 tons
When high boom speed is not activated, a message appears on display.
8.5 Gear shift and cylinder valve control
If weight lifted is over 7 tons, a signal is supplied to automatic transmission unit (Shiftronic or
Powertronic), that will shift gears at higher engine rpm.
This is to improve machine performance during traveling with a weight lifted.
The same signal is connected in parallel to the cylinder regenerative hydraulic circuit, in order to
increase lifting speed when machine is unloaded.
11
ASSISTANCE MANUAL
ATTENTION
This manual section is reserved to Technical Assistance, and it is useful for all troubleshooting and
calibrations of Logicontrol System.
An incorrect calibration affects seriously machine safety.
In order to increase the safety, all calibrations procedure can be done only using internal system’s
menus, accessible only through codes.
Calibrations and access codes must never be known by operators
The operator is the sole responsible for machine handling.
Safety bypass codes diffusion is exclusive responsibility of maintenance supervisors.

An improper use of bypass codes makes possible the machine use under unsafe conditions.
The manufacturer will not be responsible for that.
Every safety override will be stored in the system black box.
It is anyway possible to modify all codes if necessary.
ACCESS CODES LIST (STANDARD):
Main Menu: 178

Machine Calibrations: 300
Black Box Erasing: 182
Menu Access for codes change: 8356
List existing codes: 2166
BYPASS CODES LIST (STANDARD):
Overload control: 1234

Boom safeties: 2468
Load cells safeties: 2679
Engine shut off control: 3434
Speed safeties: 1111
Alarm buzzer: 4444
Odometer reset: 1135
All safeties: 1590
12
Index
1. Menu navigation ............................................................................................ 14
2. Machine Calibrations..................................................................................... 15
2.1 Angle Calibration...............................................................................................................15
2.2 Length Calibration .............................................................................................................15
2.3 Load Calibration ................................................................................................................16
2.4 Boom Limits ......................................................................................................................17
2.5 Automatic Heigths Calibration ..........................................................................................17
2.6 Machine Configuration ......................................................................................................18
2.7 Engine RPM Calibration....................................................................................................18
2.8 Other Parameters................................................................................................................19
2.9 Download Calibrations ......................................................................................................19
3. Test Inputs-Outputs ....................................................................................... 21
3.1 Test digital inputs...............................................................................................................21
3.2 Test analog inputs ..............................................................................................................21
3.3 Test PWM Outputs.............................................................................................................22
3.4 Test digital outputs.............................................................................................................22
3.5 Test rpm inputs...................................................................................................................23
4. Alarms............................................................................................................ 23
5. Geometrical Settings...................................................................................... 24
6. Safeties........................................................................................................... 25
7. Malfunctions Black Box................................................................................ 25
7.1 Show malfunctions black box ............................................................................................26
7.2 Erase malfunctions black box ............................................................................................26
7.3 Send/Print malfunctions black box ....................................................................................26
8. Operative Black Box ..................................................................................... 27
8.1 Show operative black box ..................................................................................................27
8.2 Erase operative black box ..................................................................................................27
8.3 Send/Print operative black box ..........................................................................................27
9. System Time .................................................................................................. 28
10. Change Hourmeter......................................................................................... 28
11. Changing System Codes................................................................................ 28
12. Logicontrol for Twin-Lift Machines ............................................................. 30
12.1 Main screen page and operator messages ........................................................................30
12.2 Additional safeties ...........................................................................................................30
APPENDIX 1: Null-Modem Cable....................................................................... 31
APPENDIX 2: Connectors Pin-out ..................................................................... 32
APPENDIX 3: Inclinometer sensor troubleshooting ........................................ 35
APPENDIX 4: Cable reel sensor troubleshooting............................................ 38
APPENDIX 5: Load Cells sensors troubleshooting ......................................... 41
13
1. Menu navigation
This the menu tree under the MENU key:
1. Calibrations
1. Angle Calibration
2. Length Calibration
3. Load Calibration
4. Boom Limits
5. Automatic Heights Calib.
1. Boom Up
2. Boom Dw
3. Boom Out
4. Boom In
5. Correction UP
6. Correction DOWN
6. Machine Configuration
7. Engine RPM Calibration
8. Other Parameters
9. Download Calibrations
2. Test inputs/outputs
1. Test digital inputs
2. Test analog inputs
3. Test PWM outputs
4. Test digital outputs
5. Test rpm inputs
3. Alarm settings
4. Geometrical Settings
5. Safeties
6. Malfunctions Black Box
1. Show Black Box
2. Erase Black Box
3. Send/Print Black Box
7. Black Box Operative
4. Show Black Box
5. Erase Black Box
6. Send/Print Black Box
8. System Time
9. Change Hourmeter
Any screen page always shows instructions how to get out of menus (usually DEL key) or to
change options.
14
2. Machine Calibrations
2.1 Angle Calibration
Minimum and maximum sensor values at 0 e

Minimum and maximum real machine angles,
59.3 deg stored in the last calibration
set up into “Geometrical settings” menu
1. Min.Angle: 0.0 308

2. Max.Angle: 59.3 870
SENSOR: 370 Signal supplied by sensor (inclinometer) in real

time
DEL: Exit - ENTER: OK
Proceed as follows:
• Move boom at minimum and press 1
• Move boom at 59.3° (maximum possible) and press 2
• Press ENTER to store the new calibration
• To change reference angles, go first into the menu “Geometrical settings”
During calibration, all safeties are disabled to allow complete boom movements.
Take maximum care during this procedure.
2.2 Length Calibration
1. Min.Length: 8.85 308

2. Max.Length: 15.65 870
SENSOR: 370
See “angle calibration” for an explanation of the different items.

Procedure:
• Move boom at minimum length and press 1
• Move boom at maximum possible length and press 2
• Press ENTER to store the new calibration
During calibration, all safeties are disabled to allow complete boom movements.
Take maximum care during this procedure.
15
2.3 Load Calibration
The weight is calculated measuring the sum of the currents supplied by the two load cells.
So, it is necessary to calibrate these sensors with the spreader empty and with one reference load,
whose weight must be known.
For a good calibration, the selected weight must be closest possible to the machine maximum
capacity.
Rules before starting a load calibration:
• Find a container with certified weight as much as possible close to machine maximum capacity
• Set up real container weight in the menu “8. Other parameters”
• There is a correction factor for the load in the menu “8. Other parameters”: set it to 0 before
any calibration
1.Load min: 0.0

1650
2.Load max: 23.5
885
SENSORS: 440 445
Procedure:
• With empty and centered spreader, check the load cells currents: they must be about the same.
If not, adjust the trimmer in the load cell amplifiers (located near load cell pins).
• Once currents are set, press 1 to store the value.
• Lock and lift the reference container (23.5 tons in the example) up to 20-30 degrees; wait for
currents stabilization (side shift the spreader to center the weight if necessary) and press 2 to
store the value.
• Then, press ENTER per store the final calibration.
Notes:
With the weight lifted, load cell values must decrease of about 10 units for each tons (see appendix
for more details).
Load cells values must be always quite similar: otherwise, load is not centered or load cells are not
working properly.
16
2.4 Boom Limits
This option sets the points where the boom has to be locked before it can reach the physical limit of
its stroke.
1.Offset Min.Ang: 1.0

2.Offset Max.Ang: 1.5
3.Offset Min.Len: 0.01
4.Offset Max.Len: 0.05
DEL: Exit
The values indicates how many degrees (for the angles) or meters (for the length) before the
cylinder end it is necessary to lock the movement. In the example, if maximum angle is 60.0 deg,
lifting will be locked at 58.5 deg.
To modify values, press the proper number and insert the new value. Confirm with ENTER.
2.5 Automatic Heights Calibration
Automatic heights selection works activating proportional solenoids, one for each movement,
considering the spreader distance as feed-back.
Each movement changes its speed with the error measured on the reference distance.
There are 3 error zones, at 10, 20 and 30 cm; for each one of these it is possible to set a speed
reduction in order to balance combined movements.
To change speeds, use options 1 to 4:
1. Step: system response: a high value can introduce system oscillations. Range: 10-500
2. Min.Sp.: movement minimum speed. Insert a value that corresponds to movement starting
point with engine at 1.500 rpm: check this value with test PWM. Range: 1-1000.
3. Max.Sp.: movement maximum speed. Insert a value that corresponds to maximum electro
valve opening. Check this value with test PWM. Range: 1-1000.
Options 5-6 modify movements correction, for lifting and lowering:
1. % 10 cm: percentage of speed reduction when error is over 10 cm. Range: 0-100.
17
2.6 Machine Configuration
This option allows to set up some optional possible on machine or to enable some special functions:
1. Automatic.Mov: enable/disable automatic height selection function

2. USA Standard: changes all measurement from metric system to USA standard (feet instead
of meters and pounds instead of tons)
3. Analog.Sensors: it informs the system if temperature sensors are analogue type (in this case
the real temperature will be displayed) or digital (in this case only the two
possible states will be shown: OK-ALARM)
4. Stabilizers: it informs the system if stabilizers are installed on the machine, in order to
set proper screen messages and multiple capacity charts
Pressing the proper numerical key, the message YES/NO informs if the optional has been enabled
or disabled.
2.7 Engine RPM Calibration
Real engine
RPM (minimum)
1.Min.RPM : 600 240 Frequency of alternator signal in corrispondece of

2.Max.RPM : 2200 880 minimum and maximum RPM
3.Change Min-Max
Real engine RPM
Frequency: 330 (maximum)
DEL: Exit – ENTER: OK
Engine rpm is calculated from alternator signal (W+, Logicontrol input: “r”). It is a frequency signal
proportional to engine rpm.
With this option it is possible to calibrate engine rpm from that signal. The procedure is easy:
• Leave the engine at minimum rpm

• Press 1 (the frequency value is copied into the line: “Min.RPM”)
• Accelerate engine at maximum rpm
• Press 2 (the frequency value is copied into the line: “Max.RPM”)
• Press ENTER to store calibration
If real engine rpm would be different from the example (600 and 2200) it is possible to change them
pressing first key 3 and inserting real reference rpm.
This calibration is necessary in case of replacement of alternator type.
18
2.8 Other Parameters
This option allow to modify parameters related to weight and machine speed:
1. Speed Factor: factor proportional to machine speed. This is typical for each machine
model, and it depends on tires size and differentials. It converts the number
of pulses read from sensor on drive axle into km per hour.
2. Load Factor: percentage factor that increases (if positive) or decreases (if negative) the
weight displayed on screen at maximum angles.
For example, if the value would be 5, it means that the load measured will
be increased of 5% when the boom is at 60° (maximum angle).
With the boom fully lowered (0°) there will be no increase; for all other
boom positions the increase will be proportional to the angle.
3. Load Min: reference load for load calibration (minimum). In case of standard spreader
machines, this has to be always 0.
4. Load Max: reference load for load calibration (maximum). It has to be as much as
possible close to maximum capacity, that anyway is not influenced by this
parameter.
2.9 Download Calibrations
This option allows to download most important information regarding calibrations into an external
PC o a serial printer.
On the PC there must be any serial terminal software, like, for example, HyperTerminal, always
present in any Windows operating system.
Serial port has to be configured as follows:
• Baud rate: 9.600 bps

• Data bits: 8
• Parity: No parity
• Stop bit: 1
In the following table there is the description of the numbers transmitted on the serial port.
For system maintenance, it is suggested to keep on file this information, in order to manually re-
insert them in case of Logicontrol replacement.
19
Value Description
201 - 820 Values of angle sensor corresponding to minimum and maximum calibration angles
0.0 - 59.2 Minimum and maximum calibration angles
209 - 760 Values of length sensor corresponding to minimum and maximum calibration length
8.85 - 15.65 Minimum and maximum calibration boom length
1693 – 1288 Load cells values sum corresponding to minimum and maximum calibration weights
0.0 - 25.0 Minimum and maximum calibration weights
950 - 950 Load cells limits for boom lowering control
0.00 Distance limit for distance control
0.10 Minimum height for piggy back legs control
300 Load cells difference for unbalanced load control
9.00 Maximum distance for boom control
1500 Engine RPM for high boom speed
6.95 Wheel Distance for machine geometry
1.70 Spreader-Ground Distance for machine geometry
0.30 Boom spreader distance for machine geometry
80 Overload prealarm threshold
100 Overload limit threshold
2 Delay on movements lock for overload
2 Delay on movements unlock after overload
1.50 - 1.50 Degrees before minimum and maximum angles for boom movements limits
0.08 - 0.10 Meters before minimum and maximum boom length for boom movements limits
SI NO SI NO Machine Configuration: Automatic Movements – USA standards – Analogue Sensors – Stabilizers
296 Speed Factor
690 - 2300 Real minimum and maximum calibration engine RPM
280 - 800 Frequency of alternator signal corresponding to engine minimum and maximum RPM
10 – 200 - 800 Step, minimum and maximum speed of automatic movements (lifting)
10 – 200 - 800 Step, minimum and maximum speed of automatic movements (lowering)
10 – 200 - 800 Step, minimum and maximum speed of automatic movements (extension)
10 – 200 - 800 Step, minimum and maximum speed of automatic movements (retraction)
20 – 30- 30 Percentage of speed reduction for automatic movements (lifting)
20 – 30- 30 Percentage of speed reduction for automatic movements (lowering)
178 Code for main menu access
300 Code for calibrations
182 Code for black box erasing
0 Spare Code (not used)
1234 Code bypass overload
4444 Code bypass buzzer
2468 Code bypass distance control
2679 Code bypass load cells controls
3434 Code bypass engine shut off control
1111 Code bypass automatic transmission controls
1590 Code bypass all safeties
20
3. Test Inputs-Outputs
3.1 Test digital inputs
F.(0): 1 S.(10): 1
G.(1): 0 T.(11): 0
H.(2): 1 U.(12): 0
J.(3): 1 V.(13): 0
K.(4): 0 W.(14): 0
L.(5): 0 X.(15): 0
M.(6): 0 B.(16): 1
N.(7): 0 C.(17): 1
P.(8): 0 D.(18): 1
R.(9): 1 E.(19): 1
This shows the status of digital inputs connected to each pin of input connector.
If the state is “1”, it means that the contact is closed, if it is “0”, it means that it is open.
See appendix to check which sensors are connected to each pin.
3.2 Test analog inputs
j.(0): 10 f.(8): 383

k.(1): 20 g.(9): 390
Z.(2): 1020 h.(10): 180
a.(3): 1020 j.(11): 220
b.(4): 1020 k.(12): 880
c.(5): 1020 m.(13): 875
d.(6): 1020 n.(14): 1
e.(7): 620 p.(15): 0
This shows analogue input status, in their different configuration:
Input group Type Troubleshooting

j, k Not connected
From Z to g Current generators inputs The value is 0-3 if they are short circuited to ground,
1020-1023 if not connected
From j to p Current reading: 0-20 mA The value is 0-3 if they are short circuited to ground or not
connected. If fixed at 1023 they are damaged
21
3.3 Test PWM Outputs
1.Boom Up: 0
2.Boom Dw: 100
3.Boom Out: 0
4.Boom In: 0
1-4: Increase PWM

0 : Erase PWM
This test allows manual activation of proportional electro valves connected to boom movements
(lifting, lowering, extension and retraction); pressing proper number, the PWM value is increased
by 50 unit each time.
With engine on, the movement should start at about 350-400 units, and maximum speed should be
around 750-800 units.
This test is useful to calibrate minimum and maximum movements speeds for automatic heights
selection.
Key 0 erases all PWM and stops movements.
During this test with engine on, boom will move and joystick has no effect.
Take maximum care during the test and press immediately key 0 in case of danger
3.4 Test digital outputs
G.(0): 1 R.(8): 1
H.(1): 1 S.(9): 0
J.(2): 1 T.(10): 0
K.(3): 0 U.(11): 0
L.(4): 0 V.(12): 0
M.(5): 0 W.(13): 1
N.(6): 0 X.(14): 1
P.(7): 0 Z.(15): 1
DEL: Exit-RET:Set Output
This test shows output status in real time: 1 means 24V on the output pin.
Pressing key ENTER, it is possible to force manually each output. Use key ARROW RIGHT to turn
on all outputs in sequence, as shown on display:
DEL: Exit - >:Select
22
3.5 Test rpm inputs
TEST RPM INPUTS

UNITS FREQ.
r.(0): 580 220
s.(1): 0 0
DEL: Exit
This test allows to know the number of pulses (units) and the frequency (freq) in hertz of the two
available RPM inputs. Signals connected are engine rpm (from W+ of alternator) and wheels rpm
from drive axle sensor.
4. Alarms
1.Prealarm : 85
2.Overload : 100
3.Lock Delay : 10
4.Unlock Delay : 5
Prealarm: % of maximum capacity to get overload warning. Range: 50-99

Overload: % of maximum capacity to get overload alarm. Range: 50-103
Lock Delay: Delay between the overload alarm activation and the movements interlock (in
tenth of second)
Unlock Delay: Delay in ms between the overload alarm end and the movements enabled (in
tenth of second)
23
5. Geometrical Settings
This option allows to set all geometrical parameters typical o a generic stacker machine.
See figure to understand parameters required:
1. Distance: Parameter A in figure
2. Spread.Boom D.: Parameter B in figure
3. Spread Height: Parameter C in figure
4. Min Angle: Real minimum boom angle in degrees (reference for angle calibration)
5. Max Angle: Real maximum boom angle in degrees (reference for angle calibration)
6. Min Length: Real minimum boom length in meters (reference for length calibration)
7. Max Length: Real maximum boom length in meters (reference for length calibration)
24
6. Safeties
This option allows to modify all safeties thresholds, in order to adapt machine to operating
requirements:
1. Min.Distance: Distance for “minimum distance” safety activation
2. Unbalanc.Load: Difference between load cell values for “unbalanced load” safety activation,
expressed in units. One tons means about 10 units
3. L.Cell 1 Limit : Load cell 1 value (right, in units) for lowering lock activation. The interlock
is active when measured value (owing to load cell compression) overtakes
this one
4. L.Cell 2 Limit: Load cell 2 value (left, in units) for lowering lock activation. The interlock is
active when measured value (owing to load cell compression) overtakes this
one
5. Minimum Height: Minimum height for “minimum height for piggy back” safety activation
6. Maximum Radius: Limit distance over which all boom movements except retraction are disabled
(“maximum distance” safety). Used only for empty stackers handlers.
7. Malfunctions Black Box

Alarms black box contains information of overloads, sensors errors and bypass use.
It is possible to store over 2.000 messages.
In the first page, there are 3 options and the total message number present at the moment:
EVENTS BLACK BOX

1.Show Black Box
2.Erase Black Box
3.Send/Print Black Box
Messages: 1970
25
7.1 Show malfunctions black box Date and time alarm recording
EVENTS BLACK BOX Message

Message 50/87
15/10/00 12:43 Container distance at the overload moment

(used only for overload alarms)
Message: OVERLOAD
Distance: 3.8
Maximum overload weight or maximum
MAX: 25.7
temperature in case of analog sensors.
Hourmeter: 144
Not used for other alarms
DEL: Exit - Arrows: Scroll
Machine hourmeter at alarm moment
Use arrow keys UP/DOWN to scroll through messages.
7.2 Erase malfunctions black box
This options deletes permanently data from black box. It requires a code.
7.3 Send/Print malfunctions black box
This option allows to transfer all data through the serial port RS232. See paragraph “download
calibrations” for serial port setting details.
On the PC it is necessary a terminal software like HyperTerminal for Windows.
Connecting directly to a serial printer, all data will be printed.
26
8. Operative Black Box

Operative black box contains information of all equipment lifted with the machine, with spreader or
other tools, like chains, hooks, piggy back and so on.
It is possible to store the historical number of all containers ever moved and detailed information of
the last 2.000.
OPERATIVE BLACK BOX

1.Show Black Box
2.Erase Black Box
3.Send/Print Black Box
Messages: 1970 Number of messages and total

lifts counter
Total: 115340
8.1 Show operative black box Date and time container handling
OPERATIVE BLACK BOX Container type (20-30-40) or tool type

Message 101/101
15/10/00 12:43
Handling time in seconds
Size: 20
Handling T: 120
Weight: 13.6 Container weight and machine hour meter
Hourmeter: 144 at lifting time
Container: 24
Container number (it restart from 1 every
DEL: Exit – Arrows: Scroll time machine is started)
8.2 Erase operative black box
This options deletes permanently data from black box. It requires a code.
8.3 Send/Print operative black box
This option allows to transfer all data through the serial port RS232. See paragraph “download
calibrations” for serial port setting details.
On the PC it is necessary a terminal software like HyperTerminal for Windows.
Connecting directly to a serial printer, all data will be printed.
27
9. System Time
It is possible to change system date and time. It is required to insert year, month, day, hour and
minute in sequence.
Insert correct numbers with numerical keys.
A not realistic date will be refused.
10. Change Hourmeter

It is possible to insert a new hour meter counter. This is useful in case of Logicontrol replacement,
because it may be necessary to restart the hour meter from the previous value.
11. Changing System Codes

For safety reasons, it is possible to modify all system codes, access and bypass.
It is possible to access to the special menu with the ARROW DOWN key.
It is required a access code, fixed and not changeable (8356). Then, a menu appears:
1. Change Codes
2. Codes List
Option1 shows the codes list that it is possible to change:
1. Menu 5. Overl
2. Calibr 6. Buzzer
3. E.Bbox 7. Distance
8. L.Cells
9. Eng.Stop
10. Din.Saf.
11. Total
0: Exit
28
On the left side, (from 1 to 3) there are the access codes:

Menu: code to access to the main menu (Menu key, standard 178)
Calibr: code to access to calibrations (standard 300)
E.Bbox: code to erase the black boxes (standard 182)
On the right side (from 5 to 11) there are all bypass codes:
Overl: bypass for overload control, sensors not connected and maximum distance (standard:
1234)
Buzzer: sound alarm (standard: 4444)
Distance: bypass minimum distance control, height safety and boom limits (standard: 2468)
L.Cells: bypass unbalanced load and lowering lock (standard: 2679)
Eng.Stop: bypass engine shut off control (standard: 3434)
Din.Saf: bypass automatic transmission control, in relationship with speed and stability
(standard: 1111)
Total: all safeties bypass (standard: 1590)
Inserting the number of the code that it is necessary to modify, the system asks first the old code; if
the code is correct, the new code is stored.
Option2 require a code, fixed and not changeable (2166). Then, a menu appears:
1. Menu : 178 5. Overl : 1234

2. Calibr: 300 6. Buzzer : 4444
3. E.Bbox: 182 7. Distance : 2468
8. L.Cells : 2679
9. Eng.Stop : 3434
10. Din.Saf : 1111
11. Total : 1590
DEL: Exit
System safety is strictly linked to the diffusion of the codes 8356 e 2166.
29
12. Logicontrol for Twin-Lift Machines

For special machines equipped with twin-lift spreader, Logicontrol has a special version, to adapt
signals and logic to the different pin-out and spreader safeties.
12.1 Main screen page and operator messages
As shown above, main screen page has a different spreader drawing, where additional “seated”
sensor are displayed.
There is also an additional operator message when twin lift is lowered. In this condition:
• The tool type is selected as “TW”, and so it is stored in operative black box
• The correct capacity chart is selected
12.2 Additional safeties
In the safety screen, a new parameter has been added:
7. CellDiff-Empty: 200
This parameter indicates the maximum possible unbalanced load (expressed in cells units
difference) when empty.
The reason is that it is necessary to reduce side shift when spreader is empty compared to the loaded
condition. So, this parameter needs to be lower than the standard one.
In case of any load on the spreader, the standard parameter will be used.
Besides, when load is unbalanced, there is a speed limit (if transmission is managed by
Powertronic) or third and fourth speed interlock (in case of Shiftronic unit)
30
APPENDIX 1: Null-Modem Cable

This cable is used in following conditions:
• Calibrations download to an external PC
• Black boxes (malfunctions and operative) download to an external PC
• Software update using the special tool Superloader
DB9 F
DB9 F
DCD 1
DCD 1
RD 2
RD 2
TD 3
TD 3
DTR 4
DTR 4
GND 5
GND 5
DSR 6
DSR 6
RTS 7
RTS 7
CTS 8
CTS 8
RI 9
RI 9
31
APPENDIX 2: Connectors Pin-out
Output connector, 37p straight
PIN Signal Type Notes Index

A-B-C + 24 V Power Supply
D-E-F GND Ground
G Overload Relais DIG-OUT 1 3A, 24 VDC 0
H Unbalanced Load Right DIG-OUT 2 3A, 24 VDC 1
J Unbalanced Load Left DIG-OUT 3 3A, 24 VDC 2
K Distance Safety Relais DIG-OUT 4 3A, 24 VDC 3
L Lowering Safety Relais DIG-OUT 5 3A, 24 VDC 4
M Engine Shut Down DIG-OUT 6 3A, 24 VDC 5
N Piggy Back Lowering Legs Lock Relais DIG-OUT 7 3A, 24 VDC 6
P Speed 3-4 Lock Relais DIG-OUT 8 3A, 24 VDC 7
R Speed 4 Lock Relais DIG-OUT 9 3A, 24 VDC 8
S Boom Up Limit Relais DIG-OUT 10 3A, 24 VDC 9
T Boom Down Limit Relais DIG-OUT 11 3A, 24 VDC 10
U Boom Out Limit Relais DIG-OUT 12 3A, 24 VDC 11
V Boom In Limit Relais DIG-OUT 13 3A, 24 VDC 12
W Lifting Stabilizers Lock Relais DIG-OUT 14 3A, 24 VDC 13
X EV Regenerating for Distributors DIG-OUT 15 3A, 24 VDC 14
Z EV Regenerating for Cylinders DIG-OUT 16 3A, 24 VDC 15
a Boom Up PWM 0 3A PWM 0
b Boom Down PWM 1 3A PWM 1
c Boom Out PWM 2 3A PWM 2
d Boom In PWM 3 3A PWM 3
j Reserved for bypass key ANA-INPUT 0 0
k Power supply feed-back ANA-INPUT 1 1
m-n +5 VDC Power supply
e-f-g-h-j-k-p-r-s Not Used
32
Input connector, 37p oriented
PIN Signal Typo Notes Index

A GND Common I0-I3 24 VDC or GND
B Twist Landed 1 (Front L - 24 VDC) DIG INP 0 DIG INP 0-3 close to GND 16
C Twist Landed 2 (Front R - 24 VDC) DIG INP 1 if common is at 24V 17
D Twist Landed 3 (Rear L - 24 VDC) DIG INP 2 18
E Twist Landed 4 (Rear R - 24 VDC) DIG INP 3 19
F Locked DIG INP 4 PNP o NPN 0
G Unlocked DIG INP 5 PNP o NPN 1
H Spreader 20' DIG INP 6 PNP o NPN 2
J Spreader 30' DIG INP 7 PNP o NPN 3
K Spreader 40' DIG INP 8 PNP o NPN 4
L Low Water Level DIG INP 9 PNP o NPN 5
M Low Engine Oil Pressure DIG INP 10 PNP o NPN 6
N Automatic Movements Stop DIG INP 11 PNP o NPN 7
P Stabilizers Down DIG INP 12 PNP o NPN 8
R Piggy Back Legs Lowered DIG INP 13 PNP o NPN 9
S Piggy Back Legs Clamped DIG INP 14 PNP o NPN 10
T Low Fuel Level DIG INP 15 PNP o NPN 11
U DIG INP 16 PNP o NPN 12
V DIG INP 17 PNP o NPN 13
W DIG INP 18 PNP o NPN 14
X DIG INP 19 PNP o NPN 15
Z ANA_SPEC 0 Current Gen: 30mA 2
a ANA_SPEC 1 Current Gen: 30mA 3
b ANA_SPEC 2 Current Gen: 13.5mA 4
c ANA_SPEC 3 Current Gen: 13.5mA 5
d ANA_SPEC 4 Current Gen: 13.5mA 6
e Water Temp (2mA) ANA_SPEC 5 Current Gen: 2mA 7
f Transmission Oil Temp (2 mA) ANA_SPEC 6 Current Gen: 2mA 8
g Engine Oil Temp (2 mA) ANA_SPEC 7 Current Gen: 2mA 9
h Inclinometer (4-20 mA) ANA_INP 2 0-20 mA 10
j Cable Reel (4-20 mA) ANA_INP 3 0-20 mA 11
k Load Cell Right (4-20 mA) ANA_INP 4 0-20 mA 12
m Load Cell Left (4-20 mA) ANA_INP 5 0-20 mA 13
n ANA_INP 6 0-20 mA 14
p ANA_INP 7 0-20 mA 15
r Engine RPM (W+) RPM 0 0 -24 VDC, 100 Hz - 5 kHz 0
s Wheels RPM RPM 1 1 -24 VDC, 100 Hz - 5 kHz 1
33
Input connector, 37p oriented

TWIN-LIFT MACHINES VERSION
PIN Signal Typo Notes Index

A GND Common I0-I3 24 VDC or GND
B Twist Landed 1 (Front L - 24 VDC) DIG INP 0 DIG INP 0-3 close to GND 16
C Twist Landed 2 (Front R - 24 VDC) DIG INP 1 if common is at 24V 17
D Twist Landed 3 (Rear L - 24 VDC) DIG INP 2 18
E Twist Landed 4 (Rear R - 24 VDC) DIG INP 3 19
F Locked DIG INP 4 PNP o NPN 0
G Unlocked DIG INP 5 PNP o NPN 1
H Spreader 20' DIG INP 6 PNP o NPN 2
J Spreader 30' DIG INP 7 PNP o NPN 3
K Spreader 40' DIG INP 8 PNP o NPN 4
L Low Water Level DIG INP 9 PNP o NPN 5
M Low Engine Oil Pressure DIG INP 10 PNP o NPN 6
N Automatic Movements Stop DIG INP 11 PNP o NPN 7
P Stabilizers Down DIG INP 12 PNP o NPN 8
R Twin Lift Lowered DIG INP 13 PNP o NPN 9
S Twin Lift Lifted DIG INP 14 PNP o NPN 10
T Low Fuel Level DIG INP 15 PNP o NPN 11
U Twist 2 Landed 1 (Front L - 24 VDC) DIG INP 16 PNP o NPN 12
V Twist 2 Landed 2 (Front R - 24 VDC) DIG INP 17 PNP o NPN 13
W Twist 2 Landed 3 (Rear L - 24 VDC) DIG INP 18 PNP o NPN 14
X Twist 2 Landed 4 (Rear R - 24 VDC) DIG INP 19 PNP o NPN 15
Z ANA_SPEC 0 Current Gen: 30mA 2
a ANA_SPEC 1 Current Gen: 30mA 3
b ANA_SPEC 2 Current Gen: 13.5mA 4
c ANA_SPEC 3 Current Gen: 13.5mA 5
d ANA_SPEC 4 Current Gen: 13.5mA 6
e Water Temp (2mA) ANA_SPEC 5 Current Gen: 2mA 7
f Transmission Oil Temp (2mA) ANA_SPEC 6 Current Gen: 2mA 8
g Engine Oil Temp (2mA) ANA_SPEC 7 Current Gen: 2mA 9
h Inclinometer (4-20 mA) ANA_INP 2 0-20 mA 10
j Cable Reel (4-20 mA) ANA_INP 3 0-20 mA 11
k Load Cell Right (4-20 mA) ANA_INP 4 0-20 mA 12
m Load Cell Left (4-20 mA) ANA_INP 5 0-20 mA 13
n ANA_INP 6 0-20 mA 14
p ANA_INP 7 0-20 mA 15
r Engine RPM (W+) RPM 0 0 -24 VDC, 100 Hz - 5 kHz 0
s Wheels RPM RPM 1 1 -24 VDC, 100 Hz - 5 kHz 1
34
APPENDIX 3: Inclinometer sensor troubleshooting
A3.1. Installation
INCLINOMETER BOX INTERNAL
Inclinometer board
1 2 3 (2420.010.0017)
Output (0-20 mA)
GND (Black)
+24 VDC (Red)
Figure 1
Note that arrow inclination on sensor must be about 45 ° towards ground (with box flat)
A3.2. Technical Sensor Data
Measured Angle 90°° (± 45°°)

Maximum Input Voltage 10 VDC
Input Resistance 15 kOhm ± 30%
Linearity 2% fs
Maximum Sensitivity 0,01°°
Pendulum Damper Silicon Oil
Operative Temperature -5 °C – 80 °C
Storage Temperature -40 °C – 80 °C
35
A3.3. Voltage Test
• Make sure all connections are as shown in fig.1

• Turn power supply on
Wires Correct Voltage If not...

2-3 24 VDC No power supply: check fuses
1-2 1 - 5 VDC No connection of amplifier card with main card or amplifier card
fault
A3.4 Working Test
In Test Analogue Inputs, inclinometer values must change with boom movements. It is not important if the
value increases with boom hoisting o vice-versa.
In Test Analogue Inputs, sometimes, main card converts current coming from sensor into numbers, with
following correspondence (it is an A/D conversion at 10 bit):
Sensor Value
Converted
0 mA (or 0V) 0
20 mA (or 5V) 1023
Correspondence is linear, that means that a 10 mA current is converted into a number like 512.
Values must be as follows:
• Maximum value swinging, with boom still, must be about 5 units

• During all boom movements, sensor must have a value between 100 and 1000. Out of this range, it is
possible to use inclinometer inside its non-linear zone, with errors in angle calculation
• Values below 100 cause a system alarm for sensor not connected or fault
36
A3.5 Troubleshooting
• If the value is at 1023 fixed, at any boom angle:

⇒ Check connections
⇒ Check for humidity or dirty inside box or into connections
⇒ Check inclinometer position
⇒ Replace main card and repeat calibration
• If the value is at 1023 only in some boom positions:

⇒ Inclinometer is bad positioned. Perform all tests described above
• If calibration values change during operations:

⇒ Sensor is rotating from original location. Tight nuts and repeat calibration
⇒ Sensor is damaged: replace it
⇒ Ground is not flat (i.e., if, with boom at minimum, angle displayed is not 0°, check if ground is pendent,
because this affects directly sensor reading)
• If alarm “Angle Sensor fault or not connected” appears on display:

⇒ Perform all tests described above
⇒ Check inclinometer position
• If the value never changes:

⇒ Check connections between amplifier card and main card
• If the value swings a lot or is not moving with linearity:

⇒ Check for humidity or dirty inside box and connections
⇒ Check connections quality
⇒ Replace Main Card
• The value does not change for low angles:

⇒ The box has been mounted at sensor reading limit: position the box with a different inclination
37
APPENDIX 4: Cable reel sensor troubleshooting
A4.1. Installation
CABLE REEL INTERNAL
1 2 3
7 4
Potentiometer
8 5
9 6
Output (0-20 mA)

Signal converter and
GND (Black) amplifier
(2420.010.0016)
+24 VDC (Red)
Figure 1
From figure 1, we note that:
• Jumpers on amplifier card (2420.010.0016) are not necessary

• All connections must be as shown
A4.2. Technical data cable reel and potentiometer
Cable Length 8 mt (+ 3 mt spare)

Cable Reel Mechanics Steel Cable and Springs
Potentiometer Resistance 5 kOhm ± 5%
Number of Turns 10
Linearity ± 0.25%
Operating Temperature -10°° C - +70°° C
Storage Temperature -40°° C - +70°° C
38
A4.3. Resistance Test
• Turn power supply off

• Disconnect wires 4-5-6 (fig. 1)
• Check resistance between wires 1-3: it must be about 5 Kohm for any cable length
• Resistance between wires 1-2 or 2-3 must be a value in 0 and 5 Kohm range, slipping cable off
• If you find an open circuit, 0 Ohm even if only in some points, potentiometer be replaced
A4.4. Voltage Test
• Make sure all connections are as shown in fig.1

• Turn power supply on
Wires Correct Voltage If not...

1-3 or 4-6 10 VDC No power supply or amplifier fault
4-5 or 5-6 2 - 8 VDC Potentiometer fault or bad positioned: it is out of range
7-8 1 - 5 VDC No connection amplifier -main card or amplifier fault
A4.5. Working Test
In Test Analogue Inputs, cable reel values must change with boom in/out movements.
In Test Analogue Inputs, sometimes, main card converts current coming from sensor into numbers, with
following correspondence (it is an A/D conversion at 10 bit):
Sensor Value
Converted
0 mA (or 0V) 0
20 mA (or 5V) 1023
Correspondence is linear, that means that a 10 mA current is converted into a number like 512.
Values must be as follows:
• Maximum value swinging, with boom still, must be about 5 units

• During all boom movements, sensor must have a value between 100 and 1000. Out of this range, it is
possible to use cable reel inside its non-linear zone, with errors in length calculation and the possibility to
damage the potentiometer
• Values below 100 cause a system alarm for sensor not connected or fault
• With all cable inside drum (zero position), the value must be about 180-200, that corresponds to a signal
0,8 - 1 VDC from amplifier. In the case it is necessary to replace the potentiometer, this is the condition for
a correct position on the assembly
39
A4.6. Troubleshooting
• If the value is at 1023 fixed, at any boom (or cable) length:
⇒ Check for humidity or dirty inside box or into connections
⇒ Check potentiometer signal in zero position
⇒ Replace main card and repeat calibration
• If the value is at 1023 only in some boom positions:
⇒ Potentiometer could be damaged. Perform all tests described above
• If calibration values change during operations:
⇒ Sensor is moving from its original location. Tight dowel on potentiometer shaft and repeat calibration
⇒ Sensor is damaged: replace it
⇒ Cable is slipping off or it has broken: replace all cable reel
• If alarm “Length Sensor fault or not connected” appears on display:
⇒ Try to take the cable off little by little checking the value from the sensor: if the alarm appears only in
some positions, potentiometer is damaged and must be replaced

⇒ Check connections between amplifier card and main card
• If the value swings a lot or is not moving with linearity:
⇒ Check for humidity or dirty inside cable reel or connections

⇒ Check connections quality
⇒ Replace main card
40
APPENDIX 5: Load Cells sensors troubleshooting

A5.1. Installation
Electronic Signal Amplifier

(2420.010.0018)
Load Cell: spreader pin
Military connector pin-out
PIN WIRE
A Yellow (OUT +)
B Green (OUT -)
Military Connector
C Red (Pow.Supp +)
D Blue (Pow.Supp -)
E Black (shield)
Figure 1
A5.2. Amplifier card connections
Dip-switch
load cell
selection
1.GREEN
2.YELLOW 5.Output signal 0-20 mA
3.BLU 6. Ground (black)
4.RED
7. +24 VDC (power supplì, red)
Trimmer for fine

Figure 2 adjustment
41
A5.3. Load cells technical data
Max. Capacity Strain gage output

Machines CS 7.5 (load cell type 1) 9 Ton. 1 mV / V
Machines CS 42-45-50 (load cell type 2) 40 Ton. 0,5 mV / V
The output means that the load cell supplies 0,5 mV for each volt of its power supply. Since power supply is 10
VDC, the load cell will have 5 mV as maximum output voltage, when maximum load is applied.
A5.4. Dip-switch and trimmer
Amplifier card has a dip-switch that allows the correct amplification fo all load cells types.
This table resumes dip-switch correct positions:
Pos.1 Pos.2 Pos.3 Pos.4 Pos.5 Pos.6 Pos.7 Pos.8 Load Cell Application
0 0 0 0 0 0 0 1 2mV/V FDC or MJ 450-500
0 0 0 0 0 0 1 0 1.5mV/V
0 0 0 0 0 1 0 0 1mV/V Stacker CS7.5
0 0 0 0 1 0 0 0 0.5mV/V Stacker Cs42-45 and
higher
Position 0 and 1 means:
1 2 3 4 5 6 7 8
POSITION “ON”: 1
POSITION “OFF”: 0
From figure 2 you can note a trimmer to adjust the voltage output in order to balance the two load cells. The
regulation is in 1-2 V range.
When the weight is calculated with 2 load cells, it is important that they supply the same output from the same
load applied; for unbalanced load calculations, it is important they start supply the same output when load is
balanced.
With spreader empty and centered, the maximum difference between load cells should be 20 units.
42
A5.5. Resistance Test
• Turn power off

• Disconnect wires 1-2-3-4 (fig. 2)
• Check resistances between all wires, two at time (red-blue, red-yellow, and so on)
• If there is any open circuit or 0 ohm, load cell must be replaced
A5.6. Voltage Test
• Make sure all connections are as shown in fig. 1-2

• Turn power on
• With spreader empty:
Wires Voltage Correct If not

3-4 10 VDC No power supply / Amplifier fault
1-2 1,0 mV – 2,0 mV (type 1) Load cell fault or out of range
0,5 mV – 1,8 mV (type 2)
5-6 1 - 5 VDC Bad connections amplifier-main card / Amplifier fault
A5.7. Working Test
In analogue input test, load cells values must be as follows:
Empty Spreader:
• 700 - 800 (type 1)
• 800 - 900 (type 2)
• Maximum values difference, with spreader centered, must be 20-30 units
Loaded Spreader:
• Value must decrease about 50 units per ton applied (type 1)
• Value must decrease about 10 units per ton applied (type 2)
• Maximum values difference, with spreader centered and load balanced, must be 20-30 units
43
A5.8. Troubleshooting
• If the load cell value is always 1023 (even only side shifting):
⇒ Check for humidity or water inside boxes
⇒ If working is anyway correct (value decreases when a load is applied), put a resistance (500 Kohm - 600
Kohm value) into 2-4 (see fig. 2). If values goes back to a correct value, repeat calibration; otherwise,
replace load cell
• If the calibration value changes during lifetime:

⇒ Load cell is going out of range: repeat calibration often, put resistance if necessary and replace load cell
as soon as possible
⇒ A big or too unbalanced load has moved or damaged load cell: repeat calibration
• If the values of the two load cells are different:

⇒ Check load balancing
⇒ Check connectors and wires (humidity, dirty, ...)
⇒ Recalibrate load: unbalanced load control (if exists) won’t work properly
⇒ If the value, with a load applied, goes below alarm threshold, replace load cell

⇒ Make all tests described above
⇒ Check connections Amplifier-Main Card
• If the alarm “Load Cell fault” appears on display:

⇒ Make all tests described above
⇒ Check connections Amplifier-Main Card
44

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Logicontrol - V 1.

Version 1.6 xxx

STACKER CS45/50 RS50/60/70

The manual is divided into 2 sections: operator and assistance.

Logicontrol has following features:

• Boom movements interlock in case of overload or other dangerous conditions.

• Test of all signals connected to the system.

2. Front panel description

1. Keys for system interface

3. Main page description

1. Weight lifted, in tons or pounds

4. Monitoring page description

1. Cooling water temperature: degrees or status (OK, ALARM)

Attivazione quando… Effetto Messaggio Bypass

The operator is the only responsible of safeties bypass use.

Following bypass are available:

Cod Message Description

Cod Message Description

37 Low Fuel Level Low fuel level alarm activated (< 5 %)

8. Basic functions of Logicontrol system

8.1 Automatic height selection (Vertical Movements)

Accuracy on the vertical line is about ± 30 cm.

Any overload or error from stability sensors stops automatic movements.

8.2 Dynamic overload control

• Boom lifting, lowering and extension are locked

The weight calculation is performed using two load cells.

Never lift a container with boom fully extended.

8.3 Engine shut off control

These are the alarms:

• · Low engine oil pressure

8.4 High boom speed control

• Load center distance below 4,5 meters

When high boom speed is not activated, a message appears on display.

8.5 Gear shift and cylinder valve control

Calibrations and access codes must never be known by operators

The operator is the sole responsible for machine handling.

Safety bypass codes diffusion is exclusive responsibility of maintenance supervisors.

ACCESS CODES LIST (STANDARD):

Main Menu: 178

BYPASS CODES LIST (STANDARD):

Overload control: 1234

Minimum and maximum sensor values at 0 e

1. Min.Angle: 0.0 308

SENSOR: 370 Signal supplied by sensor (inclinometer) in real

2.2 Length Calibration

1. Min.Length: 8.85 308

DEL: Exit - ENTER: OK

See “angle calibration” for an explanation of the different items.

2.3 Load Calibration

1.Load min: 0.0

DEL: Exit - ENTER: OK

2.4 Boom Limits

1.Offset Min.Ang: 1.0

2.5 Automatic Heights Calibration

Options 5-6 modify movements correction, for lifting and lowering:

2.6 Machine Configuration

1. Automatic.Mov: enable/disable automatic height selection function

2.7 Engine RPM Calibration

1.Min.RPM : 600 240 Frequency of alternator signal in corrispondece of

DEL: Exit – ENTER: OK

• Leave the engine at minimum rpm

This calibration is necessary in case of replacement of alternator type.

2.8 Other Parameters