Hydraulic Power Unit - Allied Construction Products

Transcription

Hydraulic Power Unit
R
Model
3430LS
Safety, Operation and Maintenance
Do not operate or service this equipment unless you have carefully read and understand all
instructions and warnings contained in this manual. Ensure safety-related instructions, including
this manual, are kept in a convenient location so that they are easily accessible to operators
and maintenance personnel.
Contact your Allied Dealer or the Allied Customer Service
Department for replacement manuals. Inquiries regarding
the content of this manual must include effective date
shown on inside cover.
Document No. SOMM102265
Prepared for Serial No. 02226
This page intentionally
left blank.
Allied Construction Products, LLC www.alliedcp.com
Table of Contents
Section
Description
1
Order Summary
2
Power Unit – Safety, Operation & Maintenance Manual 102265
3
Control System
TOC_effective13may
This page intentionally
left blank.
Allied Construction Products, LLC. www.alliedcp.com
ALLIED Order Summary
Sales Order No.
93868
Sold To:
RMF NOOTER, INC.
Customer PO No.
49132-123056
Ship To:
RMF NOOTER, INC.
Type & Model
Serial No.
Boom System
Part No.
None
Option Central Lube System
Option Swing Stop Install
Option Position Sensing System
Control System
Type & Model
EHC
EHC-Deluxe
Serial No.
Part No.
N/A
576490
Radio
576491
Radio
Hydraulic Install for Breaker or Other Work Tool
Hose Set – P/U To C/V
Hose Set – C/V To Boom Base
Valve Stand
Manual
Breaker Valve Package
EHC
AC40
EHC-Deluxe
AC75
Cable Assembly – Joystick To C/V (L=Ft)
(xx)
Option
---
Option
---
Power Unit
Type & Model
Serial No.
Part No.
EHPU3430
02226
813430
Option Oil Cooler (Heat Exchanger)
Option Electric Panel
Option Electric Panel Installation
---
Option Transformer
Work Tool
Type & Model
Serial No.
Part No.
None
Mounting Bracket (Side plates)
Breaker Lube CML System Opt
Option Pro-Control
Not Installed
1 of 2
Year
2013
Allied Construction Products, LLC. www.alliedcp.com
List of Drawings
Sales Order No.
93868
Part / Drawing
No.
Boom System
Boom Assembly Complete
Year
2013
Manual / MFR
DOCS
None
Boom Section W/ Tubes, Clamps, Hose & Fitting Set
Stick Section W/ Tubes, Clamps, Hose & Fitting Set
Hammer Link Ass’y
Base Assembly
Hydraulic Install – Base Assembly
Hydraulic Install – Breaker Assembly
Cylinder Package
Cylinder Boom and Stick
Cylinder Hammer
Option Position Sensing System
Option Central Lube System
+ MFR DOCS
Option Swing Stop Installation
Control System
Controller Type / Model
Manual
Valve Mounting Location
EHC
Stand
Breaker Valve Pkg
AC40
DLX
RC
On Base
AC75
Manual / MFR
DOCS
576490
+ MFR DOCS
576491
TAB
Hydraulic Schematic (HYDSCH)
C/V - Spare Parts List (
Part / Drawing
No.
HYDSCH-XX
TAB)
Breaker Valve - Spare Parts Information
Option
Power Unit
Hydraulic Power Unit Complete Assembly
Part / Drawing
No.
Manual / MFR
DOCS
813430
SOM102265
Hydraulic Sub-Assembly
Pump – Fluid Recommendations
+ MFR DOCS
Monitor Circuit
100048
Oil Immersion Heater
819693
Filtration (Use MFR Doc’s)
+ MFR DOCS
+ MFR DOCS
Option Motor Starter Panel Install
Option Starter Panel
Option Oil Cooler (Heat Exchanger Install)
2 of 2
INSERT SECTION TAB HERE
POWER UNIT
R
Model
3430LS
Safety, Operation and Maintenance
Do not operate or service this equipment unless you have carefully read and understand all
instructions and warnings contained in this manual. Ensure safety-related instructions, including
this manual, are kept in a convenient location so that they are easily accessible to operators
and maintenance personnel.
Contact your Allied Dealer or the Allied Customer Service
Department for replacement manuals. Inquiries regarding
the content of this manual must include effective date
shown on inside cover.
Document No. SOMM102265
Prepared for Serial No. 02226
Contact Information
Allied Construction Products, LLC
3900 Kelley Ave
Cleveland, Ohio 44114
Tel: 216-431-2600
www.alliedcp.com
[email protected]
Revision History of Document 102265
Enquiries regarding the content of this manual must include effective date shown. Allied Construction
Products, LLC reserves the right to change, edit, delete or modify the content of this document, including
descriptions, illustrations and specifications without prior notification. Specifications are based on
published information at the time of publication. Go to www.alliedcp.com for product or document
updates.
Effective Date
Page
Change
2012_May
All
2012_Oct
All
1st Release Models 3430LS & 3450LS
Remove Technical Data and Specifications
for 3450LS. Table 5.1 now specific to
Drawing 813430 rev-N
i
SOMM102265_3430_effective12oct
Safety Information
Hazard Alerts
Signal Words
Safety messages appear throughout this manual
and on labels affixed to the Allied equipment. Read
and understand the information contained in the
safety message before attempting to install, operate,
service or transport the Allied equipment.
“DANGER”, “WARNING” and “CAUTION” are used
to express the different degrees of hazard
seriousness. Learn to recognize and understand the
severity and consequence associated with each of
these signal words should a potentially hazardous
condition be encountered.
Keep all safety labels clean. Words and illustrations
must be readable. Before operating this equipment,
replace damaged or missing labels.
“DANGER” identifies the highest degree of hazard
seriousness. Its use is limited to the most severe
situations.
The information provided in the safety message is
important for your safety. These messages provide
instructions on how to avoid injury from potential
hazards associated with improper use, operation or
handling of the Allied equipment. Read and follow
the instructions in each safety message. Be aware
of the consequence if these instructions are not
followed.
DANGER - Indicates an imminent hazard, which, if
not avoided, will result in death or serious injury.
WARNING - Indicates an imminent hazard, which, if
not avoided, can result in death or serious injury.
CAUTION - Indicates hazards which, if not avoided,
could result in serious injury or damage to the
equipment.
Safety messages provide the following information:
Alert personnel to potential hazards
CAUTION
Burn injury from contact with hot
surfaces. Some components of the
machinery become hot during
operation. Allow parts and fluids to
cool before handling.
Identify the severity of the hazard, if encountered
Describe the nature of the hazard
Instruct how to avoid the hazard
Fig. S2 Safety Message - Typical
Non-hazard Related Signal Words
Other signal words found in this manual are:
IMPORTANT and NOTE. These messages provide
information that is not hazard-related
IMPORTANT – Identify instructions that, if not
followed, may damage or shorten the service life of
the equipment
Fig. S1 Safety Alert Symbol
NOTE – Highlight suggestions, which will enhance
installation, reliability, or operation.
ATTENTION, BECOME ALERT, YOUR SAFETY IS
INVOLVED
The exclamation point within an equilateral triangle
is the safety alert symbol. This symbol, either used
alone or with a signal word, is used to draw attention
to the presence of potential safety hazards.
ii
Safety Information – [cont’d]
Keep all safety labels clean. Words and illustrations
must be readable. Before operating this equipment,
replace damaged or missing labels. To order
replacements, refer to Table “B”. Refer to Figure “A”
for their location on the equipment.
Information Labels
Information labels affixed to the Allied equipment
include safety warnings, identification and
instructions important to operation and service.
Table A. Labels Found On the Allied Equipment
Figure
Label
Description
EQUIPMENT ID LABEL - Contains identifying information about
the equipment, including: Product name, model number, serial
number, company name and address.
1
SAFETY ALERT SYMBOL / READ INSTRUCTIONS - Directs
personnel to the manual for further information / instructions.
2
3
STAY CLEAR – Alerts personnel and by-standers to maintain a
safe distance from the work tool during operation.
4
MAXIMUM PRESSURE – Specifies the maximum operating
pressure of the Allied equipment.
5
LIFT POINT – Marks approved lift points for safe handling of the
work tool.
6
VALVE POSITION – Identifies valve located between tank and
pump inlet. Valve must remain open during operation.
ALLIED - 814903
ROTATION – Arrow indicates direction of rotation.
7
ALLIED
814904
iii
Figure
Label
Description
Maintenance Reminder – Refer to the manual for scheduled
service, including filter change intervals.
8
ALLIED - 814726
ALLIED LOGO – The Allied brand identifier and is a registered
trademark of Allied Construction Products, LLC.
9
10
3430LS
MODEL – Allied Power Unit Model 3430LS
R
Fig. “A” Label Locations
Table B. Label Ordering Information
Item Part Name
Part Number
1
Label
814038
2
Label
676984
3
Label
xxxxxx
4
Label
658542
5
Label
676982
6
Label
814903
7
Label
814904
8
Label
814726
9
Label
676656
10
Label
xxx
Description
Equipment ID Tag
Read the Manual
Stay Clear
Maximum Operating Pressure
Lift Point
Valve Position During Operation
Arrow - Rotation
Maintenance Reminder
ALLIED Logo
Model
iv
Qty
1
1
1
x
1
1
1
1
1
Meaning of Pictograms
Pictograms are used to rapidly communicate
information. For the purposes of this manual and
labels, pictograms are defined as follows:



Personnel must always maintain a
safe distance from the work tool
Read the manual
Refer to the manual for
further details
Procedures are explained in
the manual
Fragments / debris becoming
airborne projectiles
Read the Service Manual For
Additional Information
Oil / Gas under pressure
Crush point
Fluid injection
Hot surfaces
Crush point / Falling part
Fragments / debris that become
airborne projectiles. Protective
guards required on cab when
operating this work tool
Moving part (in direction
indicated by arrow)
Shut off carrier & remove key
before servicing
Falling object
Unsupported loads
Identifies lift point
Personal Protection
Equipment

Hearing protection

Safety eyewear
Prohibited actions are actions that
must be avoided to prevent
personal injury and/or equipment
damage.
Gloves
Prohibited actions bare either an
“X” or a circle with a diagonal
slash.


Illustrations which display a check
mark symbol indicate actions that
are correct, approved and
recommended
Safety shoes
v
General Construction Safety
Attention Read the Manual
Always follow procedures that promote safe
conditions for workers and bystanders. The standard
safety precautions expected and required of those
working in construction shall include, but not limited
to:
Improper installation, operation or maintenance of
the Allied equipment could result in serious injury or
death. Only qualified operators may operate the
Allied equipment. Personnel responsible for the
maintenance of the Allied equipment or its systems,
including inspection, installation or adjustments
must also be qualified. Operators and personnel
responsible for maintenance of this equipment
should read this manual. Other manuals, such as
those published by the machinery used in support
of the Allied equipment, should also be read.
Locating existing underground service and utility
lines
Establishing pedestrian barriers
Using personnel protection equipment appropriate to
working conditions, etc.
Federal, State, Local and OSHA Construction
Guidelines and Regulations
Qualified Person
For the purposes of this manual, a qualified person
is an individual that has successfully demonstrated
or completed the following:
Use the Allied equipment in accordance with all
federal, state and local regulations regarding
construction practices and public safety.
Identification of, and compliance to, governing
regulations are the responsibility of the owner and
operator.
Has read, fully understands and adheres to all
safety-related statements in this manual.
Is competent at recognizing existing and potential
hazards and possess the skills and knowledge
necessary to take prompt corrective measures to
safeguard against personal injury and/or property
damage.
In the United States, comply with the
recommendations of the Occupational Safety and
Health Administration standards of the U.S.
Department of Labor. For OSHA construction
guidelines contact your local federal government
office or write:
Has completed adequate training in safe and proper
installation, maintenance and operation of the Allied
equipment.
U.S. Government Printing Office Superintendent of
Documents P.O. Box 371954 Pittsburgh, Pa. 152507954
Website: www.osha.gov
Is authorized to operate, service and transport the
Allied equipment identified in Table 1.1.
Ask for Construction Industry OSHA Standards
Stock #869-034-00107-6.
Safety Information Overview
It is important for all personnel working with the
Allied equipment to read this manual in its entirety
and become aware of safety information so that
unsafe situations may be avoided. Instructions and
safety information described at the beginning of this
section are general in type. Later in this section and
as you continue to read further into other sections of
this manual, instructions and safety information are
written and defined by the equipment type and the
operations specific to its intended use.
Owner’s Responsibilities
Ensure that only qualified personnel operate and
service the Allied attachment.
Enforce the use of personnel protection equipment
Ensure equipment is kept in safe operating condition
Ensure safety-related instructions, including this
manual, are kept in a convenient location so that
they are easily accessible to operators and
maintenance personnel.
Allied has made every effort to provide information
as complete and accurate as possible for this
document. Allied cannot anticipate every possible
circumstance that might involve a potential hazard.
The warnings in this manual and labels affixed to the
Allied attachment are therefore not all inclusive.
vi
Operational Safety Program
Compatibility With Other Equipment
The safe and efficient use of the Allied equipment
depends upon proper installation, operation,
maintenance and repair. Operational safety
programs must encompass all of these factors.
Allied hydraulic power units are designed for
operating Allied Pedestal Booms and Allied
breakers. These hydraulic power units may also be
suitable to operate other hydraulically powered tools.
Accident prevention through operational safety
programs are most effective when the equipment
owner further develops the program by taking into
account his own experience in using and
maintaining equipment.
Before the Allied hydraulic power unit is used to
power non-Allied equipment, it is important to
confirm, through adequate research, that the tool
being considered is compatible.
First, carefully review the equipment specifications
located in the Technical Data Section of this manual.
Fully understand the operation of all of its systems,
including hydraulic and electric. If in doubt, and
further assistance is required, it is the responsibility
of the equipment owner to contact their authorized
Allied dealer or Allied’s Product / Technical Support
Department.
Developing such programs will help minimize
equipment downtime, while maximizing service life
and performance. Most importantly, it will minimize
the risk of personal injuries and equipment damage.
Protective Equipment - Guarding
Guards have been fitted to the Allied equipment to
protect against unsafe situations that could not be
eliminated through design measures. Where it was
not possible to prevent an unsafe situation by means
of a guard, safety labels on the machine warn of the
dangers that are present.
Unapproved Modifications
In order to provide and maintain efficient production
and reliable service, while ensuring operator safety,
the Allied equipment may not be modified or used
for any other purpose other than, for which it was
intended. Use of the Allied equipment, other than
those specified in this manual, may place personnel
at risk of injury and/or may subject the equipment to
damage. The Allied equipment may not be modified
or used in unapproved applications unless written
consent is received from the Allied Engineering
Department.
Guards should only be removed for purposes of
inspection and service of components. All guards
must be reinstalled after service or adjustments are
completed. Do not operate the Allied equipment
without guards installed.
In addition to the guarding installed on the Allied
equipment, guarding is necessary at the operator’s
station to protect the operator against flying debris
that may be generated while work tools, such as
breakers, are in use. Whenever possible, the
operator of the Allied equipment should distance
himself safely away from the work tool and the
material being cut or demolished. Do not handle,
demolish or cut material overhead.
vii
Table of Contents
Section
Page
Section
Page
Document Revisions……………………..
i
6.0 Unpacking, Handling & Storage……
7
Safety Information……..…………………
ii
6.1 Unpacking the Equipment…….………
7
Hazard Alerts……………………………….
ii
6.2 General Instructions For Lifting………
7
Signal Words………………………………..
ii
6.3 Safe Handling Instructions……………
7
Information Labels………………………….
iii
6.4 Storage Instructions
8
Meaning of Pictograms…………………….
v
6.4.1 Short Term Storage…………………
8
Qualified Person……………………………
vi
6.4.2 Long Term Storage………………….
8
Safety Information Overview………………
vi
7.0 Installation……………………………..
9
General Construction Safety………………
vi
7.1 General Installation Instructions.…….
9
Owner’s Responsibilities…………………..
vi
7.2 Mounting Foundation………………….
9
Operational Safety Program………………
General Instructions For Working Safely
With the Allied Equipment.………………..
vii
7.3 Mounting the Power Unit……………..
9
vii
7.4 Hydraulic Hose Connections…………
9
Intended Use………………………………..
vii
7.5 Electrical Installation…………………..
10
Guarding…………………………………….
vii
10
Compatibility With Other Equipment…..…
vii
7.6 Filling the Reservoir With Oil………….
7.7 Commissioning – Preliminary
Inspection Before Using the First Time
10
7.8 Machine Start-up…….……………….
10
Table of Contents………………….……..
viii
7.9 Machine Shut-down……………………
11
1.0 Introduction & Scope………..….…..
1
1.1 Purpose of This Manual…….….……..
1
8.0 Operation……………………..………
12
1.2 Save For Future Reference…….…….
1
8.1 Operational Safety……………………..
12
1.3 Related Documents…….……………..
1
8.2 Daily Pre-operation Checklist…………
12
8.3 Machine Start-up……………………….
12
2.0 Equipment Identification……….…...
2
8.4 Working in Extreme Temperatures…..
12
2.1 Serial Number Location……………….
2
8.5 Cold Weather Operation………………
12
2.2 Equipment Identification Tag………….
2
8.6 Hot Weather Operation……………….
12
2.3 Owner’s Record of the Equipment…...
2
9.0 Maintenance………………………….
13
9.1 Preventing Unnecessary Downtime...
13
3.0 Warranty Protection Summary
3
9.2 Importance of Frequent Inspections....
13
3.1 Overview……………………………….
3
9.2.1 Daily Inspection (Before Each Shift)
13
3.2 Owner’s Responsibilities……….…….
3
9.2.2 Inspection While In Operation……..
13
3.3 Allied Product Policies………..……...
4
9.2.3 Monthly Inspection………..…….…..
13
4.0 Familiarization of Components…...
5
9.2.4 Inspection At 6 Month Period……….
13
9.2.4 Inspection At 12 Month Period……..
13
5.0 Technical Data….……………….……
6
9.3 Keep Maintenance Records Updated
14
viii
Table of Contents –[cont’d]
Section
Page
9.5 Hydraulic System Maintenance………
15
9.6 Maintenance Overview………………..
15
9.7 Threaded Fasteners……..…..…..…..
15
9.8 Proper Preparation and Torque……..
15
9.9 Tightening Method for 1” & Larger
16
9.10 Tightening Method for 1” & Smaller
16
10.0 Troubleshooting………………..…..
17
10.1 Troubleshooting Overview…………..
17
10.2 Knowing How the System Works…..
17
10.3 Recognizing Trouble Indicators…….
17
10.4 Know the Capabilities of the System
17
10.5 Troubleshooting Tables……….……..
18
9
1.0 Introduction and Scope
Allied has made every effort to provide information
as complete and accurate as possible for this
document. The content of this document has been
reviewed for accuracy. Allied Construction Products,
LLC has endeavored to deliver the highest degree of
accuracy possible. However, continuous
improvement of our products is an Allied policy. The
material in this publication, including descriptions,
illustrations and specifications, describes the product
at the time of its publication, and may not reflect the
product in the future. Revisions made to the content
of this document are recorded on the inside cover.
1.1 Purpose of Manual SOMM-102265
The Safety, Operation and Maintenance Manual has
been prepared to assist the operator and
maintenance personnel with the information
necessary for the safe and proper use of the Allied
equipment identified in Table 1.1. Content includes:









Safety Information
Equipment Identification
Technical Data (Weight & dimensions)
Installation and Set-up
Pre-Operation Inspection
Operating Instructions
Overview of Maintenance Schedule
Basic Troubleshooting Procedures
Lifting, Transporting & Storage
1.2 How To Order Replacement Publications
This document is an integral part of this product.
Keep it in a convenient location so that it is easily
accessible for future reference.
The Technical Manual contains figures that help with
the identification and description of machine
components. Some figures may show optional
equipment that is not supplied with standard
configured equipment.
Replacement manuals can be ordered by contacting
your Allied dealer service center. Manuals may also
be viewed and downloaded at: www.alliedcp.com
1.3 Related Documents
Material presented in this manual, including
illustrations and descriptions, is applicable to the
equipment identified in Table 1.1 and may not be
suitable for use with other models.
Product Support Material From Manufacturer
Technical Manuals may also include information and
product support manuals from the manufacturers of
the hydraulic pump, filters and other individual
components that make up the power unit assembly.
Prior to use, confirm that the information recorded
on the equipment’s identification label corresponds
with Table 1.1. For the location of this label, refer to
Section 2.0.
Table 1.1 About This Manual
Document ID.
TM-102265
Type
Safety, Operation,
Maintenance and
Technical Specifications
Current Status
See Inside Cover
Product Name:
Applicable Model[s]:
EHPU3430LS
Years of Manufacture:
1993
This document is published solely for information
purposes and should not be considered all-inclusive.
If further information is required, contact your local
Allied dealer or the Allied Customer Service
Department.
1
2.0 Equipment Identification
2.1 Serial Number Location
2.3 Owner’s Record of the Equipment
Record the Model and Serial Number from the
Equipment Identification Tag to the space provided
below.
Indicate the date in which the Allied equipment was
placed into service.
Fig 2-1 Equipment Identification
Refer to Figure 2-1. The Serial Number assigned to
this equipment can be found in the following
locations:
Model:
3430LS
Part Number:
813430
Serial Number:
02226
In Service Date:
Product Registration
Date:
Stamped on the Equipment Identification Tag
2.2 Equipment Identification Tag
Your local Allied dealer requires this information to
better assist you with questions regarding parts,
warranty, operation, maintenance, or repair.
Register this equipment by returning the completed
warranty registration form 100788 to Allied.
Fig 2-2 Equipment Identification Tag
The Equipment Identification Tag is affixed to the
base. It provides the following information:

Manufacturer’s name

Address

Product name

Model number

Serial number

Year of manufacture

Weight
Confirm that the information contained on the Tag
corresponds with the information provided in Section
1, Table 1.1.
2
3.0 Warranty Protection Summary
Conduct regular inspections of the equipment as
scheduled in Maintenance section of this manual.
3.1 Overview
The Allied equipment is delivered assembled,
lubricated, and factory tested. Upon receipt of the
equipment, inspect for possible shipping damage.
Will use the Allied equipment only if it is in sound
operating condition.
For every new hydraulic power unit, Allied requires
that a Warranty Registration form be completed and
returned to Allied.
Will take prompt action to rectify any faults that, if left
uncorrected, could lead to personal injury or further
equipment damage.
To keep the Allied equipment operating within its
optimal performance range, familiarize yourself with
the equipment’s technical specifications. Know the
correct operating specifications before adjustments
are made. The equipment’s operating parameters
are shown on the hydraulic circuit drawings and the
Technical Data section of this manual.
Will use the Allied equipment only for the purpose
for which it is intended.
Understand that the standard service schedule for
the Allied equipment may require modifications to its’
time intervals to better suit any unusual
environments or conditions that may pertain to
climate or special applications.
Improper installation, including failure to calibrate
hydraulic valves correctly may result in loss of
performance or subject the equipment to conditions
beyond their design.
Understand that equipment modified from its original
configuration may require additional training for
operators and service personnel.
Use of non-Allied parts, unapproved service
methods, modifications to the attachment, or
installation, operation and maintenance, not in
accordance with the instructions outlined in this
manual may cause equipment failure or personal
injury.
Appoint Who Does What. Ensure that all personnel
understand what their specific responsibilities
include.
For details regarding warranty terms and conditions,
refer to document 100669.
Establish maintenance responsibilities to be
performed by MAINTENANCE PERSONNEL.
3.2 Owner’s Responsibilities
Establish personnel that can recognize and resolve
safety-related situations.
Establish maintenance responsibilities to be
performed by the OPERATOR.
When properly installed, operated and maintained
by qualified personnel, the Allied attachment will
remain productive with a minimum of service.
Use only genuine Allied replacement parts and
recommended lubricants to protect total warranty
coverage.
The following is an overview of general policies for
the Allied equipment. The equipment owner is
strongly encouraged to adopt these general
guidelines and further develop them in order to
manage particular applications and operating
environments.
Maintain written records of equipment maintenance,
service and repair.
The equipment owner must ensure that personnel
entrusted with installation, operation, maintenance
and transporting of the Allied equipment adhere to
the following:
Read and thoroughly understand all instructions and
safety-related warnings in this manual.
Allow only qualified operators and service personnel
to operate and service the Allied equipment as
specified in this manual.
3
3.0 Warranty Protection Summary - [cont’d]
3.3 Allied Product Policies
In this manual, Allied recommends hydraulic power
unit applications, operation, maintenance and
service consistent with industry practices.
Allied assumes no responsibility for the results of
actions not recommended in this manual and
specifically the results of:
Inadequate Training
Improper Installation
Operation in unapproved applications
Incorrect operation
Improper maintenance
Use of non-genuine Allied replacement parts
Unapproved modifications
These exclusions apply to damage to the Allied
equipment, associated equipment and injury to
personnel.
4
4.0 Familiarization of Components
4.1 Product Description
Table 4.1 Main Components
Allied power units, models 3430LS and 3450LS, are
electrically driven hydraulic power units designed for
use with the Allied pedestal boom system and Allied
breakers.
Item
4.2 Familiarization of Main Components
Description
1
Reservoir
2
Pressure-side Filter
3
Check Valve
4
Oil Temperature Sensor
5
Shut-off Valve
6
Oil Immersion Heater
7
Equipment ID Tag
8
Electric Motor
9
Pressure Measuring Point
10
Pump
11
Load Sense Line
12
Oil Supply Line
13
Case Drain Line
14
Oil Supply Line To C/V
15
Oil Return To Tank
16
Rotation Decal
17
Oil Fill
18
Breather
19
Oil Level Switch
20
Oil Drain Plug
21
Differential Pressure Switch
22
Return Filter
23
Inspection Cover
Fig. 4-1
5
5.0 Technical Data
Table 5.1 Power Unit Specifications – Values Shown are for Standard Configured Units a)
3430LS
US Units
3430LS
Metric Units
Length
50 in
1270mm
Width
40 in
1020mm
Height
42 in
1065mm
1500 lbs.
680 kg.
Optional Equipment
Dimensions
Weight (Empty)
Electric Motor
Type
480V-60
Performance – hp (kW)
RPM / Rotation
30 (22)
1750 / CCW b)
Hydraulic System
Piston c)
Pump Type
Delivery
Pump Controller
Compensator Setting
Pressure Set @ Factory
33.7 GPM d)
130 l/m d)
Pressure Compensated with Load Sense
2700 psi e)
186 Bar e)
Hydraulic Fluid
Recommendations
Refer to Bulletin 90000-S f)
Reservoir Capacity
55 gal
210 l
a)
Applicable to Standard Configured Units – Consult Allied for equipment variants / options / accessories
b)
Rotation Counter-Clockwise as viewed from the pump’s shaft end
c)
Directly driven from the motor crankshaft by means of a flexible coupling
d)
Variable volume. Max @ 1750 RPM + 3000 psi
e)
Pressure setting can vary. Always refer to drawing in control system for actual setting. Set the pump
compensator to the pressure shown on the hydraulic schematic.
f)
Refer to Oil Gear Requirements – Bulletin 90000-S
Other standard features include a filtration system to protect against contamination and a heating system for
operation in cold weather conditions. Critical conditions such as oil temperature, level and filter quality are
constantly monitored.
6
6.0 Unpacking, Handling and Storage
6.1 Unpacking The Equipment
WARNING
Upon receipt, carefully check the machine for
damage that may have occurred during shipment.
Pictogram of HOOK marks approved
lift point for safe handling of
equipment. Lifting devices must safely
carry the loads to which they will be
subjected.
Check the bills of lading against the packing list to
assure that all parts have been received.
If the machine is damaged or if items are missing,
contact Allied’s Customer Service Department
immediately to initiate a claim. Describe the nature
of the damage or the item(s) missing. This
information should also be reported to the freight
carrier and noted on the bill of lading.
Crush hazard. Falling or shifting loads
may cause injury or equipment
damage. Do not enter the danger
zone while equipment is being lifted.
Lift away from people. Never stand
under a hoisted load.
6.2 General Instructions for Lifting
Always follow safe lifting practices. The load rating of
all lifting equipment, slings, chains and other lifting
accessories must exceed the weight of the
equipment being lifted. All lifting equipment must be
in good condition.
R
Move crane and power unit to a firm level surface.
All hydraulic lines must be capped / plugged.
Secure loose hoses to avoid accidental damage.
6.3 Safe Handling Precautions
Only qualified personnel may operate hoisting
equipment.
Fig. 6-1 Lift Points
CAUTION
Refer to section Technical Data, Table 5.1 for the
weight of the Allied equipment.
Some procedures, such as
handling the power unit will
require an assistant. Both the
crane operator and assistant must
be qualified in these procedures.
All directions and signals must be
agreed upon in advance. The
operator must have an
unobstructed view of the assistant
and load at all times.
Figure 6-1 identifies the points to be used when
lifting the Allied equipment. Lift points are marked
with a pictogram.
Lift using bow shackles attached to the eyes. The
hooks of the crane can then be attached to the bow
shackles.
Lift the power unit using appropriate hoisting
equipment with sufficient load carrying capacity. All
equipment used to lift the Allied equipment must be
undamaged and in well-maintained condition.
WARNING
Falling objects/debris from hoisted
items can be hazardous to bystanders
or to the machine itself. Before lifting,
remove all loose items such as tools,
unsecured parts and debris.
7
6.0 Unpacking, Handling and Storage [cont’d]
Make sure hooks, slings and other lifting
accessories are securely attached to the power unit
and lifting machine before hoisting.
6.4.1 Short Term Storage
Short-term storage requirements apply when the
Allied equipment is not installed for a period of one
month or less.
Do not overload the lifting machine beyond its
capacity. Keep the machine and load under control
at all times. Be careful to avoid any condition that
may cause the machine to become unstable which
could lead to tipping. In travel mode, carry the load
close to the ground. Do not go near excavation,
overhang or cliff edge.
Preparation For Short Term Storage:
Make sure that all hose ends, oil supply and
drainage ports are kept capped/plugged.
Keep clean out and inspection covers closed.
CAUTION
Store the power unit and all other parts included with
the power unit in a dry building. If outdoor storage
cannot be avoided, make certain power unit is well
protected from ice, rain or snow. Be sure all
unpainted surfaces are coated with protective anticorrosive grease.
Personal protection equipment should
be worn when handling the power unit.
Equipment should include appropriate
clothing, gloves, safety eyewear and
shoes.
Cover the power unit with a waterproof tarp.
CAUTION
Crush hazard. Prevent injuries to hands
and fingers. Be aware of pinch points.
Keep all body parts clear when parts are
moving. Never use fingers to check
alignment of the components.
6.4.2 Long Term Storage
Long-term storage requirements apply when the
Allied equipment is not installed for a period of one
month or longer.
6.4 Storage Instructions
Preparation For Long Term Storage:
The following instructions cover procedures required
to protect the Allied equipment against damage until
ready to install.
Store the power unit and all other parts included with
the power unit in a dry building. To prevent moisture
and contamination from entering the reservoir,
remove breathers and replace with suitable plugs.
IMPORTANT
If outdoor storage cannot be avoided, make certain
power unit is well protected from ice, rain or snow.
Be sure all unpainted surfaces are coated with
protective anti-corrosive grease.
Contamination can shorten service life of
components. Prevent dirt and debris from
contaminating the oil. Keep all lubricants and
lubricating equipment clean and free of foreign
matter both while in use and in storage. Keep the
ball valve located in the suction line closed and all
port connections plugged or capped until ready to
install the power unit. Clean the area around
hydraulic connections prior to removal of plugs or
caps.
Cover the power unit with a waterproof tarp.
IMPORTANT
Serious equipment damage may result if proper
procedures are not followed. Condensation can
cause destructive rust and pitting. Coat exposed
surfaces of unpainted metal surfaces with a
protective film of rust inhibitor.
8
7.0 Equipment Installation
7.1 General Installation Instructions
7.4 Hydraulic Hose Connections
Power units are engineered and assembled at Allied
Construction Products, LLC in Cleveland, Ohio. Prior
to shipping, the power unit is filled with oil and
tested. Systems are checked for proper operation
and adjusted according to specifications.
Hose connections from the power unit to the valve
stand are shown on the drawing.
7.2 Mounting Foundation
Route hose to avoid sharp twist or bends.
Prepare a foundation of concrete or structural steel
that is capable of withstanding the loads.
Keep hoses clear of moving parts and away from hot
surfaces.
The design of the mounting foundation, platform or
tower is left to the customer.
Use clamps to support long runs and prevent
rubbing.
Design considerations -
Connection threads must be undamaged and free of
debris.
Hose length should permit adequate flexing and
changes in length due to expansion and contraction.
Provide clearance needed to access oil immersion
heater and components that require periodic
maintenance, such as filters.
The location of the directional valve can vary. It may
be mounted on a separate stand (typical) or on the
base assembly.
Mounting foundation must implement effective
methods for minimizing vibrations into power unit.
When making hose connections to the control valve,
refer to Allied manual A102761. If the power unit is
used with non-Allied equipment, refer to the manual
provided by the manufacturer for instructions.
7.3 Mounting the Power Unit
Lift the power unit onto the mounting foundation
according to the lifting instructions in Section 6.
CAUTION
Check that the power unit is stable and all loads are
supported before detaching hoist lines from bow
shackles.
Depressurizing the hydraulic
system can cause loads to fall or
make unexpected movements.
Make sure that all loads are
properly supported and stable
before disconnecting pressurized
lines.
Install the power unit. Anchor bolt locations are
shown on the drawing.
IMPORTANT
The mounting bolts used to anchor the power unit
and the hex nuts must be compatible strengths.
Washers are to be hardened.
WARNING
Escaping fluid under pressure can
cause injury from injection. If any fluid
appears to penetrate the skin, seek
immediate medical attention.
CAUTION
After the first 40 hours of operation, inspect the
mounting bolts and re-tighten if necessary.
IMPORTANT
Contamination can shorten service life of
components. Keep all lubricants and lubricating
equipment clean and free of foreign matter both
while in use and in storage. Prevent dirt and
debris from contaminating the oil. Always clean
the area around the connections prior to removal
of plugs or caps.
CAUTION
Crush hazard. Prevent injuries to hands
and fingers. Be aware of pinch points.
Keep all body parts clear when parts are
moving. Never use fingers to check
alignment of the components.
9
7.0 Equipment Installation [cont’d]
7.7 Commissioning – Preliminary Inspection
Before Using For The First Time
IMPORTANT
During removal of plugs or caps, environmentally
harmful substances, such as hydraulic oil, must be
collected and disposed of in accordance with local
regulations. Have a suitable container and rags on
hand before disconnecting.
Before using for the first time, read and understand
all safety precautions before operating the Allied
equipment. In the event of an emergency, know
where and how to shut down the equipment.
Preliminary Inspection:
7.5 Electrical Installation
Check that the valve, located in pump suction
line, is in the “OPEN” position.
DANGER
Ensure that the electrical panel is
locked out before work is performed
on the electrical system.
Check hoses. Threaded connections must be
tight and leak-free.
Check sight gage for proper oil level.
Follow all national, state and local electrical code
requirements.
Check the oil immersion heater. During cold
weather conditions, switch power on and adjust
thermostat.
7.6 Filling the Reservoir With Oil
The customer is responsible for filling the reservoir
with appropriate, clean, hydraulic fluid.
Check tightness of foundation bolts.
Check tightness of all other threaded fasteners.
It is not enough to just select the right type of oil; the
right oil viscosity is just as important. The correct
viscosity is determined by the maximum ambient
temperature at cold start and the maximum ambient
temperature during operation. Oil viscosities for
standard (normal) conditions are listed in Bulletin
90000S.
Check for correct electrical connections at the
starter panel and motor.
Check function of the power unit’s monitoring
circuits.
7.8 Start up
Fill the hydraulic tank until the oil level nears the
case drain connection located on the side of the
tank.
Check that work area is clear of personnel.
Before operating warn or signal anyone who might
be in the work area.
Disconnect the hose end from the tank and fill the
hose with oil. Reconnect the hose.
Switch power on to the starter panel.
Continue filling the hydraulic tank until the oil level
reaches the “Full” mark on the sight gage.
CAUTION
IMPORTANT
Contamination can shorten service life. Keep all
lubricants and lubricating equipment clean and
free of foreign matter both while in use and in
storage. Prevent dirt and debris from
contaminating the oil. Always clean the area
around the connections prior to removal of plugs
or caps.
ALLIED
814904
When starting the unit for the
first time the motor must be
jog started to verify correct
pump rotation. Stop the motor
immediately if pump rotation
is incorrect and reverse
wiring. Continued operation in
the wrong direction will
damage the pump.
Ensure hydraulic connections are leak-free.
Make sure the pressure measured at the pump
does not exceed pressure limit.
10
7.0 Equipment Installation [cont’d]
Operate the equipment under light loads until air
is purged and the oil has reached 100°F (40°C).
Recheck the sight gage to ensure oil level is
between the halfway and “Full” mark
IMPORTANT
When operated for the first time, hydraulic lines
and hydraulic actuators such as cylinders and
motors will fill with oil. This will lower the oil level
inside the tank. Top off oil level until it reaches the
halfway mark on the sight gage.
7.9 Machine Shut Down
When stopping the power unit, first reduce the load.
If the power unit is used with an Allied pedestal
boom, lower the boom to the ground or firm surface.
If equipped with a breaker, park the breaker in the
vertical position if possible. Be sure all loads are
supported and stabilized. Switch power off to the
electric motor. Shut down and lockout the motor
starter panel.
CAUTION
Contact with hot surfaces may cause
burn injuries. Some components of the
operation. Allow parts and fluids to cool
before handling.
11
8.0 Operation
8.1 Operational Safety
8.4 Working In Cold or Hot Weather Conditions
Only qualified personnel may operate this
equipment.
It is not enough to just select the right type of oil; the
right oil viscosity is just as important. The correct
viscosity is determined by the maximum ambient
temperature at cold start and the maximum ambient
temperature during operation. Refer to Bulletin
90000-S for more information.
8.2 Daily Pre-operation Inspection
Before each use, perform a visual check of the
boom system
Keep all lubricants and lubricating equipment clean
and free of foreign matter both while in use and in
storage.
Check power supply for fluid leaks.
Check hoses for wear and damage and replace
as necessary. If necessary, re-route hoses or add
hose supports to eliminate rubbing or getting
pinched.
8.4.1 Cold Weather Operation
Oil viscosity is higher at cold temperatures. Relief
valves and other components will be sluggish when
oil is cold. It is important to always follow a strict
warm-up procedure.
Check that guards are in place and secure.
Check fasteners. Replace if broken or damaged.
Fasteners must be tight and properly torqued.
Ensure power is turned on to the oil immersion
heater (if equipped) and it is operational. Set the
adjustable thermostat to 50-70°F (10-21°C).
Check oil level inside tank. Level should be at
halfway mark located on sight gage.
Do not operate the power unit under heavy loads
until the hydraulic system has reached an oil
temperature of 100°F (40°C).
Lubricate the motor as instructed by the
manufacturer.
At start up, slowly cycle cylinders to circulate warm
oil through out the system. Never allow cylinders to
fully extend or retract to stroke end.
Check the maintenance log for any problems
reported by the previous shift.
Check to make sure the work zone is clear of
personnel. Warn or signal anyone who might be in
the work area. Do not start machine until all
personnel are clear of the work zone.
Refer to the manual for the work tool for special
instructions about operating in cold weather
conditions.
8.3 Start up
8.4.2 Hot Weather Operation
Complete pre-operation inspection.
Oil viscosity is lower at hot temperatures. Check the
oil temperature frequently to ensure that it does not
exceed 176°F (80°C).
Before starting the machine, check that the work
area is clear of all personnel.
If so equipped, check oil cooler for proper operation.
Make sure the thermostat and motor are operational.
Be sure airflow through cooler fins is not obstructed.
Clean if necessary.
Switch on power at starter panel
After start up, check the following:
If equipped with an oil heater, check that the power
is turned off.
Check for fluid leaks.
Check indicator lights on the starter panel. If light
indicates fault, locate the fault and have it resolved.
Report any erratic operation, vibrations, unusual
noises, movements or change in performance.
12
9.0 Maintenance
9.1 Preventing Unnecessary Downtime
9.2.2 During Shift (While equipment is in use)
Three simple maintenance procedures have the
greatest effect on hydraulic system performance,
efficiency and life. Yet the very simplicity of them
may be the reason they are so often overlooked. We
recommend a regular schedule of these simple but
effective preventative maintenance procedures.
Check controls for proper operation
Observe efficiency and evenness of operation,
always looking and listening for anything that
deviates from normal operation
Monitor hydraulic oil temperature to assure it
remains within the required operating range
Keep oil quantity at proper levels
Maintain clean oil by changing filters when
scheduled
9.2.3 Monthly (200hrs)
Wipe off any excess lubricants that spill or overflow.
Oily or greasy surfaces tend to collect dust and
foreign matter, which can work its way into bearings
and gears.
Keep all connections tight, but not to the point of
distortion, so that air is excluded from the system.
9.2 Importance of Frequent Inspections
Measure hydraulic oil pressure to ensure it is within
the required operating range
The importance of frequent inspections cannot be
overemphasized. In addition to monitoring parts for
wear, regular inspections are useful in spotting
trends and identifying potential problem areas. It’s
important to spot potential problems early, before
they escalate into more serious and costlier repairs.
9.2.4 Every 6 Months (1200hrs)
Replace all filters
Check the quality of hydraulic oil
9.2.1 Daily Inspection (Before Each Shift)
Test the hydraulic circuit using a flow meter and
pressure gages. Make adjustments as necessary.
The purpose of the daily inspection is to visually
check the condition of the machinery to see if
components are worn or damaged










IMPORTANT
Special tools and training are necessary to test and
measure hydraulic systems. Contact your Allied
distributor for assistance.
Check mounting is secure to foundation
Check sight gage for oil level
If so equipped with, check fault indicator lamps
for operation
Check for loose or missing fasteners
Check tubes and hoses for fluid leaks
Check tubes and hoses for movement inside
clamp
Check for loose or missing guards
Inspect tank area for cracks.
Check connections and seals for fluid leaks
Check controls for proper operation
9.2.5 Every 12 Months (2400hrs)
Replace all filters
Replace hydraulic oil
Test the hydraulic circuit using a flow meter and
pressure gages. Make adjustments as necessary.
Be alert to any oil seepage on or around the pump,
as this may indicate a serious condition that requires
further investigation.
Explanation of hours shown in Maintenance
Schedule 9.1.
Daily= 10 hours per day
Shift= 8 hours per shift
6 Months= 1000 hours
Yearly= 2,000 hours per year.
Some components are viewable only when guards
are removed. Always replace guards once
inspection is completed.
13
9.0 Maintenance – [cont’d]
maintenance intervals. Intervals may vary according
to the severity of individual applications. Use regular
component inspection and fluid sampling to
determine safe change intervals.
9.3 Maintenance Schedule
The following are the recommendations of Allied
Construction Products, LLC for equipment
Table 9.1 Maintenance Intervals
Item
10
Oil level
Fasteners
Hoses
Measure Flow & Pressure
Filter – Pressure line
Filter – Return line
Filter – Breather
Hydraulic oil
X
X
X
50
200
1000
2000
Interval
Note
X
Every 10hrs
Every 10hrs
Every 10hrs
Every 200hrs
Every 1000hrs
Every 1000hrs
Every 1000hrs
Every 2000hrs
A
A
A
B
C, D, E
C, D, E
C, E
C
X
X
X
X
A) Inspection of parts. B) Conduct tests of the equipment if a change in performance is observed. C) Replace.
D) Replace if indicator remains ON. E) Always replace at oil change


9.4 Keep Maintenance Records Up To Date
Keeping records of the equipment’s maintenance,
service and repair are helpful if warranty coverage is
ever in question.


Description of Repairs or Service Performed
Records should include at least:
Description of service, maintenance or repair
performed.
Copies of purchase orders or invoices, including
part numbers used in the repair
Names of personnel involved and date
By
14
Date (Time)
9.5 Hydraulic System Maintenance
MPORTANT
The construction of the hydraulic power unit
contains high-quality components, including filters.
Over time, parts and filter replacement will be
necessary. Non-approved parts may cause loss of
performance or equipment damage. Use only
genuine Allied replacement parts to protect total
warranty coverage.
WARNING
High-pressure oil that is released when
hydraulic lines or fittings are loosened
can cause hose whip and oil spray. Use
personnel protection equipment such as
safety eyewear to protect against injury.
9.6 Maintenance Overview
Escaping fluid under pressure can cause
injury from injection. Always relieve
pressure before disconnecting
pressurized lines. If any fluid appears to
penetrate the skin, seek immediate
medical attention.
This section contains the minimum preventative
maintenance requirements necessary to keep the
machine in safe operating condition. Uninterrupted
performance of these maintenance services will help
extend the life of system components.
Recommended time intervals are based on standard
(normal) operating conditions. Time intervals must be
adjusted accordingly when operating under harsh
applications or extreme conditions. Time shown in
schedule is per day at 10 hours, or multiple shifts, at
eight-hours each and yearly hours at 2,000 hours per
year.
CAUTION
Depressurizing the hydraulic system
can cause loads to fall or make
unexpected movements. Make sure
that all loads are properly supported
and stable before disconnecting
pressurized lines.
Service intervals are based on standard (normal)
use. Service intervals are shortened when
operating with a water content hydraulic fluid or
other unusual applications such as at high
elevations, extreme temperatures or weather
conditions, dust, etc.
CAUTION
Contact with hot surfaces may cause
burn injuries. Some components of the
operation. Allow parts and fluids to cool
before handling.
9.7 Threaded Fasteners
Due to shock and vibration loads experienced by the
pedestal boom system, it is extremely important that
threaded fasteners are checked frequently for loose,
broken or missing bolts.
Servicing the hydraulic system may require the
removal of hydraulic hoses or filters. Use the
following procedure to safely disconnect a hose or
filter.
IMPORTANT
Replacement fasteners must be the same type and
grade. Do not substitute.
Refer to Section 7.9 - Machine Shut Down.
At the valve stand, manually move all the valve levers
in both directions to ensure any pressure trapped in
the hoses is relieved.
9.7.1 Proper Preparation, Pre-tensioning and
Torque
IMPORTANT
Failure to follow these instructions when tightening
can have serious consequences.
If the hose (or filter) to be disconnected is long, it may
contain several gallons of oil. The hose may still be
under some pressure due to gravity, if the other end
of the hose is higher. Be prepared with a pan to
collect oil that will drain from the hose.
1. Clean threaded fasteners and surfaces to be
bolted.
15
2. Use anti-corrosion paste or grease on the bolt
threads and under the bolt heads washer faces.
Do not apply thread lock compound to the bolt
threads unless directed to do so. Be sure to
follow the manufacture’s recommendations when
using thread locker products.
Table 9.2 Fastener Torque
Bolt head identification markings have radial lines for
SAE grade and numbers on metric hex bolts.
3. Install all bolts. Tighten the bolts by hand.
4. In Table 7.3 find the bolt size and torque.
Fig. 9-1 SAE vs. Metric Class
5. Tighten the bolts in a criss-cross pattern to 1/3 of
the specified torque.
Grade 8
6. Then tighten them again to 2/3 of the specified
torque.
7. Finally, tighten to the full torque value shown in
Table 9.2.
16
Class 8.8
Class 10.9
Size
ft-lb
Nm
ft-lb
Nm
ft-lb
Nm
M 6


8
10
11
16
1/4
10
14




5/16
20
27




M 8


18
25
27
37
3/8
35
48




M 10


38
51
55
75
M 12


60
80
90
120
1/2
80
108




M 14


90
125
135
185
5/8
170
230




M 16


140
190
205
280
M 18


200
270
290
390
3/4
290
390




M 20


290
390
415
560
M 22


385
520
550
745
7/8
400
540




M 24


500
670
700
950
M 27


730
1000
1030
1400
M 30


1000
1350
1400
1900
10.0 Troubleshooting Guide
Another invaluable tool is the ability to recognize
trouble indicators. This is usually gained through
training and years of experience.
10.1 General Troubleshooting
This section provides information useful in
diagnosing and correcting unsatisfactory machine
operation or failure of the system and its
components.
For example, excessive heat can readily identify a
misaligned coupling placing an excessive load on
bearings. A warmer than normal oil line might reveal
a relief valve is bypassing oil due to a malfunction or
mis-adjustment. Low viscosity fluids can increase
the internal leakage of components resulting in a
heat rise. Cavitation and slippage in a pump will also
generate excessive heat.
The troubleshooting process is by definition the
technique used for locating problems by testing and
eliminating possible causes in a logical sequence in
order to arrive at a correct conclusion.
Most troubles encountered with the machine will be
quickly recognized by failure of the machine to
operate properly.
Excessive noise means wear, misalignment, or
cavitation caused when air is in the fluid. Improper
fluid viscosity can cause a relief valve to stick and
chatter. Noises may be the result of contaminated
fluid, dirty filter, low oil level or loose connection at
suction line to the pump.
If the fault is not a mechanical, be sure to check one
of the most common causes of trouble in a hydraulic
system. See if there is enough oil in the hydraulic
reservoir.
Check if other nearby or related machinery is
experiencing some or all of the same problems.
Observe if the problem affects one or more
functions.
10.2 Understanding How the System Works
Knowing the system is the greatest aid to
troubleshooting. Every component in the system has
a purpose. In addition to fully understanding the
construction and operating characteristics of each
component, the troubleshooter must be aware of the
relationship between each component, such as oil
viscosity, temperature, rotation speed, and load.
Do problems occur or recur during unusual
conditions such as extreme high or low ambient
temperature, wet or humid conditions, high oil
temperature, or at times of heavy vibration.
Ask if the problem is reported by one shift or all
shifts. If the test can be done safely, ask the
operator to recreate the situation that causes
problem.
Develop a cause and effect-troubleshooting guide
similar to the tables on the following pages. Unless
the trouble is immediately apparent, try the simple
things first. Analyze the system and develop a
logical sequence for determining if the root problem
is mechanical, electrical or hydraulic.
Check maintenance log for records of previously
performed repairs, service or parts replacement.
Verify that the correct parts were used. If the oil was
changed, verify correct type.
Troubleshooting procedures for the hydraulic and
electrical system should start at the power source.
Work down from the power source and through each
circuit until the fault is located.
10.4 Know the Capabilities of the System
Some additional techniques needed to increase your
troubleshooting ability as well as the life of the
system include:
Use the provided form when testing the oil delivery
of the pump. Be sure to write down the results of the
test. An accurate record of this information is
extremely helpful when isolating and identifying
problem areas.
Each component in the system has a maximum
rated speed, torque or pressure. Loading the system
beyond the specification increases the possibility of
failure.
10.3 Recognizing Trouble Indicators
Know the correct operating pressures. Locate the
equipment’s technical specifications and drawings of
the hydraulic circuit. The compensator setting of the
pump is shown on the hydraulic schematic. Starting
at the pump, measure the hydraulic oil pressures
using a reliable gauge.
Always use the correct tools when testing or making
adjustments to the hydraulic system. The use of an
accurate pressure gage is a must have when
troubleshooting hydraulic systems.
17
10.0 Troubleshooting Guide – [cont’d]
10.5 Troubleshooting Tables
The troubleshooting tables list various faults, the
probable cause and recommended remedies. It is
virtually impossible to describe all possible
problems. Therefore, if an unusual condition is
encountered and is not covered in the
troubleshooting table, we recommend you contact
the Allied distributor in your area.
Know the correct operating specifications before
adjustments are made. The operating specifications
for this equipment are shown on the hydraulic circuit
drawings and the Technical Data section of this
manual.
WARNING
Escaping fluid under pressure can
cause injury from injection. Always
relieve pressure before disconnecting
hydraulic lines or other pressurized
lines. If any fluid appears to penetrate
the skin, seek immediate medical
attention.
CAUTION
Some components are viewable only when the
guards are removed. Always replace guards once
maintenance is completed.
CAUTION
Only qualified personnel, having knowledge of the
machine’s systems, proper test equipment and
tools should attempt adjustments and repairs.
This guide identifies several commonly encountered
conditions and the recommended corrective action.
For conditions other than these, contact the Allied
Technical Service Department
18
Table I Excessive Noise
Pump Noisy
Motor Noisy
Relief Valve Noisy
Cavitation
Coupling Misaligned
Remedy: A
Remedy: C
Air In Fluid
Pump Worn Or Damaged
Remedy: D
Remedy: B
Remedy: E
Worn Poppet And Seat
Setting Too Close To Operating
Pressure Or To Another Valve Setting
Coupling Mis-Aligned
Remedy: E
Remedy: C
Pump Worn Or
Damaged
Remedy: E
Remedy
A.
Any or all of the following: install clean filters; clean clogged inlet line; clean reservoir breather
vent; change system fluid.
B.
Any or all of the following: tighten leaky inlet connections; fill reservoir to proper level (all return
lines that enter oil reservoir must terminate below fluid level); bleed air from system; replace air
breather.
C.
Align unit and check condition of seals and bearings.
D.
Check pressure gauge and adjust to correct pressure.
E.
Overhaul or replace.
19
Table II Excessive Heat
Pump Heated
Motor Heated
Fluid Heated
Fluid Heated
Fluid Heated
Remedy: D
Remedy: D
Relief Valve Setting Too Close To
Operating Pressure
Remedy: G
Cavitation
Excessive Load
System Pressure Too High
Remedy: A, B
Remedy: C
Remedy: G
Air In Fluid
Motor Worn Or Damaged
Relief Valve Failed Open
Remedy: B
Remedy: E
Remedy: E
Excessive Load
Fluid Dirty or Low Supply
Remedy: C
Remedy: F
Pump Worn Or
Damaged
Incorrect Fluid Viscosity
Remedy: E
Remedy: F
Fault In Cooling System
Remedy: G, H
Fluid Bypass – Worn Pump, Valve,
Motor, Cylinder, or Other
Remedy: E
Remedy
A.
Any or all of the following: install clean filters; clean clogged inlet line; change air breather; change
system fluid.
B.
Any or all of the following: tighten leaky inlet connections; fill reservoir to proper level (see note on table
I); bleed air from system. Check for excessive foaming.
C.
Align unit and check condition of seals and bearings; locate mechanical binding; check for workload in
excess of circuit design.
D.
Check case drain line for excess flow; if more than 1.5 gpm, replace pump.
E.
Overhaul or replace.
F.
Fill reservoir to proper level. Change fluid if dirty (and filters) or improper viscosity.
G.
Adjust.
H.
Clean debris from cooler.
20
Table III Incorrect Flow
No Flow
Fluid Not Reaching Pump
Remedy: A, G
Low Flow
Pump Controller Mis-adjusted or
Damaged
Remedy: D, E
Excessive Flow
Volume Stop Mis-adjusted
Remedy: D
Pump Driven In Wrong
Rotation
Volume Stop Mis-adjusted
Incorrect Motor Voltage/Hz
Remedy: G
Remedy: D
Remedy: B
No Pump Rotation
Pump Worn or Damaged
Remedy: C
Remedy: E, H
Pump Controller Misadjusted or Damaged
Remedy: D, E
Remedy: B
Incorrect Motor Voltage/Hz
Remedy: E, H
Remedy: B
By-Pass At Valve
Fluid Bypass At Actuators or Valves
Remedy: D, E
Remedy: E, F
Remedy: A
Remedy
A.
Any or all of the following: Open valve at suction line; replace suction strainer, collapsed inlet line;
replace air breather; fill reservoir to proper level.
B.
Make necessary changes. System may require cooler / heater.
C.
Verify motor operation. Check for damaged pump, motor or drive coupling.
D.
Adjust to proper setting.
E.
Overhaul or replace
F.
Locate Blockage or By-Pass. Check Valve, Filter, Directional Valve, Relief Valve, Flow Restrictor
Valve and hoses.
G.
Reverse rotation
H.
Check case drain line for excess flow. If more than 1.5 gpm, overhaul or replace pump.
21
Table IV Incorrect Pressure
No Pressure
Low Pressure
Excessive Pressure
Pump Controller Misadjusted or
Damaged
Remedy: D, E
Pump Controller Misadjusted
or Damaged
Remedy: D, E
Pump Driven In Wrong
Rotation
Relief Valve Misadjusted or
Damaged
Remedy: G
Remedy: E, H
Remedy: D, E
No Pump Rotation
Remedy: C
Remedy: B
Remedy: B
Pump Controller Mis-adjusted
or Damaged
Remedy: D, E
Remedy: E, F
Erratic Pressure
Remedy: E, H
Remedy: A, F, I
Remedy: A, G
Fluid Bypass At Actuators or
Valves
Remedy: D, E, F
Remedy
A.
B.
Make changes to match operating conditions. Hydraulic system may require cooler / heater.
C.
D.
E.
Overhaul or replace
F.
Locate Blockage or By-Pass. Check Valve, Filter, Directional Valve, Relief Valve, Flow Restrictor
Valve and hoses.
G.
Reverse rotation
H.
I.
Air In Fluid – Purge Air. Fluid is contaminated – Change fluid and filters.
22
Table V Faulty Operation
Remedy: A, G
Pump Controller Misadjusted or
Damaged
Remedy: D, E
Erratic Movement /
Excessive Speed
Pump Controller Misadjusted
or Damaged
Remedy: D, E
Pump Driven In Wrong Rotation
Volume Stop Misadjusted
Remedy: G
Remedy: E, H
Remedy: D
No Pump Rotation
Relief Valve Misadjusted or
Damaged
Remedy: C
Remedy: B
Remedy: D, E
Pump Controller Mis-adjusted or
Damaged
Remedy: D, E
Remedy: E, F
Remedy: B
Flow Restrictor Valve Misadjusted
Remedy: E, H
Remedy: A
Remedy: D
Fluid Bypass At Actuators or
Valves
Mechanical Bind
Mechanical Bind
Remedy: D, E, F
Remedy: J, K
Remedy: J, K
No Movement
Slow Movement
Mechanical Bind
Remedy: J, K
Remedy
A.
B.
Make changes to match operating conditions. Hydraulic system may require cooler / heater.
C.
D.
E.
Overhaul or replace
F.
Locate Blockage or By-Pass. Check Valve, Filter, Directional Valve, Relief Valve, Flow Restrictor Valve
and hoses.
G.
Reverse rotation
H.
I.
Air In Fluid – Purge Air. Fluid is contaminated – Change fluid and filters.
J.
Locate bind and repair.
K.
Lubricate
L.
Flow control valve needs adjusting or replaced.
23
General Troubleshooting - Electrical
Use this section for diagnosing unsatisfactory operation of the electric controls.
Table VI – Faulty Electrical Operation
No Movement
Erratic Movement
No Pump Rotation
Isolate Fault Type To Mechanical, Hydraulic
or Electrical
Remedy: A
Remedy: B
Pump Driven In Wrong Rotation
Mechanical Bind
Remedy: A
Remedy: D, E
Isolate Fault Type To Mechanical, Hydraulic or
Electrical
Hydraulic Fault
Remedy: B
Remedy: F
Mechanical Bind
Electrical Fault
Remedy: D, E
Remedy: C
Hydraulic Fault
Remedy: F
Electrical Fault
Remedy: C
Remedy
A.
Check power supply at motor. Wire motor for correct rotation.
B.
Locate and remove mechanical bind or obstruction, test hydraulic hand controllers for functionality,
test electric hand controllers (if equipped) for functionality
C.
Refer to electrical schematics for specifications. Start at power source. Test for proper voltage,
amperes, and continuity. Inspect cables and connections for loose or broken wires.
D.
Locate and remove mechanical bind or obstruction. Locate bind and repair.
E.
Lubricate
F.
Refer to earlier troubleshooting tables for help with hydraulic faults
24
11.0 Technical Information
circuit against hydraulic overload. Relief valves vary
in design. Pilot controlled pressure relief valves are
designed so that the relief pressure increases very
little as the flow through the valve increases. For
Breaker applications, they are recommended over
direct acting type relief valves.
11.1 Definition of Terms
For the purposes of this manual, Hydraulic Flow,
Operating Pressure, Dynamic Relief Pressure and
Static Relief Pressure are defined as follows:
Hydraulic Flow – A measure of the volume of oil
(values given in GPM / LPM) necessary for the safe
and efficient operation of the Allied attachment. For
attachments such as Breakers, the flow value is
represented as a range. The range specifies the
upper and lower limits in which the Breaker is
designed to operate.
Dynamic Relief Pressure – Also referred to as
“Cracking Pressure”. The pressure measured at the
moment the oil pressure exceeds the preset value of
the relief valve and the spool “cracks” open.
Static Relief Pressure – Also referred to as “Full
Relief Pressure”. The pressure measured at the
moment the relief valve has opened fully and all oil
is by-passed.
Operating Pressure – A measure of the hydraulic
oil pressure (values given in PSI / BAR) taken in the
breaker’s supply line during operation. For
attachments such as Breakers, the pressure value is
represented as a range. The range specifies the
upper and lower limits in which the Breaker is
designed to operate.
Opening Curve – The opening curve is the rise of
pressure between dynamic (first open) and static (all
of the oil flow is bypassed). The dynamic pressure is
always less than the static pressure. A relief valve
adjusted to a dynamic pressure of 3000 psi (200
Bar) will crack open when the preset point is
reached, but fully opens at a higher pressure.
Relief Valve – An adjustable, spring-loaded valve
that opens when a preset pressure value is reached.
A relief valve is safety device, used to protect the
Dynamic Relief Pressure
(Relief valve cracks open)
Operating Pressure
Hydraulic
Flow Range
Opening
Curve
FLOW
Attachment
Operational
Range
Operating
Pressure
Range
Static Relief Pressure
(No flow to attachment)
PRESSURE
Fig. 11-1: Flow-Pressure Diagram
25
11.0 Technical Information – [cont’d]
Tools required for these tests include a flow meter
and pressure gages.
11.2 Testing the Hydraulic Circuit
The performance of the power unit is affected by a
hydraulic system and/or motor that is not operating
to specifications. It’s important to conduct tests of
the power unit if a change in performance is
observed.
Testing procedures can vary depending on the
specifics of your equipment. Consult your flow meter
manual provided from the manufacturer for specific
installation and testing instructions.
Testing the hydraulic circuit, including the pump, can
locate problem areas. The following test is designed
to assess the hydraulic circuit over a range of
conditions, including temperatures and load. Results
of the test will confirm the condition of the pump.
Check circuit to be tested includes a relief valve.
Before starting, be sure the restrictor valve on flow
meter is open. Include the hoses attached to the
power unit to eliminate possible faults, e.g. collapsed
hose.
Amperage
Motor
RPM
Flow
[GPM]
Load
Pressure
[PSI]
0
Oil Temp
[ºF]
Relief
Pressure
[Crack] PSI
Relief
Pressure
[Static] PSI
Return
Pressure
[PSI]
1000
1500
1800
2000
2200
2400
2600
2800
3000
3200
3400
Relief Pressure [Static] – After cracking pressure is
reached, further adjust restrictor valve until flow
gage indicates relief valve is fully open.
Amperage – Do specifications on nameplate –
Voltage, frequency correspond with load amps
RPM – Do specifications on nameplate – Voltage,
frequency correspond with measured speed
Return Pressure [PSI] – Record the pressure
measured in the return line. Measuring point for
gage must be located near breaker’s outlet port.
Flow [GPM] – Record measured flow at each load
pressure
Compare the results of the above test against the
specifications listed in the Technical Data section.
Load Pressure [PSI] – Steadily increase load with
restrictor valve on the flow meter
Oil Brand
Oil Temperature – Allow oil to reach 100°F (40°C)
before testing begins. Accurate test measurements
are achieved only while the oil temperature is at
normal operating temperatures. Stop test if
temperature exceeds 176F (80C)
Oil Type
Viscosity
Date of Test
Name
Relief Pressure [Crack] – Slowly close restrictor
valve until pressure gage indicates relief valve has
cracked open.
26
TM102265_3430_effective_12oct
BULLETIN 90000-S
FLUID RECOMMENDATIONS
FOR OILGEAR EQUIPMENT
PURPOSE OF RECOMMENDATIONS:
This information recommends certain standards when selecting
fluids for use in Oilgear equipment and components. We feel confident Oilgear equipment will provide optimum performance and
service life if these recommendations are followed. For questions
concerning operation under unusual conditions, equipment compatibility or use of fluids not referred to please contact The Oilgear
Company.
FLUID POWER MEDIUMS:
Oilgear equipment and components are available for use with
petroleum based or synthetic fluids which serve dual purposes in
lubrication of internal working parts and the transmission of power.
The buyer must specify the fluid type to be used with new, repair
or replacement equipment or parts. Consult your hydraulic fluid
supplier for flammability, toxicity and viscosity/temperature characteristics of specified fluid.
(Continued on Page 3)
REFERENCE MATERIAL
DESCRIPTION
BULLETIN
Contamination Evaluation Guide .................................................................................................................................... 90004
Storage Recommendations for Oilgear Units .................................................................................................................. 90006
Filtration Recommendations ............................................................................................................................................ 90007
Fluid Supplier Recommendations .................................................................................................................................... 90008
High Water Content Fluid/Laboratory Report ................................................................................................................. 90009
THE OILGEAR COMPANY
Revised: March, 2008
2300 So. 51st. Street, Milwaukee, WI 53219
www.oilgear.com
BULLETIN 90000-S
OPERATING CONDITIONS
MOTORS: Axial Piston
MFW
MVW
21/19/16
170
116
165
240
350
530
690
(36)
(24)
(35)
(52)
(75)
(114)
(149)
SAE 10W (1)
22
*32
*46
68
100
150
9 to 42
18 to 52
25 to 60
32 to 60
40 to 60
52 to 121
64 to 135
75 to 135
11 to 49
18 to 57
24 to 57
40 to 127
52 to 135
64 to 135
4 to 53
11 to 57
18 to 57
28 to 92
40 to 106
52 to 121
64 to 135
75 to 135
-2 to 33
4 to 41
11 to 49
18 to 57
24 to 57
30 to 150
14 to 136
27 to 155
39 to 172
50 to 190
62 to 190
74 to 190
-1 to 66
-10 to 58
-3 to 68
4 to 78
10 to 88
17 to 88
23 to 88
12
(35)
(52)
(75)
(114)
(149)
49 to 108
64 to 125
77 to 140
90 to 140
104 to 140
52
165
240
350
530
690
-3 to 58
4 to 60
10 to 60
17 to 60
23 to 60
16
32
46
68
*100
150
27 to 136
39 to 140
50 to 140
62 to 140
74 to 140
20
20/18/15
4 to 37
11 to 46
18 to 53
24 to 60
43
MOTORS: Bent Axial
MFS
MVS
40 to 98
52 to 115
64 to 128
75 to 140
28
(52)
(75)
(114)
-1 to 66
-10 to 58
-3 to 68
4 to 78
10 to 88
17 to 88
23 to 88
43
20/18/15
240
350
530
30 to 150
14 to 136
27 to 155
39 to 172
50 to 190
62 to 190
74 to 190
12
A, AN, PVA
46
*68
100
65
21/19/16
240
D-C Size 60 or smaller and
80
(75)
(114)
(149)
97
350
530
690
200
68
*100
150
130
21/19/16
200
PUMPS: Radial Piston
D-C Size 100 or larger
DN
65
(24)
(35)
(52)
(75)
(114)
432
116
165
240
350
530
410
22
*32
*46
68
100
432
21/19/16
PUMPS: Axial Piston,
Check Valve
PFCM (3)
PFCS (3)
PFBK (3)
A
X
97
(35)
(52)
(75)
(114)
(149)
410
165
240
350
530
690
410
32
46
*68
100
150
410
20/18/15
432
(52)
(75)
(114)
(149)
2000
240
350
530
690
1900
46
68
*100
150
2000
PVK
PFK
PVV
Fluid must be anti-wear
(36)
(24)
(35)
(52)
(75)
(114)
(149)
450
20/18/15
170
116
165
240
350
530
690
1900
PVL
PFL
SAE 10W(1)
22
*32
*46
68
100
150
1900
21/19/16
INLET CONDITIONS
VISCOSITY RANGE TEMPATURE RANGE (2)
O
O
MAX.
MIN.
F
C
SUS CSt SUS CSt
1900
PUMPS: AXIAL PISTON
PORT PLATE
PVW (3)
PFW (23)
PVG
PVM
RECOMMENDED VISCOSITY
GRADE
ISO VG @
SUS (CSt)
100 OF (40OC) 100OF 40OC)
2000
MAXIMUM
ISO (C)
CLEANLINESS
GRADE (4)
* Recommended viscosity for industrial applications
(1)
If SAE 10W oil is preferred to the ISO grade it should meet latest API Engine Service Classification.
(2)
The temperature range is determined to maintain the proper viscosity using a fluid with a viscosity index of 90. By using
a fluid with a higher viscosity index, one can determine what temperatures would still be within the recommended viscosity range.
(3)
For pumps using high water content fluids, bulk cleanliness target of viscosities below 65 SUS refer to Oilgear Bulletin 90009*
(4)
Per ISO (c) 4406:1999 - Bulk cleanliness target of 19/16/13 or better for optimum component life.
The maximum water content should be 0.1% or less, (except water base fluids).
Page 3
CLEANLINESS:
CONTROL OF FLUID TEMPERATURE:
Oilgear units have many parts with precision finished surfaces
working together. Contamination such as acid, water grit, etc. in
the fluid will cause trouble and the eventual need for repairs.
Use ONLY a fluid with an acceptable contamination level. Even
new fluid should be filtered prior to using. Handle all fluid in
CLEAN containers and introduce fluid into the system through
CLEAN filter with a beta 10 (c) = 200 or better. Refer to Oilgear
Bulletin 90004 which describes contaminant evaluation and remedial action recommendations.
Conditioning fluid with heat exchangers may be necessary to
keep the fluid at the pump intake within the recommended
temperature range. When starting or operating equipment in low
ambient temperature, use heaters with automatic temperature
controls in the reservoir or other precautions. Provide fluid circulation around heater elements to prevent localized overheating. When high ambient temperatures prevail or operating temperatures exceed the recommended range, use heat exchangers
with automatic temperature controls or other precautions to keep
the fluid below the maximum operating temperature. Automatic
over and under temperature alarm systems are recommended.
FILTRATION:
A filtering system should be used to keep the fluid at an acceptable contamination level (refer to Bulletin 90004). The dirt removal rate must be equal to or exceed the ingestion rate which
depends on running conditions, ambient conditions, breather effectiveness, seal conditions, etc. Refer to Oilgear Bulletin 90007
for filter selection recommendations.
AVAILABILITY OF WARNING/CONTROL DEVICES:
Many devices are available to allow the system user adequate
time to detect and correct any potentially disastrous situations
from occurring. Shutdown switches or alarms for low fluid level,
over and under temperature, over pressure, supercharge pressure and dirty filter elements switches, will immediately indicate the absence of a critical parameter. Automatic unloading
controls, gages, recorders and complete annunciator system are
other desirable devices. Refer to THE OILGEAR COMPANY
for recommendations.
AIR IN THE FLUID:
Air in the fluid is detrimental to component life and system performance. Rapid oxidation of fluid, noise, cavitation, shock,
pump damage, spongy action and lengthened machine cycle time
can all be the result of air in the fluid. To reduce the air in the
fluid it is desirable that all air leaks in the suction area be eliminated; all return lines should slowly return the fluid below the
minimum fluid level in the reservoir; the reservoir should be
kept to the maximum fluid level and a fluid with defoaments
should be used. System operation at or above 120oF. (48oC) aids
in the release of air from the fluid.
UNIT COMBINATIONS:
When two or more units connected to a common reservoir have
different viscosity requirements, use the fluid with the highest
viscosity recommendations.
FLUID CHANGE:
ADDITIVES:
If the fluid system operates under average conditions, is automatically filtered and is periodically tested to insure stability,
the fluid may be retained in service for many years. If the system operates under adverse conditions and shows signs of deterioration, the fluid must be changed.
Additives are most readily defined as materials added to the base
fluid for the purpose of enhancing natural performance qualities. Hydraulic fluids usually have rust, oxidation, foam and wear
inhibitors which can help in the reduction of wear, assist in keeping systems cleaner, minimizes sludge and deposits and usually
proves to be a very cost effective measure through improved
performance and the extended life of hydraulic components.
COMPATIBILITY FACTORS:
Consult the fluid supplier for special precautions to be taken
when changing between oil and phosphate ester type fluids. Consult THE OILGEAR COMPANY for equipment compatibility
specifying the model type(s) and serial number(s) of unit(s) involved.
VISCOSITY INDEX:
Oilgear systems and components are designed for the use of
hydraulic fluids within certain maximum and minimum operating viscosity limits depending upon the unit type and horsepower
rating. The viscosity index is a number which indicates how much
viscosity changes for a given change in temperature. If you are
using your equipment where there is a wide range of temperature swings, a high viscosity index fluid is recommended. By
providing either your fluid supplier or Oilgear salesman the temperature range, they will reference the “Operating Conditions”
table, find the acceptable viscosity limits and recommend a high
viscosity index fluid.
ADDITIONAL INFORMATION:
NOTE: “Cutting Fluids” are not recommended to be used as
hydraulic fluids.
For information on operating under unusual conditions, equipment compatibility or use of fluids not referred to in this
bulletin, please contact THE OILGEAR COMPANY.
Page 3
INTERNATIONAL STANDARDS ORGANIZATION
VISCOSITY GRADES
ISO Vis
Grade
10
15
22
32
46
68
100
150
220
320
460
680
0
cSt @ 40 C
9.00
13.5
19.8
28.8
41.4
61.2
90.0
135
198
288
414
612
-
11.0
16.5
24.2
35.2
50.6
74.8
110
165
242
352
506
748
SSU @ 1000F
(assume 95 VI)
57.6
75.8
105
149
214
317
468
709
1047
1533
2214
3298
-
65.3
89.1
126
182
262
389
575
871
1283
1881
2719
4048
THE OILGEAR COMPANY
BULLETIN 90000-S
2300 So. 51st. Street
Milwaukee, WI 53219
www.oilgear.com
Litho in USA
INSERT SECTION TAB HERE
CONTROL SYSTEM
STICK
OUT
BOOM
DOWN
SWING
RIGHT
SWING
LEFT
TOOL
IN
STOP
STICK
IN
TOOL
OUT
BOOM
UP
Typ/Type 9143
Ex i Stromversorgung
I.S. power supply
Betriebsanleitung
Inhaltsverzeichnis
Allgemeine Angaben ................................................................................................... 3
1.1
Hersteller ............................................................................................................. 3
1.2
Angaben zu Betriebsanleitung ............................................................................. 3
2 Verwendete Symbole .................................................................................................. 3
3 Sicherheitshinweise .................................................................................................... 3
4 Normenkonformität...................................................................................................... 4
5 Funktion ...................................................................................................................... 5
6 Kennzeichnung und technische Daten ........................................................................ 5
7 Projektierung ............................................................................................................... 6
7.1
Maximal zulässige Umgebungstemperaturen ....................................................... 6
8 Anordnung und Montage ............................................................................................. 7
8.1
Maßzeichnung ..................................................................................................... 7
8.2
Installation............................................................................................................ 7
8.3
Montage und Demontage ..................................................................................... 7
9 Inbetriebnahme ........................................................................................................... 9
9.1
Anschlüsse .......................................................................................................... 9
10
Betrieb- und Betriebszustände................................................................................. 9
11
Reparatur und Instandhaltung ................................................................................. 9
12
Zubehör und Ersatzteile......................................................................................... 10
1
Content
1
General information................................................................................................... 11
1.1
Manufacturer...................................................................................................... 11
2 Symbols used ........................................................................................................... 11
3 Safety instructions ..................................................................................................... 11
4 Conformity to standards ............................................................................................ 12
5 Function .................................................................................................................... 13
6 Marking and technical data ....................................................................................... 13
7 Cabinet installation .................................................................................................... 14
8 Arrangement and fitting ............................................................................................. 14
8.1
Dimension drawing ............................................................................................ 14
8.2
Installation.......................................................................................................... 15
8.3
Mounting and dismounting ................................................................................. 15
9 Commissioning ......................................................................................................... 17
9.1
Connections ....................................................................................................... 17
10
Operation and operational states ........................................................................... 17
11
Maintenance and repair ......................................................................................... 18
12
Accessories and spare parts.................................................................................. 18
EG-Konformitätserklärung / EC-Declaration of Conformity ............................................... 19
Certification drawing – CSA ............................................................................................. 20
2
deutsch
1
Betriebsanleitung
Allgemeine Angaben
1.1
Hersteller
R. STAHL Schaltgeräte GmbH
Am Bahnhof 30
74638 Waldenburg
Germany
1.2
Angaben zu Betriebsanleitung
ID-Nr.
Dokumenten Nr.
HW Revision
2
Telefon: +49 7942 943-0
Fax:
+49 7942 943-4333
Internet: www.stahl.de
9143601310
S-BA-9143-012-de/en-11/2012
A
Verwendete Symbole
!
Sicherheitshinweise, die unbedingt beachtet werden müssen.
Bei Sicherheitshinweisen auf dem Gerät sind die entsprechenden Angaben
bzw. Sicherheitshinweise der Betriebsanleitung zu beachten!
c
Das Produkt erfüllt die anwendbaren EG-Vorschriften.
e
Die so gekennzeichneten Stromkreise sind, entsprechend der jeweiligen
Kennzeichnung, für explosionsgefährdete Bereiche zugelassen.
Symbol für Eingang
Symbol für Ausgang
Hinweiszeichen: Beschreibt Hinweise und Empfehlungen.
3
Sicherheitshinweise
In diesem Kapitel sind die wichtigsten Sicherheitsmaßnahmen zusammengefasst. Es
ergänzt die entsprechenden Vorschriften, zu deren Studium das verantwortliche Personal
verpflichtet ist.
Bei Arbeiten in explosionsgefährdeten Bereichen hängt die Sicherheit von Personen und
Anlagen von der Einhaltung aller relevanten Sicherheitsvorschriften ab. Das Montage- und
Wartungspersonal trägt deshalb eine besondere Verantwortung. Die Voraussetzung dafür
ist die genaue Kenntnis der geltenden Vorschriften und Bestimmungen.
Bei Errichtung und Betrieb ist Folgendes zu beachten:
• Es gelten die nationalen Montage- und Errichtungsvorschriften (z.B. EN 60079-14).
• Die Ex i Stromversorgung ist außerhalb explosionsgefährdeter Bereiche zu installieren.
• Die Ex i Stromversorgung Typ 9143/10-...-...-10 ist auch für den Betrieb in
explosionsgefährdeten Bereichen der Zone 2 und Zone 22 zugelassen.
• Bei Einsatz in Zone 2, Zone 22 ist die Ex i Stromversorgung in ein Gehäuse einzubauen,
das den Anforderungen der EN 60079-15 genügt.
Ex i Stromversorgung Typ 9143
3
Betriebsanleitung
deutsch
• An die eigensicheren Ausgangsstromkreise dürfen eigensichere Geräte der Zone 1 und
21 angeschlossen werden.
• Die Ex i Stromversorgung darf nur an Geräte angeschlossen werden, in denen keine
höheren Spannungen als AC 253 V (50 Hz) auftreten können.
• Die sicherheitstechnischen Werte der / des angeschlossenen Feldgeräte/s müssen mit
den Angaben des Datenblattes bzw. der EG-Baumusterprüfbescheinigung
übereinstimmen.
• Bei Zusammenschaltungen mehrerer aktiver Betriebsmittel in einem eigensicheren
Stromkreis können sich andere sicherheitstechnische Werte ergeben. Hierbei kann die
Eigensicherheit gefährdet werden!
• Die nationalen Sicherheits- und Unfallverhütungsvorschriften
• Die allgemein anerkannten Regeln der Technik
• Die Sicherheitshinweise dieser Betriebsanleitung
• Beschädigungen können den Explosionsschutz aufheben.
Verwenden Sie das Gerät bestimmungsgemäß nur für den zugelassenen Einsatzzweck
(siehe „Verwendung“).
!Warnung
Durch fehlerhaften oder unzulässigen Einsatz sowie das Nichtbeachten der Hinweise
dieser Betriebsanleitung kann der vorgesehene Schutz beeinträchtigt werden, die
Gewährleistung unsererseits wird in diesen Fällen ausgeschlossen.
•
Umbauten und Veränderungen am Gerät, die den Explosionsschutz
beeinträchtigen, sind nicht gestattet.
•
Das Gerät darf nur in unbeschädigtem, trockenem und sauberem Zustand
eingebaut und betrieben werden.
Sollten Sie Fragen bezüglich der richtigen Handhabung des Gerätes haben, wenden Sie
sich bitte an R. STAHL Schaltgeräte GmbH, Am Bahnhof 30, 74638 Waldenburg,
Germany, Telefon +49-7942-943-0 wenden oder an eine unserer Niederlassungen, siehe
www.stahl-ex.com.
4
Normenkonformität
Bitte entnehmen sie die Normenkonformität der EG-Konformitätserklärung im Anhang
dieses Dokumentes.
Die aktuelle EG-Baumusterprüfbescheinigung können Sie im Internet unter www.stahl.de
herunterladen.
4 Ex i Stromversorgung Typ 9143
deutsch
5
Betriebsanleitung
Funktion
Die Ex i Stromversorgungen werden zur eigensicheren Versorgung von Feldgeräten wie
z.B. 3- oder 4-Leiter Messumformer, Magnetventile, Lichtschranken, Reglern eingesetzt.
6
Kennzeichnung und technische Daten
Typbezeichnung
CE-Kennzeichnung
Ex-Kennzeichnung
Umgebungstemperaturbereich
Global (IECEx)
Gas
Dust
Mining
Europe (ATEX)
Gas
Dust
Mining
9143/10-***-***-*0
c0158
e
-20 °C … +70 °C
IECEx BVS 12.0009X
9143/10-***-***-10
Ex nA [ib Gb] IIC/IIB T4 Gc
[Ex ib Db] IIIC
[Ex ib Mb] I
BVS 05 ATEX E 152 X
9143/10-***-***-10
II 3 (2) G Ex nA [ib Gb] IIC/IIB T4 Gc
II (2) D [Ex ib Db] IIIC
I (M2) [Ex ib Mb]I
9143/10-***-***-20
[Ex ib Gb] IIC/IIB
[Ex ib Db] IIIC
[Ex ib Mb]I
9143/10-***-***-20
II (2) G [Ex ib Gb] IIC/IIB
I (M2) [Ex ib Mb]I
Sicherheitstechnische Daten
Typ 9143/10-…-…-*0 065-200 099-220 104-220 114-200 124-150 156-065 156-160 187-050 244-060
max. Spannung Uo [V] 6,5
9,9
10,4
11,4
12,4
15,6
15,6
18,7
24,4
max. Strom Io [mA]
200
220
220
200
150
65
160
50
70
max. Leistung Po [W]
1,3
2,178
2,288
2,28
1,86
1,014
2,496
0,935
1,464
max. äußere
25
3
2,4
1,64
1,24
0,497
--0,27
Kapazität Co IIC [µF]
570
20,2
16,8
11,2
7,9
3,03
3,03
1,64
0,67
Kapazität Co IIB [µF]
Induktivität Lo IIC [mH] 0,82
0,3
0,24
0,16
0,17
0,445
--0,06
Induktivität Lo IIB [mH]
3,71
1,7
1,5
1,4
2,08
11,2
0,351
15,5
0,2
innere Kapazität, Ci / Induktivität, Li
Isolationsspannung Um
vernachlässigbar
253 V AC
Weitere Angaben und Wertekombinationen siehe EG-Baumusterprüfbescheinigung
Technische Daten (Auszug aus dem Datenblatt)
Hilfsenergie
Variante 9143/10-...-...-10
Variante 9143/10-…-…-20
Umgebungsbedingungen
Betriebstemperatur
Lagertemperatur
relative Feuchte (keine Betauung)
24V AC/DC
85…230V AC
-20...+70 °C
-40...+80 °C
< 95 %
Weitere technische Daten sind dem aktuellen Datenblatt zu entnehmen.
Bei anderen vom Standard abweichenden Betriebsbedingungen nehmen Sie bitte Rücksprache
mit dem Hersteller.
5
Betriebsanleitung
7
8
8.1
deutsch
Geräteaufbau
#
1
Schwarze Klemme
Beschreibung
2
4
LED „PWR“, grün
Blaue Klemme
21
Drehregler „UA“
Anschlussklemmen für den sicheren
Bereich
Anzeige Hilfsenergie
Anschlussklemmen für den ExBereich
Zu Einstellung der Leerlaufspannung
Projektierung
Maximal zulässige Umgebungstemperaturen
Die Geräte der Reihe ISpac sind über einen weiten Temperaturbereich einsetzbar. Je nach
Geräteausführung und Einbaubedingung ergeben sich unterschiedliche, maximal zulässige
Umgebungstemperaturen.
!Warnung
Befolgen sie die Hinweise des Dokuments “ISpac cabinet installation guideline”
•
Geräte können durch unzulässig hohe Umgebungstemperaturen ausfallen.
•
Es erlischt die Herstellerhaftung und Gewährleistung.
o
Der Schaltschrank muss in einer Art aufgebaut sein, der es erlaubt das Gerät im
spezifizierten Temperaturbereich zu betreiben.
Das Dokument ist verfügbar unter: www.stahl-ex.com.
deutsch
9
9.1
Betriebsanleitung
Anordnung und Montage
Maßzeichnung
122
Maß X
108 mm
128 mm
114,5
Schraubklemmen
Federzugklemmen
9.2
Installation
Die Ex i Stromversorgung Typ 9143/10-...-...-10 ist auch für den Betrieb in
explosionsgefährdeten Bereichen der Zone 2 und Zone 22 zugelassen. Bei Einsatz in Zone
2, Zone 22 ist die Ex i Stromversorgung in ein Gehäuse einzubauen, das den
Anforderungen der EN 60079-15 genügt.
Das Ex i Stromversorgung Typ 9143/10-…-…-20 ist außerhalb explosionsgefährdeter
Bereiche zu installieren.
9.3
9.3.1
Montage und Demontage
Montage / Demontage pac-Bus
Der pac-Bus ist ein Zubehör, dass die Verdrahtung der Hilfsenergie und das
Auslesen der Sammelfehlermeldung vereinfacht.
Die Komponenten für den pac-Bus Typ 9194 müssen separat bestellt
werden.
Gewünschte Anzahl der pac-Bus-Elemente
zusammenstecken.
pac-Bus-Elemente auf Hutschiene aufrasten.
7
Betriebsanleitung
deutsch
Klemmenset am Anfang und am Ende
einstecken.
pac-Bus ist montiert.
9.3.2 Montage / Demontage auf Hutschiene
Montage
Beim Aufschwenken des Geräts auf die Hutschiene darauf achten, dass es
nicht verkantet.
Gerät an die Hutschiene ansetzen. Die
Aussparung des Gehäuses muss dabei auf die
Außenkante der Hutschiene gesetzt werden.
Gerät auf Hutschiene aufrasten.
Demontage
Fußriegel (1) mit dem Schraubendreher etwas
herausziehen.
Gerät herausschwenken.
9.3.3
Montage / Demontage abziehbare Klemmen
Alle Geräte sind mit abziehbaren Klemmen ausgestattet.
Demontage
Schraubendreher hinter Klemme ansetzen.
Klemme herausdrücken.
Montage
Klemme in Gerät stecken, bis Klemme einrastet.
deutsch
10
10.1
Betriebsanleitung
Inbetriebnahme
Anschlüsse
pac-bus
24
- V
+V
LF 24
- +
Ex-Bereich
Hazardousarea
Sicherer Bereich
Safearea
N/9 24 V DC/AC
L/7 +
Typen 9143/10-***-***-10
1
RL
1110+
Safearea
9N/9 ~
N
115/230
V ACAC
85 ... 230V
L/7 ~
L7
Typen 9143/10-***-***-20
1
11
RL
1110+
Betrieb- und Betriebszustände
Bevor Sie das Gerät in Betrieb nehmen, stellen Sie sicher, dass
•
das Gerät vorschriftsmäßig installiert wurde
•
das Gerät nicht beschädigt ist
•
die Kabel ordnungsgemäß angeschlossen sind
12
Reparatur und Instandhaltung
Es wird empfohlen, Reparaturen an unseren Geräten ausschließlich durch uns durchführen
zu lassen. In Ausnahmefällen kann die Reparatur auch durch eine andere, zugelassene
Stelle erfolgen.
Die Geräte sind wartungsfrei.
Fehlersuchplan:
Fehlererkennung
LED „PWR“ erloschen
Keine
Ausgangsspannung,
LED „PWR“ leuchtet
Fehlerursache
- Hilfsenergie ausgefallen
- Gerätesicherung defekt
- Hilfsenergieversorgung verpolt
Eingangswiderstand des Verbrauchers zu
gering, Strombegrenzung der
Stromversorgung aktiviert
Fehlerbehebung
Hilfsenergieversorgung kontrollieren.
Bei defekter Sicherung das Gerät zur Reparatur
geben.
Korrekte Polung herstellen
Wert für maximalen Nennstrom beachten,
Verbraucher entsprechend der Nennwerte
auswählen
9
Betriebsanleitung
deutsch
Führen die beschriebenen Vorgehensweisen nicht zum gewünschten Erfolg, wenden Sie
sich bitte an unsere nächste Vertriebsniederlassung. Zur schnellen Bearbeitung benötigt
diese von Ihnen folgende Angaben:
•
Typ und Seriennummer,
•
Kaufdaten,
•
Fehlerbeschreibung,
•
Einsatzzweck (insbesondere Eingangs-/Ausgangsbeschaltung)
13
Zubehör und Ersatzteile
Verwenden Sie nur Original-Ersatzteile der Fa. R. STAHL Schaltgeräte GmbH.
deutsch
1
Betriebsanleitung
General information
1.1
Manufacturer
Am Bahnhof 30
74638 Waldenburg
Germany
Phone: +49 7942 943-0
Fax:
+49 7942 943-4333
Internet: www.stahl.de
Information regarding the operating instruction:
ID-Nr.
9143601310
Document number S-BA-9143-012-de/en-11/2012
Hardware revision A
2
Symbols used
!
Safety note, which is essential to take note.
With safety note on the equipment the appropriate data and/or safety reference
of the manual are to be considered!
c
The device complies with the applicable EC standards.
e
Electric circuits marked with the symbol are certified, according to the respective
marking, for hazardous locations.
Symbol for input
Symbol for output
Information sign: Provides a note or recommendation.
3
Safety instructions
The most important safety instructions are summarised in this chapter. It is intended to
supplement the relevant regulations which must be studied by the personnel responsible.
When working in hazardous areas, the safety of personnel and plant depends on
complying with all relevant safety regulations. Assembly and maintenance staff working on
installations therefore have a particular responsibility. The precondition for this is an
accurate knowledge of the applicable regulations and provisions.
When installing and operating the device, the following are to be observed:
•
The national installation and assembly regulations (e.g. EN 60079-14) apply.
•
The I.S. power supply is to be installed outside of hazardous areas.
•
Type 9143/10-…-…-10 I.S. power supply are also approved for operation in Zone 2,
Zone 22 hazardous areas.
•
In the case of operation in Zone 2 and 22, the I.S. power supply must be fitted in an
enclosure which complies with the requirements of EN 60079-15.
11
english
•
Zone 1 and 21 intrinsically safe devices may be connected to the intrinsically safe
signal circuits.
•
The I.S. power supply may only be connected to devices which will not be subjected
to voltages higher than AC 253 V (50 Hz).
•
The safe maximum values of the connected field device(s) must correspond to the
values of the data sheet or the EC-type examination certificate.
•
Interconnecting several active devices in an intrinsic safety circuit may result in other
safe maximum values. This could endanger the intrinsic safety!
•
National safety and accident prevention regulations
•
The generally recognised technical regulations
•
The safety guidelines in these operating instructions
•
Any damage can compromise and even neutralise the explosion protection.
Use the device in accordance with the regulations and for its intended purpose only (see
“Function”).
!Warning
With incorrect or unauthorized use or non-compliance with these instructions the
intended protection can be impaired, the warranty provision is invalidate on our part in
these cases.
o
No changes to the devices or components impairing their explosion protection are
permitted.
o
Furthermore, the device may only be operated if it is undamaged, dry and clean.
Should there be any question about the correct handling of the module, please contact R.
STAHL Schaltgeräte GmbH, Am Bahnhof 30, 74638 Waldenburg, Germany, telephone
+49-7942-943-0, or contact one of our offices or representatives see www.stahl-ex.com.
4
Conformity to standards
The information about the conformity to standards can be found in the manufacturer’s
declaration of conformity in the appendix of this document.
The current EC-Type Examination Certificate can be downloaded from the Internet
www.stahl-ex.com .
12
Vibration Transducer Supply Unit Type 9147
english
5
Operating instructions
Function
I.S. power supplies are used to provide intrinsically safe power to field devices such as 3wire or 4-wire transmitters, solenoid valves, photoelectric sensors and controllers.
6
Marking and technical data
Type designation
CE marking
Ex marking
Ambient temperature range
Global (IECEx)
Gas
Dust
Mining
Europe (ATEX)
Gas
Dust
Mining
9143/10-***-***-*0
c0158
e
-20 °C … +70 °C
IECEx BVS 12.0009X
9143/10-***-***-10
Ex nA [ib Gb] IIC/IIB T4 Gc
[Ex ib Db] IIIC
[Ex ib Mb] I
BVS 05 ATEX E 152 X
9143/10-***-***-10
II 3 (2) G Ex nA [ib Gb] IIC/IIB T4 Gc
I (M2) [Ex ib Mb]I
9143/10-***-***-20
[Ex ib Gb] IIC/IIB
[Ex ib Db] IIIC
[Ex ib Mb]I
9143/10-***-***-20
II (2) G [Ex ib Gb] IIC/IIB
I (M2) [Ex ib Mb]I
Safety data
Type 9143/10-…-…- 065-200 099-220 104-220 114-200 124-150 156-065 156-160 187-050 244-060
*0
max. voltage Uo [V]
6,5
9,9
10,4
11,4
12,4
15,6
15,6
18,7
24,4
max. current Io [mA]
200
220
220
200
150
65
160
50
70
max. power Po [W]
1,3
2,178
2,288
2,28
1,86
1,014
2,496
0,935
1,464
max. external
capacitance Co IIC [µF]
25
3
2,4
1,64
1,24
0,497
--0,27
capacitance Co IIB [µF]
inductance Lo IIC [mH]
inductance Lo IIB [mH]
570
0,82
3,71
20,2
0,3
1,7
16,8
0,24
1,5
11,2
0,16
1,4
7,9
0,17
2,08
3,03
0,445
11,2
3,03
--0,351
1,64
0,06
15,5
0,67
0,2
internal capacitance, Ci / inductance, Li
negligible
Insulation voltage Um
253 V AC
See EC-type examination certificate for further information and value combinations
Technical data (extract from the data sheet)
Power supply
Version 9143/10-...-...-10
Version 9143/10-…-…-20
Ambient conditions
Max. operating temperature
Storage temperature
Relative humidity (no condensation)
24V AC/DC
85…230V AC
-20...+70 °C
-40...+80 °C
< 95 %
Additional technical data can be found in the current data sheet.
Please consult with the manufacturer before operating under conditions which deviate
from the standard operating conditions.
I.S. Power Supply Type 9143
13
7
8
english
Device description
#
1
2
4
Black terminals
LED „PWR“
Blue terminals
Description
21
Knob “output voltage”
Connection terminals for the safe area
Indication of power supply
Connection terminals for the
hazardous area (intrinsic safe).
Adjustment of output voltage.
Cabinet installation
The ISpac isolators can be used over a wide temperature range. Depending on the isolator
version and installation method may result in different maximum ambient temperatures.
!Warning
Follow the instructions of the “ISpac cabinet installation guideline”
•
Device may fail because of high ambient temperature.
•
The manufacturer’s liability and warranty expire.
o
The cabinet need to be built in a way which allows to operate the device within the
specified temperature range
The cabinet installation guide is available on www.stahl-ex.com.
9
9.1
Arrangement and fitting
Dimension drawing
122
114,5
Screw terminals
Spring clamp terminals
14
Size X
108 mm
128 mm
english
9.2
Installation
Type 9143/10-…-…-10 I.S. power supply are approved for operation in Zone 2, Zone 22
hazardous areas. In the case of operation in Zone 2 and 22, the I.S. power supply must be
fitted in an enclosure which complies with the requirements of EN 60079-15.
Type 9143/10-…-…-20 I.S. power supply has to be installed outside of the hazardous area.
9.3 Mounting and dismounting
9.3.1
Mounting of pac-Bus
The pac-Bus is an accessory, which facilitates the wiring of the power
supply and the common fault signalization.
The components of the pac-Bus type 9194 need to be ordered separately.
Assemble the required number of pac-Bus
elements.
Snap the pac-Bus segment on the DIN rail.
Assemble the terminal set at the beginning and
the end of the pac-Bus segment.
9.3.2
Mounting / Dismounting on DIN rail with or without pac-Bus
Mounting
Take care that the devices is not canted before it is snapped on the DIN rail.
Put the device on the DIN rail. Take care that the cut out of
the enclosure fits onto the edge of the DIN rail.
Swivel the device until it is snapped on the DIN rail.
Dismounting
15
9.3.3
english
Pull the latch (1) with the screw driver out.
Swivel the device out.
Mounting / Dismounting detachable terminals
All devices are equipped with detachable terminals.
Dismounting
Place the screw driver between terminal and
enclosure.
Move the screw driver as described.
Mounting
Place the terminal into the terminal slot and press it towards the device until it is locked.
16
english
10
10.1
Commissioning
Connections
pac-bus
V
LF 24
- +
Ex-Bereich
Hazardousarea
Sicherer Bereich
Safearea
N/9 24 V DC/AC
L/7 +
Types 9143/10-***-***-10
1
RL
1110+
Safearea
N/9
N
9 ~
115/230
V ACAC
85 ... 230V
L/7 ~
L7
Types 9143/10-***-***-20
1
10.2
RL
1110+
Settings
The output voltage can be adjusted in a pre-defined range. The set-up can be arranged by
means of the knob on the front of the device. The individual range is indicated on the
device.
11
Operation and operational states
Before commissioning the device, please ensure that:
•
the device was installed in accordance with the regulations
•
the device is not damaged
•
the cables are properly connected
17
12
english
Maintenance and repair
It is recommended that all repairs to our devices be carried out by R. STAHL. In
exceptional cases, repair may be performed by approved third-parties.
The devices are maintenance-free.
Troubleshooting chart:
Error detection
“PWR” LED does not lit
Output voltage
dropped, LED “PWR”
on
Cause of error
Power supply failure
Device fuse is defective
Polarity reversal
Load resistance is too low, current
limitation of the power supply is activated
Corrective action
Check power supply.
If device fuse is defective, send device in for
repair.
Connect the power acc. to operating guide
Check the maximum nominal current, select a
load resistance acc. to the specification
If the procedure described above does not obtain the desired result, please contact your
local R.STAHL sales and service representative. In order to quickly process your request,
please provide us with the following information:
•
Type and serial number,
•
Purchase date(s),
•
Description of the error,
•
Application description (particularly the configuration of the
input/output circuitry)
13
Accessories and spare parts
Use only original spare parts from R. STAHL Schaltgeräte GmbH.
18
EG-Konformitätserklärung / EC-Declaration of Conformity
Certification drawing – CSA
21
23
Am Bahnhof 30
74638 Waldenburg (Württ.) – Germany
www.stahl.de
SAP 159855 ID-Nr. 9143601310
S-BA-9143-012-de/en-11/2012
Original Operating Instructions
spectrum EEX
AOSP2UE1
Table of Contents
Safety Instructions Intended Use Safety Instructions for Installation and Operation FCC notes IC notes Special Instructions for Use in Hazardous Areas Operation Activating the Transmitter Deactivating the Transmitter Automatic Switch-Off (APO Function) Battery and Battery Charger Charging the Battery Options Safety Features Frequency Management Catch-Release Tandem Operation Catch-Release-Tandem Operation Cable Control Pre-selection of Trolley or Hoist Feedback by LED Slewing Gear Release Technical Data Dimensions Troubleshooting Maintenance EC Type Examination Certificates Attachments: Return delivery note, system specific views, circuit diagrams and /or output wiring
Pictographs
Danger due to electrical voltage. Touching live parts inside the unit can be fatal or cause
serious injuries.
Instructions for occupational health and safety. Not following these instructions can cause
accidents, which can cause damage, serious injuries or even death.
Important information about the operation of the radio system
Manufacturer:
HBC-radiomatic GmbH • Haller Straße 45 – 53 • 74564 Crailsheim • Germany • Tel. +49 7951 393-0 • [email protected].
HBC.radiomatic GmbH is not liable for any misprints or errors! – Specifications and design subject to change without notice.
® radiomatic and radiobus are registered German trademarks.
© 22 / 2012, HBC-radiomatic GmbH, 74564 Crailsheim, Germany
No part of this document may be reproduced in any manner whatsoever without the expressed written permission of
HBC-radiomatic GmbH.
Safety Instructions
Read through these operating instructions carefully before working with the radio system. This applies in
particular to the installation, commissioning and maintenance of the radio system.
The operating instructions are a constituent part of the radio control system and must always be kept
close at hand for the responsible personnel.
The term ‘machine’ is used in the operating instructions for the different possible uses of the radio
system.
Intended Use





The radio system serves to control machines and for data transfer. Observe the job safety and
accident prevention regulations applicable to each application.
The intended use also includes reading the operating instructions and adhering to all safety
information contained therein.
The radio system must not be used for the control of machines used to convey persons, unless it is
explicitly approved by the manufacturer for this use.
Modifications to the radio system may only be carried out by specialist personnel who have been
trained and authorized by HBC-radiomatic. All modifications must be documented at the factory in
the radio control master file.
The radio control system safety devices must not be modified, removed or bypassed. In particular,
modifications to any part of the radio system's complete E-STOP system are impermissible.
Safety Instructions for Installation and Operation
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The electrical connection per the accompanying output wiring diagram must be established by a
qualified electrician exclusively.
The receiver may only be opened by trained personnel. Components inside the receiver can be
energized at life-threatening voltages. The supply voltage for the machine must be deactivated
before the receiver is opened.
Please also note with radio systems, that the presence of persons in the danger zone - in particular
beneath the load (cranes!) - is prohibited in every instance.
Select a safe location for radio control, from which you have a good and complete view of the
working movements of the machine, the load movements and the surrounding working conditions.
It is not permissible to put a radio transmitter unattended to one side whilst activated. Always switch
the radio transmitter off when it is not required. This applies in particular if you change location,
when working without radio control, during breaks and at the end of work. Always safeguard the
radio transmitter against use by unauthorized persons, for example by locking it away.
In the event of an emergency and with all faults, switch the radio transmitter off immediately by
pressing the STOP switch.
Only operate the radio system when it is in perfect working order. Faults and defects that could
influence safety must be rectified before the system is put back into operation, by specialists who
have been trained and authorized by HBC-radiomatic.
Note that the operational directions of the operating elements may appear inverted depending on
location and viewing angle to the machine. This applies in particular to rotary cranes, if your location
changes from inside to outside the radius of the crane. The operator must make himself familiar with
the directional markings on the machine before the start of work.
Repairs may only be carried out by specialist personnel who have been trained and authorized by
HBC-radiomatic. Use original replacement parts and accessories (e.g. rechargeable batteries)
exclusively; otherwise it is possible that the equipment safety and the explosion protection can no
longer be guaranteed and our extended warranty will be voided.
Remain vigilant when working with the radio system and familiarize yourself with its functions. This
applies in particular if you are working with it for the first time or if you work with it only occasionally.
Before starting to work, examine the STOP switch for mechanical ease of motion and electronic
function at least once a day:
When you press the STOP switch with the transmitter on, the status LED of the transmitter has to go
out. If the status LED does not go out then you have to disable the radio control system immediately.
Remove the battery and the radiomatic ® iON from the transmitter and inform a service technician.
FCC notes
Part 15.21 Statement
Changes or modifications made to this equipment not expressly approved by HBC-radiomatic GmbH may
void the FCC authorization to operate this equipment.
This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation. This equipment generates, uses and can radiate
radio frequency energy and, if not installed and used in accordance with the instructions, may cause
harmful interference will not occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by turning the equipment off and
on, the user is encouraged to try to correct the interference by one or more of the following measures:
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Reorient or relocate the receiving antenna.
Increase the separation between the equipment and receiver.
Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
Consult the dealer or an experienced radio/TV technician for help.
RF Exposure Statement
Radiofrequency radiation exposure information
The radiated output power of the device is far below the FCC radio frequency exposure limits.
Nevertheless, the device shall be used in such a manner that the potential for human contact during
normal operation is minimized.
IC notes
RSS-GEN – User Manual Statements (English/French)
Licence exempt
This device complies with Part 15 of the FCC Rules and Industry Canada licence-exempt RSS
standard(s). Operation is subject to the following two conditions:
1. this device may not cause interference, and
2. this device must accept any interference received, including interference that may cause
undesired operation of the device.
Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio
exempts de licence. L'exploitation est autorisée aux deux conditions suivantes:
1. l'appareil ne doit pas produire de brouillage, et
2. l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage
est susceptible d'en compromettre le fonctionnement.
Note:
The Industry Canada label identifies certified equipment. This certification means that the
equipment meets certain telecommunications network, protective, operational and safety
requirements as prescribed in the appropriate Terminal Equipment Technical Requirements
document(s). The Department does not guarantee the equipment will operate to the user’s
satisfaction. Repairs to certified equipment should be coordinated by a representative designated
by the supplier. Users should ensure for their own protection that the electrical ground
connections of the power utility, telephone lines and internal metallic water pipe system, if
present, are connected together.
This precaution may be particularly important in rural areas.
Note:
Users should not attempt to make such connections themselves, but should contact
the appropriate electric inspection authority, or electrician, as appropriate. This product meets the
applicable Industry Canada technical specifications.
Safety Instructions
In customer related documents of the end product like instruction manuals, installation guides etc.
appropriate safety instructions have to be included. The supplier of the complete system is responsible
for these safety instructions.
Special Instructions for Use in Hazardous Areas
General Instructions
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All warning notices on the transmitter and receiver must be observed.
The warning notices may not be removed.
Warning notices that have become damaged or illegible must be replaced.
The designation of transmitter and receiver is to be noted (see type plate).
In the event of damage to the transmitter or receiver casing, which impairs the class of casing
protection, the radio installation is to be taken out of operation and arrangements made for repair by
the manufacturer.
Never use a damaged connecting cable (see cable control option).
The following must be observed for installation and operation:
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National installation and erection regulations are applicable (for example EN 60079-14).
National safety and accident prevention regulations.
Generally accepted rules of engineering.
The safety notes in this operation manual.
Damages may cancel the effectiveness of explosion protection.
When using cable control option the stationary radio receiver must be installed outside hazardous
areas respectively in a standardized type of protection in accordance with EN 60079-0.
Instructions Specific to the Receiver
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An option to disconnect the receiver electrically must be provided outside the hazardous area.
The plug connection on the receiver may only be disconnected when it is in a zero voltage state.
All current paths of the switching relay of the receiver must be fused up to the maximum current
switching capability of the relay contacts.
The installer must ensure that the operating voltage range prescribed by the manufacturer is
maintained.
If the antenna is installed within the hazardous area, it may only be moistened when cleaning and
high-energy particle flows must be avoided.
Instructions Specific to the Transmitter
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The transmitter spectrum EEX may only be operated with the FuB 06 EEX battery or with the
respective connecting cable when using cable control option!
The battery contacts must be maintained clean.
The transmitter must be switched off if the battery is changed in hazardous areas.
The battery may not be charged in hazardous areas.
The battery charger may not be operated in hazardous areas.
Operation
The transmitter is equipped with an electronic radiomatic ® iON key. radiomatic ® iON contains all the data
required for operating the transmitter. Operation is not possible without radiomatic ® iON!
Depending on the version the radiomatic ® iON can also be used for operation of replacement
transmitters of identical construction.
When activating the transmitter and if the radio connection is interrupted (e. g. if the connection is lost or
the transmission range is exceeded), the transmitter reacts with the so-called enforced zero-position.
Release all operating elements so they can return to the zero-position and actuate the start button. The
machine will not react if the operating elements are not in zero-position. This prevents uncontrolled
machine movements after the radio connection has been interrupted.
Activating the Transmitter
Transmitter without start sequence:
1. Insert a charged battery into the battery compartment.
2. Turn the STOP switch to unlock.
3. Shortly actuate the start button and then release.
When the status LED flashes green, the transmitter is ready to operate.
Transmitter with start sequence:
The steps 3 and 4 need to be carried out within 4 seconds.
1. Insert a charged battery into the battery compartment.
2. Turn the STOP switch to unlock.
3. Shortly actuate the start button and then release. The transmitter will switch off if the button is
actuated for longer than half a second!
4. Actuate the start button again until the status LED flashes green. Then release the button.
The transmitter is now ready for operation.
5. Depending on the application, you must actuate the start button again before movement commands
can be carried out.
Note:
The transmitter switches off when
 the start button is actuated for longer than half a second in step 3 of the start sequence.
 the start sequence (steps 3 and 4) takes over 4 seconds.
 another button is actuated during the start sequence.
You must then repeat steps 3 and 4 or 3 to 5.
Caution:
Before starting work always trigger the acoustic signal. This warns all colleagues that the machine
is about to move.
Deactivating the Transmitter
Press the STOP switch.
Note:
Replace the battery when the status LED in the transmitter flashes red and an acoustic signal
sounds. Otherwise, the transmitter will switch off in a few minutes.
Recharge the empty battery in the respective charger.
Automatic Switch-Off (APO Function)
For safety reasons we have equipped the transmitter with an automatic switch-off (APO function).
The transmitter is automatically put out of circuit after approx. 15 minutes of non-use.
The automatic switch-off also saves battery power.
After an automatic switch-off you must reactivate the transmitter as described in chapter “Operation”.
Caution:
The automatic switch-off does not relieve the operator of his responsibility to turn off the
transmitter with the STOP switch when not in use.
Battery and Battery Charger
NiMH Battery
The battery capacity (= the ability to store electric current) and the battery charge (= the actual amount
of stored current) depend on the age of the battery and the environment temperature. Older batteries
begin to lose capacity over time. If the temperatures are below 0 °C or above 40 °C, the charge
decreases faster.
Note:
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Make sure the batteries are charged completely before initial use and at least once a month.
Use only the associated HBC charger to charge the battery.
Charge the battery at an ambient temperature of 0 – 40 °C (32 – 104 °F).
Charge the battery only when the status LED flashes red and an acoustic signal sounds.
Always store rechargeable batteries at room temperature.
Protect the battery from short circuits and always store it in the protective cover provided.
When handled properly the battery can exceed 500 charging cycles.
Battery Charger
Depending on customer selection, an AC or DC charger is available.
Ensure that you observe the following instructions:
 Use this charger only to charge the batteries specified on the type plate.
 The charger may not be used in hazardous areas.
 The charger has to be operated with the voltage indicated on the back.
 The charger has to be used in vehicles or indoors only.
 Use the charger only within the specified temperature range.
 Protect the charger against heat, dust and humidity.
 Do not cover the charger while it is in use.
 Disconnect the charger from the power supply when it is not in use.
 In case of any fault of the charger or the connecting cable disconnect it immediately and put it
out of operation.
 Do not make technical changes to the charger or the connecting cable.
 Defects must be repaired by qualified personnel only.
Three LEDs indicate the actual operating state of the battery.
LED green: Illuminates when battery is charged.
LED orange: Illuminates when battery is charging.
LED red: Illuminates when battery is deep discharged or defective.
Note:
If a deep discharged battery is inserted into the charger, the red LED will illuminate for some time
before charging is started (LED orange illuminates).
QE115600 / QE115300
The charger is supplied with a connecting cable with a matching power plug.
Charging the Battery
1. Connect the charger via the connecting cable to the power supply.
2. Insert the battery into the compartment.
Charging will start automatically.
Technical Data
Operating voltage
100 – 240 V AC (QE115600)
10 – 30 V DC (QE115300)
Charging time
ca. 3 h
Operating temperature
10 – 40 °C
Housing material
Plastic
Protection class
II
Options
The availability of the following functions depends on the design and configuration of your radio control
system.
Safety Features
radiomatic® shock-off / zero-g / inclination switch
In specific emergency situations, these safety features can prevent unintended movement commands
from being given to the machine, protecting the operator as well as other personnel in close proximity to
the machine in use.
radiomatic ® shock-off can react if the transmitter receives a hard impact.
radiomatic ® zero-g can react if the transmitter is falling down or being thrown.
inclination switch can activate if the transmitter exceeds an inclination angle of
approx. 45° for a specified time and/or is positioned upside down.
Depending on the ordered version the features can operate in three different ways:
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The complete radio system is shut down.
Safety-relevant functions are deactivated.
A previously defined function (e. g. crane horn) is activated.
To deactivate the features, press the Start button until the status LED flashes green.
Then the transmitter is ready to operate again.
The safety features do not relieve the operator of his responsibility to turn off
the transmitter with the STOP switch when not in use.
Micro Drive
With the micro drive function the speed of the machine is limited to a preselected level. Even at full
movement of the joystick/linear lever, the operator can not exceed this speed limit. In this manner
demanding drive maneuvers can be managed and inexperienced users can be protected from potential
dangers that can result from “speeding”.
Orthogonal Drive (Electronic Cross Gate)
With the orthogonal drive function dangerous situations, caused by unintentional diagonal movements
are being prevented. The operator will have to return the joystick back to zero position before another
directional command can be activated. This function is suitable for example for situations where the
operator has to make precision commands in confined areas. Diagonal movements are not possible.
Enabling switch
The two-step enabling switch provides enhanced safety during maintenance and service work on or in
the machine as well as for applications with multiple users. In order to transmit control commands to the
machine, the operator has to keep the switch pushed into the first step. Only then the other operating
elements are activated. If the operator releases the button or pushes it into the second step (e.g. as the
result of a cramp), all machine functions are immediately stopped. With this, the operator is protected
from dangerous unintended movements of the machine in case he should lose consciousness or no
longer has control over the transmitter.
If an application is controlled by more than one operator, movement commands can only be performed if
all operators keep the enabling switch pushed into the first step.
Frequency Management
Fixed Frequency
If the identification plate in the battery compartment of the transmitter shows a frequency value (e.g.
433,500 MHz), the transmitter operates with a fixed frequency.
Please contact you service department if the frequency has to be changed because the radio channel is
already assigned to another user.
Manual Frequency Switching
If the identification plate in the battery compartment of the transmitter shows the label man, the
transmitter features manual frequency switching.
This function can be used to change the radio channel during radio operation.
Actuate the start button until an acoustic signal sounds. Then release the button.
Please contact your service department if all available frequencies are occupied.
radiomatic® AFS
If the identification plate in the battery compartment of the transmitter shows the label AFS, the
transmitter is equipped with radiomatic ® AFS (Automatic Frequency Selection).
When activating the transmitter radiomatic ® AFS will check if the present radio channel is free. If the
radio channel is occupied, the system automatically finds and saves a free radio channel.
If the radio channel currently in use is occupied by another radio control system, you must switch the
transmitter off and on again in order to allow radiomatic ® AFS to switch to a free radio channel.
The radiomatic ® AFS option also includes the manual frequency switching function.
Note:
If radiomatic ® AFS is to perform optimally, all the other radio systems in the immediate working
environment (e.g. the factory hall or building site) should be switched on before starting to use the
radio system for the first time. This allows radiomatic ® AFS to detect automatically which radio
channels are already being used in the working area, and thereby to choose a suitable free
channel for its own use.
In addition, when switching the radio system on for the first time, the user should make sure that
his distance from the radio receiver and from the machine is a realistic reflection of the working
situation.
Catch-Release
Via the Catch-Release option two or more transmitters can control a
machine alternately.
When the receiver is switched on, the machine can initially be
controlled via any associated transmitter. Once the receiver was taken
over by one transmitter, the other transmitters no longer have access.
Take over machine
1. Switch the transmitter on.
2. Enter the "Catch" command on the transmitter and actuate the
start button.
The access rights for the machine remain with that transmitter until the
"Release" command is issued by that transmitter.
Release machine
1. Enter the "Release" command on the transmitter.
2. Switch the transmitter off.
The access rights for the machine are cancelled. Machine control can be taken over by another
transmitter.
Operating Example:
Transmitter 1 has taken over the machine. Transmitter 2 is to be given control.
1. Enter the "Release" command on transmitter 1.
2. Switch transmitter 1 off.
3. Switch transmitter 2 on.
4. Enter the "Catch" command on transmitter 2 and actuate the start button.
Transmitter 2 now has sole access to all machine functions.
Notes:
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If a receiver has already been adopted by a transmitter can be displayed via a lamp on the
machine.
If the operating voltage of the receiver fails, the receiver returns to the starting condition in
which it can be adopted by any transmitter. If necessary, the receiver must be adopted anew.
If the transmitter is deactivated without the command "Release" having been issued, the other
transmitters have no access to the receiver. The starting condition described above can only
be resumed by deactivating the operating voltage at the receiver.
Tandem Operation
Tandem Operation T1
The radio system consists of 1 transmitter and 2 receivers for 2
machines. The transmitter can control the machines individually or in
parallel
The machines are selected at the transmitter via a rotary switch:
A
only machine A
A+B
machine A + machine B
B
only machine B
Tandem Operation T2
The radio system consists of 2 transmitters and 2 receivers for 2 machines. Both transmitters are master
transmitters and can control the machines individually or in parallel.
During normal operation transmitter 1 controls machine A and transmitter 2 controls machine B. In order
to be able to switch to machine B or A+B at transmitter 1, for example, the key must be removed from
transmitter 2 and inserted in transmitter 1.
A
only machine A
A+B
B
only machine B
Operating Example: Control of machine A + B via transmitter 1.
1. Switch transmitter 1 and 2 off and remove the key from transmitter 2.
2. Insert the key from transmitter 2 in transmitter 1.
Machine selection via transmitter 1 is activated.
3. Turn the rotary switch of transmitter 1 to A+B.
4. Switch transmitter 1 on and actuate the start button.
The radio system now operates in tandem mode.
Warning:
For safety reasons, it is imperatively required that only one key is available for each transmitter.
The spare key must be stored at a superior, authoritative position and only be handed out in
clarified cases.
Tandem Operation TM/TS
The radio system consists of 2 transmitters and 2 receivers for 2 machines. One transmitter is a master
transmitter and can control the machines individually or in parallel. The other transmitter is a slave
transmitter and can only control machine B.
In order to be able to switch to machine B or A+B at the master transmitter, the key must be removed
from the slave transmitter and inserted in the master transmitter.
A
only machine A
A+B
B
only machine B
Operating Example: Control of machine A + B via master transmitter.
1. Switch master and slave transmitter off and remove the key from slave transmitter.
2. Insert the key from slave transmitter in master transmitter.
Machine selection via master transmitter is activated.
3. Turn the rotary switch of master transmitter to A+B.
4. Switch master transmitter on and actuate the start button.
The radio system now operates in tandem mode.
Warning:
For safety reasons, it is imperatively required that only one key is available for each transmitter.
The spare key must be stored at a superior, authoritative position and only be handed out in
clarified cases.
Catch-Release-Tandem Operation
With the Catch-Release-Tandem Operation two or more transmitters can control several machines
alternately.
Each machine is equipped with a receiver that can receive and monitor all transmitter frequencies.
After activating the receivers all transmitters have equal access to the radio control system.
Take over machine
2. Turn rotary switch on the transmitter to the respective position.
3. Enter the "Catch" command on the transmitter and actuate the start button.
The transmitter with control over the machine(s) retains the access to the receiver until the operator has
issued the "Release" command.
Release machine
1. Enter the "Release" command on the transmitter.
The access rights for the machine(s) are cancelled. Machine control can be taken over by another
transmitter.
Operating Example:
Transmitter 1 has taken over machine A. Transmitter 2 is to be given control over machine A+B.
1. Enter the "Release" command on transmitter 1.
2. Switch transmitter 1 off.
3. Switch transmitter 2 on.
4. Turn rotary switch on transmitter 2 to A+B.
5. Enter the "Catch" command on transmitter 2 and actuate the start button.
Transmitter 2 now has sole access to all machine functions.
Notes:
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If a receiver has already been adopted by a transmitter can be displayed via a lamp on the
machine.
If the operating voltage of the receiver fails, the receiver returns to the starting condition in
which it can be adopted by any transmitter. If necessary, the receiver must be adopted anew.
If the transmitter is deactivated without the command "Release" having been issued, the other
transmitters have no access to the receiver. The starting condition described above can only
be resumed by deactivating the operating voltage at the receiver.
Cable Control
With a cable you can generate a direct data connection between
the transmitter and receiver. The radio transmission is disabled.
At the same time, the power supply of the transmitter is provided
through the cable, as well.
Connecting the cable
2. Remove the screw lock on the transmitter and receiver.
3. Connect the transmitter and the receiver with the cable.
Ensure that the connector is locked.
Notes:
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If you connect the cable while working with the system, the transmitter will switch off
automatically. Actuate the start button to switch to cable operation.
When the system is in cable mode the transmitter will receive the supply voltage from the
receiver, i.e. the transmitter can be used without the battery.
If you disconnect the cable from the transmitter and receiver, the system will switch off
automatically. Actuate the start button to switch back to radio operation.
Pre-selection of Trolley or Hoist
The operator is able to select the trolley or hoist that he wishes to control. It is also possible to
simultaneously control both trolleys/hoists, for example in order to transport particularly long or wide
loads.
Feedback by LED
Using this function, system or machine data can be displayed on the transmitter by
LEDs.
Slewing Gear Release
Note:
Whenever the command "slewing gear release" is actuated by means of the radio control, it is
important that the respective check be made.
Due to the above, a clearly visible indicator lamp should be installed on the machine.
Technical Data
Max. number of control commands
32 digital + E-STOP or 24 digital + 8 prop. + E-STOP
Unique system addresses
Over 1.000.000 possibilities
Supply voltage
7,2 V
Safety function
E-STOP:
Performance Level d, category 3 according to
EN ISO 13849-1:2008
Frequency range
308 – 338 MHz, 405 – 475 MHz 1 , 865 – 870 MHz,
902 – 928 MHz, 1210 – 1258 MHz 1
1
Not all frequency ranges available.
Channel spacing
12,5 / 20 / 25 / 50 / 250 kHz
Antenna
External
Battery type
FuB 06 EEX
Battery capacity
1000 mAh
Continuous operating time
5 – 10 h
Operating temperature range
-20 °C … +60 °C (-4 °F … +140°F)
Relative humidity (no condensation)
80 % at T a > 40 °C
Housing material
Conductive plastic
Dimensions
302 x 183 x 180 mm (11.89 x 7.2 x 7.09 ")
Weight
ca. 2,0 kg (4.4 lb.)
Protection class
IP 65
EC Type Examination Certificate
IBExU06ATEX1056
Marking
I M2
II 2G
II 2D
Ex ib I (option)
Ex ib IIB T4
Ex tD A21 IP65 T80°C
Dimensions
Troubleshooting
Note:
Please check the functions using the cabin or cable controls first!
Problem
Transmitter does not react
when switched on.
Possible Cause

No power.
Remedy


Low-power indication after
minimal operating time.



Battery contacts are
contaminated or damaged.
Battery not charged.
Battery defective.





The display in the transmitter
flashes green but it is not
possible to effect control
commands.



Receiver has no voltage.
No radio communication.
"Crane On" command has
not been given.
Some commands are not
carried out.


Receiver defective.
Interruption in the
connecting cable to the
machine.



Check battery contacts for
damage or contamination.
Insert a fully charged battery
into the battery
compartment.
Recharge battery.
Recharge battery.
Ensure that recharging
process runs correctly.
Check transmitter functions
using a fully charged or
replacement battery.
Check the connecting cable
to the receiver.
Check the functions via the
LEDs in the radio status
panel of the receiver.
Check if all connecting
cables and cable junctions
are tight.
If none of the measures mentioned resolve the problem, then please contact your service technician,
dealer or HBC-radiomatic, Inc.
Maintenance
The radio control system is virtually maintenance-free. Please observe the following points:




Check the STOP switch functionality at regular intervals. Dirt deposits on the switch can hinder the
mechanism and impair the function.
Check the rubber bellows or rubber seals of the operating elements at regular intervals for leaktightness. Replace immediately if cracks appear since the penetration of dirt and humidity may
damage the function of the operating elements.
Never use a high-pressure cleaner or sharp or pointed objects to clean the transmitter.
Charge and discharge transmitter batteries regularly.
In the Event of a Fault
Warning:
Never operate a machine with a faulty or defective radio control system!


Never try to repair the electronics of the radio control system! Opening the transmitter or receiver
housing terminates the manufacturer guarantee.
 Send any defective or faulty equipment to your local distributor or to HBC-radiomatic, Inc. They
are experts and have the necessary know-how and OEM spare parts.
 Always send both transmitter and receiver and enclose a detailed description of the problem.
 Do not forget to enclose your address and telephone number so that we can get in touch with
you quickly if necessary.
To avoid damage during transport, use the original packing supplied with the transmitter and
receiver, otherwise pack securely. Send the consignment to your distributor or to the following
address:
HBC-radiomatic, Inc.
1017 Petersburg Road
Hebron, KY 41048, USA
Telephone: +1 800 410-4562
Fax: +1 866 266-7227

Should you decide to personally return a defective radio system to your distributor or
HBC-radiomatic, Inc., then please make an appointment first.
For an overview of our worldwide service and sales contacts, please visit our website
www.hbc-radiomatic.com under "Contact".
EC Type Examination Certificates
Copying of this document, and giving it to others and the use or communication of the
contents thereof, are forbidden without express authority. Offenders are liable to the
payment of damages. All rights are reserved in the event of the grant of patent or the
registration of a utility model or design.
Form
Return Delivery Note
HBC-radiomatic GmbH
Haller Str. 45 – 53
Transaction No. (provided by HBC):
74564 Crailsheim, Germany
......................................................................
Phone:
Fax:
Email:
Internet:
+ 49 (0)7951 393 800
+ 49 (0)7951 393 802
[email protected]
www.hbc-radiomatic.com
Contact for further information:
Contact person: ....................................... ……..
Phone: ...................................... Fax: ……………………………….
..........................................................................
Email: ………………………………
Reason for return *):
Repair
Estimate required?
yes
no
Modification
Wrong order
customer’s order no.: ..…………………………………………………….
Wrong delivery
HBC-radiomatic
GMBH
For credit
corresponding invoice no.: ……............................................ ….….
*) in order to work on your return rapidly, please state precisely the fault report and invoice no.
HBC Fabr. No.: ..............................
Description of problem:
Transmitter: ...................................
.............................................................................................................
Receiver: ........................................
.............................................................................................................
Charger: .........................................
.............................................................................................................
Batteries: ........................................
.............................................................................................................
Cable: ............................................
.............................................................................................................
Other accessories: .........................
.............................................................................................................
Weitergabe sowie Vervielfältigung dieser Unterlage, Verwertung und Mitteilung ihres Inhalts sind nicht gestattet, soweit nicht ausdrücklich zugestanden. Zuwiderhandlungen
verpflichten zu Schadensersatz. Alle Rechte für den Fall der Patentierung oder GM-Eintragung vorbehalten.
Absolutely necessary information::
PCB .............................. from system
Problem appears:
Fabr. No.: .......................................
.....................................
.....................................
.....................................
due to vibration / shock
if warm or hot
if cold
sometimes
always
never
commonness: ………………..
(in good order, not needed pcb)
Note:
For system repairs, please send (if possible) the complete system including transmitter, receiver, batteries, charger and cable
with detailed description of the problem.
The return is subject to the conditions described in paragraph 8 (Guarantee) in our standard terms & conditions.
Returns will only be accepted CIF Crailsheim, Germany. Preferred shipping via DPD and UPS Standard.
Please use the original HBC packaging if possible. Please use proper packaging to avoid electrostatic discharge hazards with
pcbs and/or modules. Warranty claims may not be accepted in case of improper packaging.
Returns shipped ex works or unpaid will not be accepted without express written consent by HBC.
HBC
Date: 27.07.2004
Revision: 9
U. Weissmann / G. Brose / A. Hemming
Page: 1 of 1
Formblatt
Rücklieferschein
HBC-radiomatic GmbH
Vorgangs-Nr. (von HBC vergeben)
74564 Crailsheim
………………………………………………….
Tel.:
Fax:
E-Mail:
Internet:
+ 49 (0)7951 393 800
+ 49 (0)7951 393 802
[email protected]
Kontakt bei Rückfragen
Ansprechpartner: ..................................... ……..
Telefon: .................................... Fax: ……………………………….
..........................................................................
Email: ………………………………
Grund der Rücklieferung *):
Reparatur
Kostenvoranschlag gewünscht?
ja
nein
Umbau
Falschbestellung
zu Bestell-Nr.: …………………………………………………………….
Falschlieferung
zur Gutschrift
zu Rechnungs-Nr.: .......................................................................
HBC-radiomatic
GMBH
*) Um Ihre Rücklieferung rasch bearbeiten zu können, geben Sie bitte die Fehlerbeschreibung sowie die Rechnungs-Nr. der Ware an.
HBC Fabr. Nr.: ...............................
Fehlerbeschreibung:
Sender: ..........................................
.............................................................................................................
Empfänger: ....................................
.............................................................................................................
Ladegerät: ......................................
.............................................................................................................
Akkus: ............................................
.............................................................................................................
Anschlusskabel: .............................
.............................................................................................................
Sonstiges Zubehör: ........................
.............................................................................................................
unbedingt auszufüllen::
Platine........................... aus System
mit Fabr. Nr.: ..................................
Mangel tritt auf:
bei Erschütterung
bei Wärme
bei Kälte
manchmal
immer
nie
Häufigkeit: ..............................
(intakte, nicht benötigte Platine)
Hinweis:
Bitte senden Sie bei System-Reparaturen möglichst das komplette System zurück - inkl. Sender, Empfänger, Akkus, Ladegerät und eventuell Anschlusskabel mit einer detaillierten Fehlerbeschreibung.
Die Rücksendung erfolgt unter Beachtung der in Ziffer 8 (Gewährleistung) unserer Allgemeinen Geschäftsbedingungen enthaltenen Bestimmungen.
Bitte liefern Sie die Ware frei Haus an uns zurück! Bevorzugte Speditionen: DPD und UPS Standard. Verwenden Sie möglichst die original HBC Umverpackung für die Rücklieferung. Für elektronische Bauteile und/oder Platinen ist eine ESD-SchutzVerpackung zu verwenden. Garantieansprüche können bei Fehlen der ESD-Schutz-Verpackung erlöschen.
Anlieferungen „unfrei“ ohne vorherige schriftliche Freigabe durch HBC werden nicht akzeptiert.
HBC
Erstellt am: 27.07.2004
Von: U. Weissmann / G. Brose / A. Hemming
Revision: 9
Seite: 1 von 1
Original Operating Instructions
®
FSE 727 radiobus
AO727U06
Table of Contents
Safety Instructions Intended Use Safety Instructions for Installation and Operation FCC notes IC notes Installation of the Radio Receiver Installation with Snap-In Wall Bracket Installation with integrated Mounting Loops Installation with Mounting Loops Electrical Connection Control Display Module focus C/D/T (Option) Technical Data Dimensions Receiver Housing HR168 Connection Options Troubleshooting Maintenance Attachments: Return delivery note, system specific views, circuit diagrams and /or output wiring
Pictographs
Danger due to electrical voltage. Touching live parts inside the unit can be fatal or cause
serious injuries.
Instructions for occupational health and safety. Not following these instructions can cause
accidents, which can cause damage, serious injuries or even death.
Important information about the operation of the radio system
Manufacturer:
HBC-radiomatic GmbH • Haller Straße 45 – 53 • 74564 Crailsheim • Germany • Tel. +49 7951 393-0 • [email protected].
HBC.radiomatic GmbH is not liable for any misprints or errors! – Specifications and design subject to change without notice.
® radiomatic and radiobus are registered German trademarks.
© 32 / 2012, HBC-radiomatic GmbH, 74564 Crailsheim, Germany
No part of this document may be reproduced in any manner whatsoever without the expressed written permission of
HBC-radiomatic GmbH.
Safety Instructions
Read through these operating instructions carefully before working with the radio system. This applies in
particular to the installation, commissioning and maintenance of the radio system.
The operating instructions are a constituent part of the radio control system and must always be kept
close at hand for the responsible personnel.
The term ‘machine’ is used in the operating instructions for the different possible uses of the radio
system.
Intended Use





The radio system serves to control machines and for data transfer. Observe the job safety and
accident prevention regulations applicable to each application.
The intended use also includes reading the operating instructions and adhering to all safety
information contained therein.
The radio system must not be used in areas where there is a risk of explosion, nor for the control of
machines used to convey persons, unless it is explicitly approved by the manufacturer for these uses.
Modifications to the radio system may only be carried out by specialist personnel who have been
trained and authorized by HBC-radiomatic. All modifications must be documented at the factory in
the radio control master file.
The radio control system safety devices must not be modified, removed or bypassed. In particular,
modifications to any part of the radio system's complete E-STOP system are impermissible.
Safety Instructions for Installation and Operation










The electrical connection per the accompanying output wiring diagram must be established by a
qualified electrician exclusively.
The receiver may only be opened by trained personnel. Components inside the receiver can be
energized at life-threatening voltages. The supply voltage for the machine must be deactivated
before the receiver is opened.
Please also note with radio systems, that the presence of persons in the danger zone - in particular
beneath the load (cranes!) - is prohibited in every instance.
Select a safe location for radio control, from which you have a good and complete view of the
working movements of the machine, the load movements and the surrounding working conditions.
It is not permissible to put a radio transmitter unattended to one side whilst activated. Always switch
the radio transmitter off when it is not required. This applies in particular if you change location,
when working without radio control, during breaks and at the end of work. Always safeguard the
radio transmitter against use by unauthorized persons, for example by locking it away.
In the event of an emergency and with all faults, switch the radio transmitter off immediately by
pressing the STOP switch.
Only operate the radio system when it is in perfect working order. Faults and defects that could
influence safety must be rectified before the system is put back into operation, by specialists who
have been trained and authorized by HBC-radiomatic.
Note that the operational directions of the operating elements may appear inverted depending on
location and viewing angle to the machine. This applies in particular to rotary cranes, if your location
changes from inside to outside the radius of the crane. The operator must make himself familiar with
the directional markings on the machine before the start of work.
Repairs may only be carried out by specialist personnel who have been trained and authorized by
HBC-radiomatic. Use original replacement parts and accessories (e.g. rechargeable batteries)
exclusively; otherwise it is possible that the equipment safety can no longer be guaranteed and our
extended warranty will be voided.
Remain vigilant when working with the radio system and familiarize yourself with its functions. This
applies in particular if you are working with it for the first time or if you work with it only occasionally.
FCC notes
Changes or modifications made to this equipment not expressly approved by HBC-radiomatic GmbH may
void the FCC authorization to operate this equipment.
This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation. This equipment generates, uses and can radiate
radio frequency energy and, if not installed and used in accordance with the instructions, may cause
harmful interference will not occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by turning the equipment off and
on, the user is encouraged to try to correct the interference by one or more of the following measures:




Reorient or relocate the receiving antenna.
Increase the separation between the equipment and receiver.
Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
Consult the dealer or an experienced radio/TV technician for help.
RF Exposure Statement
Radiofrequency radiation exposure information
The radiated output power of the device is far below the FCC radio frequency exposure limits.
Nevertheless, the device shall be used in such a manner that the potential for human contact during
normal operation is minimized.
IC notes
RSS-GEN – User Manual Statements (English/French)
Licence exempt
This device complies with Part 15 of the FCC Rules and Industry Canada licence-exempt RSS
standard(s). Operation is subject to the following two conditions:
1. this device may not cause interference, and
2. this device must accept any interference received, including interference that may cause
undesired operation of the device.
Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio
exempts de licence. L'exploitation est autorisée aux deux conditions suivantes:
1. l'appareil ne doit pas produire de brouillage, et
2. l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage
est susceptible d'en compromettre le fonctionnement.
Note:
The Industry Canada label identifies certified equipment. This certification means that the
equipment meets certain telecommunications network, protective, operational and safety
requirements as prescribed in the appropriate Terminal Equipment Technical Requirements
document(s). The Department does not guarantee the equipment will operate to the user’s
satisfaction. Repairs to certified equipment should be coordinated by a representative designated
by the supplier. Users should ensure for their own protection that the electrical ground
connections of the power utility, telephone lines and internal metallic water pipe system, if
present, are connected together.
This precaution may be particularly important in rural areas.
Note:
Users should not attempt to make such connections themselves, but should contact
the appropriate electric inspection authority, or electrician, as appropriate. This product meets the
applicable Industry Canada technical specifications.
Safety Instructions
In customer related documents of the end product like instruction manuals, installation guides etc.
appropriate safety instructions have to be included. The supplier of the complete system is responsible
for these safety instructions.
Installation of the Radio Receiver





The receiver should be mounted vertically with the cable connection downwards.
Ensure that there are no metal parts within a radius of 1 m (3 feet) above the receiver.
When the receiver has to be mounted into a control cabinet, an offset antenna must be installed.
Receivers with external antenna must be installed in such a way that the antenna stands freely and
does not touch walls or metal parts. Otherwise an offset antenna must be used, which can be
supplied if necessary.
Receivers with plastic housing should be protected against direct sunlight (UV radiation) with
appropriate measures.
Minimum distance to
metal parts 1 m
Illustrations exemplary
Installation with Snap-In Wall Bracket
The receiver is mounted with the snap-in wall bracket provided. Fix the wall bracket in place via the
holes provided. Only use screws (max. M6) which are suitable for the installation location.
Receiver Housing HR145
(FSE 508, FSE 509)
Push the receiver with the mounting device
downwards until it clicks into place.

from the top into the wall bracket and press the receiver
For removing the receiver, press the release device
the wall bracket.

downwards and pull the receiver upwards out of
(FSE 510, FSE 511, FSE 512)
Place the receiver with the eyelets on the wall bracket pins and press it on the wall bracket until it clicks
into place.
Press the engagement pins outwards with a large screwdriver, to remove the receiver from the wall
bracket. This releases the receiver off the wall bracket from where it can be removed to the front.
Installation with integrated Mounting Loops
(FSE 516 with housing HR268, FSE 726/727 radiobus ® )
The receiver is installed via the integrated mounting loops on the receiver sides. Use the shock mounts
provided for installation to dampen any vibrations that may occur.
Installation with Mounting Loops
(FSE 516 with housing HR270 or HR272, FSE 524, FSE 736/737/776/777 radiobus ® )
The receiver is installed via the provided mounting loops. Use the shock mounts provided for installation
to dampen any vibrations that may occur. A detailed installation guide is enclosed with the delivery.
Electrical Connection
Depending on the version the radio receiver is connected either via a cable gland or with a Harting plug
connection to the machine electrics.
Please observe that the receiver may only be connected to the supply voltage indicated on the type
plate!
Warning – shock hazard!



The electrical connection may only be carried out by skilled personnel.
The electrical connection must comply with the enclosed wiring diagram.
Switch off the supply voltage before opening the receiver. There is a risk of fatality from
touching live parts inside the housing!
Control Display
The control display with LEDs indicating the operating state of the radio system is located behind the
inspection window of the receiver cover lid.
The LEDs have the following significance:
On (yellow) illuminates as soon as operating voltage is present at the receiver, i.e. the connection to the
electronic of the machine is established and operating voltage (12 V) is present.
RF (red) illuminates whenever the transmitter is switched off. It will be extinguished the very moment a
signal is received by the receiver on its radio frequency.
Si 1 (green) illuminates after the transmitter is switched on, i.e. the receiver has identified its specific
transmitter on the basis of the common message address (code). Safety circuit Si 1 is enabled.
Si 2 (green) refers to the internal safety circuit Si 2, responsible for a double switching off of the move
commands whenever the control station is in the off (zero) position, i.e. "Si 2" will not illuminate.
It is not until one or several drive commands (e.g. turn, trolley traveling, lifting gear or crane traveling)
are input that the "Si 2" LED may illuminate!
Available for FSE 510, FSE 511, FSE 516, FSE 524, FSE 726/727/736/737/776/777 radiobus ® :
Feedback (yellow) illuminates whenever the receiver is sending a feedback telegram to the transmitter.
Module focus C/D/T (Option)
focus C
When several cranes are operated in tandem operation, a safe communication between the cranes is
crucial. I. For example, one crane reaches the limit switch and is stopped automatically, the other crane
has to be stopped as well in order to prevent dangerous situations.
focus C ensures a smooth crane communication in tandem operation. Using a CAN interface saves a
great amount of wiring effort and thus valuable time!
focus D
As an external RF module with DECT interface, focus D ensures an optimal radio connection, even
under difficult circumstances.
focus T
As an external RF module, focus T offers a perfectly working radio connection, even under difficult
circumstances over a great distance. Depending on the working situation, up to 15 modules can be
installed in different positions. As additional radio receivers, they receive all commands from the radio
transmitter and relay it to the central receiver. There, they are analyzed and sent to the machine as
output commands.
Obstacles in the radio path can thus be efficiently avoided and even long distances can be bridged with
ease.
focus T can be combined with all HBC receivers of the radiobus ® generation.
Installation



Mount the module with 4 screws (M 5) via the provided drill holes (refer to chapter Dimensions).
Do not install the module into a niche or a control cabinet.
Ensure that there are no metal parts within a radius of 1 m (3 feet) above the module base.
Electrical Connection
The module is connected to a radio receiver via a 5-pin circular connector.
Please observe that the module may only be connected to the supply voltage indicated on the type plate!
Warning - shock hazard


The electrical connection may only be carried out by skilled personnel.
The electrical connection must comply with the enclosed wiring diagram.
Control LED
A dual LED is located next to the cable connection in the module base.
 The LED illuminates red as soon as operating voltage is present at the module. The connection to
the radio receiver is established and the internal operating voltage (10 – 30 V) is present.
 The LED illuminates green when the transmitter is switched on and the module receives a valid
signal on its radio frequency.
Dimensions
Technical Data
Max. number of control commands
26 digital or 10 analog (maximum number of digital commands
depending on the configuration)
Unique system addresses
Over 1.000.000 combinations
Supply voltage
10 – 30 V DC
Power consumption
Max. 10 W
Digital inputs
Depending on equipment with input modules
Analog inputs
Depending on equipment with input modules
Serial interfaces
CANopen, Profibus-DP, RS485, RS232, DeviceNet,
Profinet, iQAN
E-STOP resp. Si1, Si2 control unit
1 x E-STOP output, high-side switch 10 A
Safety function
E-STOP:
Performance Level d, category 3 according to
EN ISO 13849-1:2008
Frequency ranges
308 – 338 MHz, 405 – 475 MHz 1 , 865 – 870 MHz,
902 – 928 MHz, 1210 – 1258 MHz 1
2402 – 2480 MHz
DECT: 1790 – 1930 MHz
1
Not all frequency ranges available.
Channel spacing
12,5 / 20 / 25 / 50 / 250 kHz
2,4 GHz: 1 MHz
DECT: 1,728 MHz
Connection possibilities
Harting Han 32
Option: Harting Han 25 or Han 50
Option: cable gland (metric M20/32)
Antenna
External, FL 30 or FL 70
Option: car antenna with 5 m cable and BNC connector
Internal (option DECT)
focus D (option DECT
Operating temperature range
-25 °C … +70 °C (-13 °F … +158 °F)
Hazardous areas zone 2: -20 °C … +60 °C (-4 °F … +140°F)
Housing material
Plastic
Dimensions
165 x 165 x 115 mm (6.5 x 6.5 x 4.5 ")
Weight
Ca. 2.6 kg (5.7 lb.)
Protection class
IP 65
Dimensions
(FSE 726/727 radiobus ® )
Height of housing:
115 mm (4.53 ")
Connection Options
Harting Plug Connections
FSE 510, FSE 511, FSE 512
FSE 516, FSE 524, FSE 726/727/736/737/776/777 radiobus ®
Metric Cable Glands
FSE 510, FSE 511, FSE 512, FSE 516
PG Cable Gland
FSE 508, FSE 509
FSE 524, FSE 726/727/736/737 radiobus ®
Troubleshooting
Note:
Please check the functions using the cabin or cable controls first!
Problem
Transmitter does not react
when switched on.
Possible Cause

No power.
Measures



Low-power indication after
minimal operating time.



Battery contacts are
contaminated or damaged.
Battery not charged.
Battery defective.




Some commands are not
carried out.


Receiver defective.
Interruption in the
connecting cable to the
crane or machine.

Insert a fully charged battery
into the battery
compartment.
Recharge battery.
Recharge battery.
Ensure that recharging
process runs correctly.
Check transmitter functions
using a fully charged or
replacement battery.
Check if all connecting
cables and cable junctions
are tight.
If none of the measures mentioned resolve the problem, then please contact your service technician,
dealer or HBC-radiomatic, Inc.
Maintenance
The radio control system is virtually maintenance-free. Please observe the following points:


Never use a high pressure cleaner or sharp or pointed objects to clean the receiver.
Whenever welding the machine:
 Switch off the radio control system.
 Switch off the machine.
 Disconnect all electrical connections to the receiver.
Otherwise the receiver electronics can be destroyed.
In the Event of a Fault
Warning:
Never operate a machine with a faulty or defective radio control system!


Never try to repair the electronics of the radio control system! Opening the transmitter or receiver
housing terminates the manufacturer guarantee.
 Send any defective or faulty equipment to your local distributor or to HBC-radiomatic, Inc. They
are experts and have the necessary know-how and OEM spare parts.
 Always send both transmitter and receiver and enclose a detailed description of the problem.
 Do not forget to enclose your address and telephone number so that we can get in touch with
you quickly if necessary.
To avoid damage during transport, use the original packing supplied with the transmitter and
receiver, otherwise pack securely. Send the consignment to your distributor or to the following
address:
HBC-radiomatic, Inc.
1017 Petersburg Road
Hebron, KY 41048, USA
Telephone: +1 800 410-4562
Fax: +1 866 266-7227

Should you decide to personally return a defective radio system to your distributor or
HBC-radiomatic, Inc., then please make an appointment first.
For an overview of our worldwide service and sales contacts, please visit our website
www.hbc-radiomatic.com under "Contact".
Form
Return Delivery Note
HBC-radiomatic GmbH
Transaction No. (provided by HBC):
74564 Crailsheim, Germany
......................................................................
Phone:
Fax:
Email:
Internet:
+ 49 (0)7951 393 800
+ 49 (0)7951 393 802
[email protected]
Contact for further information:
Contact person: ....................................... ……..
Phone: ...................................... Fax: ……………………………….
..........................................................................
Email: ………………………………
Reason for return *):
Repair
Estimate required?
yes
no
Modification
Wrong order
customer’s order no.: ..…………………………………………………….
Wrong delivery
HBC-radiomatic
GMBH
For credit
corresponding invoice no.: ……............................................ ….….
*) in order to work on your return rapidly, please state precisely the fault report and invoice no.
HBC Fabr. No.: ..............................
Description of problem:
Transmitter: ...................................
.............................................................................................................
Receiver: ........................................
.............................................................................................................
Charger: .........................................
.............................................................................................................
Batteries: ........................................
.............................................................................................................
Cable: ............................................
.............................................................................................................
Other accessories: .........................
.............................................................................................................
Absolutely necessary information::
PCB .............................. from system
Problem appears:
Fabr. No.: .......................................
.....................................
.....................................
.....................................
due to vibration / shock
if warm or hot
if cold
sometimes
always
never
commonness: ………………..
(in good order, not needed pcb)
Note:
For system repairs, please send (if possible) the complete system including transmitter, receiver, batteries, charger and cable
with detailed description of the problem.
The return is subject to the conditions described in paragraph 8 (Guarantee) in our standard terms & conditions.
Returns will only be accepted CIF Crailsheim, Germany. Preferred shipping via DPD and UPS Standard.
Please use the original HBC packaging if possible. Please use proper packaging to avoid electrostatic discharge hazards with
pcbs and/or modules. Warranty claims may not be accepted in case of improper packaging.
Returns shipped ex works or unpaid will not be accepted without express written consent by HBC.
HBC
Date: 27.07.2004
Revision: 9
U. Weissmann / G. Brose / A. Hemming
Page: 1 of 1
Formblatt
Rücklieferschein
HBC-radiomatic GmbH
Vorgangs-Nr. (von HBC vergeben)
74564 Crailsheim
………………………………………………….
Tel.:
Fax:
E-Mail:
Internet:
+ 49 (0)7951 393 800
+ 49 (0)7951 393 802
[email protected]
Kontakt bei Rückfragen
Ansprechpartner: ..................................... ……..
Telefon: .................................... Fax: ……………………………….
..........................................................................
Email: ………………………………
Grund der Rücklieferung *):
Reparatur
Kostenvoranschlag gewünscht?
ja
nein
Umbau
Falschbestellung
zu Bestell-Nr.: …………………………………………………………….
Falschlieferung
zur Gutschrift
zu Rechnungs-Nr.: .......................................................................
HBC-radiomatic
GMBH
*) Um Ihre Rücklieferung rasch bearbeiten zu können, geben Sie bitte die Fehlerbeschreibung sowie die Rechnungs-Nr. der Ware an.
HBC Fabr. Nr.: ...............................
Fehlerbeschreibung:
Sender: ..........................................
.............................................................................................................
Empfänger: ....................................
.............................................................................................................
Ladegerät: ......................................
.............................................................................................................
Akkus: ............................................
.............................................................................................................
Anschlusskabel: .............................
.............................................................................................................
Sonstiges Zubehör: ........................
.............................................................................................................
unbedingt auszufüllen::
Platine........................... aus System
mit Fabr. Nr.: ..................................
Mangel tritt auf:
bei Erschütterung
bei Wärme
bei Kälte
manchmal
immer
nie
Häufigkeit: ..............................
(intakte, nicht benötigte Platine)
Hinweis:
Bitte senden Sie bei System-Reparaturen möglichst das komplette System zurück - inkl. Sender, Empfänger, Akkus, Ladegerät und eventuell Anschlusskabel mit einer detaillierten Fehlerbeschreibung.
Die Rücksendung erfolgt unter Beachtung der in Ziffer 8 (Gewährleistung) unserer Allgemeinen Geschäftsbedingungen enthaltenen Bestimmungen.
Bitte liefern Sie die Ware frei Haus an uns zurück! Bevorzugte Speditionen: DPD und UPS Standard. Verwenden Sie möglichst die original HBC Umverpackung für die Rücklieferung. Für elektronische Bauteile und/oder Platinen ist eine ESD-SchutzVerpackung zu verwenden. Garantieansprüche können bei Fehlen der ESD-Schutz-Verpackung erlöschen.
Anlieferungen „unfrei“ ohne vorherige schriftliche Freigabe durch HBC werden nicht akzeptiert.
HBC
Erstellt am: 27.07.2004
Von: U. Weissmann / G. Brose / A. Hemming
Revision: 9
Seite: 1 von 1

Hydraulic Power Unit - Allied Construction Products

Transcription

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