10-02-00541 Bedienungsanleitung, G176 MS (Eng)

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    OPERATING INSTRUCTIONS- ENGLISH -

    Grade-Controller

    COMBI GRADEG 176 MS

    MOBA Mobil Automation GmbHVor den Eichen 4 - 65604 Elz

    Telefon 06431/9577-0 - Telefax 06431/9577-77

    MOBAMobile Automation AGKapellenstr . 15

    D-65555 Limburgwww.moba.de

    Article number: 10-02-00541Editi on 03/2006

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    Index1. General information ____________________________________ 31.1 Rights to changes ______________________________________________ 31.2 Packaging and storage __________________________________________ 31.3 Safety measures _______________________________________________ 3

    2. Introducti on ___________________________________________ 62.1 Advantages and specials ________________________________________ 6

    3. Mounti ng _____________________________________________ 73.1 Dimensions of the device ________________________________________ 73.2 Mounting of the G 176 MS ________________________________________ 83.3 Attaching the connecting cable ___________________________________ 83.4 Attaching the system components ________________________________ 93.4.1 Attaching the sensing tube to the sensor arm _______________________________ 93.4.2 A tt ac hing the s ens ing sk i t o t he s ensor arm ________________________________ 93.4.3 A tt ac hing t he sens or arm to t he cont rol ler _________________________________ 9

    4. Operation, working examples and start-up _______________ 104.1 The control elements ___________________________________________ 104.2 Mechanical sensing ____________________________________________ 114.2.1 Sensing of a s tr ingl ine _________________________________________________ 114.2.2 Sensing of a surface___________________________________________________ 11

    4.3 Ultrasonic sensing _____________________________________________ 124.3.1 Sensing of a s tr ingl ine _________________________________________________ 124.3.2 Sensing of a surface___________________________________________________ 124.4 The Handset __________________________________________________ 134.4.1 Attaching the handset _________________________________________________ 134.4.2 Operat ion of the handset _______________________________________________ 134.5 Start-up ______________________________________________________ 14

    5. Maintenance _________________________________________ 155.1 General information ____________________________________________ 155.2 Periodic maintenance __________________________________________ 15

    6. Connecting plan, specif icat ions and t roubleshoot ing ______ 166.1 Pin connections _______________________________________________ 166.2 Block diagram ________________________________________________ 166.3 Specifications _________________________________________________ 176.4 Sensitivity tables ______________________________________________ 176.5 List of failures and troubleshooting _______________________________ 18

    7. Declaration of conformance ____________________________ 20

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    Wiring and cabling:The wiring and cabling must be correctly carried out in accordance with these instructions. Allsupply cables and terminals must be sized according to the current taken. Further, allconnections must be made in accordance with VDE regulations or regulations of the area inwhich the equipment is used.

    Safety in the event of disturbances:This equipment has been developed and tested for industrial environments. Nevertheless,

    microprocessor technology requires careful installation. We would therefore like to point out thefollowing which, if not heeded to, can lead to disturbances during the operation later:

    - Pay attention to the correct polarity of the connections- Do not exceed (neither too high nor too low) the specified voltage supply range- Protect the equipment with a suitable supply fuse- Use cables of adequate current and voltage ratings- Use the shortest possible cable paths. (Avoid loops)- Lay out load, control and signal cables in separate channels where possible- Suppress contactor and relay coils- Prerequisite for a disturbing sure mode is a good electrical connection between

    the machine chassis and housing chassis of the units.- Connect screened leads to earth at one end only (equipment end)- Do not supply other equipment directly from the supply terminals- Do not use unused terminals as connections for other equipment

    Maximum voltages:Do not exceed the maximum voltages. The maximum voltage between any two circuits isolatedfrom one another, or between any isolated circuit and earth is, unless otherwise stated, limitedto its highest input voltage or the supply voltage. The connecting terminals or connectors mustbe fitted with a suitable fuse.

    Fuses:The equipment is fitted with electronic fuses which protect it against wrong polarity, voltagetransients and overvoltages of short duration. The voltages specified in the technical data maynot be exceeded.Configuration:

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    The equipment can be configured by the user. It is the responsibility of the user to reconfigureaccording to the operating conditions of the system.

    Alarm supervis ionIn complex systems, in which a fault could endanger operating personnel or damage to thesystem, it is advisable, to use an independent alarm unit. An independent alarm unit providesprotection and shut-down of the system in the event of an alarm. In many cases the use of analarm from within the controller itself does not, because of its dependence on the system, offer

    adequate protection.

    Explosive areasThe equipment is no t designed for use in explosive areas.

    Fault clearanceBefore starting to clear faults make sure that all voltages have been disconnected. Defectiveequipment should be tested in an area which has been especially built for this purpose. Anyattempt to remove faults from equipment that is still installed can be dangerous to personnel andto the system itself. Before removing or replacing sensors make sure that the voltage supply hasbeen disconnected.

    Ask for help Ask your MOBA supplier if you have questions concerning the operation and assembly of theequipment.

    Failure to observe the above safety measures can cause breakdown of the equipmentor of the system. Damages caused by such negligence are not covered by themanufacturer's guarantee.

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    2. Introduction

    2.1 Advantages and specials

    The Combi-Grade G 176 MS and the Slope-Controller S 276 M are two fully independentlyworking units which can be run separately but also together as a whole system for the automaticcontrol of level, direction and cross slope. The MOBA levelling system is most commonly usedto control the screed position of the finisher, but also works successfully on milling machines,concrete pavers, bulldozers and other construction machines.

    The reliable automatic levelling system of MOBA for the control of your road construction machines.

    Increasing costs for material and operating time call for precise working at an according capacityper day. The smallest fraction of a centimer during the laying of asphalt, or superfluous extensionof the operating time may represent for you the limit between profit and loss. With the MOBA gradecontroller G 176 MS you made the right choice.

    All advantages at a glance:

    Easy handling

    Safe to false polarity and voltage peaks

    Supply voltage 10 - 40 V DC

    Both mechanical and contact-free sensing by ultrasonics

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    3. Mounting

    3.1 Dimensions of the device

    The dimensions of the G 176 MS

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    3.2 Mounting of the G 176 MS

    The level controller G 176 MS can be mounted easily andrapidly with simple tools. For this purpouse a fasteningtube with a crank handle should be mounted as an extensionof the control unit (actuator).

    Fastening tube with

    crank handle

    Locking screws

    Centering pivot

    Mounting of the G 176 MS

    1. Set the valve switch to the STANDBY position.2. Loosen the locking screws of the fastening tube.3. Insert the round centering pivot that is on top of the

    controllers housing vertically into the fasteningtube.

    4. Turn the controllers housing so that the operator can see the lamps (front panel of the device againstthe direction of travel).

    5. Lock the controllers centering pivot to the fasteningtube with the according locking screws.

    3.3 Attaching the connecting cableSet the valve switch to the STANDBY position.Connect the 7 pole socket of the connecting cable to the 7 pole plug of the controller. Connectthe 10 pole socket of the connecting cable to the 10 pole device plug of the machine.

    To the controller To the machine

    Attaching of the connecting cable

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    3.4 Attaching the system components

    The system has two different sensors for sensing the reference. The sensing tube is used for sensing the stringline. The sensing ski is used for sensing the ground.

    Attaching of the sensing tube to the sensor arm

    3.4.2 Attaching the sensing ski to the sensor arm

    Remove the locking pin from the pin of the sensing ski;remove the pin.Insert the fastening ring of the sensor arm into the fastener of the ski.Push the pin through the fastener of the ski and the fasteningring of the sensor arm.Lock the pin with the locking pin.

    Attaching of the sensing skito the sensor arm

    Locking screw

    Attaching of the sensor arm to the controller

    3.4.1 Attaching the sensing tube to the sensor arm

    Unscrew the nut at the end of the sensing tube.Insert the end of the sensing tube into the fastening ring of the sensor arm.Lock the sensing tube with the nut.

    3.4.3 Attaching the sensor arm to the control ler

    Turn the flat part of the shaft towards the front of the controller.Loosen the locking screw of the sensor arm.Push the sensor arm on the shaft.Lock the sensor arm with the locking screw.

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    4. Operation, working examples and start-up

    4.1 The control elements

    Valve switch

    Selector switch

    Control lamp

    Control lamp

    Description of the control elements

    Sensitivity adjustment

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    4.2 Mechanical sensing

    4.2.1 Sensing of a stringline

    Switch the selector on the module to theGRADE position. Set the valve switch to theSTANDBY position.The sensing tube must be attached to thesensor arm. When attaching the sensor armtake care that the flat side of the shaft isoriented towards the front side of the controller and that the fastening screw of the sensor armrests on the flat part of the shaft. Set thecounterweight of the sensor arm in such a way

    that the sensor arm presses the sensing tubeonto the reference when the controller is set tozero. The zero setting is achieved by positioningthe controller by means of the crank handleuntil the two control lamps go out.

    Stringline

    Direction of travel

    Sensing of the stringline

    Direction of travel

    Sensing with the tube gliding under the stringline

    Note: If the tension of the stringline used asreference is too low, it is possible to guide thesensing tube beneath the stringline. For thispurpose, the counterweight has to be set in

    such a way that the sensor arm presses thesensing tube from below against the stinglinewhen the controller is set to zero.

    4.2.2 Sensing of a surface

    Switch the selector on the module to the GRADE position. Set the valve switch to theSTANDBY position.The sensing ski must be attached to the sensor arm. When attaching the sensor arm take carethat the flat side of the shaft is oriented towards the front side of the controller and that the

    fastening screw of the sensor arm rests on theflat part of the shaft. Set the counterweight of the sensor arm in such a way that the sensor arm presses the sensing ski onto the referencewhen the controller is set to zero. The zerosetting is achieved by positioning the controller by means of the crank handle until the twocontrol lamps go out.

    Direction of travel

    Sensing of a surface

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    4.3 Ultrasonic sensing

    4.3.1 Sensing of a stringline

    Switch the selector on the module to theSONIC position. Set the valve switch to theSTANDBY position.When operating in the ultrasonic mode, thesensor arm should not be attached to thecontroller in order to avoid potential damages.The working point is about 30 cm below thesensor head. At this distance the sound lobehas a width of approx. 5 cm. The stringline'sdiameter has to be at least 3 mm to be

    indentified as a reference clearly. For sensingthe stringline the Combi Grade must bepositioned at the vertical of the stringline. Itmust be ensured that the sound lobe touchesthe stringline.The zero setting is achieved by positioning thecontroller by means of the crank handle until thetwo control lamps go out. Stringline

    Sensing of a stringline with ultrasonics

    4.3.2 Sensing of a surface

    Switch the selector on the module to theSONIC position. Set the valve switch to theSTANDBY position.When operating with the ultrasonic mode, thesensor arm should not be attached to thecontroller in order to avoid potential damages.The working point is about 30 cm below thesensor head.The zero setting is achieved by positioning thecontroller by means of the crank handle until thetwo control lamps go out.

    Sensing of a surface with ultrasonics

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    4.4 The Handset

    4.4.1 Attaching the handset

    The Handset has a 6 m long connecting cable. Connect the 5 pole plug of the connecting cableto the 5 pole device socket of the Combi Grade.

    Attaching of the Handset

    4.4.2 Operation of the handset

    The Handset is workind as soon as it isconnected to the controller. Turn the knob onthe Handset to the mid position. Position thecontroller by means of the crank handle in sucha way that both control lamps are out. Turningthe knob allows the working point to be ajustedby +/- 5 cm in the SONIC mode. In theGRADE mode the working point can beadjusted by +/- 4 cm. However the workingpoint should not be adjusted by more than +/

    - 2 cm when operating with mechanical sensing,in order to avoid damaging the mechanism andthe ultrasonic sensor.

    The Handset

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    4.5 Start-up

    Turning the valve switch to the position ONconnects the output of the controller with theaccording valve. The automatic system isactivated.

    Note:

    A clockwise rotation of the sensitivity adjust-ment increases the sensitivity of the controller.

    A counterclockwise rotation decreases thesensitivity.

    Valve switch

    The valve switch

    Turn the sensitivity button clockwise until thehydraulic system starts to swing. When this isthe case, turn the adjuster slowlycounterclockwise until the hydraulic systemquiets down.

    A minor readjustment of the device may benecessary after the first operation of themachine because vibrations, temperatures etc.influence the control circuit. No further adjustment should be needed if thereadjustment had been done under workingconditions. The sensitivity adjustment (loosen the locking ring

    and adjust by turning the button).

    The Handset The crank handle

    The variation of the working level (adjustment of

    the working point) has to be done with theHandset. If the user does not have a Handset,he has to carry out this adjustment by means of the crank handle.

    Sensitivityadjustment

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    5. Maintenance

    5.1 General information

    The level controller has been designed for high working safety so that the maintenance needs aminimum of procedures only.The electronic components are mounted in a solid case in order to avoid any mechanicaldamage.

    5.2 Periodic maintenance

    Normal repair procedures carried out in the open consist in replacing burned-out lamps andother spare parts that have been located with the troubleshooting. The power supply cablesshould also be checked regularly in order to detect any damage and dirt.

    Note:

    Keep the thread of the plug-connections and of the cable connectors free of any dirt, grease,asphalt or concrete in order to avoid a bad contact. Remove any asphalt or concrete stickingto the sensor arm by means of an appropriate agent and oil the bearing afterwards.

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    2)

    1)

    6. Connecting plan, specifications and troubleshooting

    6.1 Pin connections7 pole device plug:for the connection to the machine

    Allocation: A: + supplyB: Controller output DOWNC: - supplyD: Controller output UPE: freeF: freeG: free5 pole device socket:for the connection of the Handset

    Allocation: A: + supplyB: SetpointC: - supplyD: Pot. (+)E: Pot. (-)

    Connections on the level controller

    6.2 Block diagram

    Sensor head

    Amplifier

    Ref.

    Machine

    Output

    lower

    raise

    The block diagram of the G 176 MS

    2)

    1)

    Transmitter

    Transmitter

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    6.3 Specifications

    Power supply: 10-40 V DC

    Operating current: 0.5 amp. approx. (without valves)

    Current load: 3 amp. approx. (current limited)

    Output signal: ON/OFF with pulse width modulation (*NPN)

    Frequency: 3 Hz approx.

    Operating range: +/- 80 mm level difference

    Setting range(with Handset): approx. +/- 50 mm level difference

    Resolution (synchro-transmitter) 0.25 mm level difference measured at the sensor arm

    Resolution (ultrasonic) 1 mm level differenceSensitivity: Adjustable from overswinging up to a dead range of 5 mm

    Working temperature range: -10 C to +70 C

    Storage temperature range: -25 C to +75 C

    Vibration: up to 4g, 10-100 Hz

    Weight: 2.6 kg

    Protection type: IP 54

    The values given for accuracy and resolution are purely electrical values of the controller. Thoseactually reached also depend from the construction and type of the machine respectively usedand of the operating conditions.

    6.4 Sensitivity tables

    This is a comparison of the adjustable sensitivity levels with the values for the deadband and thepulse range, hidden behind it. The deadband is given as complete band, the pulse range followsin both directions.

    ytivitisneS dnabdaeD P gnar eslu e

    1 3-/+ 52, mm mm5,42

    2 3-/+ 00, mm 0,32 mm

    3 mm57,2-/+ 0,91 mm

    4 mm52,2-/+ 61 0, mm

    5 mm00,2-/+ mm0,41

    6 mm52,1-/+ mm5,9

    7 1-/+ 52, mm mm0,7

    8 mm57,0-/+ mm0,3

    9 -/+ mm52,0 mm5,0

    01 < -/+ mm52,0 mm5,0