Sensor Height & Slew User Manual

M2000006 V1.00

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GKD Technik Ltd M2000006

Issue Date Changes Job

V1.00 09/03/2018 New Manual

Change History

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Contents

Change History 2

Page no

Introduction

System Hardware

Setting Slew Limits

Diagnostics

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5

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11

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12

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Override

Operational Mode - Sensor Slew

Safety Check

At A Limit

Reset Sensor Check

Travel Enable

Warning Messages

Display Settings

Setting a Height Limit using Sensor Height

Setting a Height Limit using Sensor Height Plus

Operational Mode - Sensor Height or Height Plus

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Introduction

Sensor Height & Slew is a stand-alone PLC based Height & Slew Limiter intended for use on hydraulic

excavators and similar machines where an upper structure – turret (cab & arm) rotates to the base

structure - undercarriage, and where height and/or slew limits are required.

Sensor Height & Slew monitors the slew position of the machine by means of counting of the teeth on the

slew ring, typically situated between the undercarriage and the turret of the vehicle. The system also

monitors the position of the front end equipment (Boom and Dipper) to allow the safe use of the machine

while under obstacles. It processes the sensor inputs, controls output valves limiting the slew movement

and/or front end equipment of the machine. The height and slew limits are set by the machine operator

UNDER CARRIDGE

SLEW RING

TURRET

ANGLE SENSORS

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System Hardware

The Sensor Slew system consists of the PLC module, PDM display and Input & Output devices. Both the PLC and the PDM display have running Real Time software and the application code loaded to the device. PLC module, Model: CR0403 IFM electronic PDM display, Model: CR0451 IFM electronic Input devices Key Switches are used for switching the system into a particular mode. They have to be turned to the required position simultaneously. Key Switches Positions

Operational

Turn the key switch to the straight position. Service Menu or Calibration Mode

Travel Mode Turn the key switch to the right position.

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Setting Slew Limits

Turn the Key Switch to the Set Limits position and select the Set Slew Limits option. The operator needs to set both of the CW (clockwise) and CCW (counter clockwise) limits.

Press the CW or CCW Ok push button when at the required limit position. The value in degrees will indicate the particular limit is set.

Rotate until in the opposite limit position that is not too close to the already set limit. The warning message will appear if so.

When in the position of the second limit, press the OK push button to confirm it. Both limits are saved as indicated on the display. The safe zone stays green and the restricted zone will turn to red.

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Setting a Height Limit using Sensor Height

Turn the Key Switch to the Set Limits position and select the Set Height Limit option. The following screen will appear.

Raise the arm to the required limit position and press OK button to capture the value or press Manual for setting the height limit manually. Press F4 key button to delete the existing limit and set the limit again. Set limit value screen will appear as below

Raise the arm to the required limit position and press OK button to set. Press F4 key button to delete the existing limit and set the limit again.

Setting a Height Limit using Sensor Height Plus

Turn the Key Switch to the Set Limits position and select the Set Height Limit option. The following screen will appear.

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Setting a Height Limit using Sensor Height Plus continued...

Confirm the required value in meters by pressing OK button.

Press Back button, the following screen will appear.

When set the height limit by capturing the arm position, the value is saved when OK button is pressed.

Override

The slew and height limits in this mode are overridden, so the operator can rotate and lift the arm freely without any restriction. The external visual flasher indicates the state.

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Operational Mode - Sensor Slew

With the key switches in the straight position (shown above), the operational screen will appear.

The ellipse represents the area around the machine. The green part is the safe zone where the operator slews the machine. The red section is the restricted zone.

Safety Check On the system start up, the crossed digger icon and warning triangle icon indicate that the safety check procedure needs to be done. This process is required in every 4 hour operating cycle. The hydraulic valves are tested whether they are fully functional (on/off). Press the push button corresponding to the icon to proceed with safety check.

The yellow arrow indicates what direction the operator should rotate until the corresponding valve cut off. When the movement is disabled, confirm that slew stopped by pressing the OK push button.

Then continue with the other direction.

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Safety check continued...

Confirm again when the movement is disabled.

Upon the successful safety check the Pass message will appear.

Escape from the safety check mode back to the operational mode.

If the Auto Set limits regime is selected in the user settings, the travel valves’ arrows are added on the screen.

Now the system is fully ready. The slew is allowed in the safe zone between the limits.

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At A Limit

When on the limit position, the external audible sounder is switched on to warn the operator and the relevant valve cut is switched off to disable any further rotating in that direction. The only movement al-lowed will be towards the opposite limit. If the arm exceeds the pre-set distance from the limit towards to the restricted zone, the system activates ‘Dead man’ feature, i.e. the main relay supplying the hydraulic valve turns off. The warning message will appear on the screen. Rectify the error by switching to override mode.

Reset Sensor Check During the normal operation the Sensor slew system checks the reset sensor position against the saved value obtained when the system configuration was performed. When the position of the sensor is outside of the expected zone, the warning message ‘Recalibrate reset sensor’ will blink on the operational screen.

Both valves enable movement unless the signal from the reset sensor is not detected in the safe zone during slewing the machine from one limit to the other. The system will cut of the valves and display the ‘Lost reset sensor’ message alongside the ‘Main relay off’ on the screen.

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When the push button is pressed, the diagnostic information screen will appear.

Operational Mode - Sensor Height or Height Plus

If Sensor Height or Height Plus only is activated the following screen will appear.

Sensor Height Sensor Height Plus

When on the limit position, the external audible sounder is switched on to warn the operator and the rel-evant valve cut off to disable any further upwards movement. When both the Sensor Slew and Sensor Height or Height Plus is activated, the operation screen is combin-ing both the ellipse and bar.

Diagnostics

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Travel Enable

When the manual Set limits setting is selected, the machine travel is enabled by turning the key switch to the travel enable mode. The slew valves are cut off to disable rotating the arm and both travel valves are enabled. The travelling screen will appear on the display.

Warning messages During the system configuration and the normal operation process the Sensor slew system calculates and evaluates all the conditions. In any abnormal condition a relevant warning message will appear on the screen.

Configure First The system is not configured when delivered. It needs to be installed and configured on the machine.

Auto Configure First When Set zero selected before the system has been configured. Start the system configuration with Auto configuration before Set zero.

Set Zero Position First When switched to operational mode before virtual zero has been set. Set zero follows Auto configuration.

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Display Settings

From the Start up initial screen press the Display Settings push button. The Display Setup screen will appear.

Brightness Select the Brightness option by using the up and down arrows and the OK push button. The correspondent screen will appear.

Software Versions Select the Software Versions option by using the up and down arrows and the OK push button. The correspondent screen will appear.

Set the display brightness by pressing the correspondent push button for pre-set values or by using the up and down arrows. Confirm the setting by pressing the OK push button.

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GKD Technologies contact details:

+44 (0) 1202 861961

+44 (0) 1202 971971

service@gkdtec.com

www.gkdtec.com

GKD Technologies reserve the right to change these instructions in line

with the policy of continuous improvement.