Litronic-Ac31 Felkodlista

Englisch
Manual for
LITRONIC tower cranes
EMS
AC 31-S
AC 31-S
MJFCIFSS
MJFCIFSS
LMB
ABB
MDE
Issued: 01/2007
litfront-en.doc EMS version 1.11
Table of Contents
1.0 General
1.1.1 Important information and safety regulations
1.1.2 Symbols used in this operating manual
1.1.3 HOTLINE
1.1.4 System overview: Litronic crane operation
1.1.5 PLC in switchbox S1
1.1.6 Changing the battery (KT98)
2.0 Electronic Monitoring System (EMS-2 AC31-S)
3.0 Load moment limitation (LMB)
4.0 Working range limitation (ABB)
5.0 Machine data capture (MDE)
6.0 Appendix
Appendix I Meaning of all symbols used in display
Appendix II Technical data
Appendix III PIN layout of the EMS interface
Appendix IV Diagnostic messages
Appendix V Frequency converter hoist gears for Litronic cranes
Appendix VI Radio remote control
Index
This operating manual, especially the safety instructions, must be complied

with by all persons working with the crane. In addition, the local rules and
safety provisions must be followed.
EMS-2 AC31-S Version 01/2007

Diagnostic list 15.01.2007
Frequency converter hoist gears 12.01.2007
inhv_allg-en.doc Litronic Manual 1-1

1-2 Litronic Manual inhv_allg-en.doc
1.1.0 General
1.1.1 Important information and safety regulations

This system cannot be regarded as a substitute for the judgement and experience of the
crane operator. The crane operator is not thus relieved of responsibility for the safe
operation of the crane.
Before the crane is used, the crane operator or the service personnel must have read and
understood this operating manual, in order to guarantee that they know how to operate the system
and are aware of its limits.
The values shown in the screenshot in this manual depend on the crane type and its
equipment. These values can therefore only be considered as an aid for the orientation of
the crane operator or the service personnel!
For all of the following display masks used by the EMS, we must remind you that
the appearance of the particular masks may have undergone changes, due to the
constant development of the software!
1.1.2 Symbols used in this operating manual:

Additional symbols, see "Meaning of all symbols used in display" in Appendix I.
Risk of accidents!
Check, verify!
Risk of injuries!
Important information! Observe proper sequence!
1.1.3 HOTLINE
For further information or questions, please contact:
LIEBHERR-WERK BIBERACH GmbH

Dept.: Customer Service Tel. +49 (0) 73 51 / 41 26 40
Tel. +49 (0) 73 51 / 41 26 82
E-Mail tkd.service@lbc.liebherr.com
For inquiries, please state:

Crane type, serial number, software version number

1.1.4 System overview: Litronic crane operation
Switchbox S2
MJF CIFSS
Control desk P1_

Hook level
Load Radius Switchbox S1
S1
SMC
KT 98 KT 94 S
(AC31) (AC31S) Switchbox S3
RS 232 CS31 ARCNET CS31 ARCNET
FU travel
trolley gear
EMS display
(Crane cabin)
B1 B2 B3 B4 B5 B6 B7
CL EAR E NT ER
Data
AKS
connection
optional ! optional ! Binary inputs
Analog inputs
Sensors
CSM-
RS 485
unit Radio receiver*
see Appendix VI
P1 Binary inputs
Control stand
Analog inputs
and
control lever
S2 Binary inputs
Binary outputs
FU hoist gear
CSM-
unit RS 485
*not standard!

1.1.4 System description: Litronic crane operation
Switchbox S1
The switchbox S1 is found in the crane cabin. The LMB, ABB and the MDE software modules are
integrated into the PLC central processing units “KT98” and “KT94S”. (Pos.8 and 10). Both CPU’s
have an integrated binary and analog I/O level. Additionally, peripheral in-place modules are
connected to both central units via the CS31 system bus (field bus). The application programs are
stored in flash EPROM. The in-place safety modules are connected only to the KT94-S.
Pos. 1 Trolley travel gear sensor [m] (4 - 20mA)
Pos. 2 Hoist gear sensor [m] (4 - 20mA)
Pos. 3 Travel gear sensor [m] (4 - 20mA)
Pos. 4 Slewing gear [°] (4 - 20mA)
Pos. 5 Wind sensor [ km/h ] and [ mph ] (4 - 20mA)
Pos. 6 Load measurement axle [t] (4 - 15mA)
Pos. 7 Load moment sensor [ mt ] (4 - 20mA)
Pos. 8 The CPU KT98 is responsible for data storage.
All data (scaling data, teach data, machine data, lift capacity tables) is stored in
RAM and in a SMC card. Additionally, the data transfer connection is
established and processed by the KT98.
Pos. 9 The CPU KT94-S controls the crane. This CPU complies with the safety
category 3 of EN 954-1. All drive movements are controlled by this CPU directly
or indirectly via the field bus. The necessary data, ex. final positions (software
limit switch), is received by the KT94-S via Arcnet from the KT98!
Pos.10 The RS232 is a serial interface of the CPU KT98. The data transfer connection
is attached here. The connection is not included in the standard scope of
delivery. It can be optionally retrofitted.
Pos.11 The ARCNET (Attached Resources Computer NETwork) is a fast field bus
for the data exchange between the PLC CPU’s and the EMS. The components
are connected through a coaxial cable and T-connectors (BNC). At each end of
the bus is a terminating resistor. The central processing units (KT94-S: 255,
KT98: 254) must receive a specific address (1-255) via the DIP switches. The
DMS is pre-set to "253".
Pos.12 The CS31 bus is a field bus developed from the ABB family, that carries the
input and output signals (I/O level) between the PLC CPU’s and the I/O units
attached to each one. The connection consists of a twin and shielded cable.
Pos.13 shows the input and output units of the PLC. The inputs and outputs are
differentiated as being either binary or analog. The sensor data of the crane is
read in via the analog inputs and transferred over the CS31-BUS to the KT94S
CPU.
"P1" The control signals coming from the control panel and the control lever are
read in through the binary and analog inputs and transferred over the BUS
system to the PLC CPU.
"S2" The control signals coming from the KT98 are transferred via the CS31-BUS to
the CSM unit. The CSM unit is connected via a RS485 interface with the
frequency converter of the hoist gear.

1.1.5 PLC in the switchbox S1
KT94-S Battery compartment KT98 CS 31-BUS
ARCNET-BUS
BNC cable with T-connector
and terminal resistor
1.1.6 Changing the battery (KT 98)
- Only use ABB tested lithium battery units!

- Only replace the battery when the supply voltage is switched on!
- Never charge or short-circuit battery! Danger of overheating and explosion!
The battery stores the time, date, the content of

the RAM and special state information of the PLC
CPU when the machine is turned off. The battery
01 02 03 04 0 storage life is ca. 5 years at 25°C.
E 62...
X1
1 2 3 4 5 6 7 8 9 1011 While the PLC CPU is turned on, the battery is
E 62.00.....E 62.07 E only taxed by its self-discharge.
ZP0
ZP1
Input 24V DC
If the battery is empty, or no battery is in place, the

ABB KT97
red LED “Battery” lights.
Battery compartment
Lithium battery unit 07 LE 90
- Operating voltage ON.

red
- Pull out the old battery.
blue - Insert the new battery.
- Plug in the battery cable.
!Pay attention to the polarity!
Battery Battery - Close the battery compartment.
compartment compartment
closed opened

Chapter 2
EMS-2 AC31-S
ems_dbl-en / LITRONIC Elektronisches Monitorsystem AC31-S

2.0 Electronic Monitoring System (EMS)
Table of Contents:
2.1.0 General Information .................................................................. 2-1

2.1.1 Usage and application 2-1
2.1.2 Layout of the EMS-2 AC31-S / Contrast adjustment 2-2
2.1.3 Layout and arrangement of display 2-3
2.1.4 Menu commands 2-4
2.1.4.1 Keyboard 2-4
2.1.5 Function of the buzzer 2-5
2.1.6 Diagnostic reports 2-6
2.1.6.1 General procedure for debugging 2-7
2.1.7 Entering code number 2-8
2.2.0 Installation and start-up ............................................................ 2-9

2.2.1 Mechanical attachment 2-9
2.2.2 Electric installation 2-9
2.2.3 Data connection 2-9
2.2.4 Special operating modes 2-10
2.2.5 The start-up of the EMS 2-10
2.2.5.1 Order of start-up 2-11
2.2.6 Self test and initialization / Selecting crane mode 2-12
2.2.7 Changing the sensor measurement units 2-13
2.2.8 Scaling 2-14
2.2.8.1 Dimensioning of the test load 2-14
2.2.8.2 Switching on scaling 2-15
2.2.8.3 Scaling: trolley travel gear 2-16
2.2.8.4 Scaling: load sensor 2-17
2.2.8.5 Scaling: load movement sensor 2-18
2.2.8.6 Scaling: hook level sensor 2-19
2.2.8.7 Scaling: travel gear sensor 2-20
2.2.8.8 Sensors for slewing angle, slewing speed and wind 2-21
2.2.8.9 Activating / deactivating the anti-collision system (AKS) 2-21
2.2.8.10 Switching off scaling 2-22
2.3.0 Display masks for the crane operator ...................................... 2-23

2.3.1 Display mask B1 2-23
ems_inhv-en.doc / LITRONIC Table of contents

2.4.0 The main menu (Adjustments for the crane operator) ...................... 2-30
2.4.1 Reference points (REF) 2-31
2.4.2 Rope run switching/ Hook block reeving 2-32
2.4.3 Lifting capacity reduction 2-33
2.4.4 Switching over the lifting capacity reduction 2-34
2.4.5 Drives hearable by the buzzer 2-35
2.4.6 /1 Adjustable slewing gear stages 2-35
2.4.6 /2 Configuration of the display masks: B5/B6 2-37
2.4.7 Setting time and date 2-37
2.5.0 The service menu (Adjustments for the service personnel!) ............ 2-38
2.5.1 EMS parameters (data transfer) 2-39
2.5.2 Sensor parameter screen (scaling screen) 2-40
2.5.3 TEST screen 2-41
2.5.3.1 Important test functions / SMC card 2-42
2.5.4 INFO screen / Input of work number 2-44
2.6.0 Procedure in case of error ........................................................ 2-45

2.6.1 Checking of displays 2-45
Appendix I Meanings of all symbols in the display

Appendix III PIN-layout of the EMS interfaces
Appendix IV List of all diagnostic messages
ems_inhv-en.doc / LITRONIC Table of contents

EMS-2 AC31-S
2.1.0 General
The Electronic Monitoring System (EMS) is used as the operation and display device in the
LIEBHERR crawler-track crane. EMS-2 signifies that the EMS belongs to the second generation of
Electronic Monitoring Systems from the firm Liebherr Biberach. AC31-S designates the product
family of the crane control, to which this EMS is connected.
The crane operator needs, above all, information over the status of his crane, data that will be
henceforth described as operating information. This includes the current coordinates (radius,
load, hook level, slewing angle, travel gear position) as well as the crane settings (currently chosen
winch gear, EGZ-drive, hoist rope reeving).
Also important is information stating to the cause of malfunctions, or the time of the switching off of
the drive. This data will henceforth be called extra information. Extra information is, for example,
the maximum permissible radius before shutoff due to the load moment or working range limitation,
wind speed readings etc.
The appearance of important extra information, such as the reaching of an overload state, is
accompanied by an acoustic signal.
2.1.1 Usage and application
The electronic monitoring system (EMS) is the central operation and display unit of the LIEBHERR
crane control components (LIKAS) in the tower crane.
Because the crane is operated by two different personnel groups, each having different demands
for a crane display, two different sets of requirements have been foreseen.
The two main types of requirements are:
• The informing of the crane operator during the operation of the crane
• The providing of settings help and diagnostic messages to the service personnel
The LIKAS components that are integrated into the LITRONIC crane are:
- the ABB (electronic working range limitation) - standard -
- the LMB (electronic load moment limitation) - standard -
- the MDE (Machine data capture) - standard -
- the AKS (electronic anti-collision system) - optional ! -
The EMS must be adapted to the intended application according to the working conditions!
This operating manual is a general description of the operation of the EMS and is
limited to EMS-specific settings.
ems-ac31s_01-46-en.doc AC31-S / EMS 2-1

2.1.2 Layout of the EMS-2 AC31-S
Front view Rear view
LCD display BNC

(640x200 Pixels)
ARCNET-
BUS
Keyboard
See chap. 2.1.4
and Appendix I
B1 B2 B3 B4 B5 B6 B7
CL EAR ENTER
Adjustment of contrast via the wheel adjustor

(bright / dark)
The EMS exchanges information with the crane control via the ARCNET bus (BNC cable).
See "Installation and start-up" Chap. 2.2.0.
COM1 is the programmer interface to the EMS-2. (9 pole Sub-D plug)

PIN layout, see "Appendix III".
The EMS-2 receives its power via COM2. (9 pole Sub-D socket)
See "Installation and start-up" chap. 2.2.0.
The multi-function interface is not used by the EMS-2 AC31-S.

(25 pole Sub-D socket)
For technical data and replacement parts list of the EMS-2 AC31-S, see
Appendix II!
2-2 AC31-S / EMS ems-ac31s_01-46-en.doc

2.1.3 Layout and arrangement of the display
The LCD display of the EMS-2 is divided into three areas.
The header is shown in every screen.

It contains:
10.01.02 E 000 M 000 15:12:48 - Current date (day, month, year)
W 000 S 000
- Diagnostic messages for crane malfunctions
17.9 35.9 (Error, Messages, Warning, Status)
0.0 0.0
-9.0 24.4 - Current time (hour, minute, second)
9.3 21.5
The display area is the actual EMS display screen.
Only in this area does the information and its
representation change.
A "0” is shown for missing or non-installed sensors.
The footer (status line) is shown in every in

9.8 m 0.0
2.0
screen. General status information about the EMS-2
and the crane control is shown here. It contains:
- chosen rope run of the hook block
- chosen gear in hoist unit
121.0 ° 0.0
-93.0
- LM1 and LM2 mode
- current wind speed and current wind
warning level
- overload and pre-overload warnings
1 4.6
m
s B4 - current operation mode (Erection, Scaling, ABB..)
- symbol for the currently chosen display
"Meaning of all symbols in the display" see
Appendix I.
Setting display measurement units:

Most of the display values in the EMS can be switched to other units of measurement. (Changing
the sensor measurement units, see chap. 2.2.7)
Crossed-through EMS data:
Parameter values that are relevant to crane movement must be checked by the crane control after
they have been received by the EMS. The sending, checking and answering of data sometimes
require a few seconds to be processed. All EMS data that has not yet been accepted by the crane
control is represented as crossed-through, in order that the operator of the EMS can recognize
whether the entered data has been accepted as valid.

2.1.4 Menu commands
The menu commands in the EMS-2 allow the special crane functions to be chosen and activated.
The adjustment and operation of the EMS-2 takes place in the service screen. This display is
composed of menu points and parameter fields:
- Menu points are small symbols or text fields.
- Parameter fields are number fields for the changing of parameter values.
No menu commands are available within the crane operator screens 1 – 6! The
necessary functions in these screens are chosen through the keys:
Changing the screen: Key B1 through B7 and key-switch
Error acknowledgement: ENTER key
Turn off buzzer: CLEAR key
Currently active menu points or currently active parameter fields are highlighted in black. This
highlighting is called the "cursor ". The cursor can be moved from one menu point or parameter
field to the next with the ÕÖ×Ø keys. This process is described as the "changing to" or
"selection of" of a menu point. The highlighted menu point is activated and executed with the
ENTER key.
2.1.4.1 Keyboard
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
B1 - B6 - choose crane operator screen 1- 6 (see chap. 2.3.0)

B7 - choose machine data screen 1 (see chap. 2.3.7)
Cursor keys: - choose menu or parameter field
- change menu or parameter field
- change a parameter in a parameter field
Õ key Moves the cursor left
Ö key Moves the cursor right
× key Moves the cursor up or increases a value
Ø key Moves the cursor down or decreases a value
CLEAR key: - chosen parameter field will be set to the standard or start value
of [ 0 ]
ENTER key: - activates the currently chosen menu
- acknowledges an error message in the crane operator screen
- confirms and sets a parameter value
(Values that are not accepted by the crane control, and therefore invalid,
are displayed in the EMS as crossed-through!)
Key key: - change to the main menu (see chap. 2.4.0)

2.1.5 Function of the buzzer
The buzzer in the EMS-2 is activated by different events. Important crane states are distinguished
by different signal melodies.
The following events set off the buzzer:
The events listed here are ordered here according to their importance from 1 to
12! When two buzzer-sounding events occur simultaneously, the event higher in
the list is always toned. Number ( 1 ) is always set through first. Number ( 12 ) is
sounded only when no other event is present in the queue, or when all other
event notifications have been turned off.
1. Occurrence of a new error short melody

2. Occurrence of a new warning short melody
3. Occurrence of a new message short melody
4. Occurrence of a new status message short melody
5. Overload state long melody can be turned off
6. Pre-overload warning state long melody can be turned off
7. Wind warning level 1 state long melody can be turned off
8. Wind warning level 2 state long melody can be turned off
9. Trolley speed long tone adjustable
10. Lowering speed long tone adjustable
11. Slewing speed long tone adjustable
12. Travel speed long tone adjustable
Short melody: Announces a new diagnostic message in the header of the EMS-2.
Cannot be turned off. Duration ca. 1 second.
Long melody: Signals a safety-related crane state and turns itself off when the corresponding
state is over.
The buzzer is activated again when the state reoccurs!
To turn off: In the crane operator screen (1-6): - Press CLEAR key.
In the menu screen: - move the cursor to the diagnostic
message in the header and press
CLEAR key.
Long tone: The different operating modes of the drive units (trolley, hoist gear, slewing gear,
travel gear) are made audible by different long tones. The pitch of the tone
raises with the increasing speed of the drive unit. To improve the perceptibility
of the signal, the tone is temporarily interrupted 10 times per second.
The long tone is adjustable and can be turned off.
See "Drives hearable by the buzzer", chap.2.4.5.

2.1.6 Diagnostic messages
The crane control sends diagnostic messages to the EMS. An acoustic signal is given when a new
message appears. There are four types of diagnostic messages that are shown in the header of
the display: (See "List of all diagnostic messages" in Appendix IV)
10.01.02 E 000 M 000 15:12:48 "E" = Error message

W 000 S 000
5.3 29.2 "W" = Warning message

0.0 0.0
-1.8 -2.6 "M" = Message (information)
"S" = Status message (crane states)

5.4 29.5
Error: E1 ... E999
Error messages show disturbances that influence the function or the safety of the crane, and that
normally cannot be remedied without the undertaking of repair or adjustment measures.
Error message acknowledgement:
In the crane operator screen (1-6): - Press the ENTER key.
In the menu screen: - Move the cursor to the corresponding
diagnostic message in the header and press
the ENTER key.
The error message disappears when the cause of the error is remedied. Should an additional error
have occurred, that error message will then be shown. Errors that are only acknowledged, without
remedying the cause of the error will be shown again and entered into the error list (EMS machine
screen 1). (For example, E705 Slewing gear safety device is activated or E10 No change in the
radius despite drive command.)
Warning: W1 ... W999

Warnings are states or events that temporarily impair the function of the machine (or
that indicate operator error), requiring increased attention from the operator. Warnings
cannot be acknowledged. They are automatically cancelled after the triggering cause
has been removed. (ex: W568 Wind speed over 50km/h or W850 Hoist gear brake
lining worn)
Message: M1 ... M999

Messages show events or states that occur during normal crane operation. (ex. M701
Free jib slewing reached)
Status: S1 ... S999

Status messages show events or states that are to be noticed, but that are not saved.
(ex. S857 Frequency converter is not ready for operation)
The last 128 diagnostic messages are shown in the machine data screen (B7 key).
The current list of all diagnostic messages can be looked up in Appendix IV or in
the operating manual for the crane!

2.1.6.1 General procedure for remedying errors
1.) Determine the meaning of the error message . See "List of all diagnostic messages" in
Appendix IV.
3.) Remedy the cause of the error! Ex. Check all automatic breakers and motor protection
switches and reactivate if necessary. If the error message does not automatically
disappear, acknowledge the error by pressing the ENTER key.
4.) Some drive unit errors can only be acknowledged by turning off the power supply.
(EMERGENCY-OFF key)
5.) Errors in the PLC can only be acknowledged by a system reboot.
Main switch on/off. (ex. E509 failure P1_EH)
*Acknowledging error messages
- in the display masks B1 to B6 - in the menu screens
ex: Error message

Error message during scaling procedure
10.01.02 E 113 15:12:48
m mt
21.5 45.0
8 0.0
550 E C -H
m t 4.95 0.0m
13.20 30.0m
11 .1 40 .00 4.95 0.0m
14 .0 30 .20
16 .0 25 .72
18 .0 22 .27
20 .0 19 .55
22 .0 17 .33
24 .0 15 .50
26 .0 14 .05
34 .0 9 .97
38 .0 8 .56
50 .0 5 .63
59 .0 4 .20
80 .0 2 .10
4.0
1 4 .6
m
s B1
B1 B2 B3 B4 B5 B6 B7 B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER CLEAR ENTER
z Acknowledge error messages with the z Change to the error message E 113
ENTER key. with the "Õ×" keys.
Acknowledge the error message with
the ENTER key.

2.1.7 Entering the code number
The following settings are locked by the code number:
- EMS parameters
- Input of the crane work number
- Deletion of the short-term machine data
- Copying of the SMC card
Settings in the code number area of the EMS may only be changed by specially
trained service personnel!
Procedure: The setting of the code number is known by the service personnel!
- Press key. (main menu)
- Press 6x Ø key, the cursor changes to the lock symbol .
- Press ENTER key. The input field for the code number appears .
- Set the code number with the × and Ø keys.
- Press ENTER key. Changes to service menu screen .
- Check that the lock symbol appears as open in the service menu screen.
- Press the key if necessary and repeat the procedure.
01.04.03 E000 M000 15:12:48 01.04.03 E000 M000 15:12:48 01.04.03 E000 M000 15:12:48
W 000 S000 W 000 S000 W 000 S000
931703301 931703301 931703301

V1.11 V1.11 V1.11
REF REF REF
100% 100% 100%
f-min f-min f-min

94% 2350Hz 94% 2350Hz 94% 2350Hz
6% 44% 6% 44% 6% 44%

18% 63% 18% 63% 18% 63%
10.01.02 15:12:48 10.01.02 15:12:48 10.01.02 15:12:48
0 0 0
4.6 t 1
4.6 t
4.6 t
1 m 1
m m
s s s
Service menu
10.01.02 E000 M000 15:12:48
W 000 S000
Main menu
M1 M2 M3
6% 44% ML2 ML3 ML5 ML6

18% 63%
Increase number
OK
ENTER
26 Decrease number
The code number is known by the service personnel!

1 4.6
m
s

2.2.0 Installation and start-up
2.2.1 Mechanical attachment
On the back of the EMS are four M6 threaded

pins, with which the EMS is to be screwed onto
the erecting angle.
The EMS is attached onto the bottom left.
The exact attachment point is found in the
the assembly plan of the crane cabin!
2.2.2 Electrical installation
The EMS-2 AC31-S is supplied with a direct-voltage current

of 24 volts (DC) via the COM 2 (SubD-9) interface.
COM 1
The power can be alternately supplied by the multi-function
interface of the EMS-2. COM 2
This interface is normally not used by the EMS-2 AC31-S!
The level of development of the device can determine Multi-function
which plug socket is to be used. interface
See the wiring plan of the crane cabin.
The PIN layout of the specific interfaces can be found in "Appendix III"!
2.2.3 Data connection
The EMS-2 AC31-S communicates with the crane [1]

control over a BUS system (Arcnet).
For the connection, the following pieces are necessary:
[2]
1x BNC plug (T piece) [1]
1x terminal resistor (93 Ohm) [2] [3]
1x COAX cable of ARCNET-Bus [3]
The terminal resistor [2] creates the end of the

ARCNET bus.
See the wiring plan of the crane cabin.

2.2.4 Special operating modes
Special operating modes may only by activated by specially trained service

personnel!
There are four special operating modes on the crane that can be activated by a key-operated
switch.
- Test mode EMS chapter 2.5.3
- Scaling mode (LMB parameter screen) LMB chapter 2.2.8.2
- 125% overload test (Test screen) EMS chapter 2.5.3.1
- Teach mode (ABB parameter screen) ABB chapter 2.3.0
When a special operating mode is chosen, the corresponding menu screen is displayed on the
EMS. The parameter values that correspond to the operating mode are unlocked. The
automatically selected menu screens may be exited at any time. When the crane operator screens
1 to 6 are selected, the EMS automatically changes back to the corresponding menu screen after a
delay of approx. 3 seconds.
After the special operating mode is over (key-operated switch back to ready position), the EMS
returns to the screen that was in use before the activation of the special operating mode.
2.2.5 The start-up of the EMS

The parameters of the EMS at start-up can be divided into three groups, according to their
function:
Safety-related parameters may only be set and/or changed by specially trained service personnel.
In order to safeguard from unauthorized changes, these parameters are unlocked only after the
corresponding key-operated switch is turned. If locked, the parameters can only be checked.
z LMB parameters (key-switch to scaling)
z Sensor parameters (key-switch to scaling)
z ABB parameters (key-switch to teach)
Function-related parameters are settings that, if incorrectly set, may not endanger crane operation
but that can cause considerable disruption. It is recommended that these parameters only be
changed by specially instructed service personnel. In order to safeguard from unauthorized
changes, these parameters are unlocked only after the code number has been entered. If the code
number is not entered, the parameters can only be checked.
z EMS parameters
z Input of the work number of the crane
z Deletion of the machine data
Display and non-critical parameters can be changed by the crane operator, without special
authorization.
z Display contrast
z Time
z Measurement units of the sensor values
z Drives hearable by the buzzer
z Format of the display masks: B5/B6

2.2.5.1 Order of start-up
Make settings changes in the order stated here during start-up!
Turn on EMS:
- Turn on main switch on the crane See crane instruction manual
- Turn on control system See crane instruction manual

EMS is turned on
- Self-test display and initialization EMS chapter 2.2.6

Informs the crane operator through the operating mode window
The following EMS settings must be undertaken during the initial system start-up:
- Set the contrast of the LCD display EMS chapter 2.1.2

Brightness of the display
- Set date and time EMS chapter 2.4.0 / 2.4.7
- Set LMB parameters LMB chapter 3.2.0

Overload / Hoist gear / Rope
- Set sensor parameters (scaling) EMS chapter 2.2.8

Software limit switch / Load / Overload /
Anti-collision system AKS
- Reeving of the hook block EMS chapter 2.4.0 / 2.4.2

Run variants of the crane
- Change sensor measurement units EMS chapter 2.2.7
- Set ABB parameters (teach) ABB chapter 4.3.3

Limitation shapes of the ABB
- Input the work number of the crane EMS chapter 2.5.0 / 2.5.4
- Delete machine data MDE chapter 5.3.0
- Drives hearable by the buzzer EMS chapter 2.4.0 / 2.4.5
- Setup, if necessary, crane operator screens 5 and 6 EMS chapter 2.4.0 / 2.4.6
- Test functions and start-up help EMS chapter 2.5.0 / 2.5.3

2.2.6 Self-test and initialization
Self-tests and initializations are automatically ran through after the crane has been turned on.
Afterwards, the crane operator is informed of the important events or system states.
The occurrence of various operating states is shown by the EMS-2 with the appearance of a large-
screen operating mode window. An overlapping EMS screen has no function, with the exception of
the header and footer!
The operating mode window can be closed at any time by pressing the CLEAR
key. It appears again after approx. 3 seconds in the crane operator screens 1- 6.
The following self-tests and initializations are shown on the EMS:
Operating mode window:
KT94S ? ? KT97 KT94S ? ? KT97 KT94S <- // -> KT97
Meaning:
Wait! KT94S and KT98 are not yet on the bus. 10.01.02 15:12:48
Wait! KT94S is not yet on the bus. Display

m mt
21 .5 45.0
Wait! KT98 is not yet on the bus. 80.0
Wait! KT98 and KT94S are exchanging parameters.

550 E C -H
Wait! Load measuring axle test not yet finished. m t
11.1 40.00
Crane control ready! 14.0
16.0
30.20
25.72
18.0 22.27
Crane control can be turned on. 20.0
22.0
19.55
17.33
KT94S ? 15.50
24.0 ? KT97
26.0 14.05
Crane control ready! 34.0
38.0
9.97
8.56
50.0 5.63
Control has been shut-off because of dead man switch. 59.0
80.0
4.20
2.10
Crane control may be turned on again. 4.0
1 4.6
Crane control OFF due to emergency stop button!

m
s B1
Turn on control when the emergency stop button is released.

2.2.7 Changing the sensor measurement units
Most of the display values in the EMS can be set to other units of measurement. The change is
done in the scaling screen (see additionally chap. 2.5.2) and applies to all displays in the crane
operator screens B1 to B6. All other data in the EMS (Scaling, Teach or LMB data) is always
shown in standard units.
The display measurement units are always set in the sensor parameter screen (scaling
screen). No code number or key is necessary for this change!
Radius: meters [m] Ö feet [ ft ]

Load: tons [t] Ö US tons [ ton ]
Hook level: meters [m] Ö feet [ ft ]
Travel gear position: meters [m] Ö feet [ ft ]
Wind speed: kilometers [ km/h ] Ö miles per hour [ mph ]
per hour Ö meters per second [ m/s ]
Slewing angle: 0 – 360 [°] Ö ---------
Load moment: metric ton [ mt ] Ö ---------
To change:
Changing the measurement units is done through the sensor parameter screen (scaling screen).
Press the key. The main menu appears on the display.
Press the key until the cursor is at .
Press 2x the ENTER key. The service menu appears on the display.
Press the key until the cursor is at (Ø3x / Ö1x).
Press 1x ENTER key. The scaling menu appears on the display.
Press the key until the cursor is at the desired symbol.
10.01.02 15:12:48
08.01.02
10:36:56
(1)
min 5.11 4.0m 6.49mA
max 15.92 80.0m 8.74mA In this way, the units are changed
5.91 9.6 ft from "m" Ö "ft".
min 4.43 0.0t The changed sensor
ref 10.79 30.0t
6.40 9.3t
measurement units affect only
the crane operator screens B1
ref 1 7.82 141mt 5.0m to B6.
ref 2 11.16 421mt 14.0m
t 7.23 77mt 88mt
Exit the scaling menu. The settings remain in effect.

2.2.8 Scaling (LMB parameters)
Requirement for the scaling of the sensors:

z Change to the scaling menu in the EMS.
The scaling screen is selected by turning the key-operated switch in the
switchgear cabinet "S1".
z Follow the proper scaling sequence!
Checking the function of a sensor in the scaling screen:

All of the sensor analog values (4 - 20 mA) are shown in the scaling screen both
numerically as well as optically with a bar graph.
By selecting the scaling screen (without key number), the sensor function-check
can be executed independently of scaling. The scaling data is thus protected from
unintentional modification.
Re- and new scaling:

When scaling or re-scaling (e.g., a new hoisting height, or through the
extension of the trolley rope), only the relevant sensors must be adjusted.
All other settings remain unchanged!
Exception: Load and load moment sensor (if available) must always be
scaled together and in the given order!
The end points of all distances must be approached slowly, since no drives
(trolley travel gear, hoist gear) are automatically stopped by the software controls
during scaling operation!
2.2.8.1 Dimensioning of the test load

The test load must be correctly dimensioned in order to ensure accurate scaling!
The test load is calculated from the lifting capacity curve of the crane. See operating manual of the
crane, chapter 3.
Cranes with moment range: Select the test load so that the trolley reaches at least the last fourth of
the jib (as shown in picture ), before the LMB shuts off the movement (W113).
For cranes with short jibs which are only operated within the constant load range, the test load =
max. lifting capacity! (see Fig. )
I II III IV
Test load in the last fourth of the jib! Test load ~ Max. load
(~ Load at the jib tip + 10 %)

2.2.8.2 Switching on scaling
Permission to modify LMB and sensor data

The key-switch for "Scaling" is found on the key-switch unit in the switchgear cabinet S1
of the crane control. After the turning of the key-switch, the EMS changes automatically
to the LMB parameter screen and unlocks the LMB and sensor parameter values for
modification.
The lock symbol in the LMB and sensor parameter screen is shown as open when the
key-switch is turned to Scaling.
Key-switch turned 01.04.03 15:12:48

The EMS display
to "Scaling" 5 50 E C -H
08.01.03
10:36:56
changes to the LMB
parameter screen.
4 0t 2 2- 80 m 37
E C -H 1 2
E C -B 8 1
E C -B _S V 10 1
1 2.6 7kg/m
1
2
3
4
4 0.0 t
2 3.0 t
1 3.0 t
0 .0t
4 3.2 t
2 5.0 t
1 3.0 t
0 .0t
3 2.4 t
1 8.0 t
8 .4t
0 .0t
- Check the
1.00
current crane
1
50.0 kmh
4 .6
m
s
72.0 kmh
type!
- Check the LMB

parameters!
- All LMB parameters are to be checked and, if necessary, to be reset before

scaling and rescaling! See chap. 3 LMB "Settings in the LMB parameter screen".
- The crane must be scaled for all available reeving possibilities, for cranes that
can change rope runs!
Scaling example: 550 EC-H 40t, 80m radius, 4-fall operation
10.01.02 15:12:48
01.04.03 15:12:48
Change with cursor " Ö " to 08.01.02
10:36:56
08.01.03 symbol " " and press (1)
10:36:56
550 E C -H ENTER. min 0.00 0.0m 0.00mA
max 0.00 0.0m 0.00mA
40t 22-80m 37
5.91 9.6m
E C -H 1 2
E C -B 8 1 The scaling screen appears. min
ref
0.00
0.00
0.0t
0.0t
E C -B _S V 10 1 6.40 9.3t
ref 1 0.00 0mt 0.0m
X = Crane control requires ref 2

t
0.00
7.23
0mt
77mt
0.0m
88mt
1 2.6 7kg/m
scaling. min
max
0.00
0.00
0.0m
0.0m
= Value is correctly scaled. 9.44 9.7m
min 0.00 0.0m

1 40.0t 43.2t 32.4t max 0.00 0.0m
2 23.0t 25.0t 18.0t Diagnostic messages: 0.32 0.0m
3 13.0t 13.0t 8.4t W556 = Scaling mode active! 9.41 121.0°

4 0.0t 0.0t 0.0t
M405 = no AKS-recognition active! 0.00 0.0rpm
1.00
Change with the cursor " Ø "

5.86 4.6m/s
50.0 km
h 72.0 km
h
to symbol " minimum".
1 4.6
m
s
4.6
1
m
s "Scaling: Trolley" see following
page.

2.2.8.3 Scaling: trolley travel gear
• When scaling the trolley, there must be no load on the hook!

• Before scaling the trolley sensor, the basic value of the load-moment sensor
must be set mechanically to a value between 4.5 and 6 mA!
10.01.02 15:12:48 Run the trolley to minimum radius,

until approx. 10 cm from the stop buffer.
08.01.02
10:36:56
(1)
min 5.11 4.0m 6.49mA
max 0.00 0.0m 0.00mA
5.11 4.0m
min 0.00 0.0t

ref 0.00 0.0t
4.23 0.0t All software limit switches
ref 1
ref 2
0.00
0.00
0mt
0mt
0.0m
0.0m are inactive!
t 6.49 0mt 0mt
min 0.00 0.0m

max 0.00 0.0m
With the "Ø" key, change from symbol to "

4.44 0.0m
minimum".
With the "Ö" key, change to the sensor value.
min 0.00 0.0m
max 0.00 0.0m
5.32 2.0m
9.41 121.0°
0.00 0.0rpm With the "×Ø" keys, set to minimum radius (ex. 4.0m).
The sensor value should show between 4.50 to 8.0 mA.
5.86 4.6m/s
If the sensor value is less than 4.50 mA, the travel gear
sensor must be adjusted.
4.6
1
m
s
Press the ENTER key. "Minimum radius" is saved.
The cursor changes to Radius " max".
10.01.02 15:12:48 Trolley-out,

08.01.02
until approx. 20 cm from the stop buffer.
10:36:56
(1)
min 5.11 4.0m 6.49mA
max 15.92 80.0m 8.74mA
15.92 80.0m
min 0.00 0.0t

ref 0.00 0.0t
4.23 0.0t
ref 1 0.00 0mt 0.0m

ref 2 0.00 0mt 0.0m
t 8.74 0mt 0mt All software limit switches
min 0.00 0.0m
max 0.00 0.0m are inactive!
4.44 0.0m
min 0.00 0.0m

max 0.00 0.0m
5.32 2.0m
With the "×Ø" keys, set the maximum radius (ex. 80m).
9.41 121.0° The sensor value increases up to maximum 20 mA.
0.00 0.0rpm
Press ENTER key. The "Maximum radius" is saved.
5.86 4.6m/s The cursor changes to load " minimum".
( X =Sensor not scaled ! / =Sensor scaled, the scaled value is valid!)

1 4.6
m
s

2.2.8.4 Scaling: load sensor
10.01.02 15:12:48 Have test load greater than

60% of the max. lifting
08.01.02
10:36:56 capacity ready in the constant
(1) load range.
min 5.11 4.0m 6.49mA
max 15.92 80.0m 8.74mA
5.13 4.0m
min
ref
4.18
0.00
0.0t
0.0t
Lower the hook block to the
4.18 0.0t
minimum hook level and trolley-
ref 1
ref 2
0.00
0.00
0mt
0mt
0.0m
0.0m
in to the minimum radius.
t 4.19 0mt 0mt
min
max
0.00
0.00
0.0m
0.0m
Enter 0.0 t with the "×Ø" keys.
4.44 0.0m
min 0.00 0.0m

max 0.00 0.0m
5.32 2.0m
The sensor values should
9.41 121.0° show 4.00 mA to 5.50 mA.
0.00 0.0rpm
5.86 4.6m/s
>60% of the max. load

1 4.6
m
s
Press the ENTER key.

"Minimum load" is saved.
The cursor changes to " ref".
10.01.02 15:12:48
08.01.02
10:36:56
(1)
Weigh the test load exactly
min 5.11 4.0m 6.49mA
(ex. 2,3 t).
max 15.92 80.0m 8.74mA
5.13 4.0m
min 4.18 0.0t

ref 6.24 2.3t
6.24 2.3t
ref 1 0.00 0mt 0.0m

Attach the test load.
ref 2 0.00 0mt 0.0m
t
4.19 121mt 120mt
min 0.00 0.0m

max 0.00 0.0m
17.14 75.9m
Enter in the weight with the
"×Ø" keys.
min 0.00 0.0m
max 0.00 0.0m
5.32 2.0m
(ex. 2,3 t)
9.41 121.0°
0.00 0.0rpm
5.86 4.6m/s Press the ENTER key.

2,3 t "Load ref" is saved.
The cursor changes to
1 4.6
m
" ref1".
s
( X =Sensor not scaled ! / =Sensor scaled, the scaled value is valid)

2.2.8.5 Scaling: load moment sensor
10.01.02 15:12:48
08.01.02
The cursor is at " ref1".
10:36:56
(1)
No adjustments
min 5.11 4.0m 6.49mA
max 15.92
5.13
80.0m 8.74mA
4.0m
are necessary!
approx. 4 - 5m min 4.18 0.0t
ref 6.24 2.3t
6.24 2.3t
Run the trolley to approx. 4-5m
ref 1
ref 2
4.19
0.00
121mt
0mt
4.0m
0.0m
from the stop buffer.
t 4.19 121mt 120mt
min 0.00 0.0m

max 0.00 0.0m
17.14 75.9m
min 0.00 0.0m

29 t max 0.00 0.0m
5.32 2.0m
9.41 121.0°
0.00 0.0rpm
5.86 4.6m/s
Constant load range
1 4.6 "Load moment ref 1" is
m
s
saved. The cursor
changes to " ref 2".
The placement of the intersection point must be known! See load moment curve of
crane. If the trolley gear does not turn off, the test load and the scaling of the load
sensor must be checked!
10.01.02 E113 M000 15:12:48

W 000 S000
08.01.02
10:36:56 Bring the trolley to the inter-
(1) section point (see left illustr.)
min
max
5.11
15.92
4.0m 6.49mA
80.0m 8.74mA
- Trolley movement is stopped
7.06 14.5m
- EMS message E 113
min
ref
4.18
6.24
0.0t
2.3t
overload appears.
6.24 2.3t
- Red lamp lights on the
STOP ref 1
ref 2
4.19
12.06
121mt
422mt
4.0m
14.5m
control desk and the signal
Inter- t 12.06 422mt 420mt
horn sounds.
section min 0.00 0.0m
max 0.00 0.0m
point 17.14 75.9m
min 0.00 0.0m

max 0.00 0.0m
5.32 2.0m
29 t 9.41 121.0°

0.00 0.0rpm
"Load moment ref 2" is
5.86 4.6m/s saved.
hook level " minimum".
1 4.6
m
s

2.2.8.6 Scaling: hook level sensor
10.01.02 15:12:48 Run the trolley, unloaded, to the minimum radius and raise the
08.01.02 hook block to the minimum hook level.
10:36:56
(1)
min 5.11 4.0m 6.49mA
max 15.92 80.0m 8.74mA
5.11 4.0m
min 4.18 0.0t

ref 6.24 2.3t
4.18 0.0t
see data sheet
ref 1 4.19 121mt 4.0m
ref 2 12.06 422mt 14.5m
t 4.19 121mt 122mt
min 4.70 0.0m

max 0.00 0.0m
4.70 0.0m
min 0.00 0.0m

max 0.00 0.0m
5.32 2.0m
All software limit switches are inactive!
9.41 121.0°
0.00 0.0rpm
Enter the minimum hook level "0.0" with the "×Ø" keys.
5.86 4.6m/s
1 4.6
m
s
Press the ENTER key. "Minimum hook level" is saved.

The cursor changes to hook level " max".
10.01.02 15:12:48
08.01.02
10:36:56
(1) Lower the hook block to the maximum hook level.
min 5.11 4.0m 6.49mA
max 15.92 80.0m 8.74mA
5.11 4.0m
min 4.18 0.0t

ref 6.24 2.3t
4.80 0.3t
ref 1 4.19 121mt 4.0m

ref 2 12.06 422mt 14.5m
t 4.19 121mt 122mt
min 4.70 0.0m

max 11.14 32.0m
11.14 32.0m
min 0.00 0.0m

max 0.00 0.0m
5.32 2.0m
9.41 121.0°
Set the maximum hook level (ex. 32.0m) with the "×Ø"
keys.
0.00 0.0rpm
5.86 4.6m/s
Press the ENTER key. "Maximum hook level" is saved.
The cursor changes to trolley " minimum".
1 4.6
m
s

2.2.8.7 Scaling: travel gear sensor
10.01.02 15:12:48
Bring the crane to the starting
08.01.02
10:36:56
point (initial point 0.0m).
(1) Maintain safety distance!
min 5.11 4.0m 6.49mA
max 15.92 80.0m 8.74mA
5.11 4.0m
min 4.18 0.0t With the "×Ø" keys, enter

STOP ref 6.24
4.80
2.3t
0.3t " minimum" 0.0m.
ref 1 4.19 121mt 4.0m
ref 2 12.06 422mt 14.5m
t 4.19 121mt 122mt
min
max
4.70 0.0m Press the ENTER key.
11.14 32.0m
6.84 10.0m " minimum" is saved.
min
max
4.90
0.00
0.0m
0.0m
4.90 0.0m the line " max".
9.41 121.0°
0.00 0.0rpm
5.86 4.6m/s
1 4.6
m
s
10.01.02 15:12:48
Bring the crane to the end limit
08.01.02
10:36:56 (30m).
(1) Maintain safety distance!
min 5.11 4.0m 6.49mA
max 15.92 80.0m 8.74mA
5.11 4.0m
min
ref
4.18
6.24
0.0t
2.3t With the "×Ø" keys enter
STOP 4.80 0.3t
" max" 30.0m.
ref 1 4.19 121mt 4.0m
ref 2 12.06 422mt 14.5m
t 4.19 121mt 122mt
min
max
4.70
11.14
0.0m
32.0m
Press ENTER key.
6.84 10.0m
" max" is saved.
30.0m min
max
4.90
11.20
0.0m
30.0m The cursor changes to "max".
11.20 30.0m
9.41 121.0°
0.00 0.0rpm
The scaling is finished!
Turn key-switch "Scaling"
5.86 4.6m/s to middle position "Ready".
1 4.6
m
s

2.2.8.8 Sensors for the slewing angle, slewing speed and wind
min 4.90 0.0m

max 11.20 30.0m
11.20 30.0m
9.41 121.0°
Slewing angle
0.00 0.0rpm
Slewing speed
5.86 4.6m/s
Check functionality of
Wind speed sensors!
Do the sensor values
1 4.6
m
change with motion?
s
The sensors for the slewing angle, slewing speed and wind speed cannot be
scaled!
The wind speed can be changed from "km/h" (kilometers per hour) to "mph"
(miles per hour) or "m/s" (meters per second).
See "Changing the sensor measurement units", chapter 2.2.7.
2.2.8.9 Activating / deactivating the anti-collision system (AKS)
The AKS is deactivated by default (not activated = not responding to signals from the AKS). If the
crane is operated in interconnection with an AKS, the AKS (in scaling operation) must be activated.
The crane control (in standard operation) recognises interconnection with the AKS (active =
responds to signals from the AKS) upon activation. If this is not recognised, all drives become
blocked and error message E406 appears in the EMS.
10.01.02 15:12:48
Select the LMB-parameter screen in the scaling screen.
08.01.02
10:36:56 Switch to the symbol " with the cursor "×Ö".
(1)
min 5.11 4.0m 6.49mA
max 15.92 80.0m 8.74mA
5.11 4.0m
min 4.18 0.0t

ref 6.24 2.3t
4.80 0.3t
01.04.03 15:12:48
In the LMB-parameter screen, switch to the symbol for
08.01.03 the anti-collision system (AKS).
10:36:56
5 50 E C -H Switch to the symbol with the cursor "ØÖ".
4 0t 2 2-80 m 37
E C -H 1 2 (Factory setting: always "OFF" following scaling operation!)

E C -B 8 1
E C -B _S V 10 1
Activate or deactivate the anti-collision system (AKS):

Exit scaling operation.
ON OFF

2.2.8.10 Switching off scaling
Key-switch to
"Ready". 22.5 59.6
112 EC-H
40.0 3.05
37.0 3.36
35.0 3.59
The crane is now operational!

33.0 3.86
31.0 4.16
29.0 4.50
27.0 4.89
25.0 5.34
23.0 5.88
21.0 6.51
19.0 7.28
17.4 8.00
15.0 8.00
Re- and new scaling:

When scaling or re-scaling (e.g., a new hoisting height, or through the extension
of the trolley travel rope), only the relevant sensors must be adjusted. See
"Scaling". All other settings remain unchanged!
Exception: Load and load moment sensor (if available) must always be
scaled together and in the given order!

2.3.0 Display masks for the crane operator
2.3.1 Display mask B1 B1
10.01.02 E 000 M 000 15:12:48
1 W 000 S 0 00
2 m mt 9
21.5 45.0
3 80.0
10
4
550 E C -H 11
5
m t
11.1 40.00
14.0 30.20
16.0 25.72
6 18.0 22.27 12
20.0 19.55
22.0 17.33
24.0 15.50
7 26.0 14.05
34.0 9.97
38.0 8.56
50.0 5.63
59.0 4.20
80.0 2.10
8 4.0
1 4.6
m
s B1 13
Header, see chap. 2.1.3.

Display of the current radius in meters [m] or feet [ft].
Maximum radius in meters [m] or feet [ft].
Bar graph display of the analog travel trolley sensors.
Display of the reference position "radius". Reference points have no stop function!
Symbol: "Limitation point of the ABB".
Current analog display of the trolley travel gear sensor in the bar graph.
Minimum radius in meters [m] or feet [ft].
Display of the current load moment in metric tons [mt].
Symbol: "Limitation point of the LMB".
Chosen crane type. (Check when starting up the EMS!)
Lifting capacity tables of the cane.
Footer, see chap. 2.1.3.
- Missing sensors are always shown with a value of "0.0"!

- The sensor measurement units can be changed! See 2.2.7.
- Settings and adjustments are applied to all display masks!

2.3.2 Display mask B2
10.01.02 E 000 M 000 15:12:48

B2
1 W 000 S 000
35.9 7
2
21.5 m
0.0
24.4 8
17.9
3 9.3 t
0.0
-9.0 9
0.0
4
9.8 m
0.0
2.0
10
0.0
5
121.0 ° 0.0
-93.0
0.0
6 0.0 m
0.0
112.7
1 4.6
m
s B2 11

Current radius (trolley) in meters [m].
Current lifting capacity in tons [ t ].
Current hook level in meters [m].
Current slewing angle in degrees [ ° ]
Current position of the crane on the rails in meters [m].
Symbol: "Shut-off point of the LMB".
This point shows the maximum permissible radius for the currently attached load.
Symbol: "Limitation point of the ABB".
The trolley is stopped automatically by the ABB at this point.
Display of the relative (rel) distance from the trolley to the reference point (ref).
Bar graph for the representation of the current sensor values (here, hook level)
with display of the reference position "Hook level". Reference points have no stop function!


10.01.02 E 000 M 000 15:12:48

B3
1 W 000 S 000
2 m t m 9
21.5 9.3 9.8
3
80.0 40.0 32.0 10
4 11
12
7
4.0 0.0 0.0
4.6
1
m
B3 13
s

Symbol radius with current number value in meters [m].
Symbol lifting capacity with current number value in tons [ t ].
Maximum radius in meters [m].
Symbol: "Limitation point of the ABB "
The trolley is stopped automatically by the ABB at this point.
Display of the reference position "radius".
Reference points have no stop function!
Symbol: "Shut-off point of the LMB"
This point shows the maximum permissible radius for the currently attached load.
Bar graph for the representation of the current sensor values (here, radius)
Symbol hook level with current number value in meters [m].
Maximum hook level in meters [m].
Maximum load in tons [ t ].
Symbol: "Shut-off point of the LMB"
This point shows the maximum permissible load for the current radius.


B4
10.01.02 E 000 M 000 15:12:48
1 W 000 S 000
2 8
17.9 35.9
0.0 0.0
-9.0 24.4 9
3 9.3 21.5 10
11
5
9.8 m 0.0
2.0
6
7
121.0 ° 0.0
-93.0
1 4.6
m
s B4 12

Maximum permissible load (17.9t) for the current radius (21.5m).
Current load in tons [ t ].
Current load in graphic representation of the load moment curve.
Current hook level in meters [m]. Distance to the reference point +2.0 meters.
Bar graph representing current sensor values (here, hook level).
Current slewing angle in degrees [ ° ]. Distance to reference point -93 degrees.
Maximum permissible radius (35.9m) for the currently attached load (9.3t).
Distance to the limitation point of the ABB.
rel Relative distance to the reference point.
Current radius in meters [m].
Load moment curve, representation LM1 drive (full line).
LM2 drive (dotted line).


B5
10.01.02 E 000 M 000 15:12:48
1 W 000 S 000
17.9 35.9
-0.0 0.0
-93.0 24.4
2 121.3 21.5 8
9
4
10
5
6
9.8 m 0.0
2.0
7
0.0 m 0.0
12 7.7
1 4.6
m
s B5 11

Current slewing angle in degrees [ ° ]
Graphic representation of the crane (from above) with the maximum possible slewing area.
ABB limitation shapes (polygon, square, circle segment).
Minimum crane radius.
Current location of the crane on the track section.
Current position of the trolley.
Current position of the jib.


B6
10.01.02 E 000 M 000 15:12:48
1 W 000 S 000
2 8
m t
4 21.5 9.3 121.0 9
5
10
6 11
4.6
1
m
B6 12
s

Maximum permissible load for the current radius (21.5m).
Load moment curve, representation LM1 drive.
Current load in graphic representation of the load moment curve.
Current load in tons [ t ].
Graphic representation of crane (from above) with the maximum permissible slewing area.
Current radius in graphic representation of the load moment curve.
Maximum permissible radius for the currently attached load (9.3t).
Current slewing angle in degrees [ ° ].
Current position of the trolley.
Current position of the jib.
- Missing sensors are always shown with a value of "0.0”!


2.3.7 Display mask B7 (Machine data screen 1)
For further information about the machine data capture, see chapter 5 MDE. B7
6
10.01.02 15:12:48
7
08.01.02
1 M2 8
10:36:56
2 8 ( 6 )
M149 9 10.01.02 09:25:54
M148 7 10.01.02 09:25:54
M146 7 10.01.02 09:25:54
M144 10 10.01.02 09:25:54
E 836 ll 12 10.01.02 09:19:24
3 E 868 ll 5 07.01.02 13:12:39
W556 l l 14 07.01.02 12:57:10
W970 ll 4 07.01.02 12:53:44 9
4 E 850 3l06.01.02 15:12:21
10
11
12
1 4.6
m M1
s
Change to "M2" short-term machine data 2 with the ENTER key.

The sum of all displayed message lines (Σ=8). The cursor is at line ( 6 ) .
Current location of the cursor. Movement with the"×Ø" keys.
Symbol for the currently appearing message.
This symbol appears when there are more than 32 displayed messages.
Cursor can be scrolled forward.
Reset the start time (time / date) of the machine data capture.
Deletion of the short-term machine data.
Date and time that the short-term machine data was last deleted.
Lock Ö closed! Only the viewing of the machine data is possible.
Message line with diagnostic message (type / number). Newest messages are always at the
top.
Message types: "E" = Error message, "W" = Warning, "M" = Message, "S" = Status message
10 Time of an occurring diagnostic message
11 Date of an occurring diagnostic message
12 Frequency of the occurrence of a diagnostic message


2.4.0 The main menu
The main menu can be chosen through the key. The crane operator can change special
settings that are necessary during normal crane operation.
Press the key!

Ident. number and
software version number
Adjustments for the crane operator
- Reference points (REF) 01.04.03 E000 M000 15:12:48

W 000 S000
see description, chap. 2.4.1. 931703301
V1.11
- Rope run switching
see description, chap. 2.4.2. REF
- Lifting capacity reduction

see description, chap. 2.4.3.
100%
- Drives hearable by the buzzer
f-min
- Adjustable slewing gear stages 94% 2350Hz
- Form of the display masks: B5 / B6 6% 44%

18% 63%
10.01.02 15:12:48
- Time and date settings
see description, chap. 2.4.7. 0
- Input code number!

1
4.6 t
m
s
Settings in the "code number area" may

only be changed by authorized service
B1 B2 B3 B4 B5 B6 B7
personnel!
CLEAR ENTER
The code number is known by the

authorized service personnel!
The "service menu" ( chap. 2.5.0 ) appears when the code number is entered.
If the code number is incorrectly entered, the lock symbol will be shown as
"closed"! In this case, the settings in the service menus can only be viewed, but
not edited!

2.4.1 Reference points (REF)
A reference point has no STOP function!

Missing sensors are always shown in the display masks with a value of "0.0"!
The display of the reference points aids the crane operator in returning to important crane
positions. The data for the relative distance to the reference point (rel) is shown to allow the exact
approach of each reference point. The display of the reference points are shown on the bar graphs
in all screens. There are two ways to set reference points:
To set all reference points at To set specific reference points:

once:
01.04.03 E000 M000 15:12:48
W 000 S000
Move crane to desired Move crane to desired
position. 931703301 position. (all drives!)
V1.11
Press key. REF Press key.
With cursor "Ø" change to Change to the corresponding

.
100%
symbol with the "Ø and Ö"
keys. (Example: trolley).
Press ENTER key. f-min
All reference points 94% 2350Hz Press the ENTER key.
are set! 6% 44%
Reference point is set.
18% 63%
35.9
Ö Changing the reference
points:
10.01.02 15:12:48
45.9 m
0.0
0.0
Move the crane to a new 0
position and repeat Ö Changing the reference point:

procedure! Move to new position and
4.6
repeat procedure!
t
1
m
s
Example: Crane operator screen B2
10.01.02 E 000 M 000 15:12:48

W 000 S 000 Current radius of the trolley
35.9
21.5 m
0.0
24.4
(rel) Relative distance from the current radius
to the reference point
Chosen reference point "trolley"

17.9
9.3 t
0.0
-0.0 (rel) Relative distance from the radius
to the chosen reference point
Chosen reference point "load"

2.4.2 Rope run switching
For cranes with rope run switching, the crane control must be informed of the currently chosen
hoist rope run. The currently chosen hoist rope run is displayed in the footer of the EMS as the
"Rope symbol”. (See "Footer" in chap. 2.1.3)
The hook block must be modified mechanically to the desired rope operation
before rope run switching!
Every possible rope run variant must be scaled!
Example: Switching from 4-fall to 2-fall operation

- Press the key. (Main menu)
- Press 2x the Ø key, cursor changes to the rope run variant .
- Change to the desired rope run variant with the Ö key.
- Press ENTER key. The new rope run variant is shown.
01.04.03 E000 M000 15:12:48 01.04.03 E000 M000 15:12:48 01.04.03 E000 M000 15:12:48
W 000 S000 W 000 S000 W 000 S000
931703301 931703301 931703301

V1.11 V1.11 V1.11
REF REF REF
100% 100% 100%
f-min f-min f-min

94% 2350Hz 94% 2350Hz 94% 2350Hz
6% 44% 6% 44% 6% 44%

18% 63% 18% 63% 18% 63%
10.01.02 15:12:48 10.01.02 15:12:48 10.01.02 15:12:48
0 0 0
4.6 t 1
4.6 t
1
4.6 t
1 m m
m
s s s

2.4.3 Lifting capacity reduction (service personnel)
The lifting capacity reduction (limiting factor) may only be selected via the
"Scaling" key-operated switch.
Setting the limiting factor: Set the key-operated switch to "Scaling". (LMB parameter
screen is displayed).
01.04.03 15:12:48
08.01.03
Using the arrow key "Ø", select the symbol.
10:36:56
55 0 E C -H
40 t 22-80m 37
E C -H
E C -B
1
8
2
1
Enter the lifting capacity reduction using the keys "×Ø".
E C -B _S V 10 1
The limitation range can be set anyway between 1.00 and 0.10
(100% to 10%).
1 2.6 7kg/m
1.00 = 100 % maximum lifting capacity

1 40.0t 43.2t 32.4t
2 23.0t 25.0t 18.0t 0.75 = 75 % of the max. lifting capacity
3 13.0t 13.0t 8.4t
4 0.0t 0 .0t 0.0t 0.50 = 50 % of the max. lifting capacity
1.00 0.25 = 25 % of the max. lifting capacity
0.50
50.0 kmh 72.0 kmh

Press the ENTER key. The entered value is transferred, stored
4 .6
and displayed in the main menu.
1
m
s
Changeover possibilities in the main menu:
The lifting capacity reduction set by authorised service

personnel can be changed in the main menu.
The diagram (left) indicates a set lifting capacity reduction of

50%
50% without changeover possibilities in the main menu!
f-min
100% 5000Hz
This changeover possibility can be switched to activated and
deactivated via the LMB parameter screen.
Activating changeover possibility: Set the key-operated switch to "Scaling". (LMB parameter
screen is displayed)
4 0 .0m 0 .0m 0.0m 0.0m
1.00
Using the arrow key "Ø", select the symbol.
0.50
Using the arrow key "Ö", select the symbol.
The symbol is represented inverse.

The symbol switches to .
5 0% (1 00% ) The changeover possibility is represented in the main menu

f-min
and activated.
100% 5000Hz
The max. lifting capacity can now be switched from 50% to
100%.

2.4.3 Reducing the lifting capacity
Blocked changeover:
With this representation of the set lifting capacity reduction

(50%), changeover by the crane operator is not possible!
50% (1 00% )
f-min
100% 5000Hz
4 0.0m 0.0m 0.0m 0.0m Setting the LMB parameter screen:

1.00 Struck through symbol = changeover OFF
0.50
Special notes concerning lifting capacity reduction:
- The lifting capacity reduction is inactive during scaling operation!

- If the lifting capacity reduction is used, the overload shut-off must be used.
- The EMS displays the reduced lifting capacity table with active lifting capacity
reduction in crane operator screens 1 and 4.
2.4.4 Changing over the lifting capacity reduction (crane operator)

01.04.03 E000 M000 15:12:48 Changeover of the lifting capacity reduction is resulted in the
W 000 S000
931703301
main menu.
V1.11
Using arrow key "Ø", select the symbol.
REF
Changeover is resulted via actuation of the ENTER key.

50% (100%)
Example: 50% (100%)
A limiting factor of 0.50 (50%) is represented here.
f-min
94% 2350Hz
The crane operator can switch to regular operation (100%).
6%
18%
44%
63%
The display changes upon actuation of the ENTER key.
10.01.02 15:12:48 100% (50%)
0 Regular operation (100%) is set.
The crane operator can switch to lifting capacity reduction (50%).
1
4.6 t
m
s

2.4.5 Drives audible by the buzzer
Because the movement of some drives is difficult to discern from the crane cabin, the possibility
was created to receive acoustic feedback for drive movements from the buzzer of the EMS.
("Function of the buzzer.", see chap. 2.1.5)
The buzzer emits a tone that corresponds to the speed of the chosen drive. To improve the
perceptibility of the signal, the tone is temporarily interrupted 10 times per second. In the main
menu of the EMS-2 the drive can be selected and the volume (%) and starting pitch (f-minimum) of
the tone can be set.
The buzzer function can only be set to one of the four drives!
Example: Activation of the "trolley travel gear"

01.04.03 E000 M000 15:12:48
W 000 S000
Press the key. (Main menu)
931703301
V1.11
With cursor "Ø" change to the symbol.
REF
With cursor "Ö" change to the symbol.

50% (100%)
With the ENTER key, turn the acoustic trolley travel gear
ON or OFF
f-min
symbol with the "Ø" cursor.

94% 2350Hz
Change to the 100%
6% 44%
18% 63%
10.01.02 15:12:48 Loudness may be set 100%

with the "Ø×" keys from 0 to 100 %.
0
To set the tone frequency, press the Ö key.
1
4.6
m
t
The tone is adjustable from 0 to 5000 Hz with the "Ø×"
s
keys. The factory setting is 500Hz.
2.4.6 /1 Adjustable slewing gear stages
The slewing gear is controlled steplessly via the control lever (cab or radio remote-control). The
set value (4-20mA) is divided proportionally from the 0-position (0%) up to full deflection (100%).
Analogue 20 Set value

in (mA)
10 Symbol "analogue"
Deflection 4
in (%) 0% 50 100
Setting carried out at the factory before delivery: Analogue, stepless!

2.4.6 /1 Adjustable slewing gear stages
Rotational characteristics of the slewing gear can be changed from analogue to 5-stage via a
menu point in the EMS (main menu). Speeds featuring restricted selection are assigned to
regulating stages 1 to 4 (as %). Stage 5 always corresponds to 100% performance.
Stage -4-
-5-
20 Set value
in (mA)
-2-
-3-
10
Symbol "stages"
-1-
Deflection 4
in (%) 0% 50 100
Activating the slewing gear stages

01.04.03 E000 M000 15:12:48
W 000 S000 Press the -key (main menu)
931703301
V1.11
Switch to the symbol using cursor "Ø".
REF
(Factory setting: analogue !)
50% (100%) Symbol change:
Press the ENTER-key

f-min
94% 2350Hz analogue stages
6% 44%
18% 63%
See "Adjusting slewing gear stages".
10.01.02 15:12:48
Adjusting slewing gear stages
Each of the four slewing stages can be adjusted with restrictions. Stage 5 corresponds with 100%
performance. Higher slewing stages can not be set at slower speeds than those featured by stages
preceeding them. See table.
Slewing stage Factory setting Adjustment range

1 6% (4.96mA) 1% - 20% (approx. 4- 7mA)
2 18% (6.88mA) 12% - 40% (approx. 6-10mA)
3 44% (11.04mA) 32% - 60% (approx. 9-13mA)
4 63% (14.08mA) 50% - 83% (approx. 12-17mA)
Setting 1-4 ( ):
6% 44%
18% 63% Switch to the percentual value of the stage being set (1, 2,
3 or 4) using the cursor "Ö".
6% 44%
18% 63% Set the desired speed with keys "Ø×" (as %).
6%
15% 44%
Press the ENTER-key. The set value (as %) is stored in the
18% 63% control.
15% 44% The cursor skips back to the symbol.

18% 63%
Points 1 to 4 describe the adjustment of all 4 speed stages!

2.4.6 /2 Configuration of the display masks: B5 / B6
The displays in the crane operator screens 5 and 6 can be adjusted to the requirements of the
crane operator. However, the screens 1,2,3 and 4 cannot be changed!
Example: Crane operator screen "B6"
10.01.02 15:12:48
Press the key. (Main menu)
Change to the B6 symbol with the "ØÖ" cursor.
Mask changes to crane operator screen B6.
m t
The first symbol of the mask can be changed
21.5 9.3 121.0 and is shown as inverted.
ÕÖ×Ø keys: Choose the specific screen area.
ENTER key: Changes the contents in a selected
screen area.
CLEAR key: Returns to the standard settings
in a selected screen area.
1 4.6
m
s B6
2.4.7 Setting time and date

The current time and date are shown in the header of the EMS. It is only necessary to set the time
after the initial system start-up, for summer or winter time changes, or for an empty battery.
Information about changing the battery is found in the description of the crane control.
01.04.03 E000 M000 15:12:48

W 000 S000
931703301 Press the key. (Main menu)

V1.11
REF Change to the symbol with the cursor "Ø".
50% (100%)
Cursor changes to the input field "Date: Day".

f-min
94% 2350Hz
6% 44% Change to the input field with the "ÕÖ" keys.

18% 63%
Change the value with the "Ø×" keys.
10.01.02
01.04.03 15:12:48
15:12:48
- Time
0 - Date
Save the entered value with the ENTER key.

4.6
1 m
s
t
Time and date are entered into the header.

With cursor "Õ" change to the symbol.

2.5.0 The service menu
The service menu is chosen by entering the code number in the main menu (chap.2.1.7).
If the code number is incorrectly entered, the settings controlled by the code number can be
viewed, but not edited!
The code number is known by authorized service personnel!
Pay attention to the function of the key switches in the switchgear cabinet S1!
See operating manual of the crane, chapter "Operation".
If lock is closed:
Incorrect key code!
Settings changed by service personnel
10.01.02 E000 M000 15:12:48

- Machine data capture (MDE) W 000 S000
see MDE, chapter 5.2.2.
M1 M2 M3
- EMS parameter screen
see EMS, chapter 2.5.1. ML2 ML3 ML5 ML6
- Sensor parameter screen (scaling)

see EMS, chapter 2.5.2.
- LMB parameter screen
see LMB, chapter 3.2.0.
- ABB parameter screen (teaching)

see ABB, chapter 4.3.2.
- Test screen
1 4.6
m
s
- INFO screen
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
If the code number is incorrectly entered, the lock symbol will be shown as
"closed"! In this case, the settings in the service menus can only be viewed not
edited!

2.5.1 EMS parameters
The EMS parameter screen can be chosen by the EMS symbol in the service menu screen. The
EMS parameters are settings for the COM1, COM2 and ARCNET interfaces.
The ARCNET connection is ex-works, COM1 and COM2 are not used.
No settings must be made for the function of the EMS-2 AC31-S!
10.01.02 15:12:48
7
1 8
B AUD 5 76 00
2 CO M 1
P ROTO K OL L RTS / C TS
B AUD 4 80 0
3 CO M 2
P ROTO K OL L X ON / X OF F
4 A R CNET
5 B OO T-EP R OM
1 4.6
m
s
Cursor location. Change to the service menu with the ENTER key.
Menu point to branch off to the COM1 diagnostic screen.
Menu point to branch off to the COM2 diagnostic screen.
Menu point to branch off to the ARCNET diagnostic screen.
Menu point to change to the BOOT-EPROM.
Menu point change the baud rate of COM1.
Settings for the baud rate and the protocol of COM2.
Lock closed! No permission to modify settings.

2.5.2 Sensor parameter screen (scaling screen)
Settings for the sensors are made in this screen. ("Scaling", see chap. 2.2.8)
Choose sensor parameter screen: - via the sensor symbol in the service menu screen
- key-switch to "Scaling".
10.01.02 15:12:48
08.01.02
1 10:36:56
(1)
min 5.11 4.0m 6.49mA
2 max 15.92 80.0m 8.74mA 10
5.91 9.6m
11
min 4.18 0.0t
3 ref 12.66 29.0t 12
6.40 9.3t
ref 1 4.19 141mt 5.0m

4 ref 2 12.06 421mt 14.0m
t 7.23 77mt 88mt
min 4.70 0.0m

5 max 11.14 32.0m
6.65 9.7m
min 0.00 0.0m

6 max 0.00 0.0m
0.32 0.0m
7 9.41 121.0°
8 6.63 0.1rpm
9 5.86 4.6m/s
1 4.6
m
s
( X =Sensor not scaled ! / =Sensor scaled, the scaled unit is valid !)
Menu point for changing the rope reeving variant / Menu point for changing to the LMB
parameter/
Time and date of the last scaling / Lock symbol (closed)
Trolley: Sensor value (mA) for min and max radius, current trolley sensor value.
Meter value (m) for min and max radius, current radius. (chap.2.2.8.3)
Load: Sensor value (mA) for min and max load, current load sensor value.
Ton value ( t ) for min and max load, current load sensor value. (chap.2.2.8.4)
Load moment: Sensor value (mA) for min and max load moment, current load moment.
Load moment data (mt) from the load moment sensor. (chap.2.2.8.5)
Hook level: Sensor value (mA) for min and max hook level, current hook level.
Meter value (m) for min and max radius, current radius. (chap.2.2.8.6)
Travel gear: Sensor value (mA) for min and max end points, current crane position.
(not scaled) Meter value (m) for min and max end points, current crane position. (chap.2.2.8.7)
Slewing angle: Current sensor value (mA), slewing angle displayed from 0-360°. (chap.2.2.8.8)
Slewing speed: Current sensor value (mA), slewing speed (rpm). (chap.2.2.8.8)
Wind speed: Current sensor value (mA), wind speed (m/s). (chap.2.2.8.8)
10 Value of the load moment sensor (dead weight moment) depending on the radius (min/max).
11 Optical representation of the current sensor values in mA. (ex.: trolley sensor = 5.91mA)
12 Optical representation of the current lifting capacity curve. (used in scaling)
Meter values (m) of the trolley sensor (in relation to each load moment).
Load moment (mt) calculated from the load (t) and radius (m) sensors. See point .

2.5.3 TEST screen
The TEST screen can be chosen via the symbol in the service menu screen. The TEST screen
contains functions for the monitoring of the crane during start-up and for quicker
debugging when errors occur.
10.01.02 E 000 M 000 15:12:48

W 850 S 000
1 t
6
2 125% 7
3 8
4
4.00mA
12.56mA
9
4.00mA
5.20mA
5
0%
10
55 %
0%
6%
1 4.6
m
s
Menu points to start specific tests. (from left to right)

Tests for pre-overload warning, overload, wind warning level 1 and wind warning level 2.
Shut-off threshold during the stability safety test. (crossed-through = currently not active!)
Menu point to save the crane parameters onto the SMC card. (KT98).
Display of the set value (control lever) on the control stand of the crane.
The analog values (4-20mA) for the trolley travel, slewing, hoist and travel gears are shown.
Displays the drive set values from the crane control for each of the four drives of the crane.
The set values (0-100%) for the trolley travel, slewing, hoist and travel gear are shown.
Lock symbol: shows access permission to "Test Starting". See point .
Lock is opened, if the key-switch is set to "Assembly".
Lock symbol: shows access permission to "Setting the shut-off threshold safety-test”.
See point . Lock is open if the key-switch "125%" is turned.
Lock symbol: shows access permission to the ”Saving of the crane parameters onto the
SMC card (KT98). Lock is open if the correct code number has been entered. See point .
Direction signal (arrow) of the reference value (control lever) for crane control.
Direction signal (arrow) of the drive reference value from the crane control to the drives.
The operator commands from and to the crane control can be more easily
checked with help from the reference values displayed in the TEST screen.

2.5.3.1 Important test functions
10.01.02 E 000 M 000 15:12:48
1 Test pre-overload warning, overload, W 850 S 000
Test wind warning 1, wind warning 2 1 t
2 125%
Procedure: 3
- Change to the desired test with the cursor.
- Press the ENTER key. The test is activated. 4.00mA
- The corresponding signal transmitter is tested. 12.56mA
Horns are toned and signal lights light up. 4.00mA
- Press the ENTER key. The test is ended.

5.20mA
Stability safety test (125%) 0%
Generally, a stability safety test with more that 100% load moment 55 %
is required to receive an operating permit. For stability safety tests, 0%

the overload function of the crane control must be proven to shut-off
only at higher load moments. 6%
The factory setting of the stability safety test is set to a load moment 1 4.6
m
of 125%. In this parameter field, the shut-off value can be adjusted s
to fit the local and workplace regulations, after the turning of the 125%
key switch.
Stability safety tests may only be performed by specially trained service personnel!
Specific provisions and hazard information is found in the operating manual of the
crane!
Procedure:
- Change to the input field (125%) with the cursor.
- Set the required shut-off threshold with the ×Ø cursor keys.
- The entered value is immediately checked for validity by the crane control.
Crossed-through inputs are values that are not yet confirmed from the crane control as valid.
These values are not processed in the crane control!
Not crossed-through inputs are valid, the crane control calculates with this value.
Storing of crane parameters on a SMC card

Control relevant parameters are stored onto the SMC card of the KT98. The data is
automatically saved after a parameter is changed.
Information about the SmartMedia Card (SMC):
z A card that has been initialized for data storage can no longer be
used as a program card.
z Protect SMC cards from:

- physical damage (ex. do not bend)
- electrostatic discharge
- dirtying of the contacts (do not touch the contacts)
z It is recommended to only use ABB-tested SMC cards.

2.5.3.1 Important test functions
Storing the crane parameters onto the SMC card
Procedure:
- Replace the original SMC card of the KT98

with the new card.
Insertion of the
SMC card. Take notice of SMC card directions!
- Input the code number in the EMS.

See chapter 2.1.7. Lock symbol open?
- In the TEST-screen, change to the

symbol with the cursor.
- Press the ENTER key. The copy procedure

is started.
- As long as the symbol blinks, the data

is being transferred and saved onto the SMC
10.01.02 15:12:48 card. Any occurring errors are shown as
W 850 a diagnostic message in the header of the
EMS.
t
See "List of all diagnostic messages",
in Appendix IV
125%
- After the copy procedure is finished, remove
the newly saved-to SMC card and re-insert
the original SMC card.
Leave the service menu!

2.5.4 INFO screen
The work number of the crane is stored in the INFO screen "Menu point WN". Cranes with a data
transfer connection require a stored work number in order to attach an identification number onto
the data packets to be transferred. The INFO screen is chosen via the symbol in the service
menu screen.
10.01.02 15:12:48
1 WN W N 42 210 2
TX T1 K ran 5
TX T2 R egN r. 12 3456 3
TX T3 U -W age n fahrbar
5 4
E M S BO O T 9758 80601 v1.4
6 E M S AC 31-S 931678601 v1.0q 7
K T 94S 931521501 v1.0
K T 97 931521201 v1.0m 8
K T 97 S M C 931520901 v1.0m
9
1 4.6
m
s
Input work number of the crane. (Example: 42210)

Text field 1 for user-defined information for the crane. (Example: Crane 5)
Text field 2 for user-defined information for the crane. (Example: RegNr. 123456)
Text field 3 for user-defined information for the crane. (Example: Undercarriage rail-going)
Article codes and software version numbers for the EMS.
Article codes and software version numbers for the crane control components.
Example: The code number must be entered before a text may be changed!
Lock open!
10.01.02 15:12:48
Press the Ø key. Cursor changes to TXT3.
2 1 Press the Ö key. Cursor changes to the

WN W N 42 210
input field for TXT3.
TXT1 K ran 5 The cursor blinks as an underline.
TXT2 3 R egN r. 12 3456
TXT3 U -W ag en _ 4 With the ×Ø keys, choose letters and
E M S BO O T 9758 80601 v 1.4
numbers. With the ÕÖ keys, the cursor
E M S AC 31-S 931678601 v 1.0q can be moved forward and backward.
Press the ENTER to save the entry.

2.6.0 Procedure in case of error
Information for the following points can be found at:

Chapter 2.1.6 Message masks
Chapter 2.1.6.1 General procedure for dealing with errors
2.6.1 Checking of displays
Error: Check: Remedy:

No display. Check the brightness control: Adjustment dial on the underside
of the display!
Measure the supplied voltage: Power voltage on the supply cable
The EMS is supplied with power either via the of the sensor interface
sensor interface or the communications Measurement (24V) from...
interface with 24 V DC. PIN 1 or 6 (+) PIN 5 or 9 (-)
or
communications interface
Measurement (24V) from...
PIN 1 or 6 (+) PIN 3,5,7,9,11,
13,15,25 (-)
No display in spite of correct power Replace the display!

supply?
Display off! Missing power supply? - Is the main crane switch on?
- Power supply to the EMS
plugged in (24 volt)?
- Are the fuses in the switch
cabinet correctly set?
Contrast incorrectly set? Adjust the contrast via the
adjustment wheel on the underside
of the EMS.
Display values are No data connection to the crane control? - Arcnet wire connection to the
EMS and to the crane control
crossed through!
attached?
Display values cannot
- Are all terminal resistors
be changed! attached?
- Defective KT94S and KT98 or
fault? Power supply?

Chapter 3
LMB
lmb_dbl-en / LITRONIC Load moment limitation

Load moment limitation (LMB)
Table of contents:
3.1.0 Task of a load moment limitation system (LMB) ..................... 3-1

3.1.1 Safety information 3-1
3.1.2 System overview 3-2
3.1.3 Principle of sensor monitoring 3-3
3.1.4 LMB mode of operation 3-4
3.1.5 LM1 and LM2 mode 3-4
3.1.6 Pre-overload warning (>90%) 3-5
3.1.7 Overload 3-5
3.1.8 Changing to the LMB parameter screen 3-5
3.2.0 Settings in the LMB parameter screen .................................... 3-6

3.2.1 Authorising / blocking LM2-mode 3-7
3.2.2 Selecting crane type 3-7
3.2.3 Rope layers and rope weight 3-8
3.2.4 Gear shutdown (hoist gear) 3-8
3.2.5 Load speed monitoring (control loads) 3-9
3.2.6 Reducing hoist gear output 3-9
3.2.7 Setting wind warning stages 1 and 2 3-10
3.3.0 LMB function test ...................................................................... 3-10
3.4.0 Diagnostic messages ................................................................ 3-11

3.4.1 Procedure in case of error 3-11
Appendix I Meaning of all symbols in the display

lmb_inhv-en.doc / LITRONIC Table of contents

3.1.0 Task of a load moment limitation system
The electronic load moment limitation system (LMB) is an intelligent measurement and display
system that provides the crane operator with important additional information. Its task is to remove
the possibility of an overload state on the crane, to avoid damage to the crane attachments as well
as to prevent accidents and thereby to protect human lives.
The crane can thus be better and more economically operated at its optimal capacity using the
electronic LMB.
3.1.1 Safety information
The sensor values given in the figures of this operating manual are specific to the type of
crane. Therefore, the sensor values in the figures may only be taken as orientation aids!
The correct functioning of the load-moment limitation is dependent on

proper daily checking of the state of the crane and compliance with the
operating manual!
Furthermore, the provisions of BGV D6 must be complied with!
Adjustment operations in service mode may only be executed by trained

and authorized service personnel.
lmb_01-12-en.doc AC31-S / LMB 3-1

3.1.2 System overview
S1 SMC
EMS-2 AC31-S
card
ARCNET-BUS
PLC central unit
KT98 / KT94S
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
with LMB software module
Load measuring axle

Load in tons [ t ]
Cabin
Tower head
Load moment sensor

Load moment in metric tons [mt]
Trolley travel gear sensor

Radius in meters [ m ]
Trolley travel gear
MJFCIFSS
LM2
LM1
Constant Moment
load area area
3-2 LMB / AC31-S lmb_01-12-en.doc

3.1.3 Principle of system monitoring
The sensors relevant for the LMB, "LOAD" and "RADIUS" are checked in every PLC cycle in
accordance with the following principle:
Sensor Sensor Load Sensor

load radius moment load moment
Comparison [ mt ] Tolerance
PLC exceeded
Sensor Error!
(E150)
Sensor values valid

Sensors OK !
The load moment is calculated as represented above from the product load * radius. This
calculated load moment is constantly compared with the load moment measured by the load-
moment sensor. If the load moment calculated deviates from the measured load moment by more
than the permitted tolerance, the error message E 150 is generated. See "List of all diagnostic
messages" in Appendix IV.
The error message E150 is shown on the EMS and a signal horn sounds on the crane. This error
cannot be acknowledged!
Only the following crane movements are possible with the error message E 150:
- Trolley in
- Hoist down
The careful scaling of the sensors is important for the accuracy of the LMB!
See EMS, chap. 2.2.8 "Scaling".

3.1.4 LMB mode of operation
The sensors of the LMB are subject to constant function monitoring. The sensor values are
recognized as valid after they have been tested by the PLC. The correct values are used to check,
via the load-capacity table, whether the load is permitted at the current radius. If the load value lies
above the permitted value in the load-capacity table, the status "Overload" is determined. The
message W113 (LM1*) and/or W123 (LM2*) are displayed in the EMS and the signal horn sounds
on the crane. Only the movements "Trolley in" and "Hoist-down" are enabled. (*See chap 3.1.5)
The LMB recognizes the following states:
1. Pre-overload warning >90 % ( M 111 / M 121 )

2. Overload ( W 113 / W 123 )
3. Gear shutdown ( W 852, W 853, W 854 )
The shut-off points of the ABB can be seen in the crane operator screens B1, B2 and B3. The
representation of the load moment curve is seen in the crane operator screens B4 and B6.
Constant overload = Maximum load is exceeded.

Moment overload = Lifting capacity is exceeded in relation to radius.
3.1.5 LM1 and LM2-mode

The safety reserves in the structural steelwork of the crane can be mobilized by the crane operator
by the press of a button. The crane is factory set to run in the load moment range 1 (LM1 =
standard load curve). By changing to the load moment range 2 (LM2 = higher load curve), the
lifting capacity of the crane can be increased by up to 20%, depending on the crane configuration.
LM2-mode must be authorised in the LMB-parameter screen!

See chapter 3.2.1 "Authorising / blocking LM2-operation"
For crane operation using the LM2-mode:

- Pay attention to the maximum permissible tower height! See crane operating
manual!
- The LM2-mode may only be used up to wind warning level 1! (W 180)
- Crane movements are only possible at half acceleration and half speed!
(Reduction of the movements speed levels via the crane control)
The load moment curve
Constant area Moment area

Pre warning
Overload (>90%)
LM1-mode LM2-mode
Load
Radius

Changing from the LM1 to the LM2-mode
50.0 km
h 72.0 km
h 50.0 km
h 72.0 km
h
1 4.6 1 4.6
m m
s s
LM1 symbol = LM1 mode Press the button on LM2 symbol = LM2 mode
the control stand.
3.1.6 Pre-overload warning (>90%)
If the moment overload or the constant overload reaches a value equal to more than 90% of the
load characteristic, the warning W 111 (LM1) or W 121 (LM2) is displayed on the EMS. The status
"Pre-overload warning" is stopped when the constant overload is less than 90%. The display
W 111 (LM1) or W 121 (LM2) disappears on the EMS. See also chap.3.3.0 "LMB function test"
3.1.7 Overload
Overload is reached when the product of current radius and the current load attached exceeds the
curve course of the permitted load-capacity table or the maximum permitted load (=constant
overload) is reached. In this operating state, only the movements, "Trolley in" and "Hoist down"
are possible.
If an overload state is reached, the error message E 113 (LM1) or E 123 (LM2) appears on the
EMS and the signal horn sounds on the crane. See also chap.3.3.0 "LMB function test"
Error correction:
Bring trolley in or set down load. The signal horn at the crane stops as soon as the overload
state is no longer in effect.
3.1.8 Changing to the LMB parameter screen
The key-operated switch for "Scaling" is found on the key-operated switch unit in the switchgear
cabinet S1 of the crane control. After the turning of the key-operated switch, the EMS changes
automatically to the LMB parameter screen and unlocks the LMB and sensor parameter values for
modification. The lock symbol in the LMB and sensor parameter screen is shown as open .
Turn key-operated The LMB parameter screen appears

switch to "Scaling". and the lock symbol is open!
10.01.02 15:12:48
08.01.02
10:36:56
550 E C -H
40t 22-80m 37

3.2.0 Settings in the LMB parameter screen
The settings for overload protection, the hoist gear, slewing gear and for the output reduction of the
crane can be made in the LMB parameter screen.
Choosing LMB parameter screen: - via the LMB symbol in the service menu screen.
(See chap.2.5.0)
- Turn key-operated switch to Scaling. (See chap.2.1.7)
01.04.03 15:12:48
1 13
2 08.01.03
10:36:56 14
550 E C -H
3 40t 22-80m 37
4 E C-H 1 2 15
E C-B 8 1
5 E C-B _S V 10 1 16
6
7 1 2.6 7kg/m
8 17
1 40.0t 43.2t 32.4t
2 23.0t 25.0t 18.0t
9 3 13.0t 13.0t 8.4t
4 0.0t 0.0t 0.0t
10 1.00
11 0.50
12 50.0 km
h 72.0 kmh
1 4.6
m
s
Menu point to change to the sensor parameter screen.

Cursor location. Change to the service menu with the ENTER key.
Currently chosen crane type.
Menu point to select the crane type.
Menu point to select the crane class (see chap. 3.2.2).
SV = Special version (special crane execution).
Maximum rope runs on the hoist gear drum with specific weight of the hoist rope.
(see chap. 3.2.3)
Loads for gear shutdown and control speed 1 and 2 (see chap. 3.2.4 and 3.2.5).
Drive gears 1 to 4.
10 Output reduction factor for the reduction of hoist gear output. (see chap. 3.2.6).
Factory setting: 100% output = factor 1.00 (only FU cranes!)
11 Symbol of the lifting capacity reduction. = Lifting capacity reduction "OFF"
12 Adjustable wind warning thresholds for wind warning stages 1 and 2 (see chap. 3.2.7).
13 Date of the last change in the LMB data.
Lock open! Permission to change LMB data.
15 Symbol for authorising or blocking the LM2-mode (see chap. 3.2.1).
LM2-mode active / LM2-mode not active!
16 Symbol for AKS-recognition; AKS active / AKS not active! (see chap. 2.2.8.9).
Symbol of the reeving of the shown gear shutdown value.

3.2.1 Authorising / blocking LM2-mode
LM2 may only be activated if the LM2-mode is allowed for the respective tower
configuration! See Chapter 2 of the instruction manual.
Following authorisation of LM2-mode, the crane operator can activate the LM2-mode at the press
of a button, see chapter 3.1.5 "Changing over from LM1-mode to LM2-mode".
10.01.02 15:12:48 Select the symbol " "

using the arrow keys " ".
Press the ENTER key once.
08.01.02
1 10:36:56 LM2-operation is authorised.
550 E C -H
40t 22-80m 37 = authorised
= blocked!
2
3.2.2 Selecting crane type

The correct lifting capacity table is created after the selecting of the crane type and the scaling of
the jib length (EMS chap.2.2.8). In order to change the parameters, the key-operated switch must
be turned to "Scaling". The EMS changes automatically to the LMB parameter screen. The lock
symbol (in the right side of the header) is displayed as "open".
01.04.03 15:12:48
" key, choose the symbol
With the " .
1 08.01.03
10:36:56
550 E C -H
40t 22-80 m 37 " and "
With the " " keys, choose the crane class
2 E C -H 1 2 (series).
E C -B 8 1
E C -B _S V 10 1
3 SV Special version
1 2.6 7kg/m
Confirm crane class with the "ENTER" key.
1 40.0t 43.2t 32.4 t

The selection list of "crane types" appears,
2 23.0t 25.0t 18.0 t the cursor is at " ".
3 13.0t 13.0t 8.4 t
4 0.0t 0.0t 0.0 t
1.00
0.50
km km
50.0 h 72.0 h
1 4.6
m
" key, choose the desired crane type.
With the "
s
Press the ENTER key 1x. The crane type with the
10.01.02 15:12:48 corresponding load curve is saved.
The cursor returns to " ".
550 E C -H
40t 22-8 0m
280 E C -H 16t 2 5-70 m Press the ENTER key 1x. The display mask
550 E C -H 40t 2 2-80 m
changes to the LMB parameter screen.

3.2.3 Rope layers and rope weight ( Only for HC-L cranes! )
The rope weight and the number of rope layers influence the maximum permissible load on
the hook! When entering the rope weight, it is of the utmost importance that the directions
in the operating manual of the crane or the manufacturer’s information for the rope be
followed exactly!
The value for the number of rope layers is a Rope layers Rope weight
measurement for the amount of hoist rope on the rope
drum. The rope layers and the rope weight are
calculated together to determine the reduction of the 1 2.6 7k g/m
maximum permissible load on the hook.
That means that for high hook heights, the weight
of the hoist rope must be subtracted from the
maximum permissible load on the hook.
Procedure:
The number of rope layers is counted by the number of free holes on the hoist drum.
The specific rope weight is to be taken from the manufacturer’s information.
- Lower the hook block to the maximum hook level. The load hook must not touch the ground!
- In order to make changes in the LMB parameter screen, the key-operated switch must be
turned to "Scaling"!
- Choose each input field with the ÕÖ keys.
- Enter the input value with the ×Ø keys.
- Press the ENTER key. The entered value is accepted and saved.
3.2.4 Gear shutdown

The gear shutdown prevents drive gear overload in the hoist gear.
The different drive gears are designed for a specific maximum weight. In order to prevent gearbox
damage, the LMB only enables gears determined for the current weight attached. The number of
gears and their settings depend on the particular hoist gear used! See "Frequency converter
hoist gears for Litronic cranes " in Appendix V.
Example: 40 t 3 gear WIW 300 VZ 401

Attention: Inputs are always for the largest possible run variant!
Label Gear 1 Gear 2 Gear 3

Constant load 40.000kg 23.000kg 13.000kg
Load speed monitoring Ref1 43.200kg 25.000kg 13.000kg Load speed monitoring
Load speed monitoring Ref2 32.400kg 18.000kg 8.400kg Ref 1 Ref 2
Change to the symbol in the LMB parameter screen. 1 2.6 7kg/m

Change to gear 1 with the "Ø" cursor.
With the "Ö" cursor, change to the input
input field. Enter the shutdown value in tons [t]
with the "×Ø" keys. 1 40.0t 43.2t 32.4t
2 23.0t 25.0t 18.0t
Confirm the entered value with the ENTER key.
3 13.0t 13.0t 8.4t
The cursor changes automatically to the next
4 0.0t 0.0t 0.0t
input field.

3.2.5 Load speed monitoring (control loads)
The maximum permissible speed is controlled in relation with the load by a frequency converter
(FU) in the hoist gear drive. This allows the performance of the drive to be optimized. The FU is
informed via external inputs of the load which is measured by the load measuring axle. These load
values correspond to a specific speed (revolutions). As soon as the speed (revolutions) becomes
too high in relation to the measured load, the FU shuts off and the error message E 981 appears
on the EMS. Two additional switch signals (control loads) are built in for this purpose – they inform
the FU of excessive loads. See list "Frequency converter hoist gears for Litronic cranes " in
Appendix V.
Example: 40 t 3 gear WIW 300 VZ 401
Label Gear 1 Gear 2 Gear 3

Constant load 40.000kg 23.000kg 13.000kg
Load speed monitoring 43.200kg 25.000kg 13.000kg
Ref1
Load speed monitoring Ref2 32.400kg 18.000kg 8.400kg
Change to the symbol in the LMB parameter screen. 1 2.6 7kg/m
With the "Ø" cursor, change to gear 1.

With the "Ö" cursor, change to the input field.
Enter the shutdown value in tons [t] with the 1 40.0t 43.2t 32.4t
"×Ø" keys. 2 23.0t 25.0t 18.0t
Confirm the entered value with the ENTER key. 3 13.0t 13.0t 8.4t
The cursor changes automatically to the next input 4 0.0t 0.0t 0.0t
field.
3.2.6 Reducing hoist gear output
The power supply requirement of the crane depends primarily on which hoist gear is chosen.
Therefore the power supply requirement of the crane can be substantially lowered by a reduction in
the output of the hoist gear. It is thus possible to adapt the crane (only those with FU hoist gears!)
to the power requirements of each construction site. This change is made by setting the hoist gear
to a lower revolution speed.
The output reduction factor is factory set to 1.00, corresponding to 100% output.
Example: 110kW Factor 1.00 = 100% Output (~110,0 kw hoist gear) Factory setting!
Factor 0.75 = 75% Output (~ 82,5 kw hoist gear)
Factor 0.50 = 50% Output (~ 55,0 kw hoist gear)
Change to the symbol in the service menu screen.
With the " Ö " cursor, change to the input field. 3 13.0t 13.0t 8.4t
4 0.0t 0.0t 0.0t
Enter the value of the field (output reduction factor)
with the "×Ø" keys. 1.00
Confirm and save the entered value with the ENTER
key.

3.2.7 Setting wind warning stages 1 and 2
01.04.03 15:12:48 Select the symbol using arrow key "Ø".

08.01.03
10:36:56
55 0 E C -H LM2
40 t 22 -80m 37 Select the wind warning stage being set using
E C-H 1 2 arrow key "Ö".
E C-B 8 1
E C-B _S V 10 1
1 2.6 7kg/m
Set the switching point of the respective wind
warning stage [km/h] using arrow keys "×Ø".
1 40 .0 t 4 3.2t 32.4t
2 23 .0 t 2 5.0t 18.0t 0.50
3 13 .0 t 1 3.0t 8.4t
4 0 .0 t 0.0t 0.0t
1.00 50.0 km
h 72.0 km
h
0.50
1
50.0 km
h 72.0 km
h
2
1 4 .6
m
s
3.3.0 LMB function test
After a new scaling, the LMB must be tested with the test load attached for the
correct function of the lifting capacity chart!
Calculate the correct test load for the crane. See EMS, chap. 2.2.8.1.
The lifting capacity curves are to be found in the general operating instructions of the crane.
The lifting capacity curve is to be used to calculate the maximum radius that the test load
may be extended. This value is to be approached carefully. The trolley drive is automatically
stopped if the overload signal sounds.
The shut-off tolerances:

- LM1 = 105%
- LM2 = 103%
- SS-125% = 128%
stop
STOP
The LMB function test is
finished.
The test load is lowered and

the crane is ready for normal
crane operation.

3.3.0 LMB function test
If the overload doesn’t shut-off:

- Correct lifting capacity table used? Check crane type and attachment!
- Test load correctly dimensioned? Re-dimension test load!
- Are the sensors correctly set and operating? Check sensors!
- Were the sensors scaled? Re-scale sensors!
See EMS, chap. 2.2.8.1.

10.01.02 E 113 M 00 0 15:12:48
W 0 00 S 000
See EMS, chap. 2.1.6 Diagnostic messages.
3.4.1 Procedure for error correction

To check the functioning of the EMS display, see EMS, chapter 2.6.0.
HOTLINE, see manual for LITRONIC tower cranes chapter 1!

Chapter 4
ABB
abb_dbl-en / LITRONIC Working range limitation

Working range limitation (ABB)
Table of contents:
4.1.0 Tasks of a working range limitation system (ABB) ............... 4-1

4.1.1 Safety information 4-1
4.1.2 Checking over before starting work 4-2
4.1.4 ABB mode of operation 4-4
4.2.0 Operating the ABB working range limitation system ............ 4-6
4.3.0 Teaching mode .......................................................................... 4-6

4.3.1 General teaching information 4-6
4.3.2 The ABB parameter screen 4-10
4.3.3 Teaching the limitation points 4-11
4.3.3.1 Turning on the teaching mode 4-11
4.3.3.2 Programming the polygon line 4-12
4.3.3.3 Programming a circle sector 4-14
4.3.3.4 Programming a quadrilateral 4-16
4.3.3.5 Turning off teaching 4-18
4.4.0 Working mode ........................................................................... 4-18
4.5.0 ABB function test ...................................................................... 4-19
4.6.0 Diagnostic messages ............................................................... 4-19


abb_inhv-en / LITRONIC Table of contents

4.1.0 Tasks of the working range limitation system
The working range limitation system (ABB) is a safety device that warns or prohibits the crane
operator from leaving a designated working area with the load hook or jib. The use of the Litronic
working range limitation system prevents damage to the crane and the surrounding buildings,
helps prevent accidents and protects human life while allowing the maximum possible working
range for the crane.
The Litronic working range limitation is used, for example, when there are obstacles within the
working range (high tension wires, railway tracks or other buildings), which the hook or jib of the
crane must under no circumstances come into contact with.
4.1.1 Safety information
The values shown in the display masks in this manual are crane type and equipment-specific.
These values can, therefore, only be considered as an aid for orientation of the crane
operator or the service personnel!
The "Teaching" process (traveling to and saving the limitation points) may
only be carried out by trained service personnel.
All crane sensors must be scaled before settings can be made in the ABB!
See EMS, chap 2.2.8 "Scaling".
For all of the following display masks used by the EMS, we must remind you that
the appearance of the particular masks may have undergone changes, due to the
constant development of the software!
To ensure correct function of the working range limitation system (ABB), it is

essential to follow the daily system checks as well as to follow the instructions
shown in the operating manual. (see chap. 4.1.2)!
In addition, BGV DG provisions must be followed!
abb_01-20-en AC31-S / ABB 4-1

4.1.2 Testing before starting work
The following points must be checked before starting work:
1. Check whether the displayed radius matches the actual radius. Move the unloaded trolley from
the minimum to the maximum radius.
2. Check whether the displayed hook level matches the actual hook level.
3. Check whether the slewing angle position of the slewing gear (set reference points) still
matches the slewing angle position in the display. Switch to the set reference points.
4. Check whether the travel gear position of the travel gear still matched the travel gear position
shown in the display. Move the crane along the entire length.
5. Check the marked-off area by cautiously approaching the border positions for the slewing as
well as for the maximum permissible trolley position when the jib is standing. At the same time,
the correct shutdown of the drives and the locking of the slewing gear brakes must be tested in
the border areas (the area between the work area and the prohibited zone).
Adjustment work must be undertaken by correspondingly trained specialists if the slewing angle
proves to have a deviation of more than ±1°(degree) or if the displayed trolley position deviates by
more than ± 0.2m from the actual trolley position.
The ABB functions automatically when properly set.

For this reason, the crane operator must be fully familiar with the use of the
system. Additionally, all tests (chap. 4.1.2) before beginning work must be
conscientiously undertaken by the crane operator!
4-2 ABB / AC31-S abb_01-20-en

S1 SMC
card EMS-2 AC31-S
ARCNET-BUS
PLC central unit
KT98 / KT94S B1 B2 B3 B4 B5
CLEAR
B6
ENTER
B7
with ABB software module
Travel gear sensor

Length in meters [ m ]
Slewing gear sensor

Angle in degrees [ ° ]
Trolley travel gear

Radius in meters [ m ]
MJFCIFSS
Prohibited area!
ex.
rail way line
see example
DA
NG E R DA
NG E R
OE
VR H E
AD OE
VR H E
AD
L IV E W R
I E
S L IV E W R
I E
S
abb_01-20-en AC31-S / ABB 4-3

4.1.4 ABB mode of operation
The totality of the system is controlled on one hand by automatically functioning components
(sensors) and on the other by manual intervention by the crane operator. The control signals
coming from the control stand and the control lever are read in by the PLC via the binary and
analogue inputs, and are transferred to the PLC central unit over the BUS system.
The work area of a freestanding crane is a circular plane, that is calculated from the maximum
radius and slewing area (360°). Prohibited areas are sections of the work area into which the load
hook of the crane may not enter.
"Prohibited areas" must be set and programmed into the ABB (PLC). The programming is done
point-by-point during the set-up of the crane by teaching process. (Teaching Î learning by
traveling to the points). The permissible limitation points are approached and the coordinates from
the position encoder are saved in the PLC central unit.
The “taught“ points are linked together by the ABB to create an area. Three different limitation
shapes are available during the "Teaching mode".
3 Circle sector Points S0 - S5

1 Quadrilateral Points V0 - V3
5 Polygonal line (straight line) Points P0 - P9
Polygonal line
Limiting point
P0 P2
P4
P1
P3
Prohibited areas Max. radius
V1
V0
S1
V2 Slewing range of the crane
Quadrilateral
Circle sector
S0
V3
Generally the ABB only limits slewing and trolley movements, therefore only the
radius and slewing angle are normally displayed for each limiting point. When
hook level and travel gear limitation points are being set, the coordinates for the
hook level and the travel gear are also displayed.
The saved data from the "teaching" process can be reset for each building site
and are therefore changeable for every application.
The crane may only pass over prohibited areas if the trolley is outside of the
prohibited area!
4-4 ABB / AC31-S abb_01-20-en

4.1.4 ABB mode of operation
Example: Using polygonal lines
Limiting point
P1 P5
P0 P4 Exclusion area
P3 P7
P2 P6
P8
P9
In this screen, a railway line with a bridge and a set of high-tension power lines are excluded. The
bridge must be accessible by the trolley! The points P0 - P3 and the points P4 - P7 cover the rail
lines on each side of the bridge. The high-tension power lines run under the area covered by
points P8 and P9.
Example: Using circle sectors
Exclusion point
S0
S5
S3
Prohibited surface
S1 S2
S4
This screen shows a building or obstacle complex with two finished buildings. These buildings (S0-
S3) and (S4-S5) are obstacles that may not be damaged or even touched by the load hook.
abb_01-20-en AC31-S / ABB 4-5

4.2.0 Operating the ABB working range limitation system
The are two operating modes for the ABB:
- Teaching mode (see chapter 4.3.0)

- Working mode (see chapter 4.4.0)
In the teaching mode, the corners of the prohibited positions are simply traveled to and the
resulting position values are saved in the central unit, after the crane has been set-up. The
teaching mode can only be turned on via key-switch.
In the working mode, the momentary position values of the crane are determined and compared
to the saved values from the teaching mode. If the crane approaches a prohibited position, the
braking procedure of the crane is automatically started for the slewing gear and the trolley travel
gear. The operation of the ABB is done over the EMS, see after chapter 4.3.2.
The "Teaching" (traveling to and saving the limitation points) may only be
undertaken by trained service personnel.
4.3.0 Teaching mode

4.3.1 General teaching information
Rope run variants:
For cranes with more than one rope-run variant (ex. 2/4-falls), all variants must
be taught separately! The error message "E053" appears if a rope-run variant
without teaching data has been selected.
Combination of quadrilaterals (V), polygonal lines (P) and circle sectors (S):
The three available limitation shapes (prohibited areas) can be combined with each other in a work
area. In order to simplify the planning of the limitation shapes, it is recommended to create a "work
range limitation plan" (see following page).
Polygonal line
P0 P2
P4
P1
P3
V1
V0
S1
V2
Quadrilateral
Circle sector
S0
V3
4-6 ABB / AC31-S abb_01-20-en

Work range limitation plan
270°
180°
10 20 30 40 50 60 m 360°
0°
90°
Polygonal line: Circle sector: Quadrilateral:

P0 .......... m, .......... ° S0 .......... m, .......... ° V0 .......... m, .......... °
P1 .......... m, .......... ° S1 .......... m, .......... ° V1 .......... m, .......... °
P2 .......... m, .......... ° S2 .......... m, .......... ° V2 .......... m, .......... °
P3 .......... m, .......... ° S3 .......... m, .......... ° V3 .......... m, .......... °
P4 .......... m, .......... ° S4 .......... m, .......... °
P5 .......... m, .......... ° S5 .......... m, .......... °
P6 .......... m, .......... °
P7 .......... m, .......... °
P8 .......... m, .......... °
P9 .......... m, .......... °
Serial number: Crane type: Construction year:
Location: Date: Prepared by:
abb_01-20-en AC31-S / ABB 4-7

Overlapping:
Complex danger and construction areas can be excluded by the overlapping of different shapes.
S0
Teachmode P1
S1
P0
Angle:
Two points must never be programmed to the same angle, as this would
cause the programmed straight line to be continued to the center point
of the crane.
As shown in the following diagram, the points P1 and P2 have been programmed to the same
angle. In order to prevent this, an angle difference of at least 1 degree must be maintained for two
successive points. P3
P1
10.01.02 15:12:48
W 5 55 P0
m ° m P2
33.3 73.0 5.3
08.01.02
10:36:56
m ° m m
P0 33 .3 0.0 5.3 0.0

P1 24 .1 35 .0 5.3 m 0.0 °
P2 7.3 35 .0 5.3 0.0
P3 P0
33 .3 73 .0 33
5.3 .3 0.0 0.0
P4 P1
0.0 0.0
24 .1 0.0
0.0 35 .0
P5 0.0 0.0 0.0 0.0
P6 P2
0.0 0.0 7.3
0.0 0.0 35 .0
P7 0.0 0.0 0.0
P3 0.0
33 .3 73 .0
P8
P9
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0 0.0 Prohibited teaching points!
V0
V1
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
(E050 / E051)
V2 0.0 0.0 0.0 0.0
V3 0.0 0.0 0.0 0.0
S0 0.0 0.0 0.0 0.0
S1 0.0 0.0 0.0 0.0
S2 0.0 0.0 0.0 0.0
S3 0.0 0.0 0.0 0.0
S4 0.0 0.0 0.0 0.0
S5 0.0 0.0 0.0 0.0
1 4.6
m
s
4-8 ABB / AC31-S abb_01-20-en

Angle:
A circle sector may cover a maximum of 179° of the slewing angle.

If the angle difference between two programmed points is greater than
180 degrees, the excluded area is automatically located in the direction of the
smaller angle between the two successive points.
In the following circle sector, the two points S0 and S1 are less than 180 degrees from each other.
The prohibited area is always set in the direction smaller than 180 degrees.
S0
S1
The polygonal line (straight line) may not divide the exactly in two! See: "same angle", page 8! In
order two create the largest possible area, three points must be taught. These areas must be
chosen at least 2 degrees less than 180 degrees!
At least P1
-1° (degree) P2 At least
P0 -1° (degree)
abb_01-20-en AC31-S / ABB 4-9

4.3.2 The ABB parameter screen
There are two different ways to display the ABB parameters. The table view and the graphical
view. When the ABB parameter screen is selected, the table view is shown first. A maximum of 24
teaching points may be displayed in the table view. More teaching points can be displayed by the
scrolling (Ø) of the display screen.
10.01.02 15:12:48 10.01.02 15:12:48

2 W555 W555
12
3 m ° m m ° m
9.6 121.0 9.7 9.6 121.0 9.7
08.01.02 08.01.02
4 10:36:56
10:36:56
5 m ° m m
S0 S1 S2 S3 S4 S5 V0 V1 13
V2 V3 P0 P1 P2 P3 P4 P5
P6 P7 P8 P9 P10 P11 P12 P13
6 P0 80.0 353 21.9 0.0
P1 47.6 99 21.9 0.0 P 14 P 15 P 16 P17 P18 P19
P2 80.0 89 21.9 0.0
7 P3 80.0 129 21.9 0.0
P4 80.0 178 21.9 0.0
P5 0.0 0 0.0 0.0 S0
P6 0.0 0 0.0 0.0
8 P7 0.0 0 0.0 0.0
P8 0.0 0 0.0 0.0
P9 0.0 0 0.0 0.0
V0 0.0 0 0.0 0.0
9
V1 0.0 0 0.0 0.0
V2 0.0 0 0.0 0.0
S1 S2
V3 0.0 0 0.0 0.0
10 S0 0.0 0 0.0 0.0
S1 56.0 218 21.9 0.0 S1
S0
S2 43.2 246 21.9 0.0
11 S3 0.0 0 0.0 0.0
1 4.6 1 4.6
m m
s s
Table view Graphical view

Current slewing angle in degrees [ ° ].
Current cursor location.
Menu point to switch to the graphical view of the ABB.
The table view can be changed to via the symbol.
The teaching points can be entered and changed in both screens!
Scroll bar "up". Pressing the arrow keys (×Ø) moves the scroll bar up/down a line.
Display of the different limitation points. Polygon (P), circle sector (S), quadrilateral (V).
10 The coordinates of the actual teaching points are displayed in this table.
Status of the limitation point (hook = this point is part of a limitation shape)
Radius of the teaching points.
Slewing angle of the teaching points.
10 Hook level of the teaching points. (Display only active by a corresponding limitation function)
11 Travel gear position of the teaching points. (Display only active by a corresponding limitation
function)
)
12 Display (W555/M090) of the mode "teaching".

13 Date and time of the last "teaching".
Graphical view des ABB parameter screen.
The teaching points not corresponding to a limitation shape are shown as crossed-through.
Display of the "teaching" mode through the symbol in the footer.
4-10 ABB / AC31-S abb_01-20-en

4.3.3 Teaching the limitation points
y The "teaching" (traveling to and saving the limitation points) may only be
carried out by trained service personnel!
y The limitation function of the ABB is deactivated during teaching!
y For safety reasons, all crane movements are disabled and the slewing gear
brake locks if the crane is left in teaching mode longer than 90 minutes. The
warning message "W 961" appears in the display of the EMS!
See "List of all diagnostic messages" in Appendix IV.
y The "teaching" is generally undertaken with no load on the hook!

y Falsely programmed points are ignored by the ABB and are no longer
available after the "teaching" finishes!
y The teach date is reset after a change in the teaching data.
The scaling procedure must be finished before the teaching mode can be
activated! See EMS, chap. 2.2.8 "Scaling".
4.3.3.1 Turning on the teaching mode
The settings for the working range limitation system (ABB) are made in the ABB parameter screen.
In order to activate the teaching mode, the control stand in the crane must be turned on.
The teaching mode is turned on by turning the key to " ".
Teaching 125%
Key-operated switch to " Teaching"
After the key-operated switch has been turned to " ", the teaching screen appears on the
screen. The messages "W 555" and "M 090" are displayed for the operating mode "TEACHING".
Each of the teaching points are immediately saved with the ENTER key. Invalid or not adopted
points are declared as invalid via status information after exiting the operating mode "teaching".
abb_01-20-en AC31-S / ABB 4-11

4.3.3.2 Programming the polygonal line
The polygonal line represents a straight line, that is, a line is drawn between at least two
programmed (taught) points.
It is important to make sure that for polygonal lines the start and end points are
always saved at maximum radius ( 0,5m)!
Otherwise no closed area can be recognized and no geometrically closed shape
can be created.
Incorrectly programmed points are ignored by the ABB and are no longer
available after the finishing of the teaching mode!
In the following programming examples are used for the graphical teaching screen!
The programming of the limitation points in the tabular teach screen functions the same way as
with the graphical teach screen.
Procedure: First point (P0)
1.) Crane: Bring the jib and trolley directly to the limitation point to be programmed.
The current crane position is shown in the EMS. See "P0".
P3
Planned prohibited
P4 area
P1 P2
P0
First teach point

is moved to.
P5
2.) EMS-2: Choose the corresponding limitation point (P0)

with the arrow keys.
3.) EMS-2: Press the ENTER key. The limitation

point "P0" is saved.
Cursor jumps to "P1".
The saved points can be deleted and reset to 0.0 with the CLEAR key!
4-12 ABB / AC31-S abb_01-20-en

4.3.3.2 Programming the polygonal line
Procedure: Second point (P1)
1.) Crane: Bring the jib and the trolley directly to the second limitation point to be programmed.
The current crane position is shown in the EMS. See "P1".
P3
Second teach point

is moved to. Planned prohibited
P4 area
P1 P2
P0
P5
2.) EMS-2: Cursor is at P1.

S0 S1 S2 S3 S4 S 5 V 0 V1
3.) EMS-2: Press the ENTER key. The limitation V2 V3 P0 P1 P2 P 3 P 4 P5
P6 P7 P8 P9 P10 P 11 P 12 P1 3
point "P1" is saved. P14 P 15 P1 6 P 17 P18 P 19
Cursor jumps to "P2".
The saved points can be deleted and reset to 0.0

with the CLEAR key!
P1
Attention! P0
A prohibited area is recognized only when the two
end points are programmed at a maximum ( 0,5m)!
The "teaching" for the points P2 to P5 is the same as

for "P0" and "P1".
An additional limitation point can be chosen using the arrow keys.

Exit teaching mode: turn key-switch from to "Ready".
Finished shapes:
P3
P4
Two prohibited areas, that
P1 P2 were programmed with polygonal
P0
lines.
Trolley is at the last limitation

point P5.
P5
abb_01-20-en AC31-S / ABB 4-13

4.3.3.3 Programming the circle sector
Only two diagonal points are necessary to program a circle sector. The third and fourth points are
automatically generated.
A circle sector may cover a maximum of 179° of the slewing angle!

available after the ending of the teaching mode!
The graphical teaching mode is used in the following programming examples!

Procedure: First point (S0)
The current crane position is shown in the EMS. See "S0".
Planned prohibited
S1
area
S0
First teach point

moved to. S3 S2
2.) EMS-2: Choose the corresponding limitation point (S0)

S0 S1 S2 S3 S4 S5 V0 V1
with the arrow keys.
V2 V3 P0 P1 P2 P3 P4 P5
P6 P7 P8 P9 P 10 P 1 1 P 1 2 P1 3
3.) EMS-2: Press the ENTER key. The limitation P 14 P15 P 16 P 17 P 18 P19
point "S0" is saved.
Cursor jumps to "S1".

with the CLEAR key! S0
4-14 ABB / AC31-S abb_01-20-en

4.3.3.3 Programming the circle sector
Procedure: Second point (S1)
The current crane position is shown in the EMS. See "S1".
Second teach point

S1 moved to.
S0
S3 S2
Planned prohibited
area
2.) EMS-2: Cursor is at S1.

S0 S1 S2 S3 S4 S5 V0 V1
3.) EMS-2: Press the ENTER key. The limitation V2 V3 P0 P1 P2 P 3 P 4 P5
P6 P7 P8 P9 P 10 P 11 P 12 P13
point "S1" is saved. P 14 P15 P 16 P 17 P 18 P 19
Cursor jumps to "S2".

with the CLEAR key! S1
S0
The "teaching" for the points S3 and S4 is the same as

for "S0" and "S1".

Finished shapes:
S1
Two prohibited areas, that
S0 were programmed with circle
sectors.
S3 S2
Trolley is at the last
limitation point S3.
abb_01-20-en AC31-S / ABB 4-15

4.3.3.4 Programming the quadrilateral
A quadrilateral must have four corner points (V0-V3). The location of the first point (V0) can be
freely chosen. After programming the first point, the remaining points may be programmed only in
one direction, so that the two straight lines do not cross.
The middle point of the crane may not be enclosed in the quadrilateral!
The four points of the quadrilateral (V0-V3) must all be in one circular direction!
available after the ending of the teaching mode!
The graphical teaching mode is used in the following programming examples!

Procedure: First point (V0)
The current crane position is shown in the EMS. See "V0".
Planned prohibited
First teach point V0
area
V1
moved to.
V3
V2
2.) EMS-2: Choose the corresponding limitation point (V0)

with the arrow keys. S0 S1 S2 S3 S4 S 5 V 0 V1
V2 V3 P0 P1 P2 P 3 P 4 P5
P6 P7 P8 P9 P10 P 11 P 12 P1 3
3.) EMS-2: Press the ENTER key. The limitation P14 P 15 P1 6 P 17 P18 P 19
point "V0" is saved.
Cursor jumps to "V1".
The saved points can be deleted and reset to 0.0 with

the CLEAR key! V0
4-16 ABB / AC31-S abb_01-20-en

4.3.3.4 Programming the quadrilateral
Procedure: Second point (V1)
1.) crane: Bring the jib and the trolley gear directly to the second limitation point to be
programmed. The current crane position is shown in the EMS. See "V1".
Second teach point

moved to.
V0 V1
V3
Planned prohibited
area V2
2.) EMS-2: Cursor is at V1.

S0 S1 S2 S3 S4 S5 V 0 V 1
3.) EMS-2: Press the ENTER key. The limitation V2 V3 P0 P1 P2 P 3 P4 P5
point "V0" is saved. P6 P7 P8 P9 P 10 P 11 P12 P13
P 14 P1 5 P 16 P17 P 18 P 19
Cursor jumps to "V2".
The saved points can be deleted and reset to 0.0 with

the CLEAR key!
V0 V1
The "teaching" for the V2 to V3 is the same as for

points "V0" and "V1".

Finished shapes:
S1
A prohibited area, that
S0 is programmed with a
quadrilateral.
S3 S2
Trolley is at the last
limitation point V3.
abb_01-20-en AC31-S / ABB 4-17

4.3.3.5 Turning off the teaching mode
Turning the key switch turns off the teaching mode. The working mode starts automatically.
Turn key-operated switch to 125%

middle position "Ready".
Key-operated switch to "Ready"
After the key-switch has been turned to "Ready", the last chosen crane operator screen reappears
on the display. The messages "W 555" and "M 090" for the operating mode "TEACHING"
disappear. The limitation points of the ABB can be viewed in the crane operator screens B1 and
B3. The representation of the taught limitation shapes is shown in the crane operator screens B5
and B6.
4.4.0 Working mode

In the working mode, the control signals from the control stand are directly transferred to the drives
by the ABB, as long as the momentary crane position is outside of the limitation shapes
programmed by the teaching mode.
If the crane approaches a limitation shape (prohibited area), the slewing gear is automatically
braked and the set-value on the trolley travel gear is stopped. The shut-off points of the ABB are
shown in each of the EMS display masks.
The following symbols are shown on the display:
This symbol appears in the display masks B1 and B3

of the EMS and shows each shut-off point in the analogue
displays (bar graphs).
This symbol appears in the display masks B2, B4

0.0 and B5 of the EMS and shows the distance in degrees [ ° ]
to each shut-off point ABB.
This symbol appears in the footer of all display masks

and shows the current operating mode "teaching".
4-18 ABB / AC31-S abb_01-20-en

4.5.0 ABB function test
The ABB function test may only be undertaken by authorized and trained service personnel!
Procedure:
Slowly approach a prohibited area (limitation shape) with the jib and trolley. (Slewing gear level
1). Always maintain a safety buffer to each secured object when testing limitation points!
ABB shuts off: Turn the jib in the opposite direction from the prohibited area.
No shut-off: Check the teaching data for programming errors and re-teach the
limitation shapes if necessary!
See chapter 4.3.0 "Teaching mode".

10.01.02 E 113 M 00 0 15:12:48
W 0 00 S 000
See EMS, chapter 2.1.6 Diagnostic messages.

Examples:
Display "E 39"

Error: The crane is > 3° from the prohibited area.
Remedy: Turn key-switch to "TEACHING" or "SCALING".
Leave the prohibited area.
Turn key-operated switch to working mode.
Display "W 961"

Error: The operating mode "TEACHING" is used for longer than 90 minutes.
Remedy: Main switch off to on and restart the machine.
abb_01-20-en.doc AC31-S / ABB 4-19

4-20 ABB / AC31-S abb_01-20-en
Chapter 5
MDE
mde_dbl-en / LITRONIC Machine data capture

Machine data capture (MDE)
Table of contents:
5.1.0 The machine data capture system (MDE) ................................ 5-1

5.1.1 The tasks of the MDE 5-1
5.1.2 Special information 5-1
5.1.4 MDE mode of operation 5-3
5.2.0 The machine data screens ........................................................ 5-3

5.2.1 Choosing the MDE screens 1-3 from the service menu 5-3
5.2.2 Machine data M1 (diagnostic screen / crane operator screen 7) 5-4
5.2.3 Machine data M2 (drive data) 5-5
5.2.4 Machine data M3 (Load collective recording) 5-6
5.2.5 Machine data M3 (Load moment collective recording) 5-7
5.2.6 Occurrence display ML5 5-8
5.2.7 Overload table ML6 5-9
5.3.0 Recognition of load movements .............................................. 5-10
5.4.0 Deleting the short-term machine data ..................................... 5-10
5.5.0 Diagnostic messages ................................................................ 5-11


mde_inhv-en.doc / LITRONIC Table of contents

5.1.0 The machine data capture system (MDE)
5.1.1 The tasks of the MDE
The data on the crane load, the switch-on time, movements and the load movements are
determined and recorded using the machine data capture system (MDE). The recorded
data is displayed on the Electronic Monitoring System "EMS" on the control stand of the
crane cabin. See after chap. 5.2.0.
The MDE is implemented via a PLC (programmable logic controller) and is standard in the
Litronic cranes.
The following machine data is collected by Litronic cranes:

- M1 Diagnostic messages
- M2 and ML2 Drive data
- M3 and ML3 Load movements
- ML5 and ML6 Occurrence display
M1, M2 and M3 data are short-term machine data and can therefore be deleted!
ML2, ML3, ML5 and ML6 data are long-term machine data and can not be deleted!
5.1.2 Important information
In order to ensure the correct operation of the MDE, the necessary measures and
settings must be undertaken according to the EMS manual.
Settings in the service mode of the EMS may only be changed by specially trained
service personnel!
mde_01-12-en.doc AC31-S / MDE 5-1

S1 SMC
card EMS-2 AC31-S
PLC central unit ARCNET-BUS

KT98 / KT94S B1 B2 B3 B4 B5
CLEAR
B6
ENTER
B7
with MDE software module
Hoist gear
Movement and switch-on time
Travel gear
Slewing gear
Control ON / dead man key

Operating time and switch-on time
Load moment sensor

Load moment collective recording
Load sensor
Load collective recording
Trolley travel gear

MJFCIFSS
5-2 MDE / AC31-S mde_01-12-en.doc

5.1.4 MDE mode of operation
The signals from the sensors and the control panel are collected by the inputs of the decentralized
PLC.
After the MDE software has received the information "control ON", all of the switching movements
of the control signals listed above are added together. The addition of the operating times of all
drives is done with the aid of a real-time clock. All switching times greater than 1 second are taken
into consideration. The MDE software module connects the incoming signals with additional
information and saves them inside the PLC onto the SMC card* of the crane control. The data from
the EMS collected through this process is displayed on the corresponding display masks.
*The SMC card is an exchangeable disk onto which all crane parameters are saved.
See EMS, chapter 2.5.3.1 "Important test functions / SMC card ".
The machine data is saved in two areas.
Short-term machine data collection ( M1 - M3 )

Short-term machine data can for example be saved over the time period of a construction
application, and can be deleted again with the input of the code number*. The collection
time period is shown above the data in the display. See chap. 5.2.2.
* Entering the code number, see EMS, chap. 2.1.7.
Long-term machine data collection ( ML2 – ML6 )

Long-term machine data is saved over the entire lifetime of the crane and the crane
control, and cannot be deleted. The collection time period is shown above the data in the
display. See chap. 5.2.2.
5.2.0 The machine data screens

5.2.1 Choosing the MDE screens 1-3 from the service menu
Service menu M1
10.01.02 E000 M000
W 000 S000
15:12:48 10.01.02 15:12:48 In the service menu change to
M1 with the cursor.
08.01.02
M2
10:36:56
8 ( 0 )
M1 M2 M3 Screen change M149 9 10.01.02 09:25:54
M148
M146
7 10.01.02
7 10.01.02
09:25:54
09:25:54
Machine data screen M1 appears.
ML2 ML3 ML5 ML6 M144 10 10.01.02 09:25:54
E 836 ll 12 10.01.02 09:19:24
E 868 ll 5 07.01.02 13:12:39
W556 l l 14 07.01.02 12:57:10
W970 ll 4 07.01.02 12:53:44 OR: from any display mask…
Screen change press "B7" .
B1 B2 B3 B4 B5 B6 B7
CLEAR ENTER
1 4.6
m 1 4 .6
s m
s

5.2.2 Machine data M1 (diagnostic screen / crane operator screen 7)
In the display mask M1, all diagnostic messages are shown sorted by the date and time. The
meaning of the specific messages can be looked up in the "List of all diagnostic messages" in the
Appendix IV. For Deleting the short-term machine data, see chap. 5.3.0.
10.01.02 15:12:48
7
08.01.02
1 M2 8
10:36:56
2 8 ( 6 )
M149 9 10.01.02 09:25:54
M148 7 10.01.02 09:25:54
M146 7 10.01.02 09:25:54
M144 10 10.01.02 09:25:54
E 836 ll 12 10.01.02 09:19:24
3 E 868 ll 5 07.01.02 13:12:39
W556 l l 14 07.01.02 12:57:10
W970 ll 4 07.01.02 12:53:44 9
4 E 850 3l06.01.02 15:12:21
10
11
12
1 4.6
m M1
s
Change to "M2" short-term machine data with the ENTER key.

The sum of all the displayed message lines (Σ=8). The cursor is on line ( 6 ) .
Current cursor location. Movement via the "×Ø" keys.
Current message.
The symbol appears when there are more than 32 messages.
It shows the possibility of scrolling forward with the cursor.
Reset the start time (date / time) of the machine data capture.
Deletion of the short-term machine data.
Date and time, that the short-term machine data was last deleted.
Lock Ö closed! The machine data may only be viewed.
Message lines with diagnostic message (type / number). Current messages are always
at the top.
Message types: "E"=Error, "W"=Warning, "M"=Message, "S"=Status message
10 Time of the diagnostic message.
11 Date of the diagnostic message.
12 Frequency of the occurrence of a diagnostic message.
Short-term machine data may be deleted in the EMS!

Long-term machine data may not be deleted in the EMS.

5.2.3 Machine data M2 (drive data)
The display mask M2 can be chosen under the menu point "M2" in the machine data screen M1 or
in the service menu. It shows the switch-on time and switching movements of the crane drives. A
switching movement is the acceleration and braking of a drive. For Deleting the short-term
machine data, see chap. 5.3.0.
9
10.01.02 15:12:48
10
08.01.02
1 M3 ML2 11
10:36:56
2 10 08:05
3 9 41:45 12
4 1 41:58
3 02:19 12
5
21 13
6 7 32:54
90
7 9 25:59
169
8 0 00:26
18
1 4.6
m M2
s
Change to the short-term machine data screen 3 pressing the ENTER key.
With the cursor key and the ENTER key, change to the long-term machine data screen 2.
Operating time counter of the EMS (EMS is running).
Switch on time for the crane control ON.
Switch on time for the dead man switch.
Switch on time and switching movement counter for the slewing gear.
Switch on time and switching movement counter for the trolley travel gear.
Switch on time and switching movement counter for the hoist gear.
Switch on time and switching movement counter for the travel gear.
Reset the start time (date / time) of the machine data capture.
Delete the short-term machine data.
10 Date and time that the short-term machine data was last deleted.
11 Lock Ö closed! The machine data may only be viewed.
12 Display: Hour minute : second
13 Display: Counted switching movements
M2 corresponds to the long-term machine data screen ML2. The data in the long-
term machine data screen ML2 cannot be deleted.

5.2.4 Machine data M3 (Load collective recording)
Display mask M3 can be chosen via the menu point "M3" in the machine data screen M2 or in the
service menu. The load collective data gives information over the stress on the hoist gear drive.
For Deleting the short-term machine data, see chap. 5.3.0.
08.01.06 E 000 M 000 10:35:44

W 000 S 000
07.01.06
1 ML3
10:36:56
2 11 12.0t 100 3
1 10.8t 90%
1 9.6t 80%
0 8.4t 70%
2 7.2t 60%
4 1 6.0t 50% 5
0 4.8t 40%
1 3.6t 30%
4 2.4t 20%
1 1.2t 10%
0
4.7t
6
0.0
M3
t
1
m
s
Change to the "ML3" long-term machine data screen 3 using the ENTER key.
With cursor key and ENTER, change to the following fields:
- Changeover to recording of load moment collective
- Browse backwards
- Start time (date / time) for resetting of machine data capture.
Deleting the short-term machine data.
Load collective counter for load classes over 100% of the max. load.
Limit value, 100% of maximum value (see also chap. 5.3)
Load collective counter for load classes over 50% of the max. load.
Limit value, 50% of maximum value (see also chap. 5.3)
Display: Current load in tons ( t ).
term machine data screen cannot be deleted.

5.2.5 Machine data M3 (Load moment collective recording)
Die display mask M3 can be chosen via the menu point "M3" in the machine data screen M2 or in
the service menu. The load moment collective data gives information over the stress on the crane
construction. For Deleting the short-term machine data, see chap. 5.3.0.
08.01.06 E 000 M 000 10:35:44

W 000 S 000
07.01.06
1 ML3
10:36:56
2 15 280mt 100 3
2 252mt 90%
0 80%
224mt
0 196mt 70%
1 168mt 60%
4 0 140mt 50% 5
2 112mt 40%
1 84mt 30%
1 20%
56mt
2 28mt 10%
6 229mt
6
0.0
M3
t
1
m
s
Change to the "ML3" long-term machine data screen 3 using the ENTER key.
With cursor key and ENTER, change to the following fields::
- Changeover to recording of load collective
- Browse backwards
- Start time (date / time) for resetting of machine data capture.
Load moment collective counter for load classes over 100% of the max. load moment.
Limiting value, 100% of maximum value (see also chap. 5.3)
Load moment collective counter for load classes over 50% of the max. load moment.
Limiting value, 50% of maximum value (see also chap. 5.3)
Display: Current load moment in metric tons (mt).
term machine data screen ML3 cannot be deleted.

5.2.6 Occurrence display ML5
In the occurrence display ML5, all diagnostic messages are displayed one after the other featuring
date and time. The meanings of the individual messages can be subsequently read in the "List of
all diagnostic messages" in Appendix IV.
08.01.06 E 000 M 000 10:35:44

W 961 S 000
7
07.01.06
1 ML2 8
10:36:56
2 8 ( 5 )
M150 9 10.01.06 09:25:54
M148 7 10.01.06 09:25:54
M146 7 10.01.06 09:25:54
M144 10 10.01.06 09:25:54
3 E 836 ll 12 10.01.06 09:19:24
E 868 ll 5 07.01.06 13:12:39
W555 l l 14 07.01.06 12:57:10 9
4 W961 ll 4 07.01.06 12:53:44
10
11
12
1
0.0 t
m
s
ML5
Change to the "ML2" long-term machine data 2 using the ENTER key.
The sum of all displayed message lines (Σ=8). The cursor is on line ( 6 ) .
Current cursor location. Movement via the "×Ø" keys.
Actual queued message.
The symbol appears when there are more than 32 messages.
It shows the possibility of scrolling forward with the cursor.
Date and time, that the occurrence list was last deleted.
Lock Ö closed! Only the machine data may be viewed.
Message lines with diagnostic message (type / number). Actual messages are always at the
top.
Message types: "E"=Error message, "W"=Warning, "M"=Message, "S"=Status message
10 Time that diagnostic message occurred
11 Date that diagnostic message occurred
12 Frequency of the occurrence of a diagnostic message
Long-term machine data can not be deleted on the EMS.

5.2.7 Overload table ML6
In the occurrence display ML5, all diagnostic messages are displayed one after the other featuring
date and time. The meanings of the individual messages can be subsequently read in the "List of
all diagnostic messages" in Appendix IV.
08.01.06 E 000 M 000 10:35:44

W 000 S 000
07.01.06
1 ML5
ML2
10:36:56
2 15 ( )
-M111 49.7m 4.63t 5.04t
08.01.06 08:20:06
3 -W113 51.5m 5.53t 4.98t
08.01.06 08:05:56
-E150 51.5m 3.51t 1.02t
4 08.01.06 08:00:01
-M111 51.5m 7.00t 2.90t
07.01.06 16:27:59
-M111 10.0m 0.00t 1.55t
07.01.06 14:55:06
-W113 51.5m 6.20t 5.08t
06.01.06 13:27:24
-E150 32.5m 6.33t 4.02t
06.01.06 12:59:33
-M111 36.5m 4.53t 4.98t
06.01.06 12:58:06
-E150 33.5m 5.53t 4.08t
06.01.06 11:05:41
5
1
0.0 t
m
s
ML6
Current position of the cursor. Movement via keys "×Ø".

Switch to "ML5" long-term machine data via the ENTER-key.
The sum of all displayed message lines (Σ = 15).

Current message lines (at the top) with...
- Diagnostic message
- Actual reach [m]
- Actual load [ t ]
- Permitted load [ t ]
- with = occurrence within the moment range
- without = occurrence within the constant range
Current message lines (at the bottom) featuring date and time.
The symbol appears with more than 32 entered messages.
It shows the possibility of scrolling downwards with the cursor.
Long-term machine data can not be deleted on the EMS.

5.3.0 Recognition of load movements
In order to recognize load movements, the following conditions must be met:
Load cycle started when - the lifted load exceeds 6% of the maximum load for 5 seconds
(static threshold value),
or - the lifted load increases to 10% of the maximum load for
5 seconds (dynamic threshold value).
Load cycle ends when - the load is below 5% of the maximum load for 5 seconds
(static threshold value),
or - the load drops by 10% of the maximum value for 5 seconds
(dynamic threshold value).
The load moment collective recording works on the same principle. In this case the load moment
value, which is a product of the load and jib values, rather than the load value is monitored.
The values for the load and load moment collective are shown in the EMS 2 on the machine data
screen "M3".
5.4.0 Deleting short-term machine data

M1, M2 and M3 are short-term machine data sets. This data can for example be saved over the
time period of a construction application, to be reset again afterwards. The collection time period is
shown in the upper part of the display with the date and time.
Settings in the code number area of the EMS may only be made by specially
The code number must be entered into the main menu in order to delete the machine data. The
service menu appears with an open lock. See EMS, chap. 2.1.7.
08.01.06 E 0 00 M 00 0 10:35:44 08.01.06 E 000 M 000 10:35:44

W 00 0 S 0 00 W 000 S 000 3 4 5
07.01.06
M2
10:36:56
8 ( 0 )
M1 M2 M3
Screen change M150 9 10.01.06 09:25:54
M148 7 10.01.06 09:25:54
ML2 ML3 ML5 ML6 M146
M144
7 10.01.06
10 10.01.06
09:25:54
09:25:54
3x
E 836 ll 12 10.01.06 09:19:24
E 868 ll 5 07.01.06 13:12:39
W555 l l 14 07.01.06 12:57:10
W961 ll 4 07.01.06 12:53:44
Service menu:
1) Move the cursor to "M1".
2) Press the ENTER key.
Machine data screen M1:
3) Move cursor to the clock
symbol.
5) Press the ENTER key.
1
0.0 t
1
0.0
m
t
M1
The machine data is deleted
m s
s
in the "M1" screen!

10.01.02 E 113 M 00 0 15:12:48
W 0 00 S 000
See EMS, chapter 2.1.6 diagnostic messages.


Chapter 6
Appendix
1_3_anhang-en / LITRONIC Appendix

Meaning of all symbols in the display Appendix I
Keyboard: functions
Change to EMS screen 1 Key "Cursor Left"

B1
B2 Change to EMS screen 2 Key "Cursor Right"
Change to EMS screen 3 Key "Cursor Up"

B3
B4 Change to EMS screen 4 Key "Cursor Down"
Delete and clear key

B5 Change to EMS screen 5 CLEAR
(Turn off EMS buzzer)
General input key

B6 Change to EMS screen 6 ENTER
Acknowledge messages
B7 Change to EMS screen 7 Change to "Main menu "
Screen:
Radius / trolley travel gear Radius / luffing gear
Load Load moment
Hook level / hoist gear Travel gear
Relative (rel) distance to the

Slewing angle / slewing gear rel
reference point (REF)
Shut-off point (radius)

t t
Limitation point LMB
of the LMB for current load
Shut-off point of ABB Limitation point ABB

Main menu:
Go back a page
REF Reference point (set)
(Menu level)
1-fall operation 3-fall operation
Customized form of
Buzzer B5 the display mask B5
Customized form of
Time / Date B6 the display mask B6
Slewing gear analogue Slewing gear 5-stage rail-going

(default) Rail-going (adjustable stages)
Lock "CLOSED"
Lock "OPEN"
(No permission to make
(Permission to make changes)
changes)
Service menu:
Machine data Long-term machine data

M1 ML2
Screen 1: Diagnostic messages Screen 1: Drive data

M2 ML3
Screen 2: Drive data Screen 2: Load movements

M3 ML4
Screen 3: Load movements Screen 3: time capture
EMS parameter screen LMB parameter screen / LMB

(Machine settings) (Lift capacity table/ crane type)
Sensor parameter screen ABB parameter screen

(Scaling screen) / Sensor (Teach screen)
Test and erection screen Info screen (only for Liebherr

(standard) service personnel)
MDE Service menu: Machine data capture
Switch-on time: Switch-on time:

"Control ON" "Dead man switch"
Switch-on time: Slewing gear capture:

"Crane powered" Movements/ switch-on time
Trolley travel gear: Hoist gear capture:

Movements / switch-on time Movements / switch-on time
1_3_anhang-en.doc / LITRONIC Appendix

MDE
Service menu: Machine data capture
Travel gear capture:

Load movement capture
Movements / switch-on time
Capture of a reached load

moment area
Service menu: LMB parameter screen
Hoist gear: Input rope layers

Constant overload
and specific rope weight
Control load 1 for frequency Reduction of speed (RPM)

converter in the hoist gear (Only HC-L cranes!)
Control load 2 for frequency Output reduction

converter in the hoist gear for FU cranes
Service menu: Sensor parameter screen (Scaling screen)
Sensor values in milli-amperes Scaling the sensor values
- Slewing angle
Wind sensor
- Slewing speed
Service menu: ABB parameter screen (Teach screen)
Change to graphical view Change to tabular view
Date and time

of the last "teach".
Footer: Rope reeving of the load hook
Footer: Current gear in hoist gear
1 3
1. gear 3. gear
2 2. gear 4 4. gear

Footer: LM1 or LM2 mode
LM1 mode LM2 mode
Footer: Wind warnings
Wind warning level 1 Wind warning level 2
Footer: Overload
Overload / LMB Pre-overload warning
Footer: Operating mode
Scaling mode (key-operated Teaching mode (key-operated

switch is at "Scaling") switch is at "Teaching")
Wait Crane control OFF (Control

Crane control not ready can be turned on)
Erection mode (key-operated

125 % Overload test mode
switch is at "Erection")

Technical Data: EMS-2 AC31-S Appendix II
Mechanical values: Value Units

Height 387 mm
Width 205 mm
Depth 111 mm
Weight < 4,0 kg
Length (in Liebherr packaging) < 450 mm
Width (in Liebherr packaging) < 250 mm
Height (in Liebherr packaging) < 150 mm
Storage temperature -20 bis 60 °C
Working temperature 0 bis 50 °C
Electrical values: Value Units

Power supply 19 to 37 V DC
Power consumption above 5°C ca. 350 ma
Power consumption below 5°C ca. 1 A
LCD values:
Active LCD display height 223 mm
Active LCD display width 97 mm
Contrast relationship 1:10
Strength of the background lighting > 50 cd/m²
Lifetime of the background lighting 10000 h
(Reduction of the strength to 50%
of the original)
Replacement parts and accessories
Part Number Drawing Number Label
931678601 SRA 4017-10104 EMS-2 AC31-S

600916301 Programming instructions EMS-2
975880601 SRA 4014-6992 EMS-2 Boot-Eprom
989157301 SRA 4012-6030 Test-Box EMS 230V 50-60Hz
989221601 SRA 4012-6030 Test-Box EMS 115V 50-60Hz
931703101 SRA 4017-9104/100 Name plate EMS-2 AC31-S Hardware
931703201 SRA 4014-9104/101 Name plate EMS-2 AC31-S
989200901 SRA 4017-9030 LCD display for EMS-2
989156301 SRA 4014-9984 Neon tubes for EMS-2
931513301 SRA 4017-1094 Terminator CS31-Bus
600913401 Control conduit SUB-D 9polig 10m
931555801 SRA 4017-10098 Control conduit AC31-S SPS-EMS 10m
(Wire + T piece + terminal resistor)

PIN layout of the EMS interface Appendix III
Work on the EMS may only be undertaken by authorized service

personnel!
Programming interface Communications interface

PIN 2 TxD OUT PIN 1 + 24V (IN)
PIN 3 RxD IN PIN 2 RxD IN
PIN 5 GND Ground PIN 3 TxD OUT
PIN 7 CTS IN PIN 4 RTS OUT
PIN 8 RTS OUT PIN 5 GND Ground
PIN 6 + 24V (IN)
COM1 PIN 7 RTS OUT
PIN 8 CTS IN
PIN 9 GND Ground
COM2
Sensor interface
PIN 1 + 24V (IN)
PIN 2 Input analogue Hook level 4...20mA
PIN 3 GND
PIN 4 Input analogue Slewing gear 4...20mA
PIN 5 GND
PIN 6 Input analogue Trolley travel gear 4...20mA
PIN 7 GND
PIN 8 Input analogue Travel gear 4...20mA
PIN 9 GND
PIN 10 Input analogue Load 4...20mA
PIN 11 GND
PIN 12 Input analogue Tacho 4...20mA
PIN 13 GND
PIN 14 Input analogue Wind sensor 4...20mA
PIN 15 GND
PIN 16 CAN +
PIN 17 + 24V (IN)
PIN 18 CAN -
PIN 19 Input 1 digital DIP switch 1
PIN 22 Output 3 digital Wind warning
PIN 25 GND

Appendix IV
1.0 List of all diagnostic messages for tower cranes

with PLC control system
1.1 List of all error messages
ABB Operating-range Limitation Errors E 0 - 99 Status: 15.01.2007
Error No. Fault Cause

1 WINKEL_>> Slewing angle sensor: difference between two measurements is too
large
2 WINKEL_<< Slewing angle sensor: difference between two measurements is too
small
3 The slewing angle modification is too great (B&R-ABB)
4 The slewing speed value is too high (B&R-ABB)
5 The slewing speed value is too low (B&R-ABB)
6 The slewing speed modification is too great (B&R-ABB)
7 AUSLAD>> Trolley sensor: difference between two measurements is too large
8 AUSLAD<< Trolley sensor: difference between two measurements is too small
9 The radius modification is too great (B&R-ABB)
10 AUSLAD=0 No change in the radius despite drive command
11 No change in the erection sensor despite drive command (MK80) /
the hook level value is too high (B&R-ABB)
12 The hook level value is too low (B&R-ABB)
13 The hook level modification is too great (B&R-ABB)
14 The test channel has failed (B&R-ABB)
15 The analog input card is faulty (B&R-ABB)
16 WINKEL=0 No change in the slewing position despite drive command
20 An input signal from the control stand is active during the

programming initialisation cycle (B&R-ABB)
21 The control lever is faulty (B&R-ABB)
22 The load value is too low (B&R-ABB)
23 The load value is too high (B&R-ABB)
25 The travel path is too great (B&R-ABB)

26 The travel path modification is too great (B&R-ABB)
30 TEACH_DATEN Teach data in KP62 memory no longer identical / Scaling data and
teach data were not stored properly (B&R-ABB)
31 It is no longer possible to record/read the internal memory (B&R-
ABB)
32 TEST_LBC Test LBC – ABB / It is no longer possible to record or read the
internal memory (B&R-ABB)
33 An input signal is missing on the I164, although the output is set to
the A163 (B&R-ABB)
34 A double read input signal is missing on input card I164 (B&R-ABB)
35 TEACH_WRITE It is no longer possible to store the teach data / The write-protect
switch is set at "WP" during storage of the teach data or scaling data
(B&R-ABB)
36 E36-SE_KAW Radius area under/overshoot
37 Teaching data transfer KP62->T200 not finished
38 Check sum error in teach data transfer from the KP62 to T200
39 E39- +-3GR Crane positioned > +/- 3 degrees in the forbidden area
40 FIGUR_ABB_K Teaching data yield no CIRCULAR SEGMENT
41 FIGUR_ABB_V Teaching data yield no QUADRILATERAL
42 FIGUR_ABB_P Teaching data yield no POLYGON
44 Teaching data are not valid – New teaching
45 Scaling data trolley are not valid – New scaling
4_meldeliste-en.doc Appendix IV 1
ABB Operating-range Limitation Errors E 0 - 99
50 Angle difference between 2 polygon points = 0°

51 Angle difference between 2 quadrilateral points = 0°
53 Current rope run variant is not taught yet
60 Double memorised input "Slewing gear right"

61 Double memorised input "Slewing gear left"
62 Double memorised input "Slewing gear brake"
63 Double memorised input "Trolley-in"
64 Double memorised input "Trolley-out"
65 Double memorised input "Hoist-up"
66 Double memorised input "Hoist-down"
67 Double memorised input "Hoist-down, stage 1, eddy current brake"
68 Double memorised input "Travel gear forwards"
69 Double memorised input "Travel gear backwards"
80 Contact check S0-AK1
90 Operating-range limitation not active
LMB Load Moment Limitation Errors E 100 - 199

110 CPU Module error FBK32
111 Vorwarnung_Ueberlast Overload pre-warning
112
113 Ueberlast Overload during "load moment 1" - operation
116 Test of the tensile stress measuring plate not OK
123 Overload during "load moment 2" – operation
144 Hoist sensor not scaled

146 Trolley sensor not scaled
148 Load sensor not scaled
149 Load-moment sensor not scaled
150 Measured load moment does not correspond to Load * Radius or
the redundant measuring axle is outside of tolerance
151 Scaling order incorrect
152 T200 has no lifting capacity table transferred from the KP62
153 Check sum error in lifting capacity table transferred from the KP62
to T200
154 Test of the load measuring shaft not OK
155 Scaling is not permitted in the two-fall operation
156 Scaling not allowed at the intermediate hook height
157 Test of the load moment sensor or Test of the redundant measuring
axle are not OK
158 4-fall operation with luffed jib position not permitted
159 Initialisation of the scaling or operating data not completely
proceeded!
160 Differential load KFA1 – KDA2 too great (>9t in 2-fall operation,
>18t in 4-fall operation)
2 Appendix IV 4_meldeliste-en.doc
EMS Electronic Monitoring System Errors E 200 – 299
203 EEPROM file error
210 Error while reading from the EEPROM

211 EEPROM cannot be described
220 EPROM not responding to request

221 EPROM-FIX-Block-1 can not be written
222 EPROM-FIX-Block-2 can not be written
223 Checksum error in FIX-Block-1
224 Checksum error in FIX-Block-2 or something other than FIX-Block-1
225 Incorrect versions number in EE-FIX-data
226 EE-FIX-data could not be read
227 EMS-module
228 EMS-module
229 EMS-module
230 EMS-module
231 EPROM-DYN-Block-1 can not be written
232 EPROM-DYN-Block-2 can not be written
233 Checksum error in DYN-Block-1
234 Checksum error in DYN-Block-2 or something other than DYN-Block-1
235 Incorrect versions number in EE-DYN-data
236 EE-DYN-data could not be read
284 Difference of angle sensor centre section too great

285 Channel error Temperature input (0-10V)
286 Guying winch sensor not within 4-20 mA
287 Angle sensor jib centre section not within 4-20 mA
288 Erection sensor not within 4-20 mA
290 Trolley sensor not within 4- 20 mA / Luffing gear angle sensor
291 Hoist sensor not within 4- 20 mA
292 Slewing sensor angle not within 4- 20 mA
293 Slewing sensor tachometer not within 4- 20 mA
294 Travel sensor not within 4- 20 mA
295 Load sensor not within 4- 20 mA
296 Wind sensor not within 4- 20 mA
297 XON Load-moment sensor not within 4- 20 mA
298 CONNECT No data connection to KP62
299 CODE Error in coding EMS DIP SWITCH
KP62/KT98 Communications Processor Errors E 300 – 399

300
301 Error while reading scaling data, Flash-EPROM Segment 0
302 Error while reading teaching data, Flash-EPROM Segment 1
303 Error while reading lifting capacity tables, Flash-EPROM Segment 2
304 Error while reading lifting capacity tables, Flash-EPROM Segment 3
305 Data in block 0, segments 2 and 3 in the Flash-EPROM are not the
same
306 Error while reading jib lengths, Flash-EPROM Segment 2
307 No lifting capacity table found for the scaled jib
308 Error while reading crane data, Flash-EPROM Segment 2
309 Error while reading radius in lifting capacity table "load moment 1",
Flash-EPROM Segment 2
310 Error while reading loads in lifting capacity table "LM1", FEPROM
Seg. 3 (PLC only) / Prelimit switch trolley (contactor control only)
311 Error while reading radius in lifting capacity table "LM2", FEPROM
Seg. 2 (PLC only) / hoist gear brake wear (contactor control only)
KP62/KT98 Communications Processor Errors E 300 – 399
312 Error while reading loads in lifting capacity table "LM2", FEPROM
Seg. 3 (PLC only) / hoisting-down in speed 1 or hoisting-up with
eddy current brake longer than 15 sec. (contactor control only)
313 Validity – lifting capacity table radius values not increasing (PLC
only) / overload or moment overload (contactor control only)
314 Validity – lifting capacity table load values not decreasing
315 Load factors for hoist gear not found
316 Load factors for trolley travel gear not found
321 Error while deleting scaling data, Flash-EPROM Segment 0

322 Error while storing scaling data, Flash-EPROM Segment 0
323 Error while deleting teaching data, Flash-EPROM Segment 1
324 Error while storing teaching data, Flash-EPROM Segment 0
325 Error while reading the MDE-data, EEPROM Segments 2+3
326 Error while writing the MDE-data, EEPROM Segments 2+3
330 S1_AA1M KT94S in "Stop"

331 Communication between KT94S and KT98 interrupted
332 Check sum error scaling data, crane type or capacity chart, data not
restorable
333 Check sum error teach data, data not restorable
334 Check sum error MDE data, data not restorable
335 In 2 rope run variants, different jib lengths were scaled
336 File allocation table on the SMC-card is incorrect! Data not restorable!
337 Lifting capacity date on the SMC-card are incorrect!
AKS Anti-collision System Errors E 400 – 419

400
404 S1_BE/BA AKS-interface (parallel) ICDG32L1 / DC91

405 AKS-interface (serial): CSM485-module failed
406 AKS-interface is not connected to the control
419
Automatic Crane Movements Errors E 420 – 499
435 Equipment error speed monitoring cabin

436 Tower sections not locked
437 Lower chord pinning not OK
438 Incorrect switch position "Tower vertical"
439 S1+A-C1 Buffer voltage PLC not available
440 Motor torque guying winch is too great
441 Motor protection switch ventilator guying winch
442 Limit switch Linak operating support not OK
443 No value modification of erection sensor despite travel command
444 Load hook not locked
445 Pawl not swung in
446 Scaling – Teaching switch faulty
447 S1-JS2M Hook height selection switch faulty
448 S1-JS1M Erection – Operation switch faulty
449 S1-ZQ1F Motor protection switch spindle has been activated
Automatic Crane Movements Errors E 420 – 499
450 Auxiliary drive is overheating

451 Centrifugal force switch of the auxiliary drive has been activated
452 Invalid erection selection
453 F-JS20Q Slack rope on the erection drum during telescopic extension or
Operating support in "Operation" position
454 Tie bar incorrectly plugged
455 The telescoping limit switch, which should limit the extension of the
tower at the intermediate hook height, has been overridden
456 C-XS43Q Limit switch "Auxiliary drive under load" has not responded
457 S1-AK17A 24 V from the diesel generator lacking in switchgear cabinet S1
458 30° cylinder not retracted
459 Angle sensor of intermediate jib section indicates incorrect value
with vertical tower
460 Angle of intermediate jib section is outside of area (<50° or >75°)
461 L-JS18Q The cabin is not in the dismantling position
462 C-AB2N The angle sensor for the jib centre section is defective
463 S1-AK10A Driving engine does not run
464 A-PS1Q Hydraulic pressure in the locking cylinders is too low
465 The hook block is too high
466 The hook block is too low
467 Slewing platform is not locked
468 Jib centre section is not locked to the jib pivot section
469 C-AS1Q The hoist rope deflection station is not locked or unlocked
470 Erection sensor reference values are not within permissible range
471 S1-XK2M Error feedback contact Auxiliary drive brake contactor
472 S1-XK1M Error feedback contact Auxiliary drive motor contactor
473 Reference values for guying winch not within permissible range
474 Error feedback contact Guying winch brake contactor
475 Error feedback contact Guying winch motor contactor
476 Motor circuit breaker Hydraulic system has been released
477 Excess temperature guying winch
478 Excess temperature telescoping gear
479 Excess temperature cabin
480 Jib head not extended or retracted
481 Erection height not clear
482 Pawl not swung out
483 Tower locking pins in a different position
484 Slack rope elevating operator's cab
485 Hoist rope not relieved of tension
486 Auxiliary hoist gear wound off too far
487 Reference value for trolley travel gear not within permissible range
488 Overspeed cabin drive
489 Engine torque at erection gear too great
490 Communication interruption to guide computer (Watchdog)
491 Limit switch "Auxiliary hoist under load" activated during operation
492 Limit switch "Tower resting on transport support" activated during
operation
493 Limit switch Linak telescope locking not o.k.
494 Limit switch Linak jib locking not o.k.
495 Limit switch Linak rope catching device not o.k.
496 Limit switch 30° ram retracted not o.k.
497 Limit switch triangular pointed section in locking position not o.k.
499
Module Error with Decentralised PLC Errors E 500 - 549

S1
500 S1_BE1/S0_BE1 S1 EB_60
501 S1_BA1 S1 AB_60
502 S1_AA1A S1 AA_60/ AA61/CSM485 (Radio)
503 S1_KP2/AA2M S1 KP_62/KT98 is not in RUN
504 S1_KP1 S1 CS_61
505 S1_BE2 or BE/BA 3 S1 07 EB 90 S / ICSK 20 F1 / DC91
506 S1_BA2 S1 07 AB 90 S
507 S1_EA1/S0_EA1 S1 07 EA 90 S
508 S1_EA2 S1 07 EA 90 S
P1
509 P1_EA P1 07 EA 90 S
510 P1_EB P1 07 EB 90 S
511 P1_BE or BE/BA P1 ICSI_16_E1 / ICSK 20 F1 / ICMK14N1
512 P1_BA P1 ICSC_08_L1
S2-SL
513 S2_EB1 S2 07 EB 90 S
514 S2_AB1/S2_BA3 S2 07 AB 90 S AB1
515 S2_AB2 S2 07 AB 90 S AB2
516 S2_BE1/S2_BE/BA1 S2 ICSI_16_E1 / ICDG 32 L1 / DC91
517 S2_BE2/S2_BE/BA2 S2 ICSI_16_E1 / ICSK 20 F1
518 S2_BE3 S2 ICSI_08_L1
S2-FU
519 S2_EB1 S2 07 EB 90 S
520 S2_BE1 or BE/BA S2 ICSC_08_L1 / ICDG 32 L1 / DC91 / ICMK14N1
521 S2_BE2 S2 ICSC_08_L1 BE2 / CSM485
522 S2_BE3 S2 ICSC_08_L1 BE3
523 S2_AA1 S2 ICSM 06 A6
S4-SL
524 S4_EB1 S4 07 EB 90 S
525 S4_AB1 S4 07 AB 90 S
526 S4_BA S4 ICSC_08_L1
527 S4_BE1 S4 ICSI_16_E1
528 S4_BE2 S4 ICSI_16_E1
529 S4_BE/BA ICMK14N1
530 S4_AA1A CSM_485
531 S2_AA1A Transmission error - Serial connection (RS485)
CSM485-module - frequency converter hoist gear
532 S4_AA1A Transmission error - Serial connection (RS485)
CSM485-module - frequency converter luffing gear
533 P2_AA1A Transmission error - Serial connection (RS485)
CSM485-module - radio
534 Transfer error – serial connection (RS485) CSM485-module –
AKS
T200-Rack
540 S1-07PS62 Program memory T200 battery error
541 S1-07KP62 Program memory KP62 battery error
542 S1-07POWER Temporary voltage failure
545 S1-AK2F Insulation defect control voltage 115 V
549
General Control Errors E 550 - 569

550 S1_TEMP<> Excess or insufficient temperature S1
551 S1-AK1F / + AF21 Phase-failure three-phase network
552 S1-AQ2F / + AF4 Motor protection switch is activated
553 S1-AF1F / + AF1 Emergency-Stop circuit is activated / Failure of Emergency-Stop
device
554 S1-AK2F Insulation defect control voltage 115 V
555 S1-AK0M Fault S1-BA2 channel 6 (main contactor)
556 S1-AK0M / + AQ0 Contact check fault on AK0M contactor
557 S1_AK01M Main contactor for S4
558 S1_AF6F / + AF6 Automatic circuit breaker is activated (MK80)
559 S1-AQ6F Automatic circuit breaker is activated
560 S1_AA1F / + AKF10 Fault Key-operated switch SCALING
561 S1_AA1F / + AKF10 Fault Key-operated switch ERECTION
562 S1_AA1F / + AKF10 Fault Key-operated switch OVERLOAD 125 %
563 S1_AA1F / + AKF10 Fault Key-operated switch TEACHING
564 DQ1F Motor protection switch twist compensator
565 S1_AF10F / + AF10 Automatic circuit breaker is activated
566 S1_AF11F / + AF11 Automatic circuit breaker is activated
567 S1-AQ9F Automatic circuit breaker is activated
568 S1-IQ1F Âutomatic circuit breaker is activated
569 S1-IQ2F Âutomatic circuit breaker is activated
Control Desk Errors E 570 - 599

570
571 P1-KS1B-I Fault P1-BE2 channel 0 (trolley travel gear/luffing gear direction IN)
572 P1-KS1B-A Fault P1-BE2 channel 1 (trolley travel gear/luffing gear direction OUT)
573 P1-DS1B-R Fault P1-BE2 channel 2 (slewing gear direction RIGHT)
574 P1-DS1B-L Fault P1-BE2 channel 3 (slewing gear direction LEFT)
575 P1-HS1B-H Fault P1-BE2 channel 4 (hoist gear direction UP)
576 P1-HS1B-S Fault P1-BE2 channel 5 (hoist gear direction DOWN)
577 P1-FS1B-V Fault P1-BE2 channel 6 (travel gear direction FORWARDS)
578 P1-FS1B-R Fault P1-BE2 channel 7 (travel gear direction BACKWARDS)
579 P1-HU1 Fault P1-EA1 channel 0 (set value-analogue-hoist gear not 4-20mA)
580 P1-FU1 Fault P1-EA1 channel 1 (set value-analogue-travel gear not 4-20mA)
581 P1-KU1 Fault P1-EA1 channel 2 (set value-analogue-trolley travel gear/
luffing gear not 4-20mA)
582 P1-DU1 Fault P1-EA1 channel 3 (set value-analogue-slewing gear
not 4-20mA)
583 P1-KS1B Trolley travel gear/luffing gear direction pre-selection IN/OUT
simultaneously active or direction pre-selection becomes active
while at the same time "Zero-position" remains active
584 P1-DS1B Slewing gear direction pre-selection RIGHT/LEFT simultaneously
active or direction pre-selection becomes active while at the same
time "Zero-position" remains active
585 P1-HS1B Hoist gear direction pre-selection UP/DOWN simultaneously active
or direction pre-selection becomes active while at the same time
"Zero-position" remains active
586 P1-FS1B Crane travel gear direction pre-selection FORWARDS/ BACK-
WARDS simultaneously active or direction pre-selection becomes
active while at the same time "Zero-position" remains active
587 +A-S1 Error operation mode pre-selection: BA2 only possible with fixed
slewing gear limit switch
590 P1-ES44Q Key-operated switch for bridging the overload protection

591 P1-ES45Q Key-operated switch boom placement
Radius Errors E 600 - 699

EZW
600 EK5F Eddy current brake current excess
601 EF1A Overheat eddy current brake + motor
603 EQ2F Motor protection switch Brake + ventilator

604 EQ3F / EQ31 Motor protection switch Brake
605 EQ6Fr Motor protection switch Eddy current brake
607 EK2B (Fault S4 BA1) luffing gear up

608 EK4B (Fault S4 BA1) luffing gear down
609 EK1M (Fault S4 BA1) luffing gear brake
610 EK20M (Fault S4 BA1) eddy current brake on
611 EK21M (Fault S4 BA1) eddy current brake, stage 3
612 EK22M (Fault S4 BA1)
613 EK23M (Fault S4 BA1)
614 Reserve channel 7
615 EK50M Contact check motor protection ventilator
616 EK40A Contact check
620 EK20M Contact check
624 EK2B Contact check
625 AS51Q Door open S4
626 ES37Q Luffing gear brake worn
627 EK4B Contact check
628 S4_BE1_0
629 S4_BE1_1
630 S4_BE1_2
631 ES7Q-1 Limit switch BOOM down
632 ES8Q Fault S1-BE2 channel 0 (pre-limit switch luffing gear UP)
633 ES7Q Fault S1-BE2 channel 1 (limit switch luffing gear DOWN)
634 ES7Q Fault S1-BE2 channel 2 (limit switch luffing gear UP)
635 ES8Q Fault S1-BE2 channel 3 (pre-limit switch luffing gear DOWN)
637 S4-EF8 Equipment failure, speed monitoring luffing gear
639 EF2V Alni (brake control) incorrectly connected

FU - KAW
640 Contact check motor moment KAW-FU (not within 4-20mA)
641 S1-KF1A Trolley travel gear motor overheat
642 S1-KU1V Fault trolley travel gear frequency converter
643 Fault trolley travel gear power dump unit
644 S1-KK0Q Fault S1-BA2 channel 7 (release frequency converter trolley travel
gear)
645 S1-KK1M Fault S1-BA2 channel 3 (trolley travel gear brake)
646 S1-FK02B Fault S1-BA2 channel 4 (travel gear forwards)
647 S1-FK04B Fault S1-BA2 channel 5 (travel gear backwards)
648 S1_KK1M Contact check trolley travel gear brake
649 S1_KF1F/KQ1F/ Contact check motor protective switch / automatic circuit breaker
KK3M trolley travel gear
650 S1_KQ50F Contact check motor protective switch trolley travel gear ventilator
651 S1_KK3M Contact check engine contactor trolley travel gear
653 =C-KS7Q Fault S1-BE2 channel 1 ("trolley-in" limit switch)
656 =C-KS8Q Fault S1-BE2 channel 0 ("trolley-out" limit switch)
658 =C-KS7Q Fault S1-BE2 channel 2 ("trolley-out" pre-limit switch)
Radius Errors E 600 - 699
660 =C-KS8Q Fault S1-BE2 channel 3 ("trolley-in" pre-limit switch)

661 S1-KQ2F Excess temperature chopper resistance trolley travel gear / auxiliary
drive / travel gear
662 Overspeed trolley travel gear recognised
663 S0/S1-KK2M Contact check "trolley-in"
664 S0/S1-KK4M Contact check "trolley-out"
665 S1-KK0Q Contact check control release frequency converter
666 S1-KF10F Motor protection switch brake
FU - EZW
670 S4-EF1F Checkback signal HF1F luffing gear (bimetal relay)
671 S4-EU1V Fault luffing gear frequency converter
672 S4-TMP<> Overheat switchgear cabinet S4
673 S4-EQ1F / S1-EQ1 Main switch / automatic breaker luffing gear
674 S4-EK50M Contact check luffing gear motor fan
675 S4-EK15A Contact check (release IGBT) luffing gear frequency converter
676 S4-EK2B Contact check (Hoisting) luffing gear frequency converter
677 S4-EK4B Contact check (Lowering) luffing gear frequency converter
678 Bus connection to switchgear cabinet S4 is interrupted
679 S4-EK10M Error engine pressure build-up additional brake
680 S4-EV1G Additional brake applied / speed too high
682 S4-EQ10F Motor protection switch (motor) additional brake

683 S4-ES10G Additional brake not released
684 S4-AA1F Error, key-operated switch: locking the luffing gear
685 S4_AQ1F Motor protection resistor cabinet fan
686 S4_AS1Q Resistor cabinet door limit switch
687 S4_AB1N Temperature monitor resistor cabinet fan
688 S4-EQ1 Contact check main contactor S4 (UL)
699
Slewing Gear Errors E 700 – 789

SL – DRW
705 S1-DF1F/DQ1F Slewing gear safety device
706 S1-DF2F/ Slewing gear brake safety device is activated
S1-DF3F/DQ4F
707 S1-DQ1F/DQ01F Slewing gear motor 1 Motor protection switch is activated
710 S1-DK2B Fault S1-BA2 channel 0 (slewing gear left)
711 S1-DK4B Fault S1-BA2 channel 1 (slewing gear right)
712 S1-DK1M Fault S1-BA2 channel 2 (slewing gear brake)
713 S1_DK40A Contact check slewing gear stage 5 Slewing gear motor 1
721 S1_DK2B Contact check slewing gear right
722 S1_DK4B Contact check slewing gear left
723 S1_DK1M Contact check slewing gear brake
724 S1_DK3M Contact check slewing gear 2 motors
725 S1_DK21A DK21A not activated
Slewing Gear Errors E 700 - 789
EDC - DRW
730 S1-DF2F Slewing gear brake safety device is activated
733 S1-DK1M Fault S1-BA2 channel 1 (slewing gear brake)

734 S1-DK1M Contact check slewing gear brake
735 S1-DK3M Fault S1-BA2 channel 0 (slewing gear engine contactor)
736 S1_DK3M / + D-Q3 Contact check slewing gear contactor
737 S1-DQ50F Contact check DQ50F
738 S1-EDC Fault EDC
739 S1-DF1A Slewing gear motor temperature monitoring
740 EDC reports overheating
741 Slewing gear not released
742 S1-DU2V Control device (Moditorque) of slewing gear brakes not ready
750 S1-DF1F Slewing gear safety

751 S1-DQ50F Motor protection switch slewing gear motor fan
752 S1-DK50M Contact check slewing gear motor fan
753 S1-DQ11/DQ12 Contact check Main contactor slewing gear (UL)
754 S1-DK0Q Contact check Slewing gear control release
755 S1-DK2B Contact check slewing gear right
756 S1-DK4B Contact check slewing gear left
757 S1-DK1M Contact check slewing gear brake
758 S1-DK2M Contact check slewing gear brake 2
759 S1-DK5 Contact check slewing gear frequency converter enabling MAX-
TORQUE (derrick)
760 S1-DU1V Error frequency converter slewing gear not ready
761 S1_DK23A Error limit switch slewing gear brake 1 released (DS62Q)
762 S1_DK023A Error limit switch slewing gear brake 1 or 2 released (DS62Q,
DS63Q)
763 S1-DK23A/DK21A DK21A and DK23A simultaneously active → microswitch error
764 S1-DU1V Contact check Parameter set selection slewing gear frequency
converter
765 Excess temperature chopper resistance slewing gear
766 S1-DQ10F Fuse DQ10F has been activated
767 S1-DQ11F Fuse DQ11F has been activated
768 S1-DF10F / + D-F10 Fuse DF10F has been activated
769 S1-DQ04F Motor protection slewing gear motor 4 has been activated
772 S1-DQ50F Motor protection Ventilator Slewing gear motor 1 has been activated
778 S1-DF1F Thermic motor protection Slewing gear motor 1 has been activated
784 S1-DK50M Contact check Ventilator Slewing gear motor 1
Hoist Gear Errors E 790 - 899

SL - WIW
790 Height check with lateral travel trolley travel gear
791 Height difference with hoist gear synchronised operation exceeds
the permissible value
792 Changing from 4- to 2-fall operation not OK
793 Contact check Hoist-down, stage 1, eddy current brake
794 Contact check motor torque slewing gear frequency converter not
within 2..10V
798 S2_HF3F Excess temperature hoist gear motor 1

799 S2-HF4F Excess temperature hoist gear motor 2
800 S2-MMP Excess / insufficient temperature in switch gear cabinet S2
801 S2-HK5F Eddy current brake current relay
802 S2-HF1A Eddy current brake Overheat
803 S2-HQ1F Motor protection switch for hoist gear motor
804 S2-HQ2F Braking hydraulics motor protection switch is activated
805 S2-HQ4F Magnetic clutch supply motor protection switch is activated
806 S2-HQ6F Eddy current brake motor protection switch is activated
807 S2-ALNI Monitoring ALNI E44
808 S2-HK1F/HK4F Contact check current relay coupling 1 / motor 2
811 S2-HK51M Contact check contactor ventilator
812 S2-HK2B Fault S2- channel 0 (Hoisting-up)
813 S2-HK4B Fault S2- channel 1 (Hoisting-down)
814 S2-HK1M Fault S2- channel 2 (Hoist gear brake)
815 S2-HK20M Fault S2- channel 3 (Eddy current brake on)
816 S2-HK21M Fault S2- channel 4 (Eddy current brake level 1)
819 S2-P1C Fault S2- channel 7 (Hoist gear operating hours counter)
820 S2_HS11Q Fault S2-BE1 channel 0 (Moment overload)
821 S2_HS12Q Fault S2-BE1 channel 1 (Constant overload)
822 S2_HS13Q Fault S2-BE1 channel 2 (Overload Gear ratio 2)
823 S2_HS14Q Fault S2-BE1 channel 3 (Overload Gear ratio 3)
824 S2_HS20Q Fault S2-BE1 channel 4 (Moment speed reduction 95 %)
825 S2_HS8Q Fault S2-BE1 channel 5 ("Hoist-up" limit switch)
826 S2_HS7Q Fault S2-BE1 channel 6 ("Hoist-down" limit switch)
827 S2_HS8Q/1 Fault S2-BE1 channel 7 ("Hoist-up" pre-limit switch)
829 S2_HK1A Contact check Gear ratio 1

832 S2_HK2B Contact check Hoisting-up
833 S2_HK4B Contact check Hoisting-down
834 S2_HK50M Contact check Fan
835 S2_HK1M Contact check Hoist gear brake (with K-cranes, S1-HK2M)
836 S2_HK1F Contact check current relay coupling 1 / motor 1
839 S2_HK20M Contact check
843 S2_HK40A Contact check
847 S2_ HS1M Key-operated switch Operation Hoist gear brake released (HCL)
Hoist Gear Errors E 790 - 899
848 S2-AS51Q Switchgear cabinet S2 not closed

849 B-HF2V Alni (brake control) incorrectly connected (only for starting up the
crane or repair)
850 S2-HK1H Hoist gear brake worn
FU - WIW
851 S2_X2_400 Ventilator overheat
852 S2_HF1A Motor overheat
853 S2_TMP<> Excess/insufficient temperature in S2
854 S2_HQ1F / S1-HQ1 Motor protection switch FU-WIW
855 S2_HQ2F/HQ50F Motor protection switch brake and ventilator
856 S1-HS1F Centrifugal switch hoist gear is activated
857 S2-HQ3F/S2-HQ31 Motor protection/automatic circuit breaker brake voltage transformer
858 S2-HQ4F/S2-HF4 Motor protection switch/automatic circuit breaker brake
859 S2-HQ1 Contact check Main contactor S2 (UL)
860 S2_HS11Q Fault S2-BE1 channel 0 (moment overload)
861 S2_HS12Q Fault S2-BE1 channel 1 (constant overload)
862 S2_HS13Q Fault S2-BE1 channel 2 (gear 2 overload)
863 S2_HS14Q Fault S2-BE1 channel 3 (gear 3 overload)
864 S2_HS20Q Fault S2-BE1 channel 4 (moment speed reduction 95 %)
865 S2_HS8Q Fault S2-BE1 channel 5 (limit switch hoist-up)
866 S2_HS7Q Fault S2-BE1 channel 6 (limit switch hoist-down)
867 S2_HS8Q/1 Fault S2-BE1 channel 7 (pre-limit switch hoist-up)
868 S2_HU1V Brake monitoring, frequency converter
869 S2-HF8 Equipment failure, speed monitoring hoist gear
870 S2_HN1M Power dump unit overheat
871 S2_AUX_OUT_2 Frequency converter hoist gear reporting malfunction
872 OVERSPEED VCI motor speed monitoring shut-off
873 S1-HQ2F Excess temperature in braking resistor
874 E874-Senk=0 No change in the hook level despite drive command
875 Gear changeover of hoist gear is incorrect
876 Contact check motor torque not 4…20mA
877 S2_HQ51F Motor protection brake 2 and ventilator 2
878 S2_HL1M Excess temperature power choke
879 S2_HK2M Contact check contactor brake 2
880 S2_HK2B/S1_HK1M Contact check motor contactor
881 S2_HK1M Contact check hoist gear brake
882 S2_HF1F Contact check HF1F (T200-E44)
883 S2_A1.30,43/HK15B Contact check "IGBT Release" hoist gear frequency converter
884 S2_HK2B Contact check "Hoisting-up" hoist gear frequency converter
885 S2_HK4B Contact check "Hoisting-down" hoist gear frequency converter
886 Bus connection (AC31) to switchgear cabinet S2 interrupted
887 S2_HF2F Contact check HF2F
889 S1-AF5F Automatic circuit breaker hoist gear brake is activated

890 S2_HS38-Q1/2 Hoist gear brake worn
891 S2_HK1H Voltage monitoring gear changeover
892 S2_HK50M Contact check motor fan
893 S2_HK3H Hoist gear brake 2 worn
894 S2_HQ10Q Error, engine additional brake (pressure switch)
895 S2_HU1G/2G/3G Speed monitoring additional brake actuated
896 S2-HS12G Brake lining additional brake worn
897 S2-HQ10F Motor protection switch additional brake
898 S2-HS10G Additional brake applied
899 S2_AS52Q Resistor cabinet is not closed
Travel Gear Errors E 900 - 929

SL -FAW
900 S1-FF1F Motor protection switch travel gear
901 Contact check travel gear forwards
902 Contact check travel gear backwards
903 S3-AB1N Excess or insufficient temperature S3
904 FK0M Contact check contactor
905 S3-FQ0F Motor protection switch has been activated
906 S3-FQ21F / FQ3F Motor protection switch has been activated
907 S3-FK0Q Contact check control release
908 S3-AS50Q Door limit switch resistor cabinet
909 S3-FU1V Fault frequency converter travel gear
910 Motor protection travel gear motors or brake safety device has been
activated
911 S3-AK20M Contact check contactor travel gear warning device
912 S3-FQ40F Motor protection switch hydraulic system rail clamp 1
913 S3-FQ50F Motor protection switch hydraulic system rail clamp 2
914 Oil pressure rail clamp 1 too high
915 Oil pressure rail clamp 2 too high
916 S3-FQ2F Motor protection switch has been activated (rail clamp supply)
917 S3-FF2F Automatic circuit breaker rail clamp 1 and 2 (valves) has been
activated
918 S1-FQ2/FQ11 Contact check Main contactor travel gear (UL)
923 Error cable drum operation
929
Luffing Gear Frequency Converter Errors E 930 - 964

FU-EZW
930 A_8 DC link undervoltage
931 A_7 DC link overvoltage
932 A_4 Phase missing
933 A_2 Resulting reference error
934 A_29 Excess temperature
935 A_32 Missing motor phase W
936 A_31 Missing motor phase V
937 A_30 Missing motor phase U
938 A_48 Tracking fault
940 A_36 Mains power failure

941 A_37 Converter error
942 A_26 Brake power error
943 A_45 Load error
944 A_44 Encoder error
945 A_46 Watchdog
946 A_43 Brake test error
947 Error stored
948 A_47 Flash memory error
949 A_3 Motor is not connected
950 A_ Switch-on error
953 A_ Bus cycle exceeding time limit

954 A_16 Short circuit
955 A_ Supply error
956 A_14 Earth error
957 A_13 Excess current
958 A_ Moment limit achieved
959 A_11 Excess motor temperature
960 A_ Excess thermal motor current
961 A_ VLT excess current
964
Hoist Gear Frequency Converter Errors E 965 - 999

FU-WIW
968 A_8 DC link undervoltage
969 A_7 DC link overvoltage
970 A_4 Phase missing
971 A_2 Resulting reference error
972 A_29 Excess temperature
973 A_32 Missing motor phase W
974 A_31 Missing motor phase V
975 A_30 Missing motor phase U
976 A_48 Tracking fault
978 A_36 Mains power failure

979 A_37 Converter error
980 A_26 Brake power error
981 A_45 Load error
982 A_44 Encoder error
983 A_46 Watchdog
Hoist Gear Frequency Converter Errors E 965 - 999
984 A_43 Brake resistance test error

985 Error stored
986 A_47 Flash memory error
987 A_3 Motor is not connected
988 A_ Switch-on error
991 A_ Bus cycle exceeding time limit

992 A_16 Short circuit
993 A_ Supply error
994 A_14 Earth error
995 A_13 Excess current
996 A_ Moment limit achieved
997 A_11 Excess motor temperature
998 A_ Excess thermal motor current
999 A_ VLT excess current
Module Error with Decentralised PLC Errors E 1500 - 1549
1503 Node-ID 3 not operational

Limit switch monitoring errors E 1600 - 1799

1600 Limit switch "Connection plate available" not OK
1601 Limit switch "Jib pinned" not OK
1602 Limit switch "Jib lower chord pinned" not OK
1603 Limit switch "Pre-centring unlocked" not OK
1.2 List of all warnings
ABB Operating-range Limitation Warnings W 0 - 99
Warning No. Fault Cause

1
90 Operating-range limitation not active
99
LMB Load Moment Limitation Warnings W 100 - 199
111 Overload pre-warning during “load moment 1” operation

113 Overload during "load moment 1" operation
121 Overload pre-warning during “load moment 2” operation

123 Overload during "load moment 2" operation
144 Trolley/luffing gear too far out during scaling of the load-moment
sensor
146 W_K<MAX Trolley too close in during scaling of the load-moment sensor
148 W_< = 60% Load for scaling < = 60 % of the maximum lifting capacity
149 Load-moment scaling only possible after load has been scaled
150 Load-moment scaling only possible after trolley has been scaled
151 Reference load larger than maximum lifting capacity (>100%)
152 Rescaling of the trolley only possible without load
153 Reference loads for frequency converter not entered in EMS
154 Load value for speed protection not entered in EMS
155 Crane type cannot be modified on the EMS, crane type programmed
in PLC
156 Dead weight recording not completely finished (HCL)
157 Hoist gear Up setting with max. radius only (HCL)
158 Hoist gear scaling only possible after radius has been scaled (HCL)
159 Repeat scaling of hoist level sensor, lowering path too short (pulse
generator)
160 Max. radius can not be scaled, as luffing gear angle not at 15° (+-2°)
161 Radius beyond articulation point and load measuring axle not scaled
162 Dead weight torque not yet recorded
163 Load for load moment scaling is too large, delta angle CAL1-CAL5
is too small (<10°)
164 Recording of load moment curve was aborted
165 Load moment points are not accepted yet
166 Active lifting capacity table is reduced
167 Crane not scaled
168 No counterballast available
180 W_WIND_140 Wind warning > 14 m/s (50km/h), no "load moment 2" - operation
permitted
181 125% key-operated switch cannot be used when "load moment 2" -
operation in progress
EMS Electronic Monitoring System Warnings W 200 - 299

200 No "load moment 2" - lifting capacity table put in
201 No lifting capacity table for crane type required by PLC
299
KP62/KT98 Communications Processor Warnings W 300 - 399
310 W_310 Trolley-OUT pre-limit position approached

311 W_311 Hoist gear brake wear
312 W_312 Hoist-DOWN stage 1 and gear ratio 1 or hoist-UP stage 1 or 2
longer than 15 sec.
313 W_313 Trolley-OUT limit position approached
331 W_331 Battery error KT98 or S7 central unit

332 W_332 SMC-card not inserted in KT98 or not initialised
333 W_333 Read or write failure on SMC-card KT98
334 W_334 Arcnet-data packet could not be sent (timeout)
335 W_335 No crane type selected
336 W_336 Check sum error in the RAM of the control. The data could be
restored.
337 W_337 File allocation table (FAT) on the SMC-card is incorrect. The data
could be restored.
338 Battery error KT94-S
339 Polygonal line incorrect → values are reset to default values
AKS Anti-collision System Warnings W 400 - 449

400 At least 1 travel gear AKS-sensor has responded
401 AKS bridged via key-operated switch
449
Automatic Crane Movements Warnings W 450 - 499

450 Emergency stop from guide computer
451 No release positions (KAW) programmed
452 Trolley travel gear outside of automatic area to start automatic
operation
469 E_469 deactivated!

470 Trolley travel gear is not allocated a limit switch, thus no
authorisation for lowering
480 Emergency cut-out trolley-out

481 Emergency cut-out trolley-in
482 Emergency cut-out hoist-up
483 Emegency cut-out hoist-down
498 Emergency operation of all drives

499 Manual operation during erection
General Control Warnings W 500 - 569

500 P1_BE/BA ICMK14N1, Output channel short circuit or overload
501 S2_BE/BA, S4_BE/BA ICMK14N1, Output channel short circuit or overload
502 S4-BE/BA ICMK14N1, Output channel short circuit or overload
510 Time or date of the real-time clock outside of the permissible

range during adjustment
511 K-crane ABB: Max. load or max. load moment of the crane not
set (MDE)
545 DA7M Fault on centralised lubrication system 1

546 Fault on centralised lubrication system 2
547 S0-AQ1M Motor protection has been activated light – heating – air
conditioning
548 Prewarning excess temperature at supply transformer
549 Excess temperature at supply transformer
551 Erection mode with tower active (derrick)

552 Luffed jib position or telescoping erection is active
553 W_AF1M Emergency-Stop (P1)
554 Emergency-Stop (S1)
555 (XOFF) Operation mode Teaching
556 Operation mode Scaling
557 Operation mode Erection
558 Stability test 125 % Overload
559 Key-operated switch Hoist gear brake released
560 Key-operated switch Luffing gear brake released
561 Key-operated switch bridging LMB and hoist-down limit switch
(HCL)
562 Key-operated switch re-reeving (auxiliary operating panel active)
563 Key-operated switch luffing gear locking
564 Emergency-Stop with erection switch bridged
566 Error with connection of temperature sensor (analogue input

KT98) or with temperature recognition S1
567 S2_HK3H Ambient temperature below -25°C, loads les s than 500 kg may
be lifted
568 W_WIND_138 Wind warning > 13,8 m/s (49,68 km/h)
569 W_WIND_200 Wind warning > 20,0 m/s (72,00 km/h)
Control Desk Warnings W 570 - 599

570 Control levers are not in the "ZERO" position when pressing the
"control on" push-button
599
Radius Warnings W 600 - 669

600
601 Trolley travelling not possible when the hook is situated in the canal
625 AS51Q Switchgear cabinet door S4 open

626 ES37Q Brake worn
627 Brake error
669
Luffing Gear Warnings W 670 - 699

670 S4-ES12G Brake lining additional brake worn
671 S4-ES51Q Luffing gear locked
672 S4_AS53Q Resistor cabinet fan out of order! Speed reduction hoist gear / luffing
gear to 25%
673 P1_AS2V Level luffing not possible: Radius or hook level not scaled or number
of layers not entered
674 Luffing gear sensor not in valid area
685 S4-AQ1F Motor protection resistor cabinet fan (S2/S4)
687 S4_AB1N Temperature monitoring resistor cabinet fan (S2/S4)
699
Slewing Gear Warnings W 700 - 799

700 Luffing gear radius too small for free jib slewing (HC-L)
701 Start position for shut-down position not yet attained (HC-L)
799
Hoist Gear Warnings W 800 - 899
801 No external activation for operation of the hoist gear
840 For automatic hoist rope re-reeving, trolley is not in "trolley-in limit
switch" position
841 For automatic hoist rope re-reeving, load hook is not in position
"hoist-up limit switch" position
842 For automatic hoist rope re-reeving, too much load is on the hook
(>= 500 kg)
843 Re-reeving procedure active. No other operation mode possible.
849 S2_HK2H Brake lining brake 2 worn

850 S2_HK1H/HS37Q Hoist gear brake lining worn
851 W_TEMP_LÜF Excess temperature ventilator hoist gear motor is activated
852 Overload Hoist gear ratio 2
856 W_HS39Q Pressure switch on hoist gear brake, pressure drop
857 Frequency converter in the hoist gear is not operational
858 Select gear ratio 1, measuring axle not yet scaled!
860 P1_ES44Q Rescaling of "Hoist-down" limit switch only without load (< 300 kg)
861 Hoist gear in limit switch range, level luffing only a limited course
possible!
862 Caution! Error during wiring of the identifier for 1-, 2- and 3-speed
hoist gear!
863 Brake error
864 Hoist gear sensor outside of valid area
870 Level luffing active. Positioning operation blocked.
Hoist Gear Warnings W 800 - 899
896 AQ10F Motor protection fan 1 resistor cabinet

897 AQ11F Motor protection fan 2 resistor cabinet
898 W_TÜR_S2 Switchgear cabinet S2 is not closed
899
Travel Gear Warnings W 900 – 927

900 S3-FK45/55M Brake lining, rail clamp 1 or 2 worn
901 S3-FM1M Motor protection or safety device brake motor 1 / motor 21 has been
activated
activated
activated
activated
activated
activated
activated
activated
909 S3-FM9M Motor protection or safety device brake motor 9 has been activated
921 S3-AS1Q Emergency-Stop 1 travel gear
927
Luffing Gear Frequency Converter Warnings W 928 - 959

928 W_2 Resulting reference error
929 W_1 10V at terminal 50 too low
930 W_ Brake supply warning
931 W_ Brake supply error
932 W_25 Brake resistor error
933 W_27 Brake IGBT error
934 W_35 Motor not ready.
937 W_36 Mains power failure
942 W_50 Error when applying brake (frequency converter luffing gear)
943 W_49 Error when releasing brake (frequency converter luffing gear)
944 W_23 Brake test error
945 W_20 Error control board
946 W_19 Power control board error
948 W_ Bus cycle exceeding time limit

949 W_13 Excess current
950 W_12 Torque limit
951 W_11 Excess motor temperature
952 W_ Excess thermal motor current
953 W_ VLT excess current
954 W_8 DC link undervoltage
955 W_7 DC link overvoltage
956 W_6 DC link voltage low
957 W_5 DC link voltage high
958 W_4 Phase missing
959 W_ No motor connected
System Warnings W 960 - 967

960 Scaling operation mode active > 90 min
961 Teaching operation mode active > 90 min
967
Hoist Gear Frequency Converter Warnings W 968 - 999

968 W_2 Resulting reference error
969 W_1 10V at terminal 50 too low
970 W_ Brake supply warning
971 W_ Brake supply error
972 W_25 Brake resistor error
973 W_27 Brake IGBT error
974 W_35 Motor not ready.
977 W_36 Mains power failure
982 W_50 Error when applying brake (frequency converter hoist gear)
983 W_49 Error when releasing brake (frequency converter hoist gear)
984 W_23 Brake test error
985 W_20 Error control board
986 W_19 Power control board error
988 W_ Bus cycle exceeding time limit

989 W_13 Excess current
990 W_12 Torque limit
991 W_11 Excess motor temperature
992 W_ Excess thermal motor current
993 W_ VLT excess current
994 W_8 DC link undervoltage
995 W_7 DC link overvoltage
996 W_6 DC link voltage low
997 W_5 DC link voltage high
998 W_4 Phase missing
999 W_ No motor connected
Module Error with Decentralised PLC Errors W 1500 - 1549

1500 Bus diagnosis active
1.3 List of all messages
ABB Operating-range Limitation Messages M 0 - 99
Message No. Fault Cause

1
90 Operating-range limitation not active!

91 Square V0-V3 inactive!
99
LMB Load Moment Limitation Messages M 100 - 199

100
111 Overload pre-warning during "load moment 1" operation
121 Overload pre-warning during "load moment 2" operation
144 Hoist sensor not scaled
146 Trolley sensor not scaled

147 Dead weight recording has not yet been carried out (HC-L)
148 Load sensor not scaled
149 Load moment sensor not scaled
150 Crane has already been scaled with other rope run variants
160 LM2 operation not activated
199
EMS Electronic Monitoring System Messages M 200 - 299

200
299
KP62 Communications Processor Messages M 300 - 399

300
310 Time or data has been changed

311 Crane interlock: KSE-bit changed
312 Crane interlock: KV-bit changed
313 Crane interlock: Password changed
314 Rope run was switched over
315 SWP-record reset
316 New drive unit group entered in the SWP-record
399
AKS Anti-collision System Messages M 400 - 449

400 AKS limits trolley travel gear
401 AKS limits hoist gear
402 AKS limits slewing gear
403 AKS limits travel gear
404 Connection to AKS-interface was deselected via the EMS
405 Connection to AKS-interface was selected via the EMS
449
Automatic Crane Movements Messages M 450 - 499

450
491 Limit switch "Auxiliary hoist gear down" activated

492 Spindle not extended and not retracted
499 Automatic crane operation running
General Control Messages M 500 - 569

500
540 Programming mode display active
551 S1_AK1H Supply voltage undervoltage control

552 No operation release from the control centre. The control system
can not be activated!
560 Operation mode KAW-synchronised selected

561 Operation mode WIW-synchronised selected
562 Operation mode automatic selected
563 Special operation mode – Ballast disassembly and jib folding
569
Control Desk Messages M 570 - 599

570 Right-hand deadman function (hoisting / travelling)
571 Left-hand deadman function (slewing / trolley travelling)
572 Deadman function via seat contact
599
Radius Messages M 600 - 699

600 P1_AS2V Level luffing active
601 S4-AB2 Tower inclination limit switch "up" actuated (derrick)
602 S4-AB2 Tower inclination limit switch "down" actuated (derrick)
699
Slewing Gear Messages M 700 - 799

700
701 S1-DK23A Free jib slewing reached
702 End position for out-of-operation position reached (derrick)
704 Pre-limit switch area slewing gear limitation active
711 Slewing gear setting stage 1 selected

712 Slewing gear setting stage 2 selected
Slewing gear setting stage 3 selected
799
Hoist Gear Messages M 800 - 899

800
801 Cable remote-control WIW in canal activated
899
Travel Gear Messages M 900 - 959

900 Rail clamp not yet open. Rail clamp only opens following a travel
command.
901 S3-NF1F Power supply fuse for cable drum has been activated
902 S3-NF2F Fuse for cable drum heating has been activated
903 S3-N1 Fault in cable drum drive: travel gear locking
904 S3-N1 Fault in cable drum drive: taut cable
905 S3-N1 Fault in cable drum drive: slack cable
906 S3-N1 Fault in main supply for cable drum drive
907 S3-N1 Fault in motor protection switch cable drum drive fan
910 End of rail reached
959
System Messages M 960 - 979

960
979
1.4 List of all status messages
ABB Operating-range Limitation Status Messages S 0 - 99
Status No. Fault Cause

1
99
LMB Load Moment Limitation Status Messages S 100 - 199

100
199
EMS Electronic Monitoring System Status Messages S 200 - 299

200
299
KP62 Communications Processor Status Messages S 300 - 399

300
399
AKS Anti-collision Status Messages S 400 - 449

400
449
Automatic Crane Movements Status Messages S 450 - 499

450 Guide computer in operation mode "Automatic"
451 Guide computer malfunction
452 Activation descent
453 Activation ascent
460 Bucket in position for filling procedure
499
General Control Status messages S 500 - 569

500
550 Main switch switched on again

551 Crane operation blocked
569
Control Desk Status messages S 570 - 599

570
599
Radius Status messages S 600 - 699

600
670 S4_HU1V Frequency converter luffing gear is not ready for operation
699
Slewing Gear Status messages S 700 - 799

700
799
Hoist Gear Status messages S 800 - 899

800
801 S1 Step 1 automatic hoist rope re-reeving 2-fall → 4-fall active!

857 S2_HU1V Frequency converter hoist gear is not ready for operation
899
Travel Gear Status messages S 900 - 959

900
959
System Status messages S 960 - 979

960 Operation mode Radio remote control active
961 Operation mode 1 active (derrick – without stifflegs)
962 Operation mode 2 active (derrick – with stifflegs)
979
1.5 Abbreviations:
FU = Frequency converter
SL = Slip-ring motor
Pol. = Pole-changing motor
EDC = Electronic slewing gear controller
ELMAG = Electromagnetic-shift gearbox
SPS = Programmable logic controller
SS = Key-operated switch
EGZ = Electronic limit status monitoring ( LITRONIC )
LM1 = Standard load moment ( LITRONIC )
LM2 = PLUS (increased) load moment ( LITRONIC )
EZW = Luffing gear
KAW = Trolley travel gear
DRW = Slewing gear
WIW = Hoist gear
FAW = Travel gear
Frequency converter hoist gears on Litronic cranes Appendix V
Status: 12.01.2007
1-speed frequency converter hoist gears "RELIANCE"
6 t 1-speed, RELIANCE VCI088 / 45kW
Description Speed 1
Constant load 6.000kg
Load speed monitoring 4.500kg
Description Speed 1
Description Speed 1
* Standard hook height = admissible free-standing height, see instruction manual chapter 2
5_fu-hubwerke-en.doc / LITRONIC Appendix V 1

1-speed frequency converter hoist gears Appendix V
on Litronic cranes up to 37 kW
Load speed monitoring Ref I: 1700 r.p.m.
Load speed monitoring Ref II: 3000 r.p.m. (maximum speed 4000 r.p.m.)
6 t 1-speed WIW 240 MZ 401, DANFOSS VLT5042 / 30kW

6 t 1-speed WIW 240 MZ 403, DANFOSS VLT5042 / 30kW*
Description Signal Speed 1 Limit switch

Constant load 6.000kg HS 12 Q
Load speed monitoring Ref. I 4.000kg HS 20 Q
Load speed monitoring Ref. II 2.500kg HS 21 Q





* Standard hook height = admissible free-standing height, see instruction manual chapter 2.
2 Appendix V 5_fu-hubwerke-en.doc
on Litronic cranes 45 kW











8 t 1-speed WIW 280 MZ 403, DANFOSS VLT5102 / 65 kW

8 t 1-speed WIW 280 MZ 409, DANFOSS VLT5102 / 65 kW

1-fall (6 layers)
1-fall (10 layers)





on Litronic cranes up to 37 kW

Load speed monitoring Ref II: 2200 r.p.m.
6 t 2-speed WIW 220 VZ 401, DANFOSS VLT5042 / 22kW
Description Signal Speed 1 Limit switch Speed 2 Limit switch

Constant load 6.000 kg HS 12 Q 3.300 kg HS 13 Q
Load speed monitoring Ref. I 4.500 kg HS 20 Q 2.600 kg HS 22 Q
Load speed monitoring Ref. II 2.600 kg HS 21 Q 1.600 kg HS 23 Q
6 t 2-speed WIW 240 VZ 403, DANFOSS VLT5052 (3052) / 30kW






2-speed frequency converter hoist gears on Litronic cranes Appendix V
up to 37 kW















45 kW



1-fall
2-fall operation for cranes with standard hook height*





65 kW
1-fall



(on cranes with 2-/4-fall operation, only the values for the 4-fall operation have to be entered)

4-fall (on cranes with 2-/4-fall operation, only the values for the 4-fall operation have to be entered)
65 kW




Description Signal Speed 1 L. switch Speed 2 L. switch Speed 3 L. switch
Constant load 16.000kg HS 12 Q 9.500kg HS 13 Q 5.200kg HS 14 Q
Load speed monitoring Ref. I 17.300kg HS 20 Q 10.300kg HS 22 Q 5.200kg HS 24 Q
Load speed monitoring Ref. II 13.000kg HS 21 Q 7.400kg HS 23 Q 3.400kg HS 25 Q


2-fall operation for cranes with standard hook height* (5 layers)






20/40 t 3-speed WIW 300 VZ 401, DANFOSS VLT5200 / 110kW

2/4-fall operation for cranes with standard hook height*

4-fall 167 m hook height (on cranes with 2-/4-fall operation, only the values for the 4-fall operation
have to be entered)
25/50 t 3-speed WIW 300 VZ 415, DANFOSS VLT5200 / 110kW*

Appendix VI: Radio remote control – with and without feedback
Example:
Radio remote control FST770 featuring integrated LCD-display (Part No.: 1003 8868)
Connecting componentry "Radio remote control" (Part No.: 9317 292 01)
Adjustments to the CSM 485-module may only be carried out by authorised service
personnel!
Setting the DIP switch:

The CSM 458–module must be set OFF ON
1
for operation with a radio remote control. 2
3 OFF ON
In the picture represented on the right, all 4
5 1
pressed DIP switches are highlighted in 6

7
2
3
4
black! 8
System summary:
S1
KT94S
CS31
SPS (TP)
Circuit board
X1
Radio remote CS31-BUS

control Control line
RS485
with feedback
10
CSM 485
Connecting Modul
componentry
"Radio remote Set DIP
switches
control" 24V+ 0V
Antenna Radio receiver

See cicuit
diagram
Id:931729201
X20
Harting-
connector
Control line 9
RS485
6_anhang_VI-en.doc Appendix VI 1
2 Appendix VI 6_anhang_VI-en.doc
Index chapter 2 (EMS)
Keyword Chapter Keyword Chapter

Acknowledging error messages 2.1.6.1 Long-term machine data 2.3.7
Acoustic drives 2.4.5 Long-tone (buzzer) 2.1.5
Acoustic signal 2.1.5 Machine data capture (MDE) Chapter 4
Anti-collision system 2.2.8.9 Machine data screen 1 2.3.7
ARCNET 2.5.1 Main menu 2.4.0
ARCNET bus 1.1.4 / 2.1.2 / 2.2.3 Menu operation 2.1.4
Article code 2.5.4 Menu point 2.1.4
B1 Display mask 2.3.1 Message 2.1.6
B2 Display mask 2.3.2 Message lines 2.3.7
B3 Display mask 2.3.3 New scaling 2.2.8
B4 Display mask 2.3.4 Number values, crossed-through 2.1.3
B5 / B6 customized 2.4.6 Operating mode window 2.2.6
B5 Display mask 2.3.5 Operator menu B5/B6, customized 2.4.6
B6 Display mask 2.3.6 Operator menus B1 - B7 3
B7 Display mask 2.3.7 Parameter field 2.1.4
Bar graph 2.3.0 Parameter screen ABB 2.5.0
Battery change (KT98) 1.1.6 Parameter screen EMS 2.5.1
Baud rate 2.5.1 Parameter screen LMB 2.5.0
BNC plug 2.2.3 Parameter screen sensors 2.5.2
BOOT-EPROM 2.5.1 PCL central unit 1.1.4
Buzzer 2.1.5 Power supply EMS 2.2.2
COAX cable 2.2.3 Protocol 2.5.1
Code number 2.1.7 Radio remote control Appendix VI
COM1 2.5.1 Reeving load hook 2.4.2
COM2 2.5.1 Reference points (REF) 2.4.1 / 2.3.2 / 2.3.4
Crane parameters 2.5.3.1 Reference value, control lever 2.5.3
Data connection 2.2.3 rel (relative distance) 2.4.1 / 2.3.2 / 2.3.4
Data transfer connection 1.1.4 Re-scaling 2.2.8
Date and Time 2.4.7 Rope-run variants 2.4.2
Diagnostic message 2.1.5 / 2.1.6 Rope-run, changing 2.4.2
Diagnostic messages (list) Appendix IV RS232 1.1.4
Diagnostic screen 2.5.1 RTS/CTS 2.5.1
Dimensioning test load 2.2.8.1 Safety provisions 1.1.1
Drive reference value 2.5.3 Scaling 2.2.8
EMS assembly 2.2.1 Scaling screen (sensors) 2.5.2
EMS parameters, setting 2.5.1 Scaling, hook level 2.2.8.6
Error message 2.1.6 Scaling, load 2.2.8.4
Footer 2.1.3 Scaling, load moment 2.2.8.5
Header 2.1.3 Scaling, travel gear 2.2.8.7
Hotline 2.1.0 Scaling, trolley travel gear 2.2.8.3
INFO screen 2.5.4 Scaling, turn-off 2.2.8.9
Initial state 2.2.6 Scaling, turn-on 2.2.8.2
Installation 2.2.0 Screen area 2.1.3
Installation, electrical 2.2.2 Self test 2.2.6
Interfaces on EMS 1.3 / Appendix III Sensor function test 2.2.8
Keyboard 2.1.4.1 / Appendix I Sensor measurement units 2.1.3 / 2.2.7
KT 94 S 2.2.6 / 2.5.3 Sensor slewing angle 2.8.8 / 3.0
KT 98 2.2.6 / 2.5.3 Sensor slewing speed 2.8.8
Lifting capacity reduction 2.4.3 Sensor value slewing angle 2.5.2
Lifting capacity table 2.3.1 Sensor value slewing speed 2.5.2
Limitation point ABB 2.3.1 / 2.3.3 Sensor value wind 2.5.2
Limitation shape ABB 2.3.5 / 2.3.6 Sensor values, hook level 2.5.2
LMB parameters, setting 3.2.1 / 5.0 Sensor values, load 2.5.2
Load moment curve LMB 2.3.4 / 2.3.6 Sensor values, load moment 2.5.2
Load moment limitation (LMB) Chapter 2 Sensor values, travel gear 2.5.2
Lock symbol 2.1.7 Sensor values, trolley 2.5.2
stichwortverzeichnis-en.doc Index 1
Sensor wind 2.2.8.8 System overview, Litronic crane 1.1.4
Service menu 2.5.0 Teaching (ABB) Chapter 4
Setting contrast 2.1.2 Technical data Appendix II
Short-term machine data 2.3.7 Terminal resistor 2.2.3
Shut-off point LMB 2.3.1 / 2.3.3 Test overload 2.5.3.1
Slewing gear stages adjustment 2.4.6 Test pre-overload warning 2.5.3.1
SMC card 2.5.3.1 Test screen 2.5.3
Software version 2.5.4 Test screen (Assembly screen) 2.5.3
Special operating modes 2.2.4 Test wind warning 2.5.3.1
Stability safety test 2.5.3.1 Text field 2.5.4
Start-up 2.2.0 / 2.2.5 Time and date 2.4.7
Status line 2.3.7 T-piece 2.2.3
Status message 2.1.6 Warning messages 2.1.6
Switchgear cabinet S1 1.1.4 Work number 2.5.4
Switchgear cabinet S2 1.1.4 Work range limitation (ABB) Chapter 3
Symbols 1.1.2 / Appendix I XON/XOFF 2.5.1
Index Chapter 3 (LMB)

B2 Display mask 2.3.2 Load speed monitoring 3.2.0 / 3.2.4
B4 Display mask 2.3.4 Main menu 2.4.0
B6 Display mask 2.3.6 Mode of operation, LMB 3.1.4
Bar graph 2.3.0 Output reduction factor 3.2.0 / 3.2.5
Changing LMB data 3.2.0 Overload 3.1.4 / 3.1.7
Control speeds 3.2.0 / 3.2.3 Parameter screen LMB 3.1.8 / 3.2.0
Crane type 3.2.0 / 3.2.1 Pre-overload warning 3.1.4 / 3.1.6
Diagnostic messages 3.5.0 / Appendix IV Radio remote control Appendix VI
Display mask B2 2.3.2 rel (relative distance) 2.3.0
Display mask B4 2.3.4 Rope layers 3.2.0 / 3.2.2
Display mask B6 2.3.6 Safety information 3.1.1
Drive gears 3.2.0 / 3.2.3 / 3.2.4 Scaling screen 3.2.0
Error 3.4.1 Sensor monitoring (principle) 3.1.3
Frequency converter hoist gear Appendix V Sensor parameter screen 3.2.0
Function test, LMB 3.3.0 Service menu 2.5.0
Gear shutdown 3.1.4 / 3.2.3 Shut-off point of the LMB 2.3.2 / 2.3.4 / 2.3.6
Hoist gear output, reducing 3.2.0 / 3.2.5 SMC card 2.5.3.1
Hoist rope (weight) 3.2.0 / 3.2.2 Special version 3.2.0 / 3.2.1
Hotline 1.1.3 Stability safety test 2.5.3.1
Key number 2.1.7 System overview, LMB 3.1.2
Lifting capacity 3.1.5 Technical data Appendix II
Lifting capacity charts 3.2.0 / 3.2.1 Test overload 2.5.3.1
Lifting capacity reduction 2.4.3 Test pre-overload warning 2.5.3.1
Limitation point of the ABB 2.3.0 Tolerance (mt) 3.1.3
LM1 mode 3.1.5 / 2.3.4 / 2.3.6 Tower head 3.1.2
LM2 mode 3.1.5 / 2.3.4 / 2.3.6 / 3.2.1 Tower height 3.1.5
LMB parameter screen 3.1.8 / 3.2.0 Travel speeds 3.1.5
Load measuring axle 3.1.2 Trolley travel gear 3.1.2
2 Index stichwortverzeichnis-en.doc
Index chapter 4 (ABB)

ABB parameter screen 4.3.2 Programming quadrilateral 4.3.3.4
Angle (circle sector) 4.3.1 Programming, circle sector 4.3.3.3
Angle (polygonal line) 4.3.1 Prohibited area 4.1.2 / 4.1.3
Bar graph 2.3.0 Quadrilateral 4.1.3 / 4.3.3.4
Circle sector 4.1.3 / 4.3.3.3 Radio remote control Appendix VI
Crane middle-point 4.3.1 Reference points 2.3.0
Date (teaching) 4.3.2 Safety information 4.1.1
Diagnostic messages 4.6.0 / Appendix IV Service menu 2.5.0
Display mask B1 2.3.1 Slewing area 4.1.3 / 2.3.5 / 2.3.6
Display mask B3 2.3.3 SMC card 2.5.3.1
Display mask B5 2.3.5 Symbols 4.0 / Appendix I
Display mask B6 2.3.6 System overview, ABB 4.1.2
E 39 (example) 4.6.1 Tabular view 4.3.2
Error 4.6.1 Teaching mode 4.2.0 / 4.3.0
Function test, ABB 4.5.0 Teaching mode, turning-off 4.3.3.5
Graphical view 4.3.2 Teaching mode, turning-on 4.3.3 / 4.3.3.1
Hook (Status limitation point) 4.3.2 Teaching points 4.3.2
Hotline 1.1.3 Technical data Appendix II
Key-operated switch 4.3.3.1 / 4.3.3.5 Time (teaching) 4.3.2
Limitation point of the ABB 2.3.1 / 2.3.3 Using the ABB 4.2.0
Main menu 2.4.0 W555 (teaching mode) 4.3.3.1
Mode of operation, ABB 4.1.3 W961 (example) 4.6.1
Overlapping 4.3.1 Working mode 4.2.0 / 4.0
Polygonal line 4.1.3 / 4.3.3.2 Working range plan 4.3.1
Programming polygonal line 4.3.3.2
Index chapter 5 (MDE)

B7 crane operator mode 5.2.2 Main menu 2.4.0
Buzzer sign 5.2.2 Message lines 5.2.2
Choosing MDE screens 5.2.1 Movements 5.2.4.1
Code number 2.1.7 Operating times 5.2.3
Diagnostic message 5.2.2 Radio remote control Appendix VI
Diagnostic messages 5.4.0 Reset date 5.2.2
Diagnostic screen 5.2.2 Re-set time 5.2.2
Drive data 5.2.3 Scrolling 5.2.2
Error 5.4.1 Service menu 2.5.0
Hotline 1.1.3 Short-term machine data 5.1.4
Important information 5.1.2 Short-term machine data, deleting 5.3.0
Load collective recording 5.2.4 SMC card 5.1.4
Load cycles 5.2.4.1 Switching movement counter 5.2.3
Long-term machine data 5.1.4 Switch-on time 5.2.3
Machine data M1 5.2.2 System overview MDE 5.1.3
Machine data M2 5.2.3 Technical data Appendix II
Machine data M3 5.2.4
stichwortverzeichnis-en.doc Index 3
4 Index stichwortverzeichnis-en.doc

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2.0 Electronic Monitoring System (EMS-2 AC31-S)

3.0 Load moment limitation (LMB)

4.0 Working range limitation (ABB)

5.0 Machine data capture (MDE)

This operating manual, especially the safety instructions, must be complied

EMS-2 AC31-S Version 01/2007

inhv_allg-en.doc Litronic Manual 1-1

1.1.1 Important information and safety regulations

1.1.2 Symbols used in this operating manual:

Important information! Observe proper sequence!

For further information or questions, please contact:

LIEBHERR-WERK BIBERACH GmbH

For inquiries, please state:

inhv_allg-en.doc Litronic Manual 1-3

Control desk P1_

1-4 Litronic Manual inhv_allg-en.doc

inhv_allg-en.doc Litronic Manual 1-5

1.1.6 Changing the battery (KT 98)

- Only use ABB tested lithium battery units!

The battery stores the time, date, the content of

If the battery is empty, or no battery is in place, the

- Operating voltage ON.

1-6 Litronic Manual inhv_allg-en.doc

ems_dbl-en / LITRONIC Elektronisches Monitorsystem AC31-S

2.1.0 General Information .................................................................. 2-1

2.2.0 Installation and start-up ............................................................ 2-9

2.3.0 Display masks for the crane operator ...................................... 2-23

ems_inhv-en.doc / LITRONIC Table of contents

2.6.0 Procedure in case of error ........................................................ 2-45

Appendix I Meanings of all symbols in the display

ems_inhv-en.doc / LITRONIC Table of contents

2.1.1 Usage and application

ems-ac31s_01-46-en.doc AC31-S / EMS 2-1

Front view Rear view

LCD display BNC

Adjustment of contrast via the wheel adjustor

COM1 is the programmer interface to the EMS-2. (9 pole Sub-D plug)

The multi-function interface is not used by the EMS-2 AC31-S.

2-2 AC31-S / EMS ems-ac31s_01-46-en.doc

The header is shown in every screen.

The footer (status line) is shown in every in

Setting display measurement units:

Crossed-through EMS data:

ems-ac31s_01-46-en.doc AC31-S / EMS 2-3

B1 - B6 - choose crane operator screen 1- 6 (see chap. 2.3.0)

2-4 AC31-S / EMS ems-ac31s_01-46-en.doc

The following events set off the buzzer:

1. Occurrence of a new error short melody

ems-ac31s_01-46-en.doc AC31-S / EMS 2-5

10.01.02 E 000 M 000 15:12:48 "E" = Error message

5.3 29.2 "W" = Warning message

"S" = Status message (crane states)

Warning: W1 ... W999

Message: M1 ... M999

Status: S1 ... S999

2-6 AC31-S / EMS ems-ac31s_01-46-en.doc

*Acknowledging error messages

- in the display masks B1 to B6 - in the menu screens

ex: Error message

10.01.02 E 113 15:12:48

ems-ac31s_01-46-en.doc AC31-S / EMS 2-7