www.hirschmann.

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HIRSCHMANN

LOAD MOMENT INDICATOR

DS 85/0002
Central Unit/ Console

CALIBRATION MANUAL
P/N 031-300-190-169 REV B 01/06/2004
 Calibration Manual DS85

NOTICE

The information in this document is subject

to change without notice.

PAT makes no warranty of any kind with regard

to this material, including, but not limited
to the implied warranties of merchantability
and fitness for a particular purpose.

PAT shall not be liable for errors contained herein

or for incidental or consequential damages in
connection with the furnishing, performance,
or use of this manual.

This document contains proprietary information

which is protected by copyright. All rights are
reserved. No part of this document may be
photocopied, reproduced, or translated to
another language without prior consent of PAT.

MANUAL REVISIONS

REV DATE NAME DESCRIPTION

- 06/20/03 PPR ECN 03-076
A 06/24/03 CSH ECN 03-076
B 01/06/04 CSH ECN 04-007

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 Calibration Manual DS85

Table of Contents

1 QUICK CALIBRATION REFERENCE............................................................................................. 1

2 QUICK REFERENCE TO "C" AND "E" CALIBRATION ................................................................ 3

2.1 MAIN BOOM WITH HOOK BLOCK ................................................................................................... 4
2.2 MAIN BOOM WITH LOAD ............................................................................................................... 4
2.3 FUNCTION X: CUTOFF TEST ......................................................................................................... 5
2.4 PROCEDURE FOR LOAD CORRECTION ........................................................................................... 5
2.4.1 Mainboom - Function C....................................................................................................... 5
2.4.2 Extensions - Function E ...................................................................................................... 6
2.5 LIST OF ADDRESSES USED FOR ACCUCAL .................................................................................... 7
2.6 DGA FUNCTION “I” ..................................................................................................................... 7
2.7 DGB FUNCTION “J”..................................................................................................................... 7
2.7.1 DGC Function “O” - Mainboom .......................................................................................... 8
2.7.2 DGC Function “O” - Extensions ......................................................................................... 9
3 IFLASH .......................................................................................................................................... 10
3.1 IFLASH PC INTRODUCTION ....................................................................................................... 10
3.2 SYSTEM PREREQUISITES ........................................................................................................... 10
3.3 PROGRAM MENU ....................................................................................................................... 10
3.3.1 Terminal ............................................................................................................................ 10
3.3.2 Flash loader upload .......................................................................................................... 11
3.3.3 Flash loader download...................................................................................................... 15

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 Quick calibration reference 1

1 Quick calibration reference

Warning switch power off when installing or removing components in the central unit.
Note: There should be no large change from the start software. If the desired display can not be
achieved the problem could be; wrong software, bad transducer or air in hydraulic line, angle or
length set wrong or bad sensor. Do not continue with further calibration until you have
contacted PAT.

1. Power ON, ensure the system version is DGCTV1.0H or newer. Power OFF.
2. Ensure correct software is used, correct software should come from PAT America or PAT
approved source. Connect PC via null modem cable to the console / CU housing, Power ON.
Follow the procedure to up load the software to the system. See section 2.
3. Acquire a test data sheet and fill in the crane model, S/N, date and the SN’s of PAT components
etc. Power OFF disconnect the PC, Power ON.
4. Follow the procedure for zeroing the Transducers and calibrating Angle and Length through the
console.
5. Power OFF connect hand terminal, Power ON.
6. PRESS "T" then "Y" to initialize the data.
7. PRESS "O" then " User code[699]", then DAY, MONTH, YEAR then crane serial number.
8. PRESS “W” then “8” then enter then “255” then enter then “K”.
9. Bleed air from lines, securely connect hydraulics and cycle the boom through entire working
range several times.
10. Boom must be fully extended and boom between 50° to the lowest angle on the load chart for the
model crane being calibrated. Note: Do not operate crane out of the load chart for the model
crane being calibrated.
11. To adjust surface relation, press “O” then “Enter” then “J” [DGB] then enter 3.1.5, move this value
until the surface relation is correct, if desired the surface relation can be set later. Note: This
affects the whole crane and once calibration starts it can not be readjusted.
12. To adjust the hook weight, press “O” then “Enter” then “J” [DGB] then enter 3.1.7, move this value
until the hook weight is correct. Note: This affects the whole crane and once calibration starts it
can not be readjusted.
13. Perform a cutoff test with a light load on the long boom. If the load display is good and the cutoff
is 90% to 100%, proceed to step 15
14. If the cutoff is not correct, the load can be adjusted with DGB 3.1.6 Note: if more change than +/-
100 is needed Check hydraulic components, call PAT. Repeat cutoff test. Note: This affects the
whole crane and once calibration starts it can not be readjusted.
15. The surface relation can be adjusted with DGB 3.1.5 but this should not be needed. Note: if more
change than +/- 100 is needed Check hydraulic components, call PAT. Repeat cutoff test. Note:
This affects the whole crane and once calibration starts it can not be readjusted.
16. Continue with all other cutoff test required for the main boom. If load changes are required then
perform a “C” function. (see “C” calibration)
17. Perform all cutoff tests on the mainboom, retracted jib. If no changes are made continue to next
step. If load changes are required then perform an “E” function. (see “E” calibration)
18. Perform all cutoff tests on the mainboom, extended jib. If no changes are made continue to next
step. If load changes are required then perform an “E” function. (see “E” calibration)
19. Power OFF connect the PC via the null modem cable to the console/ CU, Power ON follow the
procedure to download the final dat from the system See section 2.
20. Power ON check the system, ensure there are no errors.
21. Send crane final data, TLK and test sheets to PAT ASAP after calibration.

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 2 Calibration Manual DS85

CRANE MODEL: SERIAL NUMBER

LMI COMPONENTS TYPE SERIAL NUMBERS

Console/ Central unit

Cable reel

Pressure transducer piston side

Pressure transducer rod side

REFERENCE VOLTAGES DGA CHANGES DGB CHANGES

Crane power (Term #1) = DGA 7.1.3= DGB 6.20 =

DGA 7.1.4= DGB 6.21 =

Console Service Display Voltages DGA 7.2.3= DGB 6.22 =

Output of piston transducer, 0 pressure = DGA 7.3.3= DGB 6.23 =

Output of rod transducer, 0 pressure = DGA 7.8.3= DGB 10.1 =

Output of length sensor fully retracted = DGB 10.2 =
Output of length sensor fully extended = DGB 10.3 =
Output of angle sensor at zero degrees = DGB 10.4 =
DGB 10.24=

SOFTWARE INFORMATION DGB 10.25=

DAT/TLK DGB 3.1.5 =
SYSTEM DGB 3.1.6 =
DGB 3.1.7 =
CONFIGURATIONS CALIBRATED

MAIN BOOM 30’ EXT. 20’ JIB OFFSETS AUX TIP

A-2-B

MAIN BOOM AUX TIP EXT JIB

FUNCTION LOCK OUTS TESTED

BOOM DOWN

HOIST UP (MAIN)

HOIST UP (AUX)

TELESCOPE OUT

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 Quick Reference to "C" and "E" CALIBRATION 3

2 Quick Reference to "C" and "E" CALIBRATION

WARNING ALWAYS USE THE LOAD CHART FOR SAFE OPERATING DO NOT EXCEED
THE RADIUS ON THE LOAD CHART

1. Contact PAT before continuing with a "C" or "E" calibration.

2. Check DGC 1.10.1 or 3.10.1 to determine the last angle step in the software. Verify that this
corresponds to the last load on the load chart. An exception must be made for any lengths that may
have either a zero degree load chart or rigging capacities.
3. Boom up to high angle just short of topping the cylinder out.
4. PRESS "C" on hand terminal.
5. PRESS "Enter" when asked for radius.
6. Enter hook weight.
7. PRESS "A".
8. Displayed on hand terminal is "PRESS "C" PRIOR TO STOP". This will automatically change when
the last correction point is passed. PRESS "Enter" when asked for radius, "K" to finish.
9. Check the hook weight one more time through the curve.
10. Perform cutoff test with X function.
11. Repeat this at the long boom.
12. To interpolate PRESS "N" then "Y". Record on data sheet the number of length steps interpolated.
13. Check a mid boom length.
14. Calibrate each length step if not satisfied with the interpolation
Note that on the mainboom, the radius indication may change by 0.5' when "O","C","E" etc. has been pressed
on the hand terminal.
There are five correction points high angle to low angle for each boom length. These can be found in DGC as
follows:
PRESS "O" on the hand terminal
1.6.1 = boom angle e.g. 78 degrees (high angle)
1.7.1 = boom angle e.g. 70 degrees
1.8.1 = boom angle e.g. 60 degrees
1.9.1 = boom angle e.g. 40 degrees
1.I0.I = boom angle e.g. 20 degrees (low angle)

1.x.1 = boom angle e.g. 78 degrees

1.x.2 = hook weight Quick key on the hand terminal 6
1.x.3 = tare Quick key on the hand terminal 7
1.x.4 = empty radius Quick key on the hand terminal 8
1.x.5 = loaded radius Quick key on the hand terminal 9

"E" is for jib calibration

Carry out the "E" same as the "C" above.
Retracted and extended on each jib configuration.
No interpolation is needed

PRESS "O" on the hand terminal

3.6.1 = boom angle e.g. 78 degrees
3.6.2 = hook weight
3.6.3 = tare
3.6.4 = empty radius
3.6.5 = loaded radius
Note that on the jibs, the radius indication will change by 0.5' when "O","C","E" etc. has been pressed on the
hand terminal.

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4 Calibration Manual DS85

2.1 Main Boom with Hook Block

User Inputs Hand Terminal Display Remarks

OM= XXXX,LS= XX.XX

inside LS, MB-V= X
PRESS "J" B NR. (last address used)
Enter 3.1.7 3.1.7 = XXX PRESS "K" to transmit data
Change this value until load display
is correct
Note: Only a +/- 100 is allowed
PRESS "K" If Surface Relation changes are
required.
Note: This should not need
changing
PRESS "J" 3.1.5 = XXX Change this value until static to
dynamic load display is correct
using various RPM's and lever
control.
Note: Only a +/- 100 is allowed

2.2 Main Boom with Load

User Inputs Hand Terminal Display Remarks

OM= XXXX,LS= XX.XX Perform cutoff test with a light load

inside LS, MB-V= X NO
Radius changes should be
required.
If weight changes are required
PRESS "J" B NR. (last address used)
Enter 3.1.6 3.1.6 = XXX PRESS "K" to transmit data
Change this value until load display
is correct
Note: Only a +/- 100 is allowed
PRESS "K" If Surface Relation changes are
required.
Note: This should not need
changing
PRESS "J" 3.1.5 = XXX Change this value until static to
dynamic load display is correct
using various RPM's and lever
control.
Note: Only a +/- 100 is allowed

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 Quick Reference to "C" and "E" CALIBRATION 5

2.3 Function X: Cutoff test

User Input Hand Terminal Display

PRESS "X" Enter measured

radius or "ENTER"
Enter measured radius, Press RAT LOAD = XXXX
"ENTER“ ACT LOAD = XXXX
Enter actual load. Press RAT R/A = XXXX The cutoff percent will be shown
ENTER CUTOFF = XXXX on the hand terminal. Record
this on the test sheet.

2.4 Procedure for load correction

2.4.1 Mainboom - Function C

Following the initial setup and Q function, the load and radius should be correct. If the hook block
needs to be adjusted use the following procedure:

NOTE: Adjustment of radius display empty and empty tackle display is possible for any boom length

1) Use the “C” function to correct from high to low angle. Do not change the radius during the
“C” function.
2) Proceed with cutoff test.

User Inputs Hand Terminal Display Remarks

PRESS "C“ Enter measured
radius or CR:
PRESS "ENTER" Enter tackle or CR
tackle: XX:
PRESS "ENTER" A=MB down, CR=End, dynamic adjustment
B=adj. On the fly ÖA: The empty tackle weight is corrected
dynamically for all correction positions of the
present length.

PRESS "A“ PRESS "C" prior to stop Luff down boom, the dynamic adjustment will
be completed automatically upon reaching the
last correction position. It may happen that the
last angle is not attainable. In such cases do
not exceed load chart.
Enter measured radius or Do not adjust the radius
CR:

PRESS "ENTER" Function "C" finished PRESS

"K"
PRESS "K"

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6 Calibration Manual DS85

2.4.2 Extensions - Function E

If the hook block needs to be adjusted use the following procedure:

NOTE: Adjustment of radius display empty and empty tackle display is possible for any boom length

1) Use the “E” function to correct from high to low angle. Do not change the radius during the
“E” function.
2) Proceed with cutoff test.

User Inputs Hand Terminal Display Remarks

PRESS “E“ enter measured

radius or CR:
PRESS "ENTER" enter tackle or CR
tackle: XX:
PRESS "ENTER" A=MB down, CR=End, dynamic adjustment
B=adj. on the fly ÖA: The empty tackle weight is
corrected dynamically for all
correction positions of the present
length.

PRESS "A" Press "E“ prior to stop Luff down boom, the dynamic
adjustment will be completed
automatically upon reaching the
last correction position. It may
happen that the last angle is not
attainable. In such cases do not
exceed load chart.
Enter measured radius or CR Do not adjust the radius
PRESS "ENTER" Func. "E" finished
Press "K"
PRESS "K"

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 Quick Reference to "C" and "E" CALIBRATION 7

2.5 List of addresses used for AccuCal

This is a listing of the data EEPROM addresses that can be changed during the AccuCal calibration.
There are many other addresses that can be changed but these are the only ones I expect to have to
change. Many of the addresses are changed automatically and do not require the user to input data.
They are provided in the case that the user wishes to see the values that are input automatically.

2.6 DGA Function “I”

1.7 Crane Serial Number Set in automatic procedure

7.1.3 Length zero value Set in automatic procedure

7.1.4 Length end value Set in automatic procedure
7.2.3 Piston pressure zero value Set in automatic procedure
7.3.3 Rod pressure zero value Set in automatic procedure
7.8.3 Angle zero degree value Set in automatic procedure

2.7 DGB Function “J”

3.1.5 Surface relation Set automatically or manually

3.1.6 Tare Overall adjustment Set manually
3.1.7 Hook block Overall adj. Set automatically or manually

6.20 Correction length 1 Set in automatic procedure

6.21 Correction length 2 Set in automatic procedure
6.22 Correction length 3 Set in automatic procedure
6.23 Correction length 4 Set in automatic procedure

10.1 Main boom angle 1 Set in automatic procedure

10.2 Main boom angle 2 Set in automatic procedure
10.3 Main boom angle 3 Set in automatic procedure
10.4 Correction angle 1 Set in automatic procedure
10.24 Correction angle 2 Set in automatic procedure
10.25 Correction angle 3 Set in automatic procedure

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8 Calibration Manual DS85

2.7.1 DGC Function “O” - Mainboom

1.2.5 SAE Radius display factor

1.6.1 Correction angle number 1 (first angle varies e.g. 78°)

1.6.2 Block correction in lbs.
1.6.3 Load correction in %
1.6.4 Block radius correction in ft.
1.6.5 Load radius correction in ft/1000 LB

1.7.1 Correction angle number 2 (varies)

1.7.2 Block correction in lbs.
1.7.3 Load correction in %
1.7.4 Block radius correction in ft.
1.7.5 Load radius correction in ft/1000 LB

1.8.1 Correction angle number 3 (varies)

1.8.2 Block correction in lbs.
1.8.3 Load correction in %
1.8.4 Block radius correction in ft.
1.8.5 Load radius correction in ft/1000 LB

1.9.1 Correction angle number 4 (varies)

1.9.2 Block correction in lbs.
1.9.3 Load correction in %
1.9.4 Block radius correction in ft.
1.9.5 Load radius correction in ft/1000 LB

1.10.1 Correction angle number 5 (last angle varies e.g. 20°)

1.10.2 Block correction in lbs.
1.10.3 Load correction in %
1.10.4 Block radius correction in ft.
1.10.5 Load radius correction in ft/1000 LB

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 Quick Reference to "C" and "E" CALIBRATION 9

2.7.2 DGC Function “O” - Extensions

3.2.5 SAE Radius display factor

3.6.1 Correction angle number 1 (first angle varies e.g. 78°)

3.6.2 Block correction in lbs.
3.6.3 Load correction in %
3.6.4 Block radius correction in ft.
3.6.5 Load radius correction in ft/1000 LB

3.7.1 Correction angle number 2 (varies)

3.7.2 Block correction in lbs.
3.7.3 Load correction in %
3.7.4 Block radius correction in ft.
3.7.5 Load radius correction in ft/1000 LB

3.8.1 Correction angle number 3 (varies)

3.8.2 Block correction in lbs.
3.8.3 Load correction in %
3.8.4 Block radius correction in ft.
3.8.5 Load radius correction in ft/1000 LB

3.9.1 Correction angle number 4 (varies)

3.9.2 Block correction in lbs.
3.9.3 Load correction in %
3.9.4 Block radius correction in ft.
3.9.5 Load radius correction in ft/1000 LB

3.10.1 Correction angle number 5 (last angle varies e.g. 20°)

3.10.2 Block correction in lbs.
3.10.3 Load correction in %
3.10.4 Block radius correction in ft.
3.10.5 Load radius correction in ft/1000 LB

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10 Calibration Manual DS85

3 iFLASH

3.1 iFLASH PC introduction

iFLASH PC supports the user in the terminal, uploading, and downloading BRN files.:

iFLASH PC is a program for Microsoft Windows operating systems as of Windows 98. The user and
control system primarily communicate via a terminal program by using a serial interface. Within the
terminal program, basic functions can be executed using the menu selection. Furthermore, iFLASH
PC supports the user with additional dialogs for easy operation of the system, especially when
exchanging data.

iFLASH PC is a software toolbox used for configuration, start-up and service of PAT devices with
RTOS operating systems such as iFLEX5, DS85, SLI, ECIS and ¼" VGA console.

3.2 System prerequisites

To install iFLASH PC on a PC, the following conditions should be satisfied:

• PC min. 486 / 100 MHz

• Operating systems:
• Windows 98 or higher
• Windows NT4 with Service Pack 6
• Windows 2000 or higher
• Memory:
• 15 MB free memory on hard disk
• min. 32 MB RAM
• Graphics:
• VGA graphic card
• Resolution 800 x 600 (1024 x 768 recommended).
• RS232 interface

3.3 Program menu

The Menu program contains the actual work functions for exchanging data with iFLEX5.
These are:

3.3.1 Terminal
The terminal window is the communication center for the system. All outgoing messages from the
system are shown in this window, allowing for troubleshooting system inputs, output, and sensors.

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 iFLASH 11

3.3.2 Flash loader upload

This dialog is used to transfer data (BRN files) into the Flash storage of the system. There are 3
different file types system, data, and TLK that will be uploaded for operation. Upload one or all three
files as necessary to update your system. Note: Only upload files received from PAT America. System
software is the operating software, which calculates and displays the system function. Data software is
crane dimensional data, which include measurements of boom, sheaves offset, and hoist position.
TLK software is the load charts. Both data and TLK software are required for the system software to
operate.
To upload, proceed as follows:

1. Initiate the upload process by selecting Flash loader upload from the Program Pull-down
Menu.

2. Choose the open folder icon, to browse for location of software on PC.

folder icon

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12 Calibration Manual DS85

3. Select directory of where the software is stored in from the “look in” box.

4. Highlight the software file you choose to upload. Ensure that file extension reads .BRN and press
Open. The following is an explanation of the software file names:

• System software: DGCTvXXX.brn (example:

DGCTv10H.brn, where DGCT is the software
designation, v is for version and 10H is the
version number)
• Data software: DXXXXXXXX.brn, the file name
begins with a D and then is followed by 6 to 9
digits, the crane model number and 2 digits.
(example D22101c00.brn)
• TLK software: TXXXXXXXX.brn, the file
name begins with a T and then is followed by 6
to 9 digits, the crane model number and 2
digits. The 2 digits are; 00 – main boom, 10 –
fixed jib, and 20 – tele jib.. (example
T22101c00.brn)

5. After the correct file is selected, press the “Start Upload” Icon.

Start upload

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 iFLASH 13

6. Ensure the parameters correspond with the settings below before proceeding, and select “OK”.

7. At this point, the upload process will begin.

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14 Calibration Manual DS85

8. After file successfully transferred, as indicated in the Status bar. Select the “EXIT” icon.

Exit

If necessary, this process will need to be completed for each of the three file system, data, and TLK.
If there is a transfer failure you will get an error message in the status bar, retry the procedure or
contact PAT service.

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 iFLASH 15

3.3.3 Flash loader download

This dialog is used to transfer data from the flash memory of the iFLEX5 onto the PC.
A download is executed as follows:

1. Initiate the upload process by selecting Flash loader upload from the Program Pull-down Menu.

2. “Generate BRN file” will already be selected.

3. Select “Keep BIN file”, it will now have a check make by it as shown.
4. Choose the open folder icon to “select parameterfile for download process” and browse for file
location. The following software files must be given to you from PAT America in order to down
load the Data (datprom.adr).
5. Choose the open folder icon to “select filename for received data”. Name the file as follows:
D plus Serial number(XXXXX) and revision #(00,01,02…). (example DATA DXXXXX00.brn).
6. Select “Start Download” to begin down load. The progress bar will increase in blue as the
precentage.

folder icon

folder icon

Start download

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16 Calibration Manual DS85

7. The down load will be complete when the status bar shows in green “LMB_Download
successfully finished”. The progress bar will increase in blue as the precentage.

8. Choose the open folder icon to “select parameterfile for download process” and browse for file
location. The following software files must be given to you from PAT America in order to down
load the Data (tlkprom.adr).
9. Choose the open folder icon to “select filename for received data”. Name the file as follows:
serial number t plus 00(main boom), 10(fixed jib), 20(tele jib). (example 35100t20.brn).
10. Select “Start Download” to begin down load. The progress bar will increase in blue as the
precentage.

folder icon

folder icon

Start download

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 iFLASH 17

11. The down load will be complete when the status bar shows in green “LMB_Download
successfully finished”. The progress bar will increase in blue as the precentage.

If there is a transfer failure you will get an error message in the status bar, retry the procedure or
contact PAT service.

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