simocrane hardware commissioning sc standalone - … · 2 hardware commissioning ... 2.1.3.3...

0Preface

System Description 1

Hardware Commissioning 2

Project Planning SIMATIC S7

3

Commissioning Software 4

General information 5

SIMOCRANE SC Standalone

Operating Instructions

Valid for

Hardware:

- SIMOCRANE CenSOR 2.0

- SIMOTION C240 PN as of firmware V4.1.5.6

Software: - JAVA as of version V1.0.0.11 - Sway Control as of version V5.2.4.39 - CeCOMM as of version V4.4.1.16

- SCOUT as of version V4.1.5.3

Edition 01/2012 V1.16-E

Siemens AG Copyright © Siemens AG 2012 Industry Sector Subject to change without prior notice Drive Technologies Division P.O. Box 48 48 80437 Nuremberg Germany

Safety information

This manual contains information that you should observe to ensure your own personal safety and prevent material damage. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol; notices referring to property damage only are displayed without a safety alert symbol. Depending on the hazard level, warnings are displayed in descending order as follows.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or serious injury could result if proper precautions are not taken.

CAUTION

with a warning triangle indicates that minor personal injury can result if proper precautions are not taken.

CAUTION

without a safety alert symbol means that damage to property may occur if the proper precautions are not taken.

NOTICE

indicates that an undesirable result or state could occur if the corresponding instruction is not followed.

In the event of a number of levels of danger occurring simultaneously, the warning corresponding to the highest level of danger is always used. A warning on a warning triangle indicating possible personal injury may also include a warning relating to property damage.

Note

Routines or advice for the efficient use of the device and the software optimization.

Qualified personnel

The associated device/system must only be set up and operated using this documentation. A device/system must only be commissioned and operated by qualified personnel. For the purpose of the safety information in this documentation, a “qualified person” is someone who is authorized to energize, ground, and tag equipment, systems, and circuits in accordance with established safety procedures. A further requirement is the successful participation in a commissioning training course held by Siemens AG.

Siemens AG Copyright © Siemens AG 2012 Industry Sector Subject to change without prior notice Drive Technologies Division P.O. Box 48 48 80437 Nuremberg Germany

Intended use

Note the following:

WARNING

This equipment is only allowed to be used for the applications described in the catalog and in the technical description, and only in conjunction with non-Siemens equipment and components recommended by Siemens. Correct transport, storage, installation and assembly, as well as careful operation and maintenance, are required to ensure that the product operates safely and without faults.

WARNING

The electronic sway control system assists in the transportation of loads by almost completely eliminating swaying motions. The crane driver is still responsible for monitoring movements of the load on the crane and for switching off the system should any hazardous situations occur.

If the sway control system fails, the crane driver must ensure that the crane is stopped without any injury to persons or damage to objects. The functionality of the sway control system must be disabled and the crane operated manually without sway control until the fault has been corrected. If the fault cannot be corrected with the aid of the product manual, please contact the Siemens AG.

Trademarks

All names shown with the trademark symbol ® are registered trademarks of Siemens AG. If third parties use any other names in this document which refer to trademarks for their own purposes, this might infringe upon the rights of the trademark owners.

Exclusion of liability

We have checked that the contents of this document correspond to the hardware and software described. Nevertheless, as deviations cannot be precluded entirely, we cannot guarantee complete accuracy of the information contained herein. The information given in this publication is reviewed at regular intervals and any corrections that might be necessary are made in the subsequent editions.

SIMOCRANE Add-on Technology Sway Control Operating Instructions, 01/2012 Edition, V1.16-E 5

Preface Content

This document contains a description of the system structure of an sway control system for STS cranes and ship unloaders, information on the application planning, configuration, installation and commissioning as well as instructions for the maintenance and service.

Additional information

Technical support

You will find telephone numbers for other countries for technical support in the Internet (http://www.siemens.com/automation/service&support) under "Contact".

Information on the topics is available under the link http://www.siemens.com/motioncontrol/docu

• Ordering documentation / overview of documentation

• Additional links to download documents

• Using documentation online

Please send any questions about the technical documentation (e.g. suggestions for improvement, corrections) to the following e-mail address: [email protected]

Siemens Internet address

The latest information about SIMOTION products, product support, and FAQs can be found in the Internet at: http://www.siemens.com/simotion

You can find information about product support in the Internet at: http://support.automation.siemens.com/WW/view/de/10805436/130000

The latest information about SINAMICS products, product support, and FAQs can be found in the Internet at: http://www.siemens.com/sinamics

The latest information about SIMOCRANE products, product support, and FAQs can be found in the Internet at: http://support.automation.siemens.com/WW/view/en/10807397/130000

Application notes

Available in the Internet at: http://intranet.automation.siemens.com/mcms/mc/en/services/technical-consulting/application-support-production-machines/standard-applications-selection/Pages/standard-applications-selection.aspx

Siemens I DT Application Support Cranes

E-mail: [email protected]

Additional support

We also offer introductory courses to help you familiarize yourself with SIMOCRANE Basic Technology. For further information, go to: http://www.siemens.nl/training/cranes

If you have any additional questions, please contact your local Siemens sales representative.

http://www.siemens.com/motioncontrol/doku

Sway control Operating Instructions, 01/2012 Edition, V1.16-E 7

Table of Contents

1 System Description.................................................................................................................................. 13 1.1 General information .....................................................................................................................13 1.2 System overview..........................................................................................................................14 1.2.1 General information .....................................................................................................................14 1.2.2 Configurations..............................................................................................................................15 1.2.2.1 Configuration with camera for container cranes ..........................................................................16 1.2.2.2 Configuration without camera for ship unloader ..........................................................................17 1.3 Scope of supply ...........................................................................................................................18 1.3.1 SIMOTION C 240 PN...................................................................................................................18 1.3.2 Mounting rail.................................................................................................................................18 1.3.3 MMC for SIMOTION C 240 PN configured for sway control .......................................................18 1.3.4 Product CD...................................................................................................................................18 1.3.5 Certificates for the software licenses ...........................................................................................19 1.4 Product structure..........................................................................................................................19 1.5 Scope of functions .......................................................................................................................20

2 Hardware Commissioning........................................................................................................................ 21 2.1 Introduction ..................................................................................................................................21 2.1.1 Illustration of the module..............................................................................................................22 2.1.2 Type plate ....................................................................................................................................23 2.1.3 Interfaces .....................................................................................................................................24 2.1.3.1 Ethernet interface.........................................................................................................................24 2.1.3.2 PROFINET interface ....................................................................................................................25 2.1.3.3 PROFIBUS DP interface between PLC and sway control computer...........................................26 2.1.3.4 Monitoring of the communication between the components .......................................................27 2.2 Operational planning....................................................................................................................28 2.2.1 Transportation and storage conditions ........................................................................................28 2.2.2 Mechanical and climatic environmental conditions for operation of the SIMOTION C240

PN ................................................................................................................................................28 2.3 Installation/mounting ....................................................................................................................30 2.3.1 General requirements ..................................................................................................................30 2.3.2 Configuring an installation with SIMOTION C modules...............................................................31 2.3.2.1 Horizontal and vertical installation ...............................................................................................31 2.3.2.2 Clearances...................................................................................................................................31 2.3.2.3 Mounting dimensions of modules ................................................................................................32 2.3.3 Installation/mounting ....................................................................................................................34 2.3.3.1 Installing the mounting rail ...........................................................................................................34 2.3.3.2 Attaching modules to the mounting rail........................................................................................37 2.3.3.3 After the installation .....................................................................................................................38 2.4 Connecting up..............................................................................................................................38 2.4.1 Wiring ...........................................................................................................................................38

Table of Contents

Sway control 8 Operating Instructions, 01/2012 Edition, V1.16-E

2.4.1.1 General requirements for wiring.................................................................................................. 38 2.4.1.2 Configuring the electrical installation .......................................................................................... 39 2.4.1.3 Connecting the power supply...................................................................................................... 41 2.4.1.4 Connecting shielded cables via a shield connecting element..................................................... 44 2.4.2 Networking .................................................................................................................................. 46 2.4.2.1 Configuring a PROFIBUS subnet ............................................................................................... 46 2.4.2.2 Network components for a PROFIBUS subnet........................................................................... 48 2.4.2.3 Configuring an Ethernet subnet .................................................................................................. 50 2.4.2.4 Configuring an Ethernet subnet on the PROFINET interface (C240 PN)................................... 50 2.5 Operator Control (Hardware) ...................................................................................................... 52 2.5.1 Control Elements......................................................................................................................... 52 2.5.1.1 Mode selector switch................................................................................................................... 52 2.5.1.2 Micro Memory Card (MMC)......................................................................................................... 52 2.5.2 Display elements......................................................................................................................... 53 2.6 Parameter assignment / addressing ........................................................................................... 54 2.6.1 General information..................................................................................................................... 54 2.6.2 Default settings ........................................................................................................................... 54 2.6.3 Changing the addresses ............................................................................................................. 54 2.6.4 Restoring the changed IP address.............................................................................................. 55 2.7 Planning/configuring.................................................................................................................... 56 2.8 Commissioning (hardware) ......................................................................................................... 57 2.8.1 Commissioning requirements ..................................................................................................... 57 2.8.2 Initial power-up............................................................................................................................ 58 2.8.3 Simotion C240 PN overall reset.................................................................................................. 59 2.9 Installing the software ................................................................................................................. 60 2.10 Commissioning (software)........................................................................................................... 60 2.10.1 Commissioning requirements ..................................................................................................... 60 2.10.1.1 General requirements, overview ................................................................................................. 60 2.11 Service and maintenance............................................................................................................ 61 2.11.1 Removal and replacement of the C240 PN ................................................................................ 61 2.12 Alarm, error, and system messages ........................................................................................... 62 2.12.1 Alarm, error, and system messages of the SIMOTION C240 PN............................................... 62 2.12.1.1 Diagnostics using the LED display.............................................................................................. 62 2.12.1.2 Combination of LED displays...................................................................................................... 65 2.12.2 Error messages of the sway-control computer ........................................................................... 67 2.13 Dimension drawings.................................................................................................................... 68 2.14 Spare parts / accessories............................................................................................................ 68 2.15 Appendix ..................................................................................................................................... 69 2.15.1 Standards and approvals ............................................................................................................ 69 2.15.1.1 General rules............................................................................................................................... 69 2.15.1.2 Safety of electronic controllers.................................................................................................... 69 2.15.1.3 Electromagnetic compatibility ..................................................................................................... 70 2.15.2 ESD guidelines............................................................................................................................ 72 2.15.2.1 What does ESD mean?............................................................................................................... 72 2.15.2.2 Electrostatic charging of persons................................................................................................ 73 2.15.2.3 Fundamental measures to protect against static discharge ....................................................... 74

3 Project Planning SIMATIC S7.................................................................................................................. 75 3.1 Technical data............................................................................................................................. 75

Table of Contents


3.1.1 System properties ........................................................................................................................75 3.1.2 Technical data of the SIMOTION C240 PN.................................................................................76 3.1.2.1 Technical data..............................................................................................................................76 3.1.2.2 Clock ............................................................................................................................................76 3.1.2.3 Specifications for insulation tests, safety class, and degree of protection ..................................77 3.1.3 Hardware configuration and interface as well as integration in an S7 project under

STEP 7.........................................................................................................................................77 3.2 PROFIBUS DP PLC interface – sway control computer..............................................................79 3.2.1 Sway control computer input data................................................................................................80 3.2.2 Sway-control computer output data .............................................................................................95 3.2.3 Signal sequences in the sway-control computer .......................................................................106 3.3 Basic operation modes ..............................................................................................................110 3.3.1 BOM Speed control....................................................................................................................111 3.3.2 BOM Positioning ........................................................................................................................113 3.3.3 BOM Hoist Control .....................................................................................................................118 3.3.3.1 Target generator ........................................................................................................................119 3.3.4 BOM Sway Neutralization to Load Position (trolley) ..................................................................122 3.3.5 BOM Sway Neutralization to Trolley Position (trolley) ...............................................................122 3.4 Sway control configurations .......................................................................................................123 3.4.1 Sway control...............................................................................................................................123 3.4.1.1 Control in the "SC Speed Control" AddOn mode.......................................................................123 3.4.1.2 Control in the "SC Automatic" AddOn mode..............................................................................126 3.4.1.3 Control in the "SC Semiautomatic" AddOn mode......................................................................132 3.4.1.4 Taking account of blocked regions ............................................................................................135 3.4.2 Sway control with 2D-trajectory and bay scanning....................................................................135 3.4.2.1 Control in the "SC Speed Control" AddOn mode.......................................................................135 3.4.2.2 Control in the "SC Automatic" AddOn mode..............................................................................135 3.4.2.3 Control in the "SC Semiautomatic" AddOn mode......................................................................138 3.4.2.4 Taking account of blocked regions ............................................................................................139 3.4.2.5 Double spreader in coupled mode.............................................................................................144 3.4.3 TLS Control ................................................................................................................................144 3.4.3.1 Control of the "TLS Control" AddOn ..........................................................................................144 3.4.4 Sway control with TLS control....................................................................................................148 3.4.4.1 Control in the "SC Speed Control" AddOn mode.......................................................................148 3.4.4.2 Control of the "TLS Control" AddOn ..........................................................................................148

4 Commissioning Software ....................................................................................................................... 149 4.1 Preconditions .............................................................................................................................149 4.2 Ethernet communication ............................................................................................................149 4.2.1 General information ...................................................................................................................149 4.2.2 Parameter assignment / addressing ..........................................................................................150 4.3 Configuration of the Add-on functions .......................................................................................150 4.4 CeCOMM commissioning software............................................................................................152 4.4.1 Introduction ................................................................................................................................152 4.4.2 Installing the software ................................................................................................................153 4.4.3 Parameter assignment / addressing ..........................................................................................153 4.4.4 User interface.............................................................................................................................153 4.4.5 Windows menu functions ...........................................................................................................156 4.4.5.1 Windows File menu function ......................................................................................................156 4.4.5.2 Windows View menu function ....................................................................................................156 4.4.5.3 Windows Options menu function ...............................................................................................156 4.4.5.4 Windows Calculations menu function ........................................................................................158

Table of Contents


4.4.5.5 Windows Help menu function ................................................................................................... 159 4.4.6 Monitors..................................................................................................................................... 160 4.4.6.1 Monitor display screens ............................................................................................................ 161 4.4.6.2 Monitor menus and special functions........................................................................................ 165 4.4.7 File manager ............................................................................................................................. 169 4.4.8 Diagram – user interface for recording curves.......................................................................... 170 4.4.8.1 General information................................................................................................................... 170 4.4.8.2 Procedure for recording diagrams ............................................................................................ 170 4.4.8.3 Elements and functionality of the diagram user interface ......................................................... 175 4.4.8.4 X/Y diagram .............................................................................................................................. 185 4.4.9 Web server................................................................................................................................ 186 4.4.10 Telnet ........................................................................................................................................ 186 4.4.11 Effective pendulum length parameters ..................................................................................... 186 4.5 Commissioning requirements for AddOn systems.................................................................... 187 4.5.1 General requirements, overview ............................................................................................... 187 4.5.2 Preparing the PLC program ...................................................................................................... 188 4.5.3 Preparing the converters........................................................................................................... 188 4.5.4 Setting the access code............................................................................................................ 190 4.5.5 Setting the language ................................................................................................................. 190 4.5.6 Checking of the communication between PLC and SIMOTION ............................................... 190 4.6 Sway control commissioning..................................................................................................... 192 4.6.1 Functionality of Sway Control ................................................................................................... 192 4.6.2 Commissioning of the sway control system.............................................................................. 198 4.6.2.1 Commissioning steps in the Commissioning menu .................................................................. 198 4.6.2.2 Checking and fine adjustment of the sway control system....................................................... 205 4.6.3 Commissioning of the positioning ............................................................................................. 207 4.6.3.1 Changing the coordinate system .............................................................................................. 207 4.6.3.2 Position controller setting.......................................................................................................... 207 4.6.3.3 On-the-fly unloading.................................................................................................................. 208 4.6.3.4 Other settings............................................................................................................................ 209 4.6.4 Commissioning of the hoist control ........................................................................................... 210 4.7 2D-Trajectory commissioning.................................................................................................... 212 4.8 TLS Control commissioning ...................................................................................................... 213 4.9 Alarm, error and system messages .......................................................................................... 216 4.9.1 Following error monitoring......................................................................................................... 217 4.9.2 Velocity monitoring.................................................................................................................... 217 4.9.3 Start sway control monitoring.................................................................................................... 218 4.9.4 Collision protection.................................................................................................................... 218 4.9.5 Application error messages ...................................................................................................... 219 4.9.5.1 General information................................................................................................................... 219 4.9.5.2 SIMOCRANE CenSOR error list ............................................................................................... 219 4.9.5.3 AddOn technology error list....................................................................................................... 219 4.9.5.4 CeCOMM diagnostic software .................................................................................................. 231 4.9.6 Troubleshooting/FAQs .............................................................................................................. 231

5 General information ............................................................................................................................... 232 5.1 Service and maintenance.......................................................................................................... 232 5.1.1 Reflector .................................................................................................................................... 232 5.1.2 Camera...................................................................................................................................... 232 5.1.3 Spare parts / accessories.......................................................................................................... 232 5.1.4 AddOn technology parameter list.............................................................................................. 233 5.1.4.1 Overview of the parameter list .................................................................................................. 233 5.1.4.2 Trolley parameters .................................................................................................................... 234

Table of Contents


5.1.4.3 Hoisting gear parameters...........................................................................................................240 5.1.4.4 Sway-control parameters ...........................................................................................................246 5.1.4.5 General parameters ...................................................................................................................248 5.1.4.6 Camera/reflector parameters .....................................................................................................252 5.1.4.7 Travel behavior parameters .......................................................................................................253 5.1.4.8 Controlled variable parameters..................................................................................................257 5.1.4.9 TLS parameters .........................................................................................................................259 5.1.4.10 Slewing gear parameters ...........................................................................................................262 5.2 Appendix ....................................................................................................................................265 5.2.1 CeCOMM commissioning software............................................................................................265 5.2.1.1 Monitor menu tree......................................................................................................................265 5.2.2 Bibliography ...............................................................................................................................268 5.2.3 Abbreviations .............................................................................................................................268 5.2.4 Terminology (German/English) ..................................................................................................270


1 System Description 1 1.1 General information

Siemens provides add-on technologies described below for the more optimum crane use on the SIMOTION C hardware.

Siemens offers with the SIMOTION C variant a modernization solution for drives connected via PROFIBUS DP or analog values.

The Sway Control system, the "2D-Trajectory" automatic load movement, the "TLS Control" trim, list and skew control, and the "Bay Profile Scanning" container profile acquisition described below provide increased safety for persons, transport goods and equipment, relieves the crane driver by taking over the task of neutralizing the oscillation, and at the same time achieves a faster and more accurate positioning of the load.

Add-on technologies:

• Sway Control Eliminates load oscillations on container cranes and ship unloaders for the trolley through the specific influencing of the acceleration and braking actions.

• 2D-Trajectory Automatic or semi-automatic motion of the load on a path curve taking account of all blocked regions (e.g. container, crane design, etc.). The blocked regions can be transferred in various ways or learnt internally by "observing" the crane driver. Prerequisite is the "Sway Control" Add-on.

• TLS Control Controls the so-called trim, list and skew positions of a spreader. The current positions of all four TLS cylinders can be saved as zero positions and approached again. An electronic anti-skew can also be activated.

• Bay Profile Scanning A laser scanner acquires the container stack during the travel and sends the data to the PLC from where it is forwarded to the Sway Control System.

System Description 1.2 System overview


1.2 System overview

1.2.1 General information

Preconditions

• Use of a crane controller (PLC)

• SIMOTION C 240 PN for the calculation

• Sensors for the axes to be positioned (all modes)

The Add-ons are included as libraries in an existing SCOUT crane solution project. Depending on the Add-on and the variant, additional hardware may be required (e.g. camera, reflector, hoisting gear, laser, HMI, etc.) or various prerequisites must be satisfied.

Supplementary conditions

Each SIMOTION allows just one sway control system to be implemented (two independent trolleys not possible). The Siemens AG Add-on technologies use parameter sets for the activation and control of the drives. Speeds, accelerations and limitations are stored permanently during the commissioning and can only be changed by switching the parameter set.



System structure The following figures show the communication paths between the individual components.

Fig. -1-1: Assignment schema of the components of the standalone (SIMOTION C) variant

Dashed lines represent a temporary connection for commissioning and diagnostics. Solid connection lines represent a permanent communication link.

The system receives the required process information via the PLC and the camera (optional) as well as the HMI (optional) or hardware controls. After processing, for the SIMOTION C variant, the calculated speed actuator values are forwarded to the drives via the PLC.

1.2.2 Configurations

Each movement of a crane with rope guides results in the load oscillation and therefore a longer transport process. The task of the "Sway Control" and "TLS Control" Add-ons is the correction of these swaying motions. Together with "2D trajectory", they help ease the burden on the crane driver and so optimize the transfer times.

Basically two different configurations are possible for these Add-ons:

• Configuration with camera

• Configuration without camera



1.2.2.1 Configuration with camera for container cranes

Only with camera it is possible to compensate the swaying motion caused by external effects whereas in the version without camera external effects are not compensated because only mathematical model ist used without any feedback.

The camera measuring system uses an optical contact-free measurement to determine the hoisting height, swing angle and rotation angle parameters. The results are incorporated in the calculation model. The calculations are performed on the SIMOTION.

The resulting calculations are more accurate than for a system without camera and can also eliminate sway caused by external forces.

If the measuring signal of the camera fails, only the states of the model are used.

This is the preferred configuration for container cranes (STS).

Fig. -1-2: Schematic representation of a container crane with sway control components when a camera

is used

Camera and reflector

The SIMOCRANE CenSOR 2.0 camera measuring system consists of the following components:

• Digital camera (SIMOCRANE CENSOR MV440) with integrated DSP for image processing. • A weather-protection housing in IP54 with integrated heating and optional cooling is available

as option. • An infra-red flash (can be synchronized with the image recording of the camera). • Two different (300 mm; 500 mm) optical markers (subsequently designated as reflectors) with

retro-reflecting foil.



Retro reflecting foil Reflector housing

MV 440

Camera housing

Infrared flash

SIMOTION C

24 V Supply

PROFINET or ETHERNET

Components of SIMOCRANE CenSOR V2.0

Fig.-1-3: Hardware overview (power supply for heating in the camera housing not shown)

Special emphasis for the SIMOCRANE CENSOR MV440 has been placed on robustness, reliability and ease of use.

The SIMOCRANE CENSOR MV440 is characterized by its very compact construction, where all components, including the plug-in C-Mount lens, can be protected from environment effects with the IP54 protection class.

The camera is characterized with its very simple operation and commissioning that can be tracked with the help of the integrated Web server from an Internet browser without requiring a previous software installation.

For further information, consult the SIMOCRANE CenSOR Camera Measuring System Operating Instructions, as of version 05/2011 product documentation. The document can be found on the enclosed CD.

1.2.2.2 Configuration without camera for ship unloader

In the configuration without camera, the sway control function is performed exclusively with the aid of an arithmetic model. Swaying caused by external forces cannot be corrected.

This is the preferred configuration for ship unloaders (GSU).

System Description 1.3 Scope of supply


1.3 Scope of supply Depending on the task to be performed and the environmental conditions, the sway control system can be implemented with or without the SIMOCRANE CenSOR camera measuring system. The hardware and software required for the camera measuring system must be ordered separately and are not listed here.

The "SIMOCRANE CeSAR standalone STS, GSU" package contains:

1.3.1 SIMOTION C 240 PN

1.3.2 Mounting rail

1.3.3 MMC for SIMOTION C 240 PN configured for sway control

The MMC contains:

• The SIMOTION Kernel (basic system)

• Technology packages and user data (programs, configuration data, parameter settings)

• Runtime licenses

The supplied MMC already contains all required licenses.

1.3.4 Product CD

The software CD contains:

• Readme file

• Software

- The installation program for the diagnostics and the CeCOMM commissioning tool (setup file)

- Card image for MMC

- Application example

• Documentation

- In German

- In English

System Description 1.4 Product structure


1.3.5 Certificates for the software licenses

The appropriate certificates are supplied for the licenses on the MMC listed below.

• SIMOTION IT

• License for Sway Control

Depending on the required function scope, two RT licenses are used for the SIMOCRANE CeSAR standalone system.

- SIMOCRANE CeSAR STANDALONE STS, GSU

BASIC CONTROL

- SIMOCRANE CeSAR STANDALONE STS, GSU

ADVANCED CONTROL

1.4 Product structure SIMOTION Crane Sway Control Advanced Technology for SIMOTION C is supplied as a fully-configured product and only needs to be parameterized and connected via the crane PLC.

System Description 1.5 Scope of functions


1.5 Scope of functions An overview of the AddOn modes and the dependencies on other systems and the associated functions is shown in the following tables.

Table 1-1 Overview of the AddOn modes

Add-on Contained functionality AddOn mode Required license

• Sway control trave in manual mode • SC Speed Control Basic license

• Sway control travel in automatic and semi-automatic mode

• SC Automatic

• SC Semiautomatic Sway control

• Sway Neutralization at Load Position

• Sway Neutralization at Trolley Position

- Advanced license

TLS Control • TLS Control

• Skew Control

Basic license

2D Trajectory

• Sway control travel in all AddOn modes

• Hoist control with internal and external obstacle management

• Internal target generator

• SC Speed Control

• SC Automatic

• SC Semiautomatic

Advanced license

The following dependencies of the Add-ons from other systems exist:

Table 1-2 Dependency matrix

SIMATIC S7 Basic technology Commissioning tool

Sway control X o X

2D Trajectory X o X

TLS Control X X

X – required, o - optional


2 Hardware Commissioning 2 2.1 Introduction

This part of the operating instructions describes the sway-control computer based on a SIMOTION C240 PN with electronic sway control functions for container cranes and ship unloaders.

Note

The SIMOTION C240 PN should only be used as sway-control computer.

The sway control computer contains the sway control system.

Note

Further information is contained in the SIMOTION C Operating Instructions, as of version 03/2009 product documentation

http://support.automation.siemens.com/WW/llisapi.dll?aktprim=100&lang=de&referer=%2fWW%2f&func=cslib.cssearch&nodeid0=10805045&viewreg=WW&siteid=csius&extranet=standard&groupid=4000002&objaction=cssearch&content=adsearch%2Fadsearch%2Easpx




Hardware Commissioning 2.1 Introduction


2.1.1 Illustration of the module

View of the C240 PN

The following figure shows the C240 PN module with its interfaces and components on the front panel (error and status displays).

Fig. 2-1: Position of the C240 PN interfaces and front panel elements



2.1.2 Type plate

The following figure explains all the information on the type plate.

Note

The information contained in the individual fields of the type plate on the actual module may differ from the information described in these operating instructions (e.g. enhanced product version, approvals and designations not yet granted, etc.).

Fig. 2-2: Type plate of the C240 PN



2.1.3 Interfaces

2.1.3.1 Ethernet interface

Definition

Interface for connecting an Industrial Ethernet.

Industrial Ethernet is a communications network with a transmission rate of 10/100 Mbit/s.

Position of the X7 connector

The following figure shows the installation position and the designation of the connector on the module.

Fig. 2-3: Position of the X7 connector

Connector pin assignment

Designation: X7 (Ethernet) Type: 8-pin RJ45 socket

Table 2-1 Pin assignment of X7 connector

Pin Name Type Pin Name Type

1 TDP O 5 Not assigned

2 TDM O 6 RDM I

3 RDP I 7 Not assigned

4 Not assigned 8 Not assigned

Signal names

RDP, RDM - Receive Data +/- TDP, TDM - Transmit Data +/-



Signal type

I - signal input O - signal output

2.1.3.2 PROFINET interface

Definition

A SIMOTION C240 PN provides an interface for connecting to PROFINET IO with three ports (X11 P1, X11 P2, X11 P3) with a transmission rate of 100 Mbit/s. The PROFINET interface supports the parallel operation of:

• IRT with the "high flexibility" and "high performance" options - isochronous real-time communication:

o Equidistant transmission of input/output data between an IO controller and its IO devices with high stability for time-critical applications (e.g. motion control). The required bandwidth is in the bandwidth reserved for cyclic data. For "high flexibility", a fixed bandwidth of the transmission resources is reserved for the real-time communication. The "high flexibility" enables simple planning and expansion of the system. For "high performance", a fixed bandwidth of the transmission resources is also reserved for the real-time communication. The data traffic is further optimized and accelerated through an additional topology planning. The "high performance" option always requires a configuration of the topology.

o With the aid of IRT "high performance", IO devices (I/O modules and drive units) that support IRT can be operated isochronously on PROFINET IO and data can be exchanged between the SIMOTION devices via the controller-controller data exchange broadcast.

• RT - real-time communication: Transmission of input/output data between an IO controller and its IO devices in prioritized Ethernet message frames, but not isochronously. The required bandwidth lies within the bandwidth of PROFINET IO reserved for cyclic data.

• Standard Ethernet communication such as TCP/IP, UDP, HTTP, FTP, etc. as well as communication with STEP 7 / SIMOTION SCOUT and communication with SIMATIC NET OPC: The required bandwidth lies within the range of the free bandwidth for PROFINET IO. A SIMOTION C240 PN can be used as IO controller or I device. PROFINET IO differentiates between an IO controller and the IO devices assigned to it. IO controller and IO devices form a PROFINET IO system, comparable to a master-slave system for PROFIBUS DP.



Interface position

Fig. 2-4: Position of the PROFINET interface


Designation: X11 (PROFINET), three ports P1, P2, P3

Type: 8-pin RJ45 socket

Table 2-2 Pin assignment of X7 connector


1 TDP O 5 Not assigned

2 TDM O 6 RDM I

3 RDP I 7 Not assigned

4 Not assigned 8 Not assigned

Signal names

RDP, RDM - Receive Data +/-

TDP, TDM - Transmit Data +/-

Signal type

I - signal input

O - signal output

2.1.3.3 PROFIBUS DP interface between PLC and sway control computer

General

The SIMOTION C240 PN provides two interfaces for connection to the PROFIBUS DP. Baud rates up to 12 Mbit/s are possible. The X8 interface is used in this system.


Designation: X8, X9 DP1, DP2/MPI type: 9-pin Sub-D socket connector



Table 2-3Pin assignment of connectors X8, X9


1 Not assigned 6 P5 VO

2 M24 VO 7 P24 VO

3 B I/O 8 A I/O

4 RTS O 9 Not assigned

5 M5 VO

Signal names Table 2-4 Signal names

Signal name Meaning

A, B Data input/output (RS 485)

RTS Transmission request

P5 5 V power supply 60 mA, short-circuit-proof

M5 5 V reference potential

P24 24 V supply 150 mA, short-circuit-proof, not isolated

M24 24 V reference potential

Signal type

O - signal output I/O - signal input/output VO - voltage output

Note

The "PLC – sway control computer" interface is described in Chapter 3.

2.1.3.4 Monitoring of the communication between the components

The following connections are monitored:

Communication between the sway-control computer and the PLC Faulty communication is indicated with error E13 (field bus error). The error is displayed in the diagnostics tool ("E" screen).

Communication between the sway-control computer and the camera The cause of the faulty communication is indicated with an error message. The error is displayed in the diagnostics tool ("E" screen) and on the crane operator panel (see "Crane Operator Panel" Operating Instructions).

Hardware Commissioning 2.2 Operational planning


2.2 Operational planning

2.2.1 Transportation and storage conditions

With regard to transport and storage conditions, the C240 PN surpasses the requirements specified in IEC 1131, Part 2. The following conditions apply to modules that are transported and stored in the original packaging.

Table 2-5 Transport and storage conditions for C240 PN

Type of condition Permissible range

Free fall ≤ 1m

Temperature (transport) From -40° C to +70° C

Atmospheric pressure From 1060 to 700 hPa (equivalent to a height from sea level up to 3000 m)

Relative humidity (transport) From 5% to 95%, without condensation

2.2.2 Mechanical and climatic environmental conditions for operation of the SIMOTION C240 PN

Operational conditions

The SIMOTION C240 PN is designed for use in a stationary, weather-protected installation.

The SIMOTION C240 PN satisfies the operating conditions for Class 3C2 in accordance with DIN EN 60721 3-3 (operating locations with high traffic densities and in the immediate vicinity of industrial equipment with chemical emissions).

The SIMOTION C240 PN must not be used in the following locations without additional measures being taken:

• Locations with a high percentage of ionizing radiation

• Locations with severe operating conditions, e.g. due to:

– Dust accumulation

– Corrosive vapors or gases

• Installations requiring special monitoring, such as:

– Elevator installations

– Electrical installations in highly sensitive areas

A possible additional measure for the use of the C240 PN could be installation in a cabinet.

Hardware Commissioning 2.2 Operational planning


Climatic environmental conditions

The C240 PN may be used under the following climatic environmental conditions:

Table 2-6 Climatic environmental conditions

Environmental conditions Application range Remarks

Temperature: Horizontal mounting Vertical mounting

From 0° to 55° C From 0° to 40° C

-

Relative humidity From 5% to 95% Without condensation, corresponds to relative humidity (RH) severity level 2 in accordance with IEC 1131-2

Atmospheric pressure From 1060 to 700 hPa Equivalent to a height from sea level up to 3000 m

Pollutant concentration SO2: < 0.5 ppm Relative humidity < 60%, no condensation H2S: < 0.1 ppm Relative humidity < 60%, no condensation

Test: 10 ppm; 4 days 1 ppm; 4 days

Moisture condensation and ice formation

Not permissible

Mechanical environmental conditions

The mechanical environmental conditions for the C240 PN are specified in the following table in the form of sinusoidal vibrations.

Table 2-7 Climatic environmental conditions

Mechanical environmental conditions

Operation Transport (in packaging)

Vibration tested in accordance with DIN EN 60068-2-68

10 to 58 Hz: 0,35 mm 58 to 200 Hz: 50 m/s²

5 to 9 Hz: 3.5 mm 9 to 200 Hz: 10 m/s²

Shock resistance tested in accordance with DIN EN 60068-2-27

10 g peak value, 6 ms duration 100 shocks in each of the three axes vertical to one another

10 g peak value, 6 ms duration 100 shocks in each of the three axes vertical to one another

Reducing vibration

If the SIMOTION C240 PN is subjected to greater shocks or vibrations, you must take appropriate measures to reduce the acceleration or the amplitude.

We recommend mounting on shock-absorbing material (e.g. rubber-metal anti-vibration mountings).

Hardware Commissioning 2.3 Installation/mounting


Compatibility between the components

Currently, the sway-control computer and the optional crane operator panel can only be used in the following configuration and combination of components ( 54Table 2-8):

Table 2-8: Compatibility of the components

Component Subcomponent Version number

SIMOTION C Hardware C240 PN

SCOUT software 4.1.5.3 (47.80.14.00)

DCC software 2.0.3.1

Java software 1.0.0.10

Sway Control Runtime Software 5.2.4.34_1

2.3 Installation/mounting

2.3.1 General requirements

Overview

In this section we will explain how to design the mechanical configuration, prepare the SIMOTION components for installation and install them.

During the installation of SIMOTION C modules, you must pay attention to the electrical configuration. Therefore, also refer to Section 542.4.1 "Wiring".

Open equipment

These modules are open equipment. This means they may only be installed in housings, cabinets or in electrical equipment rooms that can only be entered or accessed with a key or tool. Housings, cabinets or electrical equipment rooms may only be accessed by trained or authorized personnel.



2.3.2 Configuring an installation with SIMOTION C modules

2.3.2.1 Horizontal and vertical installation

Structure

You can install the rack either horizontally or vertically. A horizontal mounting position should be given preference.

Permissible ambient temperature

• Horizontal assembly: from 0° to 55° C

• Vertical assembly: From 0 to 40 °C

Fig. 2-5: Horizontal and vertical installation

2.3.2.2 Clearances

Rules

If you comply with the minimum clearances, you will:

• Ensure that the modules are cooled.

• Have sufficient space to insert and remove the modules.

• Have sufficient space for laying cables.

• Increase the mounting height of the rack to 205 mm!

To guarantee the functionality, clearances of 40 mm must be maintained.



Note If you use a shield connecting element, the dimensions are measured from the lower edge of the shield connecting element.

Clearances

The following figure shows the clearances between the individual racks and the clearance to adjacent equipment, cable ducts, cabinet walls, etc.

Fig. 2-6: Clearances

2.3.2.3 Mounting dimensions of modules

Overview of mounting dimensions

The following table shows the mounting dimensions of modules.



Table 2-9Mounting dimensions of modules

Modules Module width Module height Max. mounting depth

PS 307 power supply, 2 A PS 307 power supply, 5 A PS 307 power supply, 10 A

50 mm 80 mm 200 mm

C240 PN 200 mm

Signal modules (SMs) 40 mm

Function modules (FM) 40 mm or 80 mm

Communications processors (CP)

40 mm

125 mm, 185 mm with shield-connection element

130 mm or 180 mm with an open C240 PN front panel

Mounting rail lengths

Depending on the configuration you have chosen, you can use the following mounting rails: Table 2-10 Mounting rails

Mounting rail Usable length for modules Comment

160 mm 482,6 mm 530 mm 830 mm 2000 mm

120 mm 450 mm 480 mm 780 mm Cut to required length

Mounting holes are provided

Mounting holes must be drilled



2.3.3 Installation/mounting

2.3.3.1 Installing the mounting rail

Installing a 2-meter mounting rail

You must prepare the 2-meter mounting rail for installation. Proceed as follows:

• Shorten the 2-meter mounting rail to the required dimension.

Mark in

– Four holes for fastening screws (dimensions: see following table)

– One hole for a protective conductor mounting screw.

• Is the mounting rail longer than 830 mm?

– If so: You must drill additional holes for more mounting screws to stabilize the mounting rail. Mark out these holes along the groove in the middle section of the rail (see the figure below). These additional holes should be spaced approximately every 500 mm.

– If not: No additional work required.

• Drill the 6.5 + 0.2 mm diameter holes where marked for M6-size screws.

• Fit an M6 screw to secure the protective conductor.

Fig. 2-7: Mounting holes in a 2-meter mounting rail



Dimension drawing for mounting holes

The mounting hole dimensions for the mounting rail are shown in the table below.

Table 2-11 Mounting holes for rails

"Standard" mounting rail 2-meter mounting rail

Mounting rail length

Distance a Distance b -

160 mm 10 mm 140 mm

482,6 mm 8,3 mm 466 mm

530 mm 15 mm 500 mm

830 mm 15 mm 800 mm

Fastening screws

Choose one of the following screw types to mount the mounting rail:

Table 2-12 Fixing screws

For You can use... Explanation

Fillister head screw M6 acc. to ISO 1207 / ISO 1580 (DIN 84 / DIN 85)

Outer fastening screws

M6 hexagonal screw acc. to ISO 4017 (DIN 4017)

Additional mounting screw (2-meter mounting rail only)

Fillister head screw M6 acc. to ISO 1207 / ISO 1580 (DIN 84 / DIN 85)

Select a screw length that is appropriate for your configuration You also need 6.4 mm washers acc. to ISO 7092 (DIN 433)



Installing the mounting rail

Install the mounting rails as follows:

• Fit the mounting rail in a position that will allow enough room for the modules to be installed and for the heat to dissipate (a minimum of 40 mm above and below the mounting rail; refer to the "Mounting holes for mounting rails" table above).

• Screw the mounting rail onto the surface where it is to be affixed (screw size: M6). Is this substrate a grounded metal plate or a grounded equipment mounting plate? If so: Ensure that there is a low-resistance connection between the mounting rail and the substrate. use suitable electro-lubricant or contact washers with painted and anodized metals, for example. If not: No special action required.

• Connect the mounting rail with the protective conductor. An M6 protective conductor screw is provided on the mounting rail for this purpose. Minimum cross-section of protective conductor line: 10 mm2.

Note Always ensure that there is a low-resistance connection to the protective conductor (see figure below). If the rack is mounted on a movable frame, for example, make sure that the line to the protective conductor is flexible.

Protective conductor connection

The figure below shows the proper way of connecting the protective conductor to the mounting rail.

Fig. 2-8: Protective conductor connection on the mounting rail



2.3.3.2 Attaching modules to the mounting rail

Accessories

Installation accessories are included with the module package. Section "Spare parts and accessories" contains a list of accessories and spare parts, together with the relevant order numbers.

Table 2-13 Module accessories

Module Accessories included Explanation

C240 PN 1 x slot number plates For the assignment of slot numbers

Label For the labeling of the integrated inputs and outputs of the C240 PN

One labeling plate For the labeling of the inputs and outputs on the module

Sequence in which modules are affixed to the mounting rail

• Power supply module

• C240 PN

Installation sequence

The individual steps for the installation of the modules are described below:

• Except for the C240 PN, each signal module is supplied with a bus connector. When the bus connectors are inserted, always begin with the C240 PN.

• Remove the bus connector from the next module and insert it on the C240 PN bus connector. (The bus connector is located on the rear side, see Fig. "Position of interfaces and front panel elements".) You must not plug a bus connector into the "last" module in the row.

• Fit the modules by hooking them into position, push them against the left-hand module and lower them down into position.

• Screw down the modules, applying a torque of 0.8 to 1.1 Nm.

Hardware Commissioning 2.4 Connecting up


2.3.3.3 After the installation

Inserting slot numbers

This figure shows the proper way of inserting the slot numbers. The slot number plates are included with the C240 PN.

Fig. 2-9: Inserting slot numbers on the modules

2.4 Connecting up

2.4.1 Wiring

2.4.1.1 General requirements for wiring

Basic rules

Because of the wide range of application of a C240 PN, only the basic rules for the electrical configuration can be included in this section. As minimum, you must comply with these basic rules to ensure problem-free operation.

Safety regulations

In order to ensure safe operation of your equipment, implement the following measures, adapting them to suit your conditions:

• An EMERGENCY STOP concept in accordance with the generally accepted rules of current engineering practice (e.g. European standards EN 60204, EN 418, and similar).

• Additional measures for the end-position limiting of axes (e.g. hardware-limit switches).

• Equipment and measures for protection of motors and power electronics in accordance with the installation guidelines for SIMODRIVE and FM STEPDRIVE/SIMOSTEP.



In addition, in order to identify hazards, we recommend that a risk analysis be conducted on the entire system in accordance with the basic safety requirements detailed in Appendix 1 of EU Machinery Directive 89/392/EEC.

Additional references

Please also note the information in the following sections of this manual:

• Guidelines on Handling Electrostatic Sensitive Devices (ESD guidelines)

• For additional information on installing a system containing S7-300 process I/O, refer to the "Wiring" section of the S7-300 Automation System, Hardware and Installation, CPU Data manual.

For further information on EMC directives, we recommend the publication: EMC Installation Guidelines, Configuration Instructions (HW), Order no.: 6FC5 297-0AD30-0AP1.

Standards and specifications

When wiring the C240 PN, you must observe the appropriate VDE guidelines, in particular VDE 0100 and VDE 0113 for tripping devices and short-circuit and overload protection.

2.4.1.2 Configuring the electrical installation

General rules for operating a C240 PN

You must observe the following primary rules for integrating a C240 PN in an automation system or plant.

Supply voltage

The following table identifies the considerations required for the supply voltage.

Table 2-14 Supply voltage

For ... the ...

Stationary systems without all-pole power disconnect switches

A power disconnect switch or fuse is provided in the electrical installation for the building.

Load power supplies, power supply modules

The set rated voltage range corresponds to the local supply voltage.

All electric circuits The fluctuation/deviation of the supply voltage from the rated value must be within the permissible tolerance (see Technical Data for S7-300 Modules).

24 V DC supply

The following table identifies the considerations required for the 24 V supply.



Table 2-15 24 V supply

For ... you must ensure ...

Buildings External lightning protection Lightning protection measures

24 V DC supply lines, signal lines

Internal lightning protection (e.g. lightning conductors)

24 V supply Safe (electrical) isolation of the extra-low voltage

Protection against external electrical phenomena

The table below shows how you must protect your system against electrical interference or faults.

Table 2-16 Protection against electrical interference

For ... you must ensure that ...

All plants or systems in which the SIMOTION C or S7-300 is installed

The plant or system is connected to a protective conductor for the discharge of electromagnetic interference.

Supply, signal and bus lines The wiring arrangement and installation comply with the EMC regulations.

Signal and bus lines A cable or wire break cannot lead to undefined states in the plant or system.

Rules for current consumption and heat loss in a central configuration

The I/O modules on the I/O bus take the current required for their operation from the I/O bus as well as, when necessary, from an external load power supply.

• The current consumption of all I/O modules from the I/O bus must not exceed 1.2 A. This is the current that the C240 PN can supply on the I/O bus.

• PS 307 power supply modules are available for different loads (2 A, 5 A, 10 A). The selection of the appropriate power supply depends on the sum of the current consumption of the C240 PN, the connected I/O modules and any other connected loads fed by the load power supply.

• The power loss of all components used in a cabinet must not exceed the maximum heat that can be dissipated from the cabinet.

Tip: When selecting the cabinet design, make sure that the temperature in the cabinet will not exceed the permissible ambient temperature for the installed components, even if the outside temperatures are high.

You will find information on the current consumption and heat loss of a module in the technical data of the corresponding modules.

DANGER

All interfaces of the C240 PN may only be used on circuits with protective extra low voltage (PELV).



2.4.1.3 Connecting the power supply

Screw-type terminal block

The required 24 V DC load power supply is connected at the screw-type terminal block.

Properties of the load power supply

DANGER

The 24 V DC must be configured as functional extra-low voltage with safe isolation.

Note The connecting cable between the voltage source and the load current supply connector L+ and the associated reference potential M should not exceed a maximum length of 10 m.

Table 2-17 Electrical parameters of the load current supply

Parameters min max Unit Conditions

Voltage range - mean value 20,4 28,8 V

Ripple 3,6 Vpp

Non-periodic overvoltage 35 35 V 500 ms duration 50 s recovery time

Rated current consumption 2,2 A

Starting current 8 A

Terminal assignment

The table below shows the pin assignment on the screw-type terminal block.

Table 2-18 Assignment of the screw-type terminal block

Terminal Terminal assignment

Functional ground

M Mass

L+ 24 V DC

M Mass

If you want to ground the reference potential, you must not remove the jumper between terminals M and functional ground on the C240 PN.



Supply power buffering

The PS 307 load current supplies from the S7-300 system guarantee supply power buffering for 20 ms.

Fig. 2-10: Module supply options

Supply system lines

Use flexible cables with a cross-section of 0.25 to 2.5 mm² (or AWG 18 to AWG 14) for wiring the power supply.

If you only use one wire per connection, a ferrule is not required.

You can use ferrules without an insulating collar in accordance with DIN 46228, Form A long version.

Connecting comb

Use the connecting comb to connect the PS 307 power supply module to the C240 PN. The connecting comb comes with the power supply module.

Other 24 V connections

On the PS 307 power supply, there are 24 V connections available via the connecting comb for connecting the supply of the I/O modules.



Wiring with the connecting comb

Proceed as follows to wire the PS 307 power supply module and the C240 PN.

WARNING

You could come into contact with live wires if the power supply module and any additional load power supplies are switched on.

Ensure that the system is de-energized when you wire the modules!

• Open the front doors of the PS 307 and the C240 PN.

• Release the clip for the cable strain relief on the PS 307.

• Strip the power supply cable (230 V / 120 V) (stripped length of 12 mm) and connect it to the PS 307.

• Tighten the clip for the cable strain relief.

• Insert the connecting comb and tighten it.

• Close the front doors.

Fig. 2-11: Connect power supply module and C240 PN with connecting comb



Setting the power supply to the required supply voltage

Check whether the supply voltage selection switch is set correctly for your supply voltage. The basic setting on the PS 307 is always 230 V. Proceed as follows to change the setting for the supply voltage:

• Remove the covering cap using a screwdriver.

• Set the switch to the available supply voltage.

• Refit the covering cap over the switch opening.

Reverse polarity protection

If the connection is correct and the power supply is switched on, the "5 V DC" LED is illuminated green.

Note Your module will not work in the case of reverse polarity. However, a built-in reverse polarity protection protects the electronics against damage.

Fuse

If a fault is present on the module, a built-in fuse protects the electronics against consequential damage (e.g. fire). In this case, the module must be replaced.

2.4.1.4 Connecting shielded cables via a shield connecting element

Application

With the shield connecting element, you can easily connect all the shielded wires of the C240 PN or S7 modules to ground - by directly connecting the shield connecting element with the mounting rail.

Design of the shield connecting element

The shield connecting element consists of:

• Retaining bracket with two screw bolts to mount the shield connecting element on the mounting rail (order no.: 6ES5 390-5AA00-0AA0).

• The shielding terminals.

You must use the following shielding terminal, depending on the cable cross-section used:

Table 2-19 Assignment of cable cross-sections and terminal elements

Wire with shield diameter Shielding terminal Order no.:

2 cables, each with 2 to 6 mm shield diameter 6ES7 390-5AB00-0AA0

1 cable with 3 to 8 mm shield diameter 6ES7 390-5BA00-0AA0

1 cable with 4 to 13 mm shield diameter 6ES7 390-5CA00-0AA0

The shield connecting element is 80 mm wide and provides space for two rows, each with four shielding terminals.



Fitting the shield connecting element

Fit the shield connecting element as follows:

• Push the two threaded studs for the retaining bracket into the guide on the bottom of the rail. Position the retaining bracket under the modules to be wired.

• Screw the retaining bracket tight on the mounting rail.

• The bottom of the shield connection terminal consists of a web interrupted by a slot. Place this part of the shielding terminal on edge a of the retaining bracket (see the following figure). Press the shielding terminals down and pivot them into the required position. You can fit a maximum of four shield terminals on each of the two rows.

Fig. 2-12 Mounting the shield connecting element

Laying the cables

Only one or two shielded cables can be attached per shielding terminal (see table "Assignment of cable cross-sections and shielding terminals"). Attach the cable to the stripped cable shield. The stripped section of cable shield must have a minimum length of 20 mm. If you require more than four shielding terminals, start the wiring on the back row of the shield connecting element.

Tip: Make sure you allow a sufficient length of cable between the shielding terminal and the front connector. This will, for example, ensure that if a repair is required, you can unplug the front connector without also having to remove the shielding terminal.



2.4.2 Networking

2.4.2.1 Configuring a PROFIBUS subnet

Device = node

Declaration: All devices connected in a subnet will be referred to hereafter as nodes.

PROFIBUS addresses

In order for all nodes to communicate with each other, you must assign a "PROFIBUS address" to each node before connecting them:

The "highest PROFIBUS addresses" are preset for each PROFIBUS subnet. You can change these.

Rules for PROFIBUS addresses

Before assigning PROFIBUS addresses, note the following rules:

• All PROFIBUS addresses in a subnet must be unique.

• The highest PROFIBUS address in a subnet must be ≥ the largest actual PROFIBUS node address in this subnet.

Rules for connecting nodes in a subnet

• Connect all nodes in a subnet "in series". In addition, integrate the programming devices and SIMATIC HMI devices for commissioning or servicing in the subnet in series.

• If you are operating more than 32 nodes in one subnet, you must use RS 485 repeaters to connect the segments (see also the description of the RS 485 repeater in the S7-300, M7-300 Automation Systems, Module Data manual).

• In a PROFIBUS subnet, all bus segments combined must have at least one DP master and one DP slave.

• Use RS 485 repeaters to connect ungrounded bus segments and grounded bus segments.

• The maximum number of nodes per bus segment decreases with each RS 485 repeater. This means that when a bus segment contains an RS 485 repeater, the bus segment can contain no more than 31 additional nodes. The number of RS 485 repeaters, however, does not affect the maximum number of nodes on the bus.

• Up to 10 segments can be connected in a row.

• Switch on the terminating resistor at the first and last node of a segment.



Components

Connect the individual nodes via the bus connector and the PROFIBUS bus cable (also see Section "Network components for PROFIBUS subnet"). Remember to provide a bus connector with a programming device socket at the ends of the subnet. This will give you the option of expanding the subnet if required (for example, for a programming device or SIMATIC HMI device).

Use RS 485 repeaters to connect segments or extend cable lengths.

Terminating resistor

A cable must be terminated with its own surge impedance to prevent line disturbances caused by reflections. To this end, activate the terminating resistor at the first and last node of a subnet or segment (see figure "Bus connector (6ES7...): terminating resistor switched on and off" in Section "Network components for PROFIBUS subnet").

Make sure that the nodes to which the terminating resistor is connected are always supplied with voltage during power-up and operation.

Segment in subnet

The baud rate determines the cable length of a subnet segment (see the following table).

Table 2-20 Permissible cable length of a subnet segment for specific baud rates

Baud rate Max. cable length of a segment (in m)

1.5 Mbit/s 200

Note The project for SIMOCRANE SwayControl stored on the SIMOTION C 240 PN supports only 1.5 Mbit.

Longer cable lengths

If the cable lengths you require exceed the permitted length for a segment, you must use RS 485 repeaters. The maximum possible cable length between two RS 485 repeaters corresponds to the cable length of a segment (see the previous table). Note that these maximum cable lengths only apply if there is no further node interconnected between the two RS 485 repeaters. You can connect up to nine RS 485 repeaters in series.

Note that an RS 485 repeater must be counted as a subnet node when determining the total number of nodes to be connected. This is true even if the RS 485 repeater is not assigned its own PROFIBUS address.



2.4.2.2 Network components for a PROFIBUS subnet

PROFIBUS cable

The following PROFIBUS cables are available:

Table 2-21 PROFIBUS cables

Cable Order No.

PROFIBUS bus cable 6XV1 830-0EH10

PROFIBUS direct-buried cable 6XV1 830-3FH10

PROFIBUS drum cable 6XV1 830-3EH10

Features of the PROFIBUS bus cable

The PROFIBUS bus cable is a two-stranded, twisted, and shielded cable with the following properties:

Table 2-22 Properties of the PROFIBUS cable

Characteristics Values

Surge impedance Approx. 135 to 160 Ω (f = 3 to 20 MHz)

Loop resistance ≤ 115 Ω/km

Effective capacitance 30 nF/km

Damping 0.9 dB/100 m (f = 200 kHz)

Permitted wire cross-section 0.3 mm2 to 0.5 mm2

Permissible cable diameter 8 mm ± 0.5 mm

Rules for laying

PROFIBUS bus cables must not be twisted, stretched, or compressed.

When installing the indoor bus cable, you should also remember the following boundary conditions (dO = outer diameter of the cable):

Table 2-23 Supplementary conditions for the laying of indoor bus cable

Characteristics Supplementary conditions

Bending radius for a single bend ≥ 80 mm (10 x dO)

Bending radius for multiple bends ≥ 160 mm (20 x dO)

Permissible temperature range for cable routing -5° C to +50° C

Temperature range for storage and stationary operation

-30° C to +65° C



Bus connector

The bus connector is used to connect the PROFIBUS bus cable to the PROFIBUS DP interfaces (X8, X9), thus establishing a connection to additional nodes.

The following bus connectors are available:

• Up to 12 Mbit/s, cable outlet 90°

– Without PG socket (6ES7 972-0BA12-0XA0 or 6ES7 972-0BA50-0XA0)

– With PG socket (6ES7 972-0BB12-0XA0 or 6ES7 972-0BB50-0XA0)

• Up to 12 Mbit/s, angled cable outlet

– Without PG socket (6ES7 972-0BA41-0XA0)

– With PG socket (6ES7 972-0BB41-0XA0)

Inserting a bus connector in a module

Follow the steps below to connect the bus connector:

• Plug the bus connector into the module.

• Screw the bus connector tightly onto the module.

• If the bus connector is located at the start or the end of a segment, you must connect the terminating resistor ("ON" switch setting) (refer to the following figure).

• Make sure that the nodes at which the terminating resistor is located are always supplied with voltage during startup and operation.

Fig. 2-13: Bus connector (6ES7 ...): Terminating resistor switched on and off



Unplugging a bus connector

You can unplug a bus connector with a looped-through bus cable at any time from the PROFIBUS DP interface without interrupting data exchange on the bus.

WARNING

Data traffic error might occur on the bus! A bus segment must always be terminated with the terminating resistor at both ends. This is not the case, for example, if the last node with a bus connector is deenergized. Because the bus connector takes its voltage from the station, this terminating resistor is ineffective. Make sure that the stations at which the terminating resistor is connected are always energized.

2.4.2.3 Configuring an Ethernet subnet

When a camera and/or a crane operator panel is deployed, the use of a hub is recommended for the communication between the function units. A hub is required during the commissioning and for diagnostic purposes.

The sway-control computer is connected to the hub via Ethernet using a patch cable.

Overview

An Industrial Ethernet can be connected to the 8-pin RJ45 socket X7.

Industrial Ethernet is a communications network with a transmission rate of 10/100 Mbit/s.

You can use a PG/PC to communicate with STEP 7, SIMOTION SCOUT and SIMATIC NET OPC.

A shielded twisted pair cable is used for the networking. For additional information, see the SIMATIC NET, Industrial Twisted Pair and Fiber Optic Networks manual. This documentation is supplied in electronic format with SIMOTION SCOUT.

The following connection cables are recommended:

• SIMATIC NET, Ind. Ethernet TP XP CORD RJ45/RJ45, TP cable assembled with two RJ45 plugs, send and receive cables crossed

Order no.: 6XV1870-3R ( - length code)

• SIMATIC NET, Ind. Ethernet TP CORD RJ45/RJ45, TP cable assembled with two RJ45 plugs

Order no.: 6XV1870-3Q ( - length code)

You can obtain additional information about the different cable systems for Ethernet from your SIEMENS contact.

2.4.2.4 Configuring an Ethernet subnet on the PROFINET interface (C240 PN)

Overview

You can connect a PROFINET node to the X11 P1, X11 P2 and X11 P3 8-pin RJ45 sockets, see Figure "Overview of the cable connecting the C240 PN to the servo drive (digital connection) - example" in Section "Wiring diagram overview" . PROFINET is a communications network with a transmission rate of 100 Mbit/s.

You can use a PG/PC to communicate with STEP 7, SIMOTION SCOUT, and SIMATIC NET OPC.

A shielded twisted pair cable is used for the networking in this case. For additional information, see the SIMATIC NET, Industrial Twisted Pair and Fiber Optic Networks manual. This documentation is supplied in electronic format with SIMOTION SCOUT. All ports of the PROFINET interface support



auto-MDI(X) in contrast to the Ethernet interface. A crossover cable is therefore not required for a direct connection to the PG/PC.

The following connecting cables are recommended:

• SIMATIC NET, Ind. Ethernet FC TP standard cable GP, order no.: 6XV1840-2AH10 (sold by the meter)

• SIMATIC NET, Ind. Ethernet FC TP Trailing Cable GP, order no.: 6XV1870-2D (sold by the meter)

• SIMATIC NET, Ind. Ethernet TP XP CORD RJ45/RJ45, TP cable assembled with two RJ45 plugs, send and receive cables crossed, order no.: 6XV1870-3R ( - length code)

• SIMATIC NET, Ind. Ethernet TP CORD RJ45/RJ45, TP cable assembled with two RJ45 plugs, order no.: 6XV1870-3Q ( - length code)

The following bus connectors can be used with the C240 PN:

• SIMATIC NET, Ind. Ethernet FC RJ45 plug 145, order no.: 6GK1901-1BB30-0AA0 (1 item),

order no.: 6GK1901-1BB30-0AB0 (10 items)

You can obtain additional information about the different cable systems for PROFINET and Ethernet from your SIEMENS contact.

Loading the PROFINET configuration via PROFIBUS DP (loading of the IP address)

For configuration using PROFINET, the SIMOTION C must be provided with an IP address, the subnet mask and the router address. To configure and transfer PROFINET addresses to the C240 PN, proceed as follows:

1. Open your project.

2. Open HW Config. Double-click the X11 "PNxIO" slot of the C240 PN module to open the "Properties - PNxIO" dialog box.

3. Click the "Properties" button of the Ethernet interface. The "Properties - PNxIO Ethernet Interface" dialog box is displayed.

4. In this dialog, click "New". The "New Industrial Ethernet" subnet dialog is displayed. In this dialog box, you can change the name of the new subnet or confirm the factory setting with "OK".

5. The newly created Ethernet subnet is now shown under Subnet in the "Properties - Ethernet Interface" dialog box and must be selected.

6. In this dialog box, enter the required addresses for IP address and subnet dialog box. Under Router, choose whether a router is to be used. If using a router, enter the router address.

7. Confirm this dialog box with "OK".

8. Close the "Properties - PNxIO" dialog box with "OK".

9. Save and compile the modified hardware configuration.

10. Load the new hardware configuration to the C240 PN via PROFIBUS DP.

Loading the PROFINET configuration via Ethernet (loading of the IP address)

If a PROFIBUS DP is not available for the initial loading of the IP address, the following procedure starting from Windows 2000 can be used: The "Automatically Assign IP Address" setting must be enabled in the TCP/IP configuration of the PC.

1. Connecting a Windows PC and C240 PN directly via RJ45 crossover cable

Hardware Commissioning 2.5 Operator Control (Hardware)


2. Boot the Windows PC. The PC does not find a DHCP server and automatically selects an IP address from the APIPA subnet (Automatic Private IP Addressing) 169.254.0.0.

3. Load the new hardware configuration with the new IP address via Ethernet at the IP address 169.254.11.22 (default IP address of SIMOTION C as delivered).

2.5 Operator Control (Hardware)

2.5.1 Control Elements

2.5.1.1 Mode selector switch

Certain operation modes can be selected using the mode selector.

Mode selector positions

The positions of the mode selector are explained in the order in which they appear on the C240 PN.

Table 2-24 Operation modes and switch positions

Operation mode

Explanations

RUN C240 PN is processing the user program and the associated system functions:

• Reading process image of inputs

• Execution of the user programs assigned to the execution system.

• Writing process image of outputs The technology packages are active in this mode. They can execute commands from the user program.

STOP C240 PN is not processing any user program.

• It is possible to load a complete user program.

• All system services (communications, etc.) are active.

• The I/O modules (SMs) are in a safe state. The technology packages are inactive, i.e. all enables are deleted. No axis motions can be executed.

MRES (overall reset)

Selector position for overall reset on the C240 PN. An overall reset by means of a mode selector requires a specific sequence of operation, see Section 2.8.3 ).

2.5.1.2 Micro Memory Card (MMC)

The following micro memory card is available:

order no.: 6AU1 720-1JA00-0AA0

The micro memory card is mandatory for operating the SIMOTION C240 PN.

The micro memory card is supplied in a bootable format with the latest SIMOTION Kernel.

Hardware Commissioning 2.5 Operator Control (Hardware)


Note

The C240 PN has no firmware.

The micro memory card for the SIMOTION C240 PN can be used:

• To store the SIMOTION Kernel (basic system)

• To store the technology packages and user data (programs, configuration data, parameterizations)

CAUTION

The micro memory card may only be inserted or removed when the control unit is disconnected from the power supply.

Memory module slot

The micro memory card is inserted in the memory module slot.

2.5.2 Display elements

LED displays

The following LED displays are on the front panel of the C240 PN. This table describes the LEDs and their function.

Table 2-25 Status and fault displays

LED Meaning

SF (red) This LED indicates an error on the C240 PN.

5 V DC (green) This LED indicates that the power supply for the electronics is ready.

RUN (green) - C240 PN in RUN

This LED indicates that the user program is running.

STOPU (yellow) - C240 PN in STOP user program

This LED indicates that the technology packages (for example, synchronous operation and cam) are active. The user program is not active.

STOP (yellow) - C240 PN in STOP

This LED indicates that no user program is running. The technology packages are not active.

BUS1F (red) - Group fault

This LED indicates a fault on the PROFIBUS DP1 interface (X8) of the C240 PN.

BUS2F (red) - Group fault

This LED indicates a fault on the PROFIBUS DP2/MP1 interface (X9) of the C240 PN.

Q0...Q7 , I0...I11 , B1...B4, M1, M2 (green) - digital inputs/outputs

These LEDs show the status of the digital inputs/outputs.

Hardware Commissioning 2.6 Parameter assignment / addressing


2.6 Parameter assignment / addressing


Each device must have its own IP address for communication in the Ethernet network. NOTICE

The IP address of the sway-control computer may not be used for another device within the network.

NOTICE

The IP address of the sway-control computer must not be changed when a crane operator panel is used.

2.6.2 Default settings

The following settings are specified as default in the MMC card image.

PROFIBUS X8 DP1:

PROFIBUS DP address of the sway-control computer: 100 Baud rate 1.5 Mbit/s

Note

For the initial commissioning, the DP address must be set via CeComm - even when the default address should be retained.

UDP X7 IE:

IP address of the camera: 192.168.1.155 IP address of the SIMOTION: : 192.168.1.158 Subnet mask: 255.255.255.0 Note

As delivered, the camera has the IP address 0.0.0.0 and must be adapted to this address.

PROFINET X11 P1:

IP address of the SIMOTION: 192.168.0.2 IP address of the camera: 192.168.0.3 Subnet mask: 255.255.255.0 Camera device name: MV440

NOTICE

If the SIMOTION C and the camera are operated in the PROFINET, the IP address of the camera cannot be changed via PST. The address of the PG/PC must be modified to the above network for the communication to the camera.

2.6.3 Changing the addresses

The IP address and PROFIBUS DP address of the SIMOTION C can be changed in the diagnostics software from the Parameters menu. After calling the Parameters menu with the "P" key and calling the "I - Change communications addresses" function, follow the instructions.

Hardware Commissioning 2.6 Parameter assignment / addressing


Note If the IP address of the SIMOTION has been changed, after confirmation and saving, the connection between the diagnostic tool and the SIMOTION C will be lost. Before a connection with the new IP address can be re-established (via Options/Interface), the SIMOTION C must be briefly switched to the STOP mode and then back to RUN.

Note If the PROFIBUS address is changed, the SIMOTION C restarts automatically after confirmation and saving. After this boot process, a new connection with the current IP address is required.

2.6.4 Restoring the changed IP address

If the actual IP address of the SIMOTION C240 PN is not known it can be restored by following the steps below.

• Set the default IP address from the "Options/Interface" menu as provided in the documentation.

• Switch the operation mode of the SIMOTION C240 PN to stop and then provide a power cycle.

• Establish a connection with the default IP address via the diagnostics tool. The sought IP address is now shown on the screen (following figure).

• When the SIMOTION C240 PN mode selector is changed to "RUN", the SIMOTION starts with the sought IP address, the started connection attempt is not successful and must be stopped with the "Cancel" button.

After correcting the IP address from the "Options/interface" menu item and making another attempt to establish a connection, the SIMOTION device can be accessed again via the diagnostics tool.

Hardware Commissioning 2.7 Planning/configuring


Fig. -2-14: Screen of the diagnostics tool after ramping up the SIMOTION device in STOP mode

2.7 Planning/configuring All devices must have been connected, commissioned and interconnected for the commissioning of the sway control system. This applies not only to the main component, the SIMOTION C240 PN, but also all required components.

The individual components are described in the following sections:

Component Description

PROFIBUS DP interface Section 3.2

SIMOCRANE CenSOR 2.0 camera measuring system

SIMOCRANE CenSOR 2.0 documentation

Diagnostic program Section 4.4

Additional products

Crane Operator Panel "Crane Operator Panel" Operating Instructions

The commissioning PC is only connected for diagnostics and commissioning purposes.

In practice, the Ethernet connection is sufficient to perform all the diagnostics and setting tasks.

Examples for the implementation of the signal sequences in the PLC are contained in Chapter 3.

Hardware Commissioning 2.8 Commissioning (hardware)


2.8 Commissioning (hardware)

2.8.1 Commissioning requirements

Preconditions

Table 2-26 Requirements

Prerequisite action See ...

Your system with C240 PN is installed Section 542.3 "Installing/mounting"

Your system with C240 PN is wired Section 542.4.1 "Wiring"

For networking via PROFIBUS DP

• The PROFIBUS addresses of the bus nodes with which the C240 PN communicates are set

• The terminating resistors are switched on (at segment ends) For networking via Ethernet

• The Ethernet addresses of the bus nodes with which the C240 PN communicates are set

Section 542.4.2 "Networking"

Section 542.4.2.3 "Configuring an Ethernet subnet"

System requirements

Note Information on the hardware and software requirements can be found in the Readme file of the associated software version.

The connection from the PG/PC to the C240 PN (X8 connector) must be established for the online communication via PROFIBUS DP.

The connection from the PG/PC to the C240 PN (X7 connector) must be established for the online communication via Ethernet.

The programming device must be equipped with a PROFIBUS or Ethernet card.

You require the MMC adapter to write to the micro memory card (SIMOTION Kernel update) on the PG/PC.

Connecting the PG/PC to a C240 PN

You can connect the PG/PC to the PROFIBUS of the C240 PN (X8 connector) with a connecting cable (see Section 2.4.2).

You can connect the PG/PC to the Ethernet of the C240 PN (X7 connector) with a shielded twisted-pair cable.

Inserting/replacing the micro memory card

Proceed as follows:

• Switch off the power supply module.

• Is a micro memory card inserted? If so: Remove the micro memory card. To permit the removal of the micro memory card, the module slot holder is provided with an ejector. Press the ejector and remove the micro memory card.



• By applying slight pressure, insert the ("new") micro memory card into the module slot of the C240 PN until it snaps into place. Make sure the beveled edge of the micro memory card faces the ejector (see the following figure).

• Switch the power supply module on again.

Fig. 2-15: Inserting the micro memory card into the C240 PN

Note With the SIMOTION C240 PN, the micro memory card must always be inserted for operation.

For the purpose of data backup, the contents of the micro memory card can be copied to the hard drive of a PG/PC with an MMC card reader.

2.8.2 Initial power-up

Prerequisite

Your system with C240 PN has been installed and wired.

The mode selector must be set to STOP!

Initial power-up

Switch on the power supply module.

• The 24 V DC LED on the power supply module is illuminated.

• On the C240 PN:

– The 5 V DC LED illuminates.

– All other LEDs illuminate briefly (approx. 2 seconds).

Note If a micro memory card is not inserted in the C240 PN or the micro memory card does not contain a SIMOTION Kernel, all LEDs except the RUN LED illuminate on the SIMOTION C240 PN.



2.8.3 Simotion C240 PN overall reset

Introduction

Overall reset is a procedure that entails a reboot.

During the overall reset, the RAM on the C240 PN and the non-volatile data in the SRAM, except for the communication configuration (baud rates, network addresses, etc.), are deleted. The data on the micro memory card is retained during the overall reset.

You can perform an overall reset reset using the mode selector on the C240 PN or via SIMOTION SCOUT.

Overall reset with the mode selector

Note The operation for the overall reset with the toggle switch is described below.

The operation with the toggle switch on the C240 PN is similar to the operation with the key-operated switch on the C230-2.

Proceed as follows (see following figure):

• Place the toggle switch of the mode selector at the STOP position.

• Place the toggle switch at the MRES position. Keep the toggle switch at this position until the STOP LED switches from flashing to steady illumination.

• Within 3 seconds, you must release the switch and return it to the MRES position. The overall reset will now be performed. All the LEDs will illuminate during this time. The C240 PN has completed the overall reset when the STOP LED illuminates.

• The C240 PN has reset the memory.

Fig. 2-16: Mode selector operation sequence for the overall reset

Hardware Commissioning 2.9 Installing the software


2.9 Installing the software A micro memory card with the sway control software is included in the scope of delivery.

This card contains:

• The sway control software

• The communication software for the diagnostics and

• All supplied license keys.

The following files also belong to the firmware and are also on the memory card in the /SWAYCONTROL/ directory:

Sprache0.txt, Sprache1.txt Language files, German and English.

Help_D.chm, Help_E_.chm Help files, German and English.

The copy protection is implemented with the Key file in the /KEYS/ directory.

The micro memory card can be used in a SIMOTION C240 PN of the same design.

WARNING

The SIMOTION C240 PN must be de-energized when the micro memory card is inserted.

An additional installation is not required.

If required, the card can be read out or rewritten via a commercially available read/write unit. The required files are available on the supplied CD. To prevent an unauthorized copying of the software, the copy protection is bound to the MMC card. Should it be corrupted, contact your supplier.

2.10 Commissioning (software)

2.10.1 Commissioning requirements

2.10.1.1 General requirements, overview

The drive system and all safety functions of the crane, especially limit trips, safety interlocks, EMERGENCY STOP functions and load monitoring must be commissioned and operational.

WARNING

The commissioning and testing of the Sway Control functions may only be performed by trained personnel who are familiar with the operation of the crane. The regulations of the crane owner must be observed. A further requirement is the successful participation in a commissioning training course held by Siemens AG.

Hardware Commissioning 2.11 Service and maintenance


Warning notice

WARNING

All safety functions of the crane must be implemented independently of the sway control system. Measures must be taken to ensure that the crane stops without any adverse affects on persons or goods when a fault occurs.

WARNING

The PLC programmer is obligated to evaluate the error messages of the sway-control computer. In an error situation, the speed actuator values of the sway control computer may no longer be used. The drive control system must be implemented exclusively via the PLC.

WARNING

The automatic reduction of the speed at the prelimit switch and the shutdown of the drives at the limit switches are not safety functions, but only serve to reduce the oscillation of the load when stopping.

2.11 Service and maintenance

2.11.1 Removal and replacement of the C240 PN

Overview

The C240 PN can only be replaced as a complete unit.

WARNING

The C240 PN can only be replaced when the load power supply is switched off. You must therefore switch off the power supply, e.g. by means of the on/off switch on the PS module.

Removing a defective module

To remove the C240 PN, proceed as follows:

• Switch off the power supply.

• Remove the micro memory card.

• Open the front doors. If necessary, remove the labeling strip.

• Unplug the connections on the terminal block for the power supply.

• Unplug the connectors to the PROFIBUS DP interfaces (X8).

• Release the front connector (X1).

• To do this, unscrew the fastening screw in the middle of the front connector and then pull out the connector by the grips.

• Loosen the module's mounting screws and swing it upwards and out.

Hardware Commissioning 2.12 Alarm, error, and system messages


Installing a new module

The procedure is as follows:

• Remove the upper part of the front connector coding from the new module.

• Insert a module of the same type, swing it down and screw it tight.

• Plug in the front connector and move it into operating position (tighten fastening screw). The coding element will adjust such that the front connector only fits this module type.

• Terminate the load voltage supply cables at the terminal block.

• Close the front panel doors and insert the labeling strips. The controller is once again ready for operation and can be commissioned.

• Insert the micro memory card.

• Switch on the power supply.

2.12 Alarm, error, and system messages

2.12.1 Alarm, error, and system messages of the SIMOTION C240 PN

2.12.1.1 Diagnostics using the LED display

Diagnostic LEDs

The LEDs are explained in the order in which they are arranged on the C240 PN.



Table 2-27: Diagnostic LEDs of the C240 PN

Display Meaning Explanations

SF (red)

LED - ON

LED - flashing (0.5 Hz)

LED - OFF

System fault This LED indicates a fault on the C240 PN.

An event (alarm, message, note) that can be acknowledged is present. (See the SIMOTION Description of System and Functions documentation package)

No license for technology/option objects under license. Technology/option objects under license include, for example:

• Cam (synchronous axes with connected cam)

• Ethernet (Ethernet interface)

• TControl (temperature control)

C240 PN is operating fault-free

5 V DC (green)

LED - ON

LED - OFF

Power supply for the electronics

This LED indicates that the power supply is ready for operation.

The power supply of the C240 PN is operating fault-free.

If it does not illuminate, possible reasons include:

• No connected or switched-on network

• No specified load power supply connected

• Module not connected correctly

• Module defective

RUN (green) LED - ON

LED - flashing (2 Hz)

C240 PN in RUN

This LED indicates that the user program is running.

The time from when the "RUN" operation mode is selected until this operation mode has been attained is indicated by the LED flashing.

STOPU (yellow) LED - ON

LED - flashing (2 Hz)

LED - "flickering"

C240 PN in STOP user program

This LED indicates that the technology packages are active. A user program is not being processed.

The time from when the "STOPU" operation mode is selected until this operation mode has been attained is indicated by the LED flashing.

Formatting the micro memory card.

STOP (yellow) LED - ON

LED - flashing (2 Hz) (0.5 Hz)

LED - "flickering"

C240 PN in STOP

This LED indicates that no user program is running. The technology packages are inactive.

The time from when the "STOP" operation mode is selected until this operation mode has been attained is indicated by the LED flashing. An overall reset request is indicated by slow flashing.

Writing to the micro memory card.



Display Meaning Explanations

BUS1F (X8) (red) or BUS2F (X9) (red)

LED - ON


LED - OFF

LED - ON


LED - OFF

Fault on interface

This LED indicates a fault on the PROFIBUS DP interface.

Interface configured as a slave: Bus fault Search for baud rate

Parameterization error No cyclic data exchange

Cyclic data exchange

Interface configured as master: Bus fault (bus short-circuit)

Bus fault (slaves failed or cable interrupted)

No fault or no interface configured

Note

All LEDs illuminate briefly while the C240 PN is powering up. You can perform a detailed diagnosis with a PG/PC and the engineering system. Projects cannot be downloaded in STOPU mode.



2.12.1.2 Combination of LED displays

Combination of LED displays

The following table provides an overview of all permissible and/or required LED display combinations.

The meaning of the symbols used in the table is as follows:

1 - LED ON 0 - LED OFF 0.5/1 - LED flashing (0.5 Hz) 2/1 - LED flashing (2 Hz) - LED flickering → - Running light x - LED can illuminate



Table 2-28 Summary of the LED displays

LED displays Meaning

SF (red)

5 V DC(green)

RUN (green)

STOPU(yellow)

STOP (yellow)

BUS1F (red)

BUS2F(red)

Power-up 1 1 1 1 1 1 1

STOPU → RUN x 1 2/1 1 0 x x

RUN x 1 1 0 0 x x

RUN → STOPU x 1 1 2/1 0 x x

STOPU x 1 0 1 0 x x

STOPU → STOP x 1 0 1 2/1 x x

STOP x 1 0 0 1 x x

STOP → STOPU x 1 0 2/1 1 x x

Power supply is ready for operation x 1 x x x x x

Write to micro memory card (copy RAM to ROM)

x 1 0 0 x x

Formatting the micro memory card x 1 0 0 x x

Request for overall reset by the C240 PN itself or via the mode selector of the C240 PN

x 1 0 0 0,5/1 x x

Overall reset in progress 1 1 1 1 1 1 1

Overall reset completed x 1 0 0 1 x x

SIMOTION C240 PN without micro memory card

1 1 0 1 1 1 1

Copy SIMOTION Kernel to micro memory card

0,5/1 1 0,5/1 0,5/1 0,5/1 0,5/1 0,5/1

C240 PN is operating fault-free 0 1 x x x 0 0

An interrupt that can be acknowledged (alarm, message, note) is pending

1 1 x x x x x

Fault to which the user program cannot respond. The following actions may be required to rectify the fault:

• Power OFF/ON

• Check micro memory card

• Re-commission

• Replacement of the C240 PN

x 1 x

No license exists for technology/optional objects under license

0,5/1 1 x x x x x



SIMOTION - HOLD status User program is running at the break point

x 1 0,5/1 1 1 x x

PROFIBUS DP interface as slave

Bus fault Searching for baud rate

x 1 x x x 1 1

Parameterization fault No cyclic data exchange

x 1 x x x 0,5/1 0,5/1

Cyclic data exchange x 1 x x x 0 0

PROFIBUS DP interface as master

Bus fault (bus short-circuit) x 1 x x x 1 1

Bus fault (slaves have failed or cable faulty)

x 1 x x x 0,5/1 0,5/1

No fault or no interface configured x 1 x x x 0 0

SIMOTION C240 PN system error

The diagnostic buffer of the sway-control computer must be exported when a system error occurs. These errors cannot be displayed in plain text via the CeCOMM diagnostic program. Access to the diagnostic buffer can be via a Web server implemented on the sway-control computer. To do this, the Web server is called in the diagnostics tool via the "Web server" tab. After establishing a connection to the sway-control computer, the start page is displayed and the errors displayed in hexadecimal format via the options "Diagnostics" and "Diag buffer".

2.12.2 Error messages of the sway-control computer

During the commissioning or a diagnosis, errors of the sway control system can be detected and corrected with the "CeCOMM.EXE" diagnostic program. The currently pending errors are displayed by pressing the "E" key from the main menu or the display screens. The error history can be called via the "H" key.

Each error has a number, a title, an error description and remedy information.

During crane operation, these errors are also visible on the crane operator panel (see "Crane Operator Panel" operating instructions).

Errors that are transferred to the PLC, are identified by an error bit.

WARNING

The PLC programmer is required to evaluate the error messages of the sway-control computer. In an error situation, the manipulated values of the sway-control computer may no longer be used. The drive control system must be implemented exclusively via the PLC.

There is a detailed description of all errors in the error list in Chapter 4.

Hardware Commissioning 2.13 Dimension drawings


2.13 Dimension drawings

Fig. 2-17: Dimension drawing of the C240 PN

2.14 Spare parts / accessories Table 2-29 Spare parts and accessories

Components Order number Accessories Spare parts

Bus connectors 6ES7 390-0AA00-0AA0 - X

Connecting comb between power supply and C240 PN

6ES7 390-7BA00-0AA0 - X

Micro memory card for SIMOTION C240 PN 6AU1 720-1JA00-0AA0 X -

Labeling plate (10 items) 6ES7 392-2XX00-0AA0 - X

Slot number plate 6ES7 912-0AA00-0AA0 - X

Front connector, 40-pin Screw-type technology Spring-tension type

6ES7 392-1AM00-0AA0 6ES7 392-1BM01-0AA0

X -

Shield connecting element 6ES7 390-5AA00-0AA0 X -

Shield connection terminals for 2 cables, each with 2 to 6 mm shield diameter 1 cable with 3 to 8 mm shield diameter 1 cable with 4 to 13 mm shield diameter

6ES7 390-5AB00-0AA0 6ES7 390-5BA00-0AA0 6ES7 390-5CA00-0AA0

X -

Hardware Commissioning 2.15 Appendix


2.15 Appendix

2.15.1 Standards and approvals

2.15.1.1 General rules

IEC 1131

The SIMOTION programmable controller meets the requirements and criteria of the Standard IEC 1131, Part 2.

CE marking

Our products meet the general and safety-related requirements of the following EC guidelines and conform to the uniform standards (EN) for programmable controllers published in the official gazettes of the European Union:

89/336/EEC "Electromagnetic Compatibility" (EMC guideline)

The EC declaration of conformity is contained in this manual.

EMC Directive

SIMOTION products are designed for industrial use. Table 2-30 EMC directive

Application range Requirements for

Interference emission Immunity

Industry EN 50081-2 EN 61000-6-2

UL certification

Recognized component mark for United States and the Canada Underwriters Laboratories (UL) in accordance with UL 508, File 16 4110.

Declaration of conformity

The current declaration of conformity is on the Internet at

22Uhttp://support.automation.siemens.com/WW/view/de/15257461

2.15.1.2 Safety of electronic controllers

Introduction

The remarks made here relate to fundamental criteria and apply irrespective of the type of controller and the manufacturer.

Reliability

The reliability of devices and components is maintained at the highest possible level thanks to comprehensive and cost-effective measures implemented during the development and manufacturing processes.

These include

• The selection of high-quality components



• Worst-case dimensioning of all circuits

• Systematic and computerized inspection of all supplied components

• Burning in of all LSI circuits (e.g. processors, memories, etc.)

• Measures to prevent static discharge when handling MOS circuits

• Visual checks during various stages of manufacture

• Continuous heat testing at higher ambient temperatures for several days

• Thorough computerized final inspection

• Statistical analysis of all returned goods so that corrective measures can be initiated immediately

• Monitoring of the primary controller components using online tests.

These measures are considered to be basic measures for safety engineering. They avoid or control the majority of faults that may occur.

Risk

A higher degree of safety standard applies to all applications and situations where there is a risk of material damage or injury to persons if there is a failure. Special regulations specific to the system apply to such applications. These must be taken into account for configuration of the controller (e.g. VDE 0116 for furnaces).

For electronic controllers with safety responsibility, the measures required for preventing or controlling faults depend on the hazard inherent in the plant. In this respect, the basic measures listed above are no longer adequate once the hazard exceeds a certain potential. Additional measures (e.g. double redundancy, tests, checksums, etc.) for the controller must implemented and certified (DIN VDE 0801).

Division into safety-critical and non-safety-critical areas

Nearly all systems contain parts that perform safety-related tasks (e.g. emergency-stop switch, protective grating, two-hand controls). To avoid having to apply safety-related criteria to the entire controller, it is customary to divide the controller into two areas - one that is critical to safety and one that is not critical to safety. No special demands are made concerning safety in the area that is not safety-critical as an electronic fault would not have any effect on the safety of the system. However, in the safety-critical area, only controllers and circuits that comply with the relevant regulations, may be used.

Important note

Even if an extremely high level of conceptual safety has been achieved in the design of an electronic controller - e.g. through implementation of a multi-channel design - strict adherence to all instructions in the operator's guide is mandatory, as incorrect handling could invalidate measures taken to prevent hazardous faults or create additional potential hazards.

2.15.1.3 Electromagnetic compatibility

Definition

Electromagnetic compatibility is the capability of an electrical apparatus to function satisfactorily in its electromagnetic environment without affecting this environment.

The C240 PN satisfies the requirements of the EMC regulations of the internal European market.

The following provides information about noise immunity and radio interference suppression.



Pulse-shaped interference

The following table shows the electromagnetic compatibility of modules with regard to pulse-shaped interference.

Table 2-31 Electromagnetic compatibility of modules

Pulse-shaped interference Test voltage Corresponds to severity

Electrostatic discharge tested in accordance with DIN EN 61000-4-2

8 kV 4 kV

3 (air discharge) 2 (contact discharge)

Burst pulses (fast transient interferences) tested in accordance with DIN 61000-4-4

2 kV (supply cable) 1 kV (signal cable)

3 3

Surge tested in accordance with DIN EN 61000-4-5 Can only be achieved with protectors Asymmetric coupling

Symmetric coupling

0.5 kV (supply cable) 1 kV (signal line/data line) 0.5 kV (supply cable)

1 2

1

Note To maintain the surge strength (lightning protection), the following requirements must be satisfied:

The connecting cable between the voltage source, the load power supply connection L+, and the associated reference potential M must not exceed 10 m.

DEHN FDK/2 60 surge protection terminal blocks are required to maintain lighting protection of the digital inputs and outputs.

Sinusoidal interference

HF radiation on the device in accordance with EN 61000-6-2 requirements:

• Electromagnetic HF field, amplitude-modulated

– From 80 to 1000 MHz

– 10 V/m

– 80% AM (1 kHz)

• Electromagnetic HF field, pulse-modulated

– 900 ±5 MHz

– 10 V/m

– 50% ED



– 200 Hz repetition rate

• HF-coupling on signal and data cables, etc., in accordance with EN 61000-6-2 requirements, high frequency, asymmetric, amplitude modulated

– From 0,15 to 80 MHz

– 10 V rms value, unmodulated

– 80% AM (1 kHz)

– 150 Ω source impedance

Emission of radio interference

Interference emission of electromagnetic fields as per EN 55011: Limit value class A, Group 1.

Table 2-32 Interference emission of electromagnetic fields

From 20 to 230 MHz < 30 dB (μV/m)Q

From 230 to 1000 MHz < 37 dB (μV/m)Q

Measured at a distance of 30 m

Interference emission via network alternating current supply in accordance with EN 55011: Limit value class A, group 1.

Table 2-33 Interference emission via mains AC supply

From 0,15 to 0,5 MHz < 79 dB (µV)Q < 66 dB (µV)M

From 0,5 to 5 MHz < 73 dB (µV)Q < 60 dB (µV)M

From 5 to 30 MHz < 73 dB (µV)Q < 60 dB (µV)M

Expanded application

If you use the C240 PN in residential areas, you must ensure the observance of limit value class B in accordance with EN 55011 with regard to the emission of radio interference.

Recommendation: Install the C240 PN in grounded metal cabinets, such as 8MC cabinets (see NV 21 catalog). Connect filters to the supply lines.

2.15.2 ESD guidelines

2.15.2.1 What does ESD mean?

All electronic modules are equipped with large-scale integrated ICs or components. Because of the technology used, these electronic components are very sensitive to overvoltages and thus to electrostatic discharge.

These Electrostatic Sensitive Devices/Modules are commonly abbreviated ESD. The ESD designation is used internationally to refer to electrostatic sensitive devices.



Electrostatic sensitive devices are identified by the following symbol:

Fig. 2-18: Symbol for identification of electrostatic sensitive devices

CAUTION

Electrostatic sensitive devices can be irreparably damaged by voltages that are far lower than anything a person can perceive. Voltages of this kind occur as soon as a component or an assembly is touched by a person who is not grounded against static electricity. Any damage that occurs to a module as a result of overvoltage is generally not recognized immediately and only comes to light after the equipment has been operating for some time.

2.15.2.2 Electrostatic charging of persons

Anyone who is not connected to the electrical potential of their surroundings is subject to electrostatic charge.

This figure indicates the maximum electrostatic charges that can accumulate on operators when they come into contact with the indicated materials. These values comply with the specifications in IEC 801-2.

Fig. 2-19: Electrostatic voltage that can accumulate in operating personnel



2.15.2.3 Fundamental measures to protect against static discharge

Make sure the grounding is good

When working with electrostatically sensitive devices, make sure that the person, the workstation and the packaging are properly grounded. This prevents the accumulation of static electricity.

Avoid direct contact

You should only touch ESD components if this is unavoidable (for example, during maintenance work). Hold the modules so that you touch neither pins nor printed conductors. If you follow these instructions, electrostatic discharge cannot reach or damage sensitive components.

If you have to carry out measurements on a module, discharge yourself before carrying out any actions. To do this, touch a grounded metal object. Only use grounded measuring instruments.


3 Project Planning SIMATIC S7 3 3.1 Technical data

3.1.1 System properties

SIMOTION C240 PN

The sway control functions as well as the interfaces for diagnostics and commissioning are implemented on a SIMOTION C240 PN.

At present, it is not intended to implement further PLC functions in addition to the sway control and positioning.

The SIMOTION C240 PN receives control commands via PROFIBUS DP. Output data is also transferred via PROFIBUS DP.

PLC

In principle, it is intended to use the main crane control in a separate PLC. This PLC performs all tasks not directly related to the positioning.

The PLC should perform at least the following functions:

• Enabling and disabling of travel movements

• Preprocessing of sensor data (position data, load locking, load mass, slack rope, etc.)

• Determination of limits (prelimit switches, limit switches)

• Evaluation of error messages

• Monitoring functions

The PLC can also take over the following functions (if a crane operator panel is not being used):

• Provision of target positions (in millimeters)

• Selection of the operation mode

Project Planning SIMATIC S7 3.1 Technical data


3.1.2 Technical data of the SIMOTION C240 PN

3.1.2.1 Technical data

Connection values Table 3-1 Connection values

Power supply 24 V DC (permissible range: 20.4...28.8 V)

Power consumption from 24 V 0.9 A (inputs/outputs open)

Power loss 15 W

Starting current 8 A

Dimensions and weight Table 3-2 Dimensions and weight

Dimensions W x H x D [mm] 200 x 125 x 118

Weight [g] approx. 1,150

3.1.2.2 Clock

This table lists the properties and functions of the SIMOTION C240 PN clock.

Table 3-3: Properties of the SIMOTION C240 PN clock

Properties C240 PN

Type Hardware clock (integrated "real-time clock")

Factory setting upon delivery DT#1992-01-01-00:00:00

Backup Permanently installed accumulator (maintenance-free goldcap)

Accuracy

• With supply voltage on 0 to 55° C

• With supply voltage off 25° C -20° C to 70° C

-12 s to +4 s

-1 s to +4 s

-9 s to +4 s

Backup time Typically 4 weeks (at 0 to 25° C)

Charging time 1 h



With POWER OFF

The SIMOTION C240 PN clock continues to operate in POWER OFF for the battery backup time (excluding software clock). The battery is recharged in the POWER ON state.

No error message is output if the backup function is defective. With POWER ON, the clock resumes at the time at which POWER OFF occurred.

When the SIMOTION C240 PN is reset to the factory setting, the clock is also reset to the "factory setting as delivered".

3.1.2.3 Specifications for insulation tests, safety class, and degree of protection

Test voltages

During the routine test, the insulation resistance is tested at the following test voltage in accordance with IEC 1131 Part 2:

Table 3-4 Test voltages

Circuits with rated voltage Ue relative to othercircuits or ground

Test voltage

0 V < Ue ≤ 50 V 500 V DC

Protection class

Protection class I in accordance with IEC 536 (VDE 0106, Part 1), i.e. a protective-conductor connection is required on the mounting rail!

Protection against ingress of solid foreign bodies and water

IP 20 degree of protection in accordance with IEC 529, i.e. protection against contact with standard test fingers.

Also: Protection against ingress of solid foreign bodies with diameters greater than 12.5 mm.

No special protection against ingress of water.

3.1.3 Hardware configuration and interface as well as integration in an S7 project under STEP 7

The hardware configuration by means of a GSD file for the sway-control computer from the viewpoint of the master (an arbitrary PLC) is shown as example in the following figure.



Fig. -3-1: NETPRO overview using the standard interface

The Properties dialog box of the DP slave for inserting the universal modules for the inputs and outputs appears as follows:

Fig. 3-2: Properties dialog box of the DP slave for inserting the universal modules

Note that when configuring the slave (sway-control computer), a maximum of 32 bytes or 16 words per module can be read or written. However, in the hardware configuration, only a maximum of 16 words may be agreed for the universal modules. The number 16, irrespective of whether word or byte, represents the upper limit that can be entered. This means that if 32 bytes are to be transferred, 16

Project Planning SIMATIC S7 3.2 PROFIBUS DP PLC interface – sway control computer


words have to be agreed. Consistency over the entire length has to be set under Properties of the DP slave.

In the S7 project, the data is read or written using the system functions SFC14/15 to or from a previously defined data block. The integration in the S7 program always depends on the interface used. Because the hardware configuration is a permanently configured component of the project, two sway-control computer projects are provided. The decision as to which project is to be used depends on the application and should be specified when ordering. Both projects are available on the supplied CD.

Note The project for SIMOCRANE SwayControl stored on the SIMOTION C 240 PN supports only a PROFIBUS baudrate of 1.5 Mbit.

3.2 PROFIBUS DP PLC interface – sway control computer Content

First the input data is imported and then the output data is written. Command or status bits within the input or output data are described again in more detail later. This applies to all values identified by a hyphen "-" in the "Name" column.

General information on the interface description

The input and output data is described in the tables below as follows: Table 3-5:

Column Content

Name Short form of the designation that is used in the S7 sample blocks or in other parts of the documentation

Type Exact type specification SINT, INT, DINT signed 8-, 16-, 32-bit number USINT, unsigned 8-, 16-, 32-bit number WORD 16 bits

Address Consecutive number of the bytes, starting with 0

Designation Designation of the value to be transferred in plain text

Unit Describes the unit and therefore size of the values to be transferred

The specified addresses are relative addresses and if addresses have already been assigned an offset must be added.



3.2.1 Sway control computer input data

In the SIMOTION C, the input data of the higher-level controller is limited by a SIMOTION application.

The table below lists the limits for the input values.

Table 3-6 Limits for the sway-control computer input data

Name Designation Unit min max

Trolley

Speed override % 0 100

Actual position + mm min. P23 max. P28

Set position + mm min. P23 max. P28

Speed setpoint Standardized -P103 P103

Hoisting gear

Speed override % 0 100

Actual position + mm min. P63 max. P69

Set position + mm min. P63 max. P69

Speed setpoint Standardized -P103 P103

General

Load weight 10 kg Increment for each 10 kg

0 INT

Bay scanner mm min. P63 max. P69

Counter for scanner Counter DINT DINT

Total width, double spreader mm INT INT

TLS

Set skew + 1/100 min. P232 max. P233

Cylinder A position + mm min. P188 max. P189

Cylinder B position + mm min. P188 max. P189

Cylinder C position + mm min. P188 max. P189

Cylinder D position + mm min. P188 max. P189

Obstacles

Trolley position 1 (5x) + mm min. P23 max. P28

Trolley position 2 (5x) + mm min. P23 max. P28

Hoisting position (5x) + mm min. P63 max. P69

Camera

Deflection X DINT DINT

Speed X DINT DINT

Deflection Y DINT DINT

Speed Y DINT DINT

Skew DINT DINT



Name Designation Unit min max

Skew speed DINT DINT

Reflector distance DINT DINT

IP1 IP format 0 usint




Port IP format 0 uint

Automatic

Loading lane 0 99

Unloading lane 0 99

Learning lane 0 99

If the input value lies outside the set limits of the value range (Table 3-6), the value will be set to the limit value and the output bit 20 (in the error message 1 word of the SwayControl output data on the PLC) set.

This error bit must be evaluated by the higher-level controller because it is not visible in the CeCOMM.

Overview

The input data has the structure listed in the following table.

Table 3-7 Input data of the sway-control computer

Name Type Addr. Designation

Trolley

- 2x WORD

0-3 Command bits, trolley See Table 3-8

Reserved 2x WORD

4-7 Not used

s_act DINT 8-11

Actual position, trolley The actual position of the trolley is converted with the help of parameters into an internal position variable. This internal variable is used for the BOM Speed Control, BOM Positioning and BOM Hoist Control. ± mm

s_set DINT 12-15

Position setpoint, trolley The position setpoints are numbers from the value range of the actual positions. They are only used in the BOM Positioning and BOM Hoist Control. ± mm

Reserved INT 16-17 Not used




v_set INT 18-19

Speed setpoint, trolley The speed setpoint is transferred in the BOM Speed Control, otherwise the current actuator speed of the relevant axis. The normalizing value can be set with a parameter. For the set default value, the speed setpoint lies between –32,767 and +32,767.

OV_Trolley INT 20-21

Speed override, trolley This value can be used to limit the speed in all basic operation modes. With a value of 100, the path speed is not reduced, with 0, the controller stops the associated axis. 0 ... 100 %

Note

The too-frequent changing of the override is not necessary from a technological viewpoint and leads only to increased system wear.

Reserved 7x WORD

22-35 Not used

Hoisting gear

- 2x WORD

36-39

Command bits, hoisting gear See 5

Table 3-9

Reserved 2x WORD

40-43 Not used

s_act DINT 44-47

Actual position, hoisting gear The hoisting gear position must increase from the ground upwards. This variable specified here is used for the BOM Speed Control, BOM Positioning and BOM Hoist Control. The conversion of the hoisting position to an effective pendulum length is performed with the aid of parameters. ± mm




s_set DINT 48-51

Position setpoint, hoisting gear The position setpoints are numbers from the value range of the actual positions. They are only used in the BOM Positioning and BOM Hoist Control. ± mm


v_set INT 54-55

Speed setpoint, hoisting gear The speed setpoint is transferred in the BOM Speed Control, otherwise the current actuator speed of the relevant axis. The normalizing value can be set with a parameter. For the set default value, the speed setpoint lies between –32,767 and +32,767.

OV_Hoist INT 56-57

Speed override, hoisting gear This value can be used to limit the speed in all basic operation modes. With a value of 100, the path speed is not reduced, with 0, the controller stops the associated axis. 0 ... 100 %

Note


Reserved 7x WORD

58-71 Not used

General

- 2x WORD

72-75 General command bits See 54Table 3-10

Reserved 2x WORD

76-79 Not used


Load INT 82-83

Load weight The complete load (weight of the payload, including the weight of the load carrying device) must be transferred here. This value is used for the analog correction of the effective pendulum length (see Section 4.6.2.2) 1 increment for each 10 kg

WidthDoubleSpreader INT 84-85

Total width, double spreader In double-spreader operation, this value informs the sway control system how wide the two containers are, incl. the spacing of the cylinders. The current total width (dynamic value) is expected, from the outside edge of the container on the first spreader to the outside edge of the container on the second spreader. The current total width is taken into account in the calculation of the path curve. + mm

LaneShipLoading USINT 86 Number of the lane to be loaded




These values specify the numbers of the lanes on which the trucks are loaded or unloaded. The information is generated by the crane operator panel or a control element and is transferred to the sway control computer. 0…99

LaneShipUnloading USINT 87

Number of the lane to be unloaded These values specify the numbers of the lanes on which the trucks are loaded or unloaded. The information is generated by the crane operator panel or a control element and is transferred to the sway control computer. 0…99

StoreCurrentPosition USINT 88

Learn current position as This value specifies which lane number is to be assigned to the current position (0 = none; 1 = Lane1; 2 = Lane2, etc.). It is mainly used during the commissioning, but can also be used for later corrections. This value is generated by the crane operator panel or a control element and is transferred to the sway control computer. 0… none 1… Lane1 2… Lane2

Reserved USINT 89 Not used

ValueBayscan DINT 90-93

Bay scanner Current distance between the trolley and an obstacle that has been determined and transferred by the bay scanner. If the value is valid (bit 3 of the general command bits), it has priority over the curve calculated from the learnt blocked regions (target generator). + mm

CounterBayscan DINT 94-97

Counter for the new value for the bay scanner. This counter checks whether the transferred Bay scanner value is a currently determined value or an old value. Because each scanner has its own counter value, they are prepared by the PLC so that only one value is transferred to the sway control system.

Reserved 14x WORD

98-125 Not used

Set_Tr_1 Set_Tr_2 Set_Hoist

15 x DINT

126-185

Data sets, blocked regions [5][3] The interface allows for each transfer a data set with up to five blocked regions. Not only a start and an end position of the trolley, but also the associated hoisting position, can be specified for each blocked region. An unused blocked region contains the value zero for all three entries. ± mm

Reserved 7x WORD

186-199 Not used




TLS

- 2x WORD

200-203 Command bits, TLS See 5Table 3-11

Reserved 2x WORD

204-207 Not used

TLS Pos 4x DINT

208-223

Position of the TLS hydraulic cylinders Position data from four hydraulic cylinders, which is used for the trim, list, skew and skew control. The application is specified with the aid of parameters. + mm

extSkewAngle DINT 224-227

External set skew External value for the set skew of the spreader by a specified angle. ± 1/100 °

Reserved 8x WORD

228-243 Not used

Command bits for trolley and hoisting gear Table 3-8 Command bits for trolley (see address 0-4 in Table 3-7)

Bit no. Name Meaning

0 LS_F Limit switch forward 0: Actuated 1: Not actuated

1 LS_B Limit switch backward 0: Actuated 1: Not actuated

2 ALS_F Prelimit switch forward This bit is active only when P115 < 1. Otherwise the dynamic prelimit switch will be used. 0: Actuated 1: Not actuated

3 ALS_B Prelimit switch backward This bit is active only when P115 < 1. Otherwise the dynamic prelimit switch will be used. 0: Actuated 1: Not actuated

4 Brake_closed Actuator value release 0: Actuator value and direction signals are released. 1: Actuator value is not released (braking with maximum deceleration); direction signals are released.




5 AS_Stop Sway control only when stopping 0: Sway control system is active for approaching and stopping 1: Sway control system is only active when stopping

Note

This bit acts only when bit 7 (AS_ON) has been set and the BOM Speed Control selected.

6 Stop_contr Controlled stop Sway-controlled stop of the trolley with normal deceleration (set acceleration P6*P8) in all basic operation modes. In the BOM Hoist Control, this bit also affects the hoisting gear.

0: Not active 1: Active

WARNING

With Controlled stop, all travel signal bits (Release, Travel signal, Basic operation mode, Brake closed) must remain set as for normal travel and may only be reset after output of the "Positioning complete" signal.

7 Flying On-the-fly unloading With this bit, the "On-the-fly unloading" function can be selected (see Section 4.6.3.3).

0: On-the-fly unloading not selected 1: On-the-fly unloading selected

8 Release Release request Release request for the trolley. The values are processed and actuator values issued. Can be used for disabling "Sway Control".

0: Stop with maximum deceleration (P50) without sway control 1: Basic operation modes and travel signal are evaluated

9 Travelling Travel signal A direction signal, with which the brake can be opened, is not output until this signal is present. The current basic operation mode is taken over.

0: Stop with maximum deceleration (P50) without sway control 1: Activation of the specified basic operation mode

WARNING

The travel signal may be reset only after the motion has been completed, i.e. when the output signals "Active" and "Positioning complete" have been sent from the sway-control computer.




10 OM_PositionContr BOM Positioning A set position is specified by the higher-level controller or the internal setpoint encoder. In this basic operation mode, the hoisting gear travels to this position.


WARNING

Exactly one of the operation mode bits must be set to select the corresponding operation mode. Any other combination is considered to be an invalid operation mode and initiates an emergency stop.

When using the hoist control, the operation mode bit must be set simultaneously for trolley and hoisting gear.

11 OM_SpeedContr BOM Speed Control The higher-level controller specifies a speed setpoint.


12 OM_ContrLoadPos BOM Sway Neutralization to Load Position 0: Not active 1: Active

13 OM_ContrTrolleyPos BOM Sway Neutralization to Trolley Position 0: Not active 1: Active

14 OM_HoistContr BOM Hoist Control If the trolley and the hoisting gear are in this basic operation mode and target positions are specified for both axes, a calculated path curve will be travelled.


15 AS_On Sway control On 0: Sway control not active 1: Sway control active

16 – 23 - Reserved

24 EncoderSync Synchronize encoders An increasing edge synchronizes the encoders. This bit is valid only when the encoder values are processed directly in the sway control system.

25 FastStop Stop with maximum deceleration When this bit is set, stopping is performed with maximum deceleration in manual operation and for controlled stop. The bit should preferably be used when one or more axes are to be stopped when an error occurs.

Table 3-9: Hoisting gear command bits (see address 36-39 in Table 3-7)




0 LS_U Limit switch up 0: Actuated 1: Not actuated

1 LS_D Limit switch down 0: Actuated 1: Not actuated

2 ALS_U Prelimit switch up This bit is active only when P115 < 1. Otherwise the dynamic prelimit switch will be used. 0: Actuated 1: Not actuated

3 ALS_D Prelimit switch down This bit is active only when P115 < 1. Otherwise the dynamic prelimit switch will be used. 0: Actuated 1: Not actuated

4 Brake_closed Actuator value release 0: Actuator value and direction signals are released. 1: Actuator value is not released (braking with maximum deceleration); direction signals are released.

5 - Not used

6 Stop_contr Controlled stop Step the hoist with normal deceleration (P51*P52) in all basic operation modes. In the BOM Hoist Control, this bit also affects the trolley. 0: Not active 1: Active

WARNING

With Controlled stop, all travel signal bits (Release, Travel signal, Basic operation mode, Brake closed) must remain set as for normal travel and may only be reset after output of the "Positioning complete" signal.

7 - Not used

8 Release Release Hoisting gear release. The values are processed and actuator values issued. Can be used for disabling "Sway Control".

0: Stop with maximum deceleration (P50) without sway control 1: Basic operation modes and travel signal are evaluated




9 Travelling Travel signal A direction signal, with which the brake can be opened, is not output until this signal is present. The current basic operation mode is taken over.

0: Stop with maximum deceleration (P50) without sway control 1: Activation of the specified basic operation mode

WARNING

The travel signal may be reset only after the motion has been completed, i.e. when the output signals "Active" and "Positioning complete" have been sent from the sway-control computer.

10 OM_PositionContr BOM Positioning A set position is specified by the higher-level controller or the internal setpoint encoder. In this basic operation mode, the hoisting gear travels to this position.


WARNING

Exactly one of the operation mode bits must be set to select the corresponding operation mode. Any other combination is considered to be an invalid operation mode and initiates an emergency stop.

When using the hoist control, the operation mode bit must be set simultaneously for trolley and hoisting gear.

11 OM_SpeedContr BOM Speed Control The higher-level controller specifies a speed setpoint. 0: Not active 1: Active

12 - 13 - Not used

14 OM_HoistContr BOM Hoist Control If the trolley and the hoisting gear are in this basic operation mode and target positions are specified for both axes, a calculated path curve will be travelled.


15 – 23 - Not used

24 EncoderSync Synchronize encoders An increasing edge synchronizes the encoders. This bit is valid only when the encoder values are processed directly in the sway control system.




25 FastStop Stop with maximum deceleration When this bit is set, stopping is performed with maximum deceleration in manual operation and for controlled stop. The bit should preferably be used when one or more axes are to be stopped when an error occurs.

General command bits Table 3-10 General command bits (see address 72-75 in Table 3-7)


0 - 1 Container_lock

Locking state of the spreader 00: No spreader locked 01/10: Spreaders are partly locked. Spreaders are partly locked

• when only one spreader of a double spreader in coupled mode has been locked or

• a 20-foot container has been locked on a spreader at maximum width.

The travel curves are calculated as required with loaded spreader. The automatic learning does not take account of the height of the locked container. 11: Spreaders are completely locked. The travel curves are calculated as required with loaded spreader. The lower edge of the container(s) is used to learn the blocked regions.

Note: Left bit = LOCKED_BIT1 Right bit = LOCKED_BIT0

2 Slackrope

Slack rope 0: No slack rope 1: Slack rope available If the "Slack rope" bit is set, no learning travel will be performed, i.e. the internally learnt variable obstacles are not affected.

NOTE

This bit has no effect in the "SC Speed Control" AddOn mode.

3 ValueBayScanalid Bay scanner value valid 0: Bay scanner values not valid 1: Bay scanner values valid




4 HeightProfileLearn Activate

Learn height profile

HeightProfile- LearnActivate

HeightProfile- Delete

Learn mode

0 0 A: Obstacle profile is not updated

0 1 B: Delete the height profile

1 0 C: Learn the height profile (regular operation)

1 1 D: Delete the height profile

Only learn mode C is provided for automatic operation. The modes B or D are functionally equivalent and required only for the initialization and should remain selected until the HeightProfile-Deleted confirmation bit indicates the successful deletion of the internally learnt variable obstacles. Mode C must then be selected again. Also refer to Section 3.4.2.4 "Taking account of blocked regions"

5 HeightProfileDelete Delete height profile Refer to the previous description for the "Learn height profile" bit

6 - -

7 DoubleSpreaderActive

Spreaders coupled Bit indicates whether the two spreaders are coupled when using a double spreader. This affects the width for the specification of the blocked regions and so the calculation of the path curve. 0: Spreaders not coupled 1: Spreaders coupled

8 Par_Set_Bit0

9 Par_Set_Bit1

Select parameter set Bit combination for the selection of the parameter set:

Par_Set_Bit1 Par_Set_Bit0

0 0 Parameter Set 1

0 1 Parameter Set 2

1 0 Parameter Set 3

1 1 Parameter Set 4

The parameter P101 "Parameter set locked during travel" can be used to specify whether switchover of the current parameter set is permissible at any time or only at standstill.

10 No_WaitingPosition

Do not approach waiting position This bit specifies whether the waiting position defined in the P25 (trolley) and P65 (hoisting gear) parameters is to be approached. 0: Approach waiting position 1: Do not approach waiting position




11 Prg_Block

Program blocked regions Bit for accepting the external variable blocked regions. Zero data sets are ignored. 0: Do not accept 1: Accept

12 Del_Block

Delete blocked regions Bit to delete the variable blocked regions. 0: Do not delete 1: Delete

WARNING

If the "Program blocked regions" and "Delete blocked regions" bits are both set, all blocked regions will be deleted.

13 WatchDog Life bit for SIMOTION 0 Connection to the PLC is interrupted 1 Connection to the PLC is active

14 HW_man

Manual hoisting gear If this bit is set, the hoisting gear can be raised manually without having to change the basic operation mode. The specified target position is still approached by the trolley. 0: Not active 1: Active

15 Start-2D-Calc

Start 2D calculation The bit informs the "Sway Control" that the calculation of the 2D travel curve can be started. It should be set when all blocked regions have been transferred completely from the PLC. The automatic mode performs the path calculation and starts travel. Note: It is not recommended to change the blocked regions during travel because in most cases this is not necessary and the optimum space trajectory can no longer be guaranteed. 0: Not active 1: Active

NOTICE

As soon as this bit changes from active to not active, the crane stops sway-controlled.

16

Barge_LS Offset landside When positioning the trolley, an offset is added to the target position on the landside. This signal, for example, is generated by the crane operator panel or a control element and is transferred to the sway control system. 0: Offset landside is not active 1: Offset landside is active




17

Barge_WS Offset waterside (WS) When positioning the trolley, an offset is added to the target position on the waterside. This signal, for example, is generated by the crane operator panel or a control element and is transferred to the sway control system. 0: Offset waterside is not active 1: Offset waterside is active

18 DigitalLiftCorrection

Digital "Correction of the effective pendulum length" If this bit is set, the effective pendulum length is changed by a specified amount (p80). This can be necessary if different load carrying devices are in use because in that case also a change of the center of gravity can occur. A change in the center of gravity results also in a change of the effective pendulum length. 0: Not active 1: Active

19-23 - Not used

24 StoreParkPosition

Save parking position This bit is used for saving the current position as parking position. 0: Do not save parking position 1: Save parking position The associated control bit must remain present until the "Position learning successful" status bit (Table 3-16: Status bits for crane operator panel (see address 112-115 in ) provides the confirmation that the position has been learnt. The brake must be applied during the learning process. After the learning, the control bit must be reset.

25 StoreIntermediateStop

Save lashing position This bit is used for saving the current position as lashing platform. 0: Do not save lashing platform 1: Save lashing platform The associated control bit must remain present until the "Position learning successful" status bit (Table 3-16: Status bits for crane operator panel (see address 112-115 in ) provides the confirmation that the position has been learnt. The brake must be applied during the learning process. After the learning, the control bit must be reset.

26 - Not used

27 IntermediateStop

Approach lashing position This bit must be set if the lashing platform is to be approached during loading or unloading. 0: Do not approach lashing platform 1: Approach lashing platform




28 STACK_FORM_BIT0

29 STACK_FORM_BIT1

Stacking type

STACK_FORM_BIT1 STACK_FORM_BIT0

0 0 Approach parking position

0 1 Row-by-row WS direction

1 0 Row-by-row LS direction

1 1 Column-by-column

30 - Not used

31 Cycling

Simultaneous loading and unloading in one cycle 0: Not active 1: Active This bit specifies whether a new container should be picked up after the container has been placed on the ship or truck. This function is only significant for the positioning. It is generated by the crane operator panel or a control element and is transferred to the sway control computer.

Command bits, TLS Table 3-11 Command bits for trolley (see address 200-203 in Table 3-7)


0 SAVE_ZERO Save zero position 0: No command 1: Save current cylinder positions as zero positions command

1 REF_EXT External rotational position The internally learnt values are always used as target for trim and list.

0: The internal rotational position is used separately according to water- or landside as target in the "automatic skew control" mode 1: The "Position setpoint, slewing gear" input value is used as target in the "automatic skew control" mode

2 SPREADER_BIT0

3 SPREADER_BIT1

Spreader length Bit 2 log0 and bit 3 log0 20 ft Bit 2 log1 and bit 3 log0 30 ft Bit 2 log0 and bit 3 log1 40 ft Bit 2 log1 and bit 3 log1 45 ft The bits must be set appropriately for the spreader length.

4 SKEW_ZERO Approach zero position 0: No command 1: Move all cylinders to zero position command




5 - 7 - Not used

8 TRIM_RIGHT Trim right 0: No command 1: Incline to the right command

9 TRIM_LEFT Trim left 0: No command 1: Incline to the left command

10 LIST_WATER List waterside 0: No command 1: Incline to the waterside command

11 LIST_LAND List landside 0: No command 1: Incline to the landside command

12 SKEW_RIGHT Skew in clockwise direction 0: No command 1: Rotate in clockwise direction command

13 SKEW_LEFT Skew in counterclockwise direction 0: No command 1: Rotate in counterclockwise direction command

14 MOVE_ZERO Approach zero position 0: No command 1: Move all cylinders to zero position command

15 ANTI_SKEW_AUTO Automatic skew control 0: No command 1: Suppress skewing motion automatically command

3.2.2 Sway-control computer output data

Overview

The output data has the structure listed in 54Table 3-12. Table 3-12: Output data of the sway-control computer


Trolley

- 2x WORD

0-3 Status bits, trolley See Table 3-13

v_POS INT 4-5

Actuator speed, trolley This value is output normalized. The following is true: v_POS = actuator speed [mm/s] * P103 / P0




a_POS INT 6-7

Actuator acceleration, trolley This value is output normalized. The following is true: a_POS = actuator acceleration [mm/s] * P103 / P5

DeflectionAngle INT 8-9

Load deflection Relative position difference between the trolley and load.

• STS (with camera): The value corresponds to the load deflection measured by the camera. If the camera fails, the deflection is zero for the duration of the "Tripping time for camera error" (P127). If the tripping time (P127) has expired and error E4 is present, the deflection corresponds to the value from the model.

• GSU (without camera): The value corresponds to a calculated quantity. With travel command = 0 this value also becomes zero.

± mm

Reserved 22x WORD

10-53 Not used

Hoisting gear

- 2x WORD

54-57

Status bits, hoisting gear See

Table 3-14

v_POS INT 58-59

Actuator speed, hoisting gear This value is output normalized. The following is true: v_POS = actuator speed [mm/s] * P103 / P40

a_POS INT 60-61

Actuator acceleration, hoisting gear This value is output normalized. The following is true: a_POS = actuator acceleration [mm/s] * P103 / P50

Reserved 23x WORD

62-107 Not used

General

- 2x WORD

108-111 General status bits

See Table 3-15

- 2x WORD

112-115 Status bits for crane operator panel

See Table 3-16: Status bits for crane operator panel (see address 112-115 in

Reserved 12x WORD

116-139 Not used




ErrorMessage1 2x WORD

140-143

Error message1 Address 140-141 contains the error bits 16-31; address 142-143 contains the error bits 0-15 (see: Table 4-5 Error messages from the sway control system to the PLC)

ErrorMessage2 2x WORD

144-147 Error message2 Address 144 to 147 not used

No_Blocks INT 148-149

Number of variable blocked regions This consists of the number of externally learnt blocked regions plus the number of internally learnt blocked regions.

LaneLoadingShip USINT 150 Confirmation of the lane number for loading 0-99

LaneUnloadingShip USINT 151 Confirmation of the lane number for unloading 0-99

Reserved 23x WORD

152-197 Not used

TLS

- 2x WORD

198-201 Status bits, TLS See Table 3-17: TLS status bits

ISpeed Cyl A INT 202-203 Cylinder A speed This value is output normalized: The following is true: ISpeed Cyl A = speed setpoint mm/s2] * P204 / P180

Reserved 17x WORD

210-243 Not used



Trolley and hoisting gear status bits Table 3-13: Status bits for trolley (see address 0-3 in Table 3-12X)


0 - 7 - Not used

8 Ready Ready 0: Response for Release bit 1: The drive axis is ready for operation and can be activated by setting a basic operation mode and activating the travel signal

9 Active Active 0: The actuator speed is zero 1: The drive axis is active and outputs the currently required actuator speed

10 Pos_complete Positioning complete 1: For BOM Positioning and BOM Hoist Control is valid:

For more than 0.6 seconds, the distance between the actual position and the target position has been smaller than the positioning accuracy (P162).

For BOM Speed Control is valid:

For 0.6 seconds, the external speed setpoint is 0 and the internal speed setpoint and its difference to the actuator speed are smaller than the speed zero message (P3). For activated sway control system (As_On) bit, the sway-neutralized (AS_complete) bit is another necessary condition in both cases.

0: The conditions for case Pos_complete =1 are not fulfilled.

11 AS_complete Sway-neutralized 0: The swaying motion of the load is greater than the specified tolerance (P169) 1: The swaying motion of the load is smaller than the specified tolerance (P169)

12 Travel_F Travel direction forwards (position values increasing) 0: Actuator speed is negative or zero 1: Actuator speed is positive.

13 Travel_B Travel direction backwards (position values decreasing)0: Actuator speed is positive or zero 1: Actuator speed is negative As long as the actuating signal is zero, the direction of travel – depending on the basic operation mode – is set depending on the speed setpoint or the difference between the position setpoint and the actual position.




14 Release_Sync Request synchronization 0: Synchronization is not requested 1: Synchronization is requested

If the difference of the axis position between the encoder signal and the signal via PROFIBUS is greater than parameter P117 (Request for encoder synchronization), the bit of the relevant axis is set and therefore an encoder synchronization requested. If parameter P117 = 0 mm, the synchronization is not requested.

15 AS_ON Sway control On 0: The sway-control function is active 1: The sway-control function is not active Under certain circumstances, the sway control function can be disabled even if the " Sway Control ON" command is activated.

16-31 - Not used

Table 3-14: Hoisting gear status bits (see address 54-55 5 in Table 3-12)


0 - 7 - Not used

8 Ready Ready 0: Response for Release bit 1: The drive axis is ready for operation and can be activated by setting a basic operation mode and activating the travel signal

9 Active Active 0: The actuator speed is zero 1: The drive axis is active and outputs the currently required actuator speed

10 Pos_complete Positioning complete 1: For BOM Positioning and BOM Hoist Control is valid: For 0.6 seconds, the distance between the actual position and the target position has been smaller than the positioning accuracy (P165).

For BOM Speed Control is valid: For 0.6 seconds, the external speed setpoint is 0 and the internal speed setpoint is smaller than the speed zero message (P44).

0: The conditions for case Pos_complete = 1 are not fulfilled.

11 - Not used

12 Travel_U Raise travel direction (position values increasing) 0: Actuator speed is negative or zero 1: Actuator speed is positive.




13 Travel_D Lower travel direction (position values decreasing) 0: Actuator speed is positive or zero 1: Actuator speed is negative As long as the actuating signal is zero, the direction of travel – depending on the basic operation mode – is set depending on the speed setpoint or the difference between the position setpoint and the actual position.

14 Release_Sync Request synchronization 0: Synchronization is not requested 1: Synchronization is requested If the difference of the axis position between the encoder signal and the signal via PROFIBUS is greater than parameter P117 (Request for encoder synchronization), the bit of the relevant axis is set and therefore an encoder synchronization requested. If parameter P117 = 0 mm, the synchronization is not requested.

15-31 - Not used

General status bits Table 3-15: General status (see address 108-111 in Table 3-12X)


0 Grab_Open Open grab 1: Open grab request for on-the-fly unloading 0: No open grab request for on-the-fly unloading

This status bit can be used to initiate in the higher-level controller the opening of the grab. The bit is set when the distance for opening the grab is attained (P31). The reset is made after the abort speed is undershot (P30). The bit is set only when on-the-fly unloading has been activated.

1 Camera_OK Camera OK

2 - 3 Not used

4 HeightProfilLearnActive Height profile learnt Response bit for "Learn height profile" mode is activated. The height profile is being learnt.

5 HeightProfilDeleted Height profile deleted Response bit for the deletion of the internally learnt variable blocked regions. The height profile has been deleted.




6 BeepStartAuto Automatic start permitted 1: Conditions for starting the automatic satisfied 0: Conditions for starting the automatic not satisfied This bit represents a group message for the status bits listed in Table 3-16: Status bits for crane operator panel (see address 112-115 in . Note: Without the appropriate evaluation of this bit or the individual bits from Table 3-16: Status bits for crane operator panel (see address 112-115 in in the PLC, under some circumstances the automatic can also be started when this bit is not set.

7 HoistTakeoverAllowed Hoist takeover allowed 1: Hoist takeover allowed 0: Hoist takeover not allowed

8 Parset_Bit0

9 Parset_Bit1

Parameter set active Bit combination for the confirmation of the active parameter set

Parset_Bit1 Parset_Bit0

0 0 Parameter Set 1

0 1 Parameter Set 2

1 0 Parameter Set 3

1 1 Parameter Set 4

10 No_WaitingPosition Do not approach waiting position

This bit specifies whether a waiting position, defined from the trolley and the hoisting position, is to be approached. The positions are defined in the P25 (trolley) and P65 (hoisting gear) parameters. 0: Not active 1: Active

11 Prgblock Blocked regions programmed Confirmation of the general command bits "Program blocked regions". The blocked regions have been programmed.

12 DelBlock Blocked regions deleted Confirmation of the general command bits "Delete blocked regions". The blocked regions have been deleted.

13 WD Watchdog (200 ms) Signal flashes in the 200-ms cycle




14 Change_Target Change target Only GSU: 0 – Request target on the landside 1 – Request target on the waterside If the on-the-fly unloading is active, the bit is set concurrently with the reset of the "Grab Open" bit. If the on-the-fly unloading is not active, the bit will be set when the target position on the landside within the positioning accuracy (P162) is attained. If the travel signal is reset, this bit is also reset irrespective of whether on-the-fly unloading has been activated.

Status bits for crane operator panel Table 3-16: Status bits for crane operator panel (see address 112-115 in Table 3-12)


0

StartPosEqualTargetPos Starting position is same as target position The starting position is identical with the target position. The bit will be output when the trolley position at the time of starting the automatic differs by less than twice the positioning accuracy from the target position. The "Automatic Start permitted" bit is not set. This prevents an automatic start.

1

InitialSway Initial sway This bit is set while the initial oscillation is greater than the permitted initial oscillation specified by P156. If the initial oscillation is too large, the E62 error message will be issued at the start of an automatic travel. A travel is then not possible irrespective of what happens in the PLC. This affects both the waterside and the landside. This message can be forwarded to the crane operator panel (COP) where it is displayed as a symbol (see Operating Instructions "Crane Operator Panel").

2

SlackropOnWS Slack rope on the waterside

1: The slack rope bit is set and the trolley drive is located on the waterside.

0: The slack rope bit is not set or the trolley drive is not located on the waterside.

If this bit is set, the "Automatic permitted" bit (bit 6, General status bits) is not set.




3 HoistUnderImmersionPoint Hoisting gear below immersion point No automatic start when the hoisting gear is below the immersion point. This affects only the waterside. This message can be forwarded to the crane operator panel (COP) where it is displayed as a symbol (see Operating Instructions "Crane Operator Panel").

4 TargetPosInVarArea Target moved The target lay in a variable blocked region and was moved in front of or above this blocked region. This message can be forwarded to the crane operator panel (COP) where it is displayed as a symbol (see Operating Instructions "Crane Operator Panel").

5 Target too deep Only GSU: The target for the on-the-fly unloading must not be lower than the highest obstacle. If this is not the case, the automatic does not start.

6 - 7 - Not used

8

StorePositionReady

Position learning successful 0: Position learning unsuccessful 1: Position learning successful This bit is used for the visualization of the successful learning of the positions for parking, lashing platform and lane. This message can be forwarded to the crane operator panel (COP) where it is displayed as a symbol (see Operating Instructions "Crane Operator Panel").

9

AutoTargetLand

Next target in the landside direction If a target position has been entered for the trolley or determined by the target generator, which, compared to the current position, lies in the land direction, this bit is set. This message can be forwarded to the crane operator panel (COP) where it is displayed as a symbol (see Operating Instructions "Crane Operator Panel").

10

AutoTargetWater

Next target in the waterside direction If a target position has been entered for the trolley or determined by the target generator, which, compared to the current position, lies in the water direction, this bit is set. This message can be forwarded to the crane operator panel (COP) where it is displayed as a symbol (see Operating Instructions "Crane Operator Panel").




11 TargetPosNotInLimit Target position not in permitted limits The target position is not contained within the set limits for the positioning (P23, P28, P63, P69). This message can be forwarded to the crane operator panel (COP) where it is displayed as a symbol (see Operating Instructions "Crane Operator Panel").

12 StartPosNotInLimit Starting position not in permitted limits The starting position is not contained within the set limits for the positioning (P23, P28, P63, P69). This message can be forwarded to the crane operator panel (COP) where it is displayed as a symbol (see Operating Instructions "Crane Operator Panel").

13 StartPosInFixedArea Starting position in a fixed blocked region Current starting position is in a fixed blocked region. This message can be forwarded to the crane operator panel (COP) where it is displayed as a symbol (see Operating Instructions "Crane Operator Panel").

14 TargetPosInFixedArea Target position in a fixed blocked region Target position is in a fixed blocked region. This message can be forwarded to the crane operator panel (COP) where it is displayed as a symbol (see Operating Instructions "Crane Operator Panel").

15 NoWayFound No path found A travel curve cannot be calculated for the starting and target point by the target generator. This message can be forwarded to the crane operator panel (COP) where it is displayed as a symbol (see Operating Instructions "Crane Operator Panel").

16 - 23 Not used



Status bits, TLS Table 3-17: TLS status bits (see address 198-201 in Table 3-12)


0 PRESS1 Oil pressure 1 Select pressure 1 (cylinder speed 1)

1 PRESS2 Oil pressure 2 Select pressure 2 (cylinder speed 2)

2 ZERO Zero position reached All cylinders are in the tolerance range around the zero position.

3 - 7 - Not used

8 CYLA_OUT Move cylinder A out Control signal for extending cylinder A

9 CYLB_OUT Move cylinder B out Control signal for extending cylinder B

10 CYLC_OUT Move cylinder C out Control signal for extending cylinder C

11 CYLD_OUT Move cylinder D out Control signal for extending cylinder D

12 CYLA_IN Move cylinder A in Control signal for retracting cylinder A

13 CYLB_IN Move cylinder B in Control signal for retracting cylinder B

14 CYLC_IN Move cylinder C in Control signal for retracting cylinder C

15 CYLD_IN Move cylinder D in Control signal for retracting cylinder D

16-31 - Not used



3.2.3 Signal sequences in the sway-control computer

Formation of the "Travelling" travel signal

Note

The travel signal must be set while the travel request exists or the "Pos_complete" signal has not yet been set. Otherwise, the compensation of the swaying motion will be aborted and the target position not reached.

Fig. 3-3: Generation of the travel signal

Conversion of the Bay Scanner values

If a bay scanner is also used, this signal of the obstacle height is evaluated in addition to the traveled curve. If the Bay Scanner signal is valid, it takes priority over the learnt travel curve. This allows more exact values of the container stack to be determined.

Note

Depending on the installation position of the laser, the system is able to travel to the next position in automatic loading operation.

The distance (hm) from the scanner to the surface of the container stack is measured (dashed lines; measured laser value hm). The PLC must convert this value into a laser value (hVB; vB bay scanner value) that represents the distance between the hoisting height ZERO (h0) to the upper edge of the container stack at this position (bay scanner value, see following figure). The height between two valid measuring points is direction-dependent and is set to the height of the second measuring point.

Fig. 3-4: Measurement of the height of the container stack with the laser scanner



Formula for calculating the obstacle height:

hVB=hs-hm

The conversion can be performed as follows in the PLC software for the evaluation of the Bay Scanner data (FC84 SIMO_Bayscanner):

1. Lower the spreader to the quay and record the actual position of the hoisting gear (hoistQuay actual position) and the bay scanner value (valueQuay measured laser).

Fig. 3-5: Record bay scanner value

2. The measured laser value (measured laser valueQuay) and the actual position of the hoisting gear (hoist actual positionQuay) at a defined position produce the installation height of the scanner (scanner height hs) that can be calculated manually: hs = Measured laser valueQuay + Actual position hoistQuay hs = 45000 mm + 1000 mm hs = 46000 mm

3. The converted laser value (bay scanner value hVB) is then calculated using the scanner height hs in the following equation and transferred with the "ValueBayscan" signal to the sway-control computer: hVB = hs - hm

Fig. 3-6: Measured laser value



hVB = 46000 mm – 31000 mm hVB = 15000 mm

Fig. 3-7: Example of the conversion in S7 FC84 "SIMO_Bayscanner"

This converted laser value (bay scanner value hVB) is also displayed in the "Hoist control [6]" display screen (Section 544.4.6.1).

4. Check the adjustment of the bay scanner values and the hoisting height in the "Hoist control [6]" display screen. These must be approximately the same (±100 mm) as the spreader lowered to the quay.

Fig. 3-8: Check the adjustment of the bay scanner values and the hoisting height

Acceleration and deceleration behavior



The load oscillations on container cranes and ship unloaders can be eliminated through the specific influencing of the acceleration and braking actions of the trolley.

The acceleration or deceleration behavior of the sway control system is set by means of three ramps or acceleration values.

The ramp applied in the case of acceleration without sway control / minimum acceleration (P7) is generally the same as the ramp along which the drive accelerates when the sway control is completely deactivated. The minimum acceleration rate acts as a limit if one of the following conditions is fulfilled:

• Prelimit switches have been activated

• Speed reduction by changing the external override

• The crane is being operated by the sway control software, but with the "AS_ON" (= Sway Control On) bit equal to "0".

The minimum acceleration does not act in the normal travel range and when the override does not change. The sway control system can then brake more slowly in order to compensate any load sway.

The maximum acceleration (P5) represents a limit in the opposite direction. The sway control system will never accelerate or decelerate faster than the limits imposed by this ramp. It should ideally be set to the maximum possible physical value.

The setpoint acceleration (P6) provides the basis for calculating the control speed of the sway control. However, in order to compensate for any load sway, the sway control system does not rigidly limit acceleration/deceleration to this ramp.

The following settings are recommended:

• P5: The maximum possible acceleration rate of the drive

• P6: Approx. 75% of P5

• P7: The following condition applies: P7 < P6 < P5. The specific value is determined by the position of the prelimit switches relative to the limit switches. The optimum values must then be determined experimentally on the crane.

Compliance with the limit values always has priority over compensation of load sway.

Project Planning SIMATIC S7 3.3 Basic operation modes


Fig. 3-9: Acceleration and deceleration behavior of the sway control system

Note

The brake must be closed when no further direction signals are output; the brake must be opened in the opposite situation. The real mechanical brake opening times mean a time delay occurs between the "brake open" and "brake closed" signal. For this reason, the "brake closed" signal should always be applied to the "Brake_Closed" bit for trolley and hoisting gear. This means a dead time behavior for the control can be avoided.

3.3 Basic operation modes The following basic operation modes are available for the trolley and hoist axes:

• Speed Control

• Positioning

• Hoist Control

• Sway Neutralization to Load Position (trolley only)

• Sway Neutralization to Trolley Position (trolley only)

Only one basic operation mode can be selected for each axis at any time. The basic operation mode is selected by the PLC by setting the appropriate operation mode bit.

The AddOn operation modes listed in the following table result from the linking of various basic operation modes for trolley and hoisting gear in the PLC. AddOn operation modes are virtual operation modes as used by the crane driver.



Table 3-18: AddOn operation modes - basic operation modes relationship

AddOn mode 3rd axis

Basic operation mode (BOM) Operation mode bit

Trolley Speed Control OM_PositionContr SC Speed Control

Hoist Speed Control OM_PositionContr

Trolley Hoist Control OM_HoistContr SC Automatic

Hoist Hoist Control OM_HoistContr

Trolley Positioning Positioning

Hoist Speed Control OM_PositionContr

Trolley Sway Neutralization at Load Position

OM_ContrLoadPos SC Semiautomatic

Trolley Sway Neutralization at Trolley Position

OM_ContrTrolleyPos

Note

The limit switches are direction-dependent and only the BOM Speed Control is permitted at the limit switch, for which braking with the maximum ramp is performed in the limit switch region. (See E7: "Invalid basic operation mode at the limit switch, trolley")

3.3.1 BOM Speed control

In the BOM Speed Control the speed is specified manually from a higher-level controller. This operation mode is also called manual mode in the rest of the documentation. The trolley is accelerated or decelerated to the speed setpoint in such a way that the load sway has been eliminated when the speed setpoint is reached. If the crane is to be operated in manual mode without sway control, this must be specified explicitly.

The possibilities of the different activation in this basic operation mode are described in Section "54Setting options".

Activation of the basic operation mode

The BOM Speed Control is activated by setting the appropriate operating mode bit (OM_SpeedContr, bit 11, trolley and hoisting gear command bits) on the axes.

This basic operation mode can be started from all other basic operation modes without having to stop the drives.

Hoisting gear movements are possible in active speed control mode and have very little effect on the quality of the sway control.

Internal deactivation of the sway control system

The sway control system is internally disabled under the following conditions (although the axes can still be moved by the system):

• The "Sway Control ON" command bit (AS_On, bit 15, trolley command bits) is reset.

• The activation speed (P146) has not been reached.

• The sway control switch-on delay (P147) has not yet expired.



• If the sway control switch-off delay (P148) after undershooting the activation speed (P146) has expired.

• The "Sway control only when stopping" command bit (AS_Stop, bit 5, trolley command bits) is set. The sway control system is only active when stopping. This bit is only effective in the speed control mode.

• The hoisting gear is located above the set upper or below the lower sway control limit (P83, P84).

• The license is damaged or missing.

Suppress opposite direction (P141)

Fig. 3-10: Conventional control, P141 = 75%, master controller 50%

Red represents the master controller. It is activated only briefly in one direction. The blue line indicates the actuator speed; the pink line indicates the oscillation model characteristic.

With P141 = 0, a short forward travel is performed and then relatively long backwards for the compensation of the load sway. If the crane driver wants to position very accurately, this behavior often causes problems.

It is easier for the crane driver when in this case the crane does not travel back but rather waits until the oscillation swings forward and then always travels in just one direction.

There are two ways of also releasing the other direction:

a) Travel faster than the parameter (141).

b) Use the master controller to also release the opposite direction by applying the appropriate deflection.

These two variants do not have any effect on the physics. It is easier to cater for special customer requirements.



3.3.2 BOM Positioning

In the BOM Positioning, the higher-level controller or the internal target generator can specify a target position for each individual axis. Internal targets (only STS) are approached when the external target position = 0.

Note

No monitoring is performed whether trolley = 0 AND hoisting gear = 0. This must be monitored by the higher-level controller.

After release, the target position is approached automatically. The trolley is controlled in such a way so that the load sway is eliminated when the maximum speed is reached as well as at the target position.

Both axes do not need to be in this basic operation mode.

CAUTION

Blocked regions are not considered for the calculation of the travel curve.

The possibilities of the different activation in this basic operation mode are described in the "Setting options" section.


The BOM Positioning is activated by setting the appropriate operation mode bit (OM_PositionContr, bit 10, trolley and hoisting gear command bits) on the axes (trolley, hoisting gear).

Abort the positioning

The positioning can be aborted at any time, when

• the "controlled stop" (Stop_contr, bit 6, trolley and hoisting gear command bits) command bit is set or

• the travel signal (Travelling, bit 9, trolley and hoisting gear command bits) is reset.

Causes

The abort of the positioning in the PLC is recommended in the following cases:

• Overload

• Twist-lock motion - however only when an axis is traversed manually

• Drive faults

• Emergency off

• Position acquisition error

• Loss of position reference

If a limit switch has been overtraveled, the software internally aborts the positioning.



Response to overtraveling a limit switch

• The crane stops with maximum deceleration and does not travel any further

• The sway control function is deactivated

• The automatic operation is not possible (see E7: "Invalid basic operation mode at the limit switch, trolley")

• The crane can only be traversed in manual operation without sway control

On-the-fly unloading

The positioning with on-the-fly unloading utilizes the oscillation of a grab when unloading bulk goods and saves turnover time in this way. The trolley is braked before the target position while the grab sways to the target (e.g. funnel).

Note

On-the-fly unloading with constant or maximum angle can be used only with time-optimized control. In conventional operation, on-the-fly unloading is possible only with an approximately constant angle.

CAUTION

In time-optimized operation, the high acceleration change means the crane-driver cabin should not be linked to the trolley.



The following figure below shows an example of such a travel operation.

Fig. 3-11: Travel operation over time (in seconds) for on-the-fly unloading

The trolley initially decelerates from the 60 m position with time-optimized control to -1.7 m/s (travel from the waterside to land). The target position at 20 m is reached with a load deflection of approx. 0.8 m. The return travel is restarted shortly after the "Grab_open" status bit (= open grab) has been reset. The grab remains for approximately two seconds in the target area of 20 m … 21 m. The duration that the grab is present within a target area results mainly from the braking acceleration. The smaller the braking acceleration, the longer the duration.



The following figure illustrates the unloading:

Fig. 3-12: Unloading operation for on-the-fly unloading

Section 1:

Travel is started with time-optimized control. The "on-the-fly unloading" control bit (Flying, bit 7, trolley command bits) must be set and activated in P152.

Section 2:

During the acceleration, because of the moment of inertia the load trails behind the trolley. The sway control system compensates this oscillation as fast as possible.

Section 3:

Because the trolley is in the braking phase, the grab sways forward. The signal to "open grab" (Grab_open, bit 0, General status bits) is set when the "distance for opening the grab" (P31) has been undershot. The unloading begins (the loading good is dispatched in the funnel).

Section 4:

Once the trolley speed is smaller than the "on-the-fly unloading abort speed" (P30), the "open grab" (Grab_open, bit 0, General status bits) bit is reset and the "change target" bit (CHANGE_TARGET, bit 14, General status bits) set. This allows a new target (on the waterside) to be specified. The "on-the-fly unloading" control bit (Flying, bit 7, trolley command bits) must be reset.



Activation of on-the-fly unloading

To be able to use on-the-fly unloading, the following conditions must be satisfied:

• The specified target must be on the landside.

• The BOM Positioning (command bit "OM_POS") must be set for the trolley and either the BOM Positioning or the BOM Speed Control (command bit "OM_SPEED") for the hoisting gear or the BOM Hoist Control (command bit "OM_HOIST_CONTROL") for both axes.

• The "Flying" control bit (= "on-the-fly unloading", see Table 3-8, trolley command bits) must also be set.

• The actuator speed > "on-the-fly unloading abort speed" (P30).

• The signal to "open grab" is set when the "distance for opening the grab" (P31) is undershot.

• The best results are achieved with time-optimized control and on-the-fly unloading with constant angle.

• P30 and P31 must be set correctly o The "open grab" signal must first be provided via P31. o P30 is used to set the time for resetting the "open grab" signal (GRAB_OPEN_ status bit)

and so provides the time for setting the "change target" (CHANGE_TARGET status bit).

• The sway control must be active.

Note

No prelimit-switch function may be active for on-the-fly unloading.

On-the-fly unloading with the help of a PT1 element (P38)

If automatic operation with time-optimized control is selected, short deceleration ramps are inserted in the acceleration operation and short acceleration ramps inserted in the deceleration operation. This achieves the quickest possible suppression of a swaying motion.

In particular in this mode, the grab for relaxation oscillations are initiated. To reduce these, a PT1 element can be used to round or delay the actuating signal.

The PT1 filter must be adjusted so that its characteristic frequency lies significantly below the frequency of the grab oscillation but not significantly above that of the load oscillation.

Example: A rope length of 20 m results in a load-swaying frequency of 0.11 Hz. For a grab-oscillation frequency of approx. 0.7 Hz, the time constant of the PT1 must be set to approx. 1.4 seconds (corresponds to 0.7 Hz)

The grab-oscillation frequency must be determined empirically.

The larger the time constant, the greater is the effect of the PT1 element while, however, also negatively influencing the effect of the sway control.

It is recommended that the best compromise between the effectiveness of the sway control and the suppression of the relaxation oscillation is determined empirically.

If the parameter is set to zero, the effect of the PT1 element will be deactivated.

On-the-fly unloading with the help of an input shaper (P39)

For rectifying the relaxation oscillation (see: On-the-fly unloading with the help of a PT1 element)

alternatively, an input shaper can also be used.

The input shaper must be exactly matched to the grab-oscillation frequency.



The grab-oscillation frequency must be determined empirically.

For the correct operation of the input shaper, the grab frequency must not equal the load-oscillation frequency. The load-oscillation frequency can be calculated with

Where g = earth gravity and l = effective pendulum length.

Example:

Frequencies for typical grab oscillations at GSU cranes lie between 0.4 Hz and 1 Hz. The effective pendulum lengths typically vary between 5 m and 30 m. This results in load-oscillation frequencies in the range 0.22 Hz to 0.091 Hz. This ensures the correct operation of the input shaper because it can never match the grab frequency.

If, however, both frequencies are unexpectedly equal, the input shaper should not be deployed.

The influence on the effectiveness of the sway control system must be significantly less than for the PT1 element.

It is, however, recommended that the best compromise between the effectiveness of the sway control and the suppression of the relaxation oscillation is determined empirically.

If the parameter is set to zero, the effect of the input shaper will be deactivated.

Note

Only one of the two filters can be activated. The input shaper has priority, this means, if is it active, the PT1 parameter is not used.

3.3.3 BOM Hoist Control

Obstacles are taken into consideration during the automatic target approach in the BOM Hoist Control. The load is moved along an optimum path curve. The oscillation of the load has been eliminated when the stationary speed or standstill is reached. With the BOM Hoist Control collisions with obstacles located in blocked regions can be avoided.

The travel behavior with hoist control exhibits the following characteristics:

• Advanced calculation of the travel course from the starting position to the target position taking account of the blocked regions.

• Like in the BOM Positioning, the automatic target approaches to the waterside can also be disabled (P109 automatic mode). Automatic travel is only possible towards the landside. This only applies when no external targets are specified.

• Both axes (hoist, trolley) must be in this basic operation mode and should be controlled concurrently.

In the BOM Hoist Control, the higher-level controller or the internal target generator can specify a target position for each individual axis. If s_set=0 is the external position, internal targets are approached, otherwise s_set will be set as target position. Each drive is considered individually, even in the BOM Hoist Control. This means, when only one of the two external target positions (s_set = hoisting gear position setpoint or s_set = trolley position setpoint) is "zero", the internal target position is used for this drive. The external target position is still used for the other drive. Consequently, the actually approached target position can be a combination of an external target for one drive and an internal target for the other drive. The hoist control does not monitor the resulting inconsistency.



Note

There is no monitoring whether s_set=0 for trolley AND hoisting gear. This must be monitored by the higher-level controller.


The BOM Hoist Control is activated by setting the appropriate operation mode bit (OM_HoistContr, bit 14, trolley and hoisting gear command bits) on the two axes (trolley, hoisting gear).

On-the-fly unloading

The on-the-fly unloading can also be used in the BOM Hoist Control. The trolley and the hoisting gear must be in this basic operation mode for this.

Further information on the activation can be found in Section 3.3.2, "On-the-fly unloading".

Horizontal trolley travel above the hopper (P75/P76)

The parameters specify the minimum length that the trolley should travel above the hopper (unloading shoot) without a hoist movement being performed. These parameters can be used for calculating the travel curve independent of the blocked regions; in effect, a horizontal path is added. One parameter acts in one direction (ship to the hopper, P75) and the other parameter acts in the other direction (hopper to ship, P76). If one value is zero, neither acts.

P75/P76 are optimized for the special requirements for the on-the-fly unloading for GSU. This means the following supplementary conditions apply to their use:

• To permit an adequately long straight-line travel the obstacle surrounding the hopper must be significantly higher than all other obstacles between the start and the target (this is also normally the case).

• The target above the hopper must be higher than the obstacle + safety clearance and travel clearance.

If the parameters P75/P76 are not observed, i.e. the starting point of an automatic travel lies below the minimum clearance (value of the parameters 75/76), the horizontal travel over the hopper also reduces. Angular travel curves can occur. This requires, however, also the observance of the previously described supplementary conditions. For changes of the target during the travel, ensure that the system responds immediately. Consequently, for changes during the on-the-fly unloading, the hardware target must never come before the trolley target, because otherwise the target position briefly lies in the hopper obstacle. The sway control then correctly initiates an error. Consequently, the S7 programmer must always change the trolley target first because a consistent transfer via PB is not possible over the complete interface.

3.3.3.1 Target generator

The term target generator characterizes a functionality in the sway control system that independently calculates the target positions for the loading and unloading operations for container ships.

Preconditions

To permit the sway control system to use the target generator, the parameter P102 (configuration) must be given the value 1 (STS crane). In addition, the target positions specified by the PLC must both be zero.



Sequence for the example of unloading a ship

The following steps show an example of the sequence followed for unloading a container ship.

1. The learning travel for determining the blocked regions on the waterside must be prepared by briefly activating the "delete height profile" bit and then permanently setting the "learn height profile" bit. This produces a maximum blocked region (see Section 3.4.2.4) on the waterside.

2. After activating the manual operation, the empty spreader ("locked" bits are 0) is moved once over the container stack. This causes the sway control system to adapt itself to the maximum blocked region and so produce internally a new height profile on the waterside. This is corrected successively during the removal of containers. The height profile defines blocked regions that in addition to the internal fixed blocked regions and the external variable blocked regions specified by the PLC are considered by the BOM Hoist Control.

3. The empty spreader (still in manual operation) is then moved over the container that should be locked at the waterside. The container is locked ("locked" bits set to 1) and moved in manual operation to the target position on the landside and then unlocked ("locked" bits set to 0). This ends the learning travel; the SC system now knows the container stack and the target position on the landside.

4. The crane driver must manually raise the spreader.

5. The travel in BOM Hoist Control can now be activated and the empty spreader moved taking account of the blocked regions to a position above the next container to be locked. This position was calculated by the internal target generator as appropriate for the selected stack type.

6. After the end of the positioning, the manual operation is activated and the container locked in this mode ("locked" bits set to 1) and the crane driver must then manually raise the container again. (For this operation, the internal height profile is also corrected.)

7. The travel in BOM Hoist Control can be activated and the crane moves to the target position on the landside. After completion of this automatic travel, the crane driver must lower the container in manual operation and unlock the spreader.

8. The process sequence now continues at step 4.

A similar procedure is followed for loading a ship. The SC system uses the locations where the locked bits are changed to determine whether a loading or unloading operation is involved.

Fig. 3-13: Unloading a ship



Features and other options

• Stacking type Depending on the stack type, the target generator calculates the target positions on the ship (on the waterside) for the BOM Hoist Control and the sequence with which they are approached (see previous figure and Table 3-10).

Row-by-row landside direction: 10, 5, 2, 1, 6 Row-by-row waterside direction: 6, 1, 2, 5, 10 Column-by-column (depending on the approached column): 1, 3, 7, 12

The change of the lock bits on the landside causes the corresponding new target position on the waterside to be created internally where it is available for the next automatic travel. After changing the stack type, a manual learning travel is required (this does not affect the selection of the parking position). The current travel is terminated.

• Landside

On the landside, by default, travel is always made to the selected lane. Alternatively, travel can also be made to the last lock/unlock position (also refer to the description for P109). It is always assumed that the unlocked containers are removed. Stacking on the landside is not possible.

• Lanes A lane is a target position on the landside at which a container can be locked or unlocked. If a lane for the target position is selected on the landside, this shortens the learning phase. After locking and raising the container (on the waterside) in step (3), the travel in BOM Hoist Control can be started directly. The crane moves the container to the selected lane position and continues with the lowering of the container (manually) as described above. The positions of the lanes must be learnt in the SC system by traveling to the appropriate locations. (The StoreCurrentPosition USINT input (Tab. 3-7) is the number of the lane to which the current position is assigned.) LaneShipLoading/LaneShipUnloading (see Table 3-7) can be used to set the associated lane.

• Boundary regions After the end of a pass of the row/column-oriented loading (at the boundary of the container stack or with the last container in the column), the target generator does not automatically travel to the next lower/higher row or neighboring column. Application example of the row-oriented unloading in Landside direction (see Figure 1): If container no. 6 was lowered on the landside, no new BOM Hoist Control travel should be started. Instead, the crane driver must manually move, lock and raise the empty spreader over the highest container in the last column (here E). The BOM Hoist Control travel can then be restarted and the crane travels to the target position on the landside.

• Bay scanner See Section 3.2.3

• Parking position If both bits for the stack type are deactivated, the BOM Hoist Control or the BOM Positioning is used for travel to the parking position.

• Lashing platform The lashing platform is always approached with the BOM Hoist Control or the BOM Positioning when the appropriate input bit is set and at least one of the two lock bits is set. A stacking type must also be selected. The lashing platform is not approached when travel is made to the parking position or when the starting position lies between the target and the lashing position. In order to travel away from the lashing position and to the final target position, the travel signal must be reset and set again.



The lashing position must be learnt by the user (see StoreIntermediateStop bit, Table 3-10).

Warning

The lashing position should normally always be approached from above. This means that a fixed blocked region must be defined below this position and two others that are higher, in front and behind. The automatic mode then always lowers from above down to the lashing platform.

• Raising and starting the BOM Hoist Control from manual operation From the manual raising, it is possible to directly start a BOM Hoist Control travel without stopping the hoisting gear. See Section 3.4.1.2, "Start of the "SC Automatic" AddOn mode"

• Immersion point See Section 3.4.2.2, "Immersion point"

3.3.4 BOM Sway Neutralization to Load Position (trolley)

The BOM Sway Neutralization to Load Position (only for the version with camera) is used to eliminate swaying motions of the load from standstill. The sway neutralization is combined to a positioning, whereby the target position is the load position at the time of activating the travel signal when the basic operation mode is activated.

The load position is determined from the actual position of the trolley + the load deflection.

Sway neutralization results in small travel movements at both sides of the target position.

The signal sequence corresponds to that of positioning.

3.3.5 BOM Sway Neutralization to Trolley Position (trolley)

The BOM Sway Neutralization to Trolley Position (only for the version with camera) is used to eliminate swaying motions of the load from standstill. The sway neutralization is combined to a positioning, whereby the target position is the trolley position at the time of activating the travel signal for activated basic operation mode.

Sway neutralization results in small travel movements at both sides of the target position.

The signal sequence corresponds to that of positioning.

Project Planning SIMATIC S7 3.4 Sway control configurations


3.4 Sway control configurations The SC system is configured using parameters (Section 544.3) and can be controlled by the PLC by setting various control bits.

3.4.1 Sway control

3.4.1.1 Control in the "SC Speed Control" AddOn mode

In the "SC Speed Control" (OM_SpeedContr) AddOn mode, the travel signal is set by actuating the master controller. If all input signals are fault-free, the sway control system issues an actuator speed to the drives.

If one of the two direction signals is active, the brake must be opened. As long as the brake is closed, no control speed value is output.

The travel signal can be reset when "Positioning complete" is signaled (Pos_complete, bit 10, trolley/hoist status bits).

CAUTION

As soon as a drive axis of the sway control system receives valid travel signals, the actuating signals should also be used for the drives. In the reverse case, if control is not requested by the sway control system, the travel signals have to be reset. Otherwise there may be sudden travel movements.

CAUTION

With an "EMERGENCY OFF" or "EMERGENCY STOP", the crane is stopped abruptly without braking ramps or sway neutralization. The crane driver must take this into account.

Stopping through the specification of a speed setpoint of zero is recommended.



S

R

≠0.0

OM_SpeedContr (1)Brake_closed

v_set

travelling

MS-trolley (Hoisting gear)

≥1

v_posactive

travel_Ftravel_R

Pos_complete

SCR 1

00.0 SpeedDrive Trolley (Hoisting gear)

Travel signals Brake control Actuating signalsSway control computer

Fig. 3-14: Control in the "SC Speed Control" AddOn mode trolley (hoisting gear)

Start of a travel movement

A travel movement is triggered by setting the travel signal with the master controller and by resetting the "Brake_Closed" signal.

The following signal sequence is performed:

Fig. 3-15: Signal sequence at the start of a travel movement

Section 1:

The sway control system is activated and the BOM Speed Control selected (OM_SpeedContr, bit 11, trolley and hoisting gear bits).

Section 2:

The master controller is deflected. The travel signal (Travelling, bit 9, trolley and hoisting gear command bits) must be set. If this is the case and no fault is present, the direction signals, and thus the signals for opening the brake, are output.

Section 3:

The brake is opened. The actuator signals are transferred to the drives.



End of a travel movement

The travel movement is complete when the actuator speed is small and the "positioning complete" status bit (Pos_complete, bit 10, trolley/hoist status bits) is set by the sway control system.

This requires that the set speed (v_set) is set to zero.


Fig. 3-16: Signal sequence at the end of a travel movement for the "SC Speed Control" AddOn mode

Section 1:

Sway-controlled travel.

Section 2:

The travel has been terminated by the master controller; the actuator speed becomes smaller.

Section 3:

The actuator speed is ZERO; this causes the "Positioning complete" signal (Pos_complete, bit 10, trolley/hoist status bits) to be set.

Section 4:

The travel signal must be reset. This causes no direction signals to be output and the brake must be closed.

Section 5:

The brake has been applied.

Setting options

Mode

Two different operation modes are possible for the trolley in the speed control:

• Mode 1: Sway control is permanently active. The sway control function is already active when accelerating to a specified constant speed. In this way, the load sway is suppressed during travel and has been eliminated when a constant speed is reached.

• Mode 2: Sway control is only active when stopping. In this mode, the load sway is only eliminated when stopped. As with mode 1, the load sway has been eliminated after stopping. The load sway is not corrected when starting.

The changeover is made with the "Sway control only when stopping" command bit (AS_Stop, bit 5, trolley command bits) from the crane PLC.



Activating/deactivating the sway control function

The "Sway control ON" command bit (AS_On, bit 15, trolley command bits) can be used to activate or deactivate the sway control function. When the function is switched off, the controller generates standard ramps according to the set acceleration rates.

The internal activation of the sway control function is indicated by the "Sway control ON" status bit (AS_On, bit 15, trolley status bits).

3.4.1.2 Control in the "SC Automatic" AddOn mode

For the "SC Automatic" (OM_HoistContr) AddOn mode, the BOM Hoist Control is activated. In this AddOn mode, the travel signal is triggered by the "Start Automatic" signal (e.g. by foot-operated pushbutton). The system checks whether the automatic can be started. The reasons why an automatic start should not occur can be queried at the status bits for the crane operator panel. If one of these conditions is satisfied, the "BeepStartAuto" status bit (bit 6, General status bits) will not be set. An automatic start should occur only when this bit is set.

CAUTION

If the "BeepStart Auto" status bit is not used for starting the automatic, the PLC programmer must provide an appropriate monitoring of the conditions listed in Table 3-16: Status bits for crane operator panel (see address 112-115 in .

The positioning speed of the trolley and the hoisting gear is determined by the P1 and the P41 parameters, respectively.

If a direction signal is set, the appropriate drive can be activated and subsequently the brake opened in the higher-level controller. As long as the brake is closed, no control speed value is output. The travel signal can be reset when "Positioning complete" is signaled.

CAUTION

If the automatic travel is interrupted by signals but the travel signal is not present, the crane continues with automatic travel when the signal returns. Uncontrolled travel movement can result. It is recommended that the travel signals are reset when automatic travel is interrupted.

Various setpoints and actual values can be checked during travel with the "Hoist control [6]" display (see Section 544.4.6.1).



Fig. 3-17: Control in the "SC Automatic" AddOn mode (trolley and hoisting gear)

Start of a travel movement

Preconditions

All Boolean input signals should be set or reset for a simple positioning as described. For at least one axis, the target position must differ from the actual position. All other signals should have a value within the value range.

When the specified values are created, only those fixed blocked regions saved during the commissioning in the parameter file are considered during the travel.

As in the other AddOn modes, the travel signals must remain set throughout the entire travel movement. If a travel signal is canceled, the actuating signals of both axes are immediately set to zero.


Fig. 3-18: Signal sequence at the start of "SC Automatic" AddOn mode

Section 1:

The sway control system is activated and the BOM Hoist Control selected for the hoisting gear and the trolley. A target position has been specified.



Section 2:

The automatic start (e.g. with foot-operated pushbutton) has been triggered. If no fault has occurred that blocks this AddOn mode, the travel signal must be set. The control bit must be set only when all external variable blocked regions have been transferred. This starts the calculation of the travel curve. The direction signals, and thus the signals for opening the brake, are output when the calculation has completed.

Section 3:

The brake is opened. The actuating signals are issued to the trolley and the hoisting gear and the positioning of the trolley commenced.

The hoist operation begins with 48% of the maximum speed (P40). During the hoisting, the field weakening is determined and the speed during the travel adapted.

End of a travel movement

The travel movement in the "SC Automatic" AddOn mode is complete when the positioning status bit is set by the sway control system.

• The actual position is reached in the tolerance range of the target

• The "Sway-neutralization complete" bit is set at the trolley block. This is achieved for load deflections less than P169.


Fig. 3-19: Signal sequence at the end of positioning in the "SC Automatic" AddOn mode

Section 1:

Sway-controlled travel of both axes to the target position.

Section 2:

The actual position comes near the target position; the actuator speed becomes smaller.

Section 3:

The target position is attained, the actuator speed is ZERO, this causes the "Positioned" signal to be set.

Section 4:

The travel signal must be reset. This causes no direction signals to be output and so the signal to close the brake initiated.



Section 5:

The brake has been applied.

Setting options

Approach of the waiting position

In this AddOn mode, the travel movements can be interrupted at one of the positions (P25, P65) specified with parameters provided the command bit "No_WaitingPosition" is not set.

If a waiting position is to be controlled, approach is first made to the trolley position (P25) located on the travel curve. Shortly before reaching this position, the hoisting gear will be lowered to the parameterized value (P65). If the "No_WaitingPosition" command bit is set before the waiting position is reached, travel will be continued to the target position without interruption.

Start of the "SC Automatic" AddOn mode during a manual hoist operation with sway control

General It is possible to start the "SC Automatic" AddOn mode during a manual hoist operation. In this way, the crane driver can first lift the spreader out of the hazardous area and then switch to automatic control without stopping. A reduction of the hoisting speed (such as that caused by considering the load-dependent field weakening) must be achieved with the override.

Note

Protection must be provided in the PLC against an unintentional operator error so that the automatic travel is stopped when the master controller is not released within two seconds after the automatic start.

Start of the "SC Automatic" AddOn mode with slack rope

If the "SC Automatic" AddOn mode should be started although the "Slack rope" bit is still present, the "BeepStartAuto" bit should not be evaluated.

If P47 > 0 is set, the automatic starts with a slower speed until the "Slack rope" bit is no longer present. If, because of a defect (e.g. defective force transducer), the "Slack rope" bit is present continually during a hoisting operation, hoisting is made until the maximum travel range or limit switch; the trolley, however, does not travel.

CAUTION

The monitoring of the force transducer must be implemented in the PLC. The PLC decides when the automatic operation will be aborted provided the "Slack rope" signal is present without interruption.



Override

The travel speed can be reduced in all basic operation modes using an externally definable override ("Override", see Table 3-9) between 0% and 100%.

This speed reduction is useful for:

• External specification of the field weakening speed for the hoisting gear, i.e. raising and lowering with reduced speed

• Commissioning purposes, test with reduced speed of the trolley and hoisting gear

• Dynamic reduction of the maximum speed in the prelimit switch area

The external override may change in steps. The effect is delayed as internal acceleration limits are maintained.

During an automatic travel, deviations from the spatial trajectory calculated at the start time can occur if the override changes suddenly too often.

This can also cause the hoisting gear to travel to the range limit and then remain stationary with error message E35 (e.g. if the override switches from 10% to 100% and back in the 100 ms frequency).

The trajectory is recalculated for changes of the override that exceed 10%.

In the BOM Speed Control, the override refers to the maximum speeds P0 (trolley) and P40 (hoisting gear), in the BOM Positioning it refers to the maximum speed setpoint P1 (trolley) and P41 (hoisting gear).

Note




Fig. 3-20: Override sequence diagram (speed limitation) for the hoisting gear in the "speed control"

mode

①⑦ Override = 0 and speed setpoint = 0, thus no actuator speed.

② Override at the hoisting gear is 20%, an actuator speed, however, is not output because speed setpoint = 0.

③④

⑤⑥ The override and speed setpoint change over time. The actuator speed is always adapted to the minimum of the two values.

The speed setpoint is specified in the "SC Speed Control" AddOn mode by the master controller and in the "SC Automatic" AddOn mode by the internally calculated speed setpoint.

Use of the "open grab" status bit

The time after which the opening of the grab is possible is specified with parameter P31 (distance for opening the grab) and triggers the setting of the "open grab" status bit. This bit can be used to open the grab.

The reset of this bit indicates that the grab can be closed again. The positioning control expects at this time a new target (position over the ship) for the start of a new travel. A new target (ship) must be specified. The Change_Target bit should be used for this purpose.

The reset is triggered by parameter P30 (on-the-fly unloading abort speed).



3.4.1.3 Control in the "SC Semiautomatic" AddOn mode

This AddOn mode is a combination of automatic and manual operation. One axis is in the BOM Positioning ("OM_PositionContr" bit) and the other axis in the BOM Speed Control ("OM_SpeedContr" bit). The axis in the BOM Positioning continues to travel automatically to the assigned target. Note that blocked regions are not considered. The crane driver controls the other axis with the master controller in the "Speed control" basic operation mode. An application example for this AddOn mode is the so-called hoist takeover.

Hoist takeover

For this operation, after the start of the automatic travel, the crane driver takes over the hoisting gear with the master controller, for example, to lower faster.

When the trolley and the hoisting gear are in the BOM Hoist Control, an operation mode switchover can be performed by actuating the master controller with the following logic.

• The basic operation mode of the hoisting gear is immediately switched to Speed Control ("OM_SpeedContr" bit).

• The basic operation mode of the trolley switches to Positioning ("OM_PositionContr" bit) when the "HoistTakeoverAllowed" confirmation bit (bit 7, General status bits) is set. The trolley continues to travel automatically to the target.

• If the "HoistTakeoverAllowed" bit is not set, the trolley will also be switched to the BOM Speed Control.

The "HoistTakeoverAllowed" bit is set at the height above which the trolley positioning motion starts. A manual takeover of the hoisting gear is possible as of this time. If this bit is not set, no manual control for the hoisting gear is permitted during the automatic trolley travel. A collision with obstacles could occur. In this case, the automatic must be aborted for the trolley and the hoisting gear.

CAUTION

If the drives are not in the BOM Hoist Control , collision control is no longer possible. The crane driver is responsible for avoiding any obstacles.



Fig. -3-21: Switching of the basic operation modes

Fig. 3-22: Hoisting gear acceptance status diagram



Case A

Section 1:

Hoisting gear and trolley are in the BOM Hoist Control (OM_HoistContr). The hoisting gear is not yet at a safe height.

Section 2:

The crane driver deflects the master controller and so requests a hoist takeover. Because the danger of a collision still exists, this action must cause termination of the trolley motion. The trolley and the hoisting gear are switched to the BOM Speed Control (OM_SpeedContr).

Section 3:

Trolley and hoisting gear are in the BOM Speed Control (OM_SpeedContr), the crane driver has complete control over both axes with the master controllers.

Case B

Section 1:

Hoisting gear and trolley are in the BOM Hoist Control (OM_HoistContr). The hoisting gear is at a safe height, i.e. the "HoistTakeOverAllowed" confirmation bit is set.

Section 2:

The crane driver deflects the master controller and so requests a hoist takeover. Because no danger of a collision exists, the trolley can be switched to basic operation mode positioning and the hoist gear can be switched to basic operating mode speed control.

Section 3:

The trolley is in the BOM Positioning (OM_PositionContr), i.e. it moves further in the direction of the specified target without, however, taking account of any obstacles. The crane driver is responsible for the safe height of the load. The crane driver has complete control over the hoisting gear with the master controller.

Note

An acceptance of the hoisting gear from the automatic into the manual mode should be prevented by the PLC when the master controller is actuated only very briefly (unintentional operator error). This delays the acceptance of the hoisting gear into manual mode by the wait time.



3.4.1.4 Taking account of blocked regions

DANGER

The blocked regions are only taken into account in the BOM Hoist Control. In all other basic operation modes, also the BOM Positioning, collisions can occur if the crane driver is inattentive.

Note

For the calculation of the path curve, the PLC requires the position of the lower edge of the spreader as the position to the hoisting gear (concerns hoist actual position).

3.4.2 Sway control with 2D-trajectory and bay scanning


The control in the "SC Speed Control" AddOn mode is made in this configuration as for Sway Control (see Section 543.4.1.1). The statements concerning the parameter sets also apply here (see Section 544.3).

3.4.2.2 Control in the "SC Automatic" AddOn mode

The control in the "SC Automatic" AddOn mode is made in this configuration as for Sway Control (see Section 543.4.1.2). The statements concerning the parameter sets also apply here (see Section 544.3). In addition to the settings specified in Section 543.4.1.2, the following functions can be controlled:

Setting options

Target generator

The function notes where containers are accepted or lowered. If the automatic control knows useful positions, it approaches these independently at the automatic start. Further information for the execution and for the target generator is contained in Section 543.3.3.

Position offset

To simplify the loading and unloading tasks above deck, the trolley position can be automatically given an offset for the automatic target approach. A stop is made shortly before or after a calculated target.

The most recently approached target position is saved internally at the load change when loading or unloading and an offset is added for the next target approach of the trolley.

The load change is detected by the software when the locking state of the spreader (bit 0/1, General command bits) changes from unlocked to partly locked or completely locked and vice versa.

Two different offset values can be saved in the P35 (position offset for unloading) and P36 (position offset for loading) parameters. Depending on the locking state of the spreader, the corresponding value in the target generator is used.

Selection option for the direction of the position offset

The "Barge_LS" and "Barge_WS" (bits 16/17, General command bits) control bits can be used to select the offset added in the waterside or landside direction. The control can be made, for example,



from a Crane Operator Panel or a control element. A negative or a positive offset is added for the next target position approach (trolley only). If none of the control bits is set, the trolley positions again at the last target position.

Fig. 3-23: Normal path for container pick-up in automatic mode

Fig. 3-24: Changed stopping point in automatic mode with landside offset (Barge_LS)

Figure 3-25 Changed stopping point in automatic mode with waterside offset (Barge_WS)

Immersion point



The immersion point is active for the STS crane. The immersion point is deactivated for the GSU crane.

The immersion point is a conservative estimate of the hoisting height learnt by observing the manual travel above which the trolley can be freely positioned above the ship. This means, no superstructure (cell guides, frames for container fastening, etc.) is present above this height.

No automatic travel is possible below the immersion point, because it is assumed that the spreader is located in the cell guides or between two container stacks.

The following figure shows the principle of the immersion point. At point A, the immersion point is set to a value that lies above the "real" deck height because the spreader immerses between two container stacks. Under some circumstances, an automatic travel in this area would cause damage to the ship and the crane. Point B lies approximately in the height of the ship deck and corresponds to the begin of the cell guides.

Fig. 3-26: Principle of the immersion point

The "Delete height profile" bit (= HeightProfile-Delete, bit 5, General command bits) is used to set the immersion point to the initialization value and delete the internally-learnt variable blocked regions.

The initialization value for the immersion point results from P69 (maximum position for hoisting gear positioning) – 3*P108 (maximum container height).

The immersion point is dynamically set to the current hoisting height when one of the two following conditions is satisfied:

• The trolley moves on the waterside above the speed limit P46 + 10%, the hoisting gear, however, is located below the current immersion point.

• For the transition of the trolley speed from 10% above to 10% below the speed in parameter P46, the current immersion point is set on the waterside. The value refers to the maximum speed of the trolley.

Example (following figure):

P46: 20% (upper limit value: 30%; lower limit value: 10% of the maximum speed of the trolley) P0: 3500 mm/s (upper limit value: 1050 mm/s (lower limit value: 350 mm/s) Immersion point at the begin (before overtraveling the waterside): 31000 mm



Fig. 3-27: Setting the immersion point

The first condition is satisfied in the A area. The immersion point is rematched to the current hoisting height in each cycle.

A traversal of the band between the upper and lower limit value for the speed is then made in which the immersion point is not updated.

The second condition takes effect at point B. The lower speed setpoint is undershot and the current hoisting height is assigned as new immersion point. The new value for the immersion point is located at approx. 18600 m.

3.4.2.3 Control in the "SC Semiautomatic" AddOn mode

The control in the "SC Semiautomatic" AddOn mode is made in this configuration as for Sway Control (see Section 543.4.1.3). The statements concerning the parameter sets also apply here (see Section 544.3).



3.4.2.4 Taking account of blocked regions

DANGER

The blocked regions are only taken into account in the BOM Hoist Control. In all other basic operation modes, also the BOM Positioning, collisions can occur if the crane driver is inattentive.

General characteristics

Table 319: General features of the blocked regions

Variable blocked regions

Fixed blocked regions

External Internally learnt

Input, edit and save

Region menu in the CeCOMM diagnostic program, "B" key

Deletion and transfer via PLC before automatic start

By monitoring the movements of the trolley and the hoisting gear in manual operation By acquisition of the laser values from the Bay Scanner

Default values for the activation

Saved regions in the parameter files

None

Maximum position for the hoisting gear positioning (P69) when HeightProfile-Delete=0 and HeightProfile-LearnActivate=1, otherwise none

Start position in the blocked region

Automatic does not start Although automatic starts, only the hoisting gear is controlled until the blocked region is exited

Target in the blocked region

Automatic does not start The trolley is stopped at the target position before or over the blocked region

List display of the blocked regions

"Region menu" for CeCOMM (with the "B" key) (Section 544.4.6.2)

"Variable blocked regions" screen page in CeCOMM (with the "G" key) (Section 544.4.6.2).

Graphical display of the blocked regions

CeCOMM diagnostic program, Diagram function in the X/Y representation (Section 544.4.9.4).



External variable blocked regions

Transfer sequence for external variable blocked regions:

• First delete all external variable blocked regions of the previous travel job.

• Unsorted transfer of the current container stack via the PLC. The blocked regions are written with the data field, an array comprising five elements each with three int32 values.

It is recommended that the transfer of the external variable blocked regions be checked thoroughly before the commissioning.

Transfer

The transfer of a data set containing up to five blocked regions is performed with the following signal assignment:

Fig. 3-28: Transfer of external variable blocked regions



Sequential transfer

If more than five blocked regions have to be transferred, the transfer must be sequential, i.e. over several cycles. A special control bit and confirmation bit are provided for this.

• The adjacent blocked regions are accepted with the rising edge of the control bit "Prg_Block" (bit 11, General command bits).

• The checkback bit "PrgBlock" (bit 11, General status bits) is set as acknowledgement and the next block transfer can begin.

• The current total number of blocked regions in the sway control system is returned in the "No_Blocks" data field (sway-control computer output data).

• If zero values have been assigned to blocked regions, these are not transferred and therefore less than five blocked regions can be transferred.

• Once all blocked regions have been transferred fully ("Start-2D-Calc", bit 15, General command bits), the automatic operation calculates the path and makes the transition to path travel.

The current list of the transferred blocked regions can be displayed in the diagnostic program on the "Variable blocked regions" screen page (with <G> key) (Section 544.4.6.2).

Fig. 3-29: Sequential transfer of external variable blocked regions



Delete

The deletion of external variable blocked regions is made with the following signal assignment:

Fig. 3-30: Deletion of all external variable blocked regions

The deletion of external variable blocked regions is performed according to the same principle as the transfer, with two bits in the interface section "Obstacles".

• The list of external variable blocked regions is deleted in the sway control system by setting the "Del_Block" control bit (bit 12, General command bits).

• The checkback bit "DelBlock" (bit 12, General status bits) signals the successful execution to the PLC.

• The current total number of internal variable blocked regions in the sway control system is also returned in the "No_Blocks" data field (sway-control computer output data).

• The deletion deletes only the external variable blocked regions. The internally learnt variable blocked regions are retained. This means it must be known beforehand how many internally learnt variable blocked regions are required so that the total number of 200 is not exceeded. For the maximum number of external variable blocked regions that can be transferred, the following is true: maximum value = 200 – maximum number of internally learnt blocked regions

Fig. 3-31: Deletion of external variable blocked regions (sequence)

Internally learnt variable blocked regions

(Also refer to Table 3-10: General command bits)

The height profile begins at parameter P26 (start waterside) and ends either at P28 (maximum position, if P29<P28) or at P29 (end waterside, if P29>P28).

During the initialization, a blocked region is created that reaches from the start of the waterside (P26) to the end of the waterside or to the maximum position (P28 or P29) and that covers the complete hoisting range (P63 to 69) that can be approached in automatic operation. This means no automatic travel on the waterside is possible in this situation, a learning travel must first be performed in the BOM Speed Control.



Initialization of the internally learnt variable blocked regions

The following sequence must be followed:

• first delete all internally learnt variable blocked regions by setting the "HeightProfile-Delete" bit (bit 5, General command bits). This also deletes those target positions developed from the twistlock-change (Container_lock bits).

The checkback bit "HeightProfileDeleted" (bit 5, General status bits) signals the successful execution to the PLC. The "HeightProfile-Delete" command bit must be reset after the deletion.

Note

If the "HeightProfile-Delete" bit is set, the internal variable blocked regions are no longer present, and with the configuration GSU (P102=0) it is possible to approach the target position on the waterside whereas with the configuration STS (P102=1) the target position for the hoisting gear on the waterside is set to the initialization value of the immersion point. This mode should only occur during the initialization (refer to the bit description in Table 3-10; General command bits).

• Initialization of the internally learnt variable blocked regions after resetting the "HeightProfile-Delete" bit by setting the "HeightProfileLearnActivate" bit (bit 4, General command bits). This creates the described blocked region.

Notice

After a restart of the system, the internally learnt variable blocked regions are also initialized.

Initialization conditions for internally learnt variable blocked regions

Should situations occur that cause doubt concerning the validity of the current height profile, the automatic travel is no longer permitted to continue with this height profile. The internally learnt variable blocked regions must be reinitialized and a new learning travel performed.

An initialization of the internally learnt variable blocked regions must be performed, when

• The crane has been switched off for an extended period (e.g. 5 minutes)

• The crane travelling gear travels more than approx. 4 m (approach a new container row)

• The Boom Hoist is not down

• Errors occur in the trolley, hoisting gear and travelling gear (PLC) position sensors

• The variations of the redundancies are too large in the position mapping of the trolley and hoisting gear

• A container has not been locked or unlocked for 15 minutes

Warning

For reset "HeightProfileLearnActivate" and "HeightProfile-Delete" bits, the internally learnt variable blocked regions are retained unchanged and are not updated. If, in this state, the real container stack is changed as the result of transport operations, the software would no longer recognize this and collisions resulting from the now faulty height profiles would no longer be excluded. This mode should generally be avoided.



Starting the learning process

The learning process can be commenced once the initialization has been performed. This requires that the "HeightProfileDelete" bit is reset and the "HeightProfileLearnActivate" bit (bit 4, General command bits) remains set. All movements of the spreader are then recorded as height profile (internally learnt variable blocked ranges) in the BOM Speed Control. All blocked regions above the spreader (current hoisting position) at the current trolley position are truncated because no obstacle can be located there.

If the "slack rope" bit is set, the hoisting height profile will not be learnt.

3.4.2.5 Double spreader in coupled mode

Note

For the calculation of the path curve, the PLC requires the position of the lower edge of the spreader as the position of the hoisting gear (relevant for hoist actual position). The middle of the landside spreader is required for the position of the trolley (relevant for trolley actual position).

The operation of coupled double spreaders is activated by setting the "spreader coupled" control bit (bit 7, General command bits).

The current total width of the double spreader "WidthDoubleSpreader" is also required (see sway-control computer input data, address 84-85). The total width is used to calculate the path curve and is displayed on the "PROFIBUS-Interface [2]" display screen in the CeCOMM.

3.4.3 TLS Control

"TLS Control" controls the so-called trim, list and skew positions of a spreader.

Activation of the "TLS Control" AddOn

This AddOn is activated in parameter P197 ("Trim/List/Skew control") by enabling "Trim/List/Skew control On".

The AddOn can be used independently of all other basic operation modes, AddOn modes and AddOns.

3.4.3.1 Control of the "TLS Control" AddOn

Activation and deactivation of the TLS commands

The "Trim", "List", "Skew" and "Approach zero position" TLS functions are activated by setting the associated TLS command bits. Depending on these command bits the set positions for each cylinder are determined. The cylinder remains controlled until each cylinder has reached its set position – even when the command bits have already been reset.

With the help of the status bits, the cylinder states are returned to the PLC and the hydraulic cylinders controlled (binary move in/out bits).



Note

If, for technical reasons with one of the TLS commands the target is not attained within 30 seconds after resetting the command bits, the control of the affected cylinder will be terminated.

Activation and deactivation of the Skew Control function

The Skew Control function is activated by setting the "ANTI_SKEW_AUTO" command (bit 15, TLS command bits). All other TLS command bits (Trim, List, Skew, "MOVE_ZERO") are not set.

A deactivation of the Skew Control function is disabled by resetting the "ANTI_SKEW_AUTO" command bit or setting another TLS command bit.

The control of the anti-skew cylinder is terminated when

• The oscillation of the internal skew model is less than the set residual sway, or

• The determined cylinder speed is less than the "TLS speed for zero signal" parameter (P186).

The following signal sequence is performed with activated Skew Control function during skew in clockwise direction and the correction of the skew:

Fig. 3-32: Signal sequence with activated Skew Control function

Section 1:

Skew Control function is switched on. There is no skew.

Section 2:

Skew in clockwise direction starts. This resets the "ZERO" status bit.

Section 3:

Skew is finished.

Section 4:

"Correct skew" is requested with the "Skew_ZERO" control bit.

Section 5:

The "ZERO" status bit is set when the skew is corrected. This signal can be used to reset the "Skew_ZERO" control bit.



Designation of the cylinders

The hydraulic cylinders are designated as follows: Cylinder designation Carrying cable

A Landside, left

B Waterside, left

C Waterside, right

D Landside, right

Fig. -3-33: Hydraulic cylinder identifier

Priorities

If several commands are present concurrently, the following priorities apply:

1. "Move_ Zero" (highest priority),

2. Trim, list and skew commands and

3. "Automatic Skew Control".

Internal setpoints are calculated for each cylinder with all commands. Position controllers ensure that each cylinder reaches the calculated target position. If, for example, one cylinder moves in or out slower than the others, then it runs on for a certain time until it has also reached the target position.

The limit values that can be set for the trim, list and skew with the P194, P195, P196 parameters are relative to the position saved with "SAVE_ZERO" (= "Save zero position", TLS command bits). The limits are monitored in all directions. When the end positions are reached, further movement in or out is prevented.

TLS commands

Trim

The inclination of the container is set left/right with the help of the binary control commands "TRIM_LEFT" and "TRIM_RIGHT" (= "Trim left/right", TLS command bits).

List

The inclination of the container to the landside/waterside with the help of the binary control commands "LIST_WATER" and "LIST_LAND" (= "List waterside/landside", TLS command bits).

Skew

The skew is set with the help of the binary control commands "SKEW_RIGHT" and "SKEW_LEFT" (= "Skew right/left", TLS command bits).

Approach/save zero position

The current cylinder positions can be saved with "SAVE_ZERO" (= "zero position for skew", TLS command bits) and automatically approached with "MOVE_ZERO" (= "Approach zero position", TLS command bits).

Skew Control

The "ANTI_SKEW_AUTO" command (= "Automatic Skew Control", TLS command bits) activates the automatic approach to the target point with anti-skew. This command is preferred for the automatic positioning operation of the trolley.



In this case, the target point is the last position set with the TLS or "MOVE_ZERO" commands (and not the position saved with "SAVE_ZERO"). One last position is used for the waterside and one for the landside. These two target points can only be learnt, not parameterized.

By setting the command "REF_EXT" (= "External rotational position", TLS command bits), the rotational position specified as "extSkewAngle" (= "set angle", sway-control computer input data, TLS) converted into cylinder positions is used as target point rather than the internally saved last position on the landside or waterside. The set angle must be specified in 1/100 degrees.

When the skew control is switched on, the "SKEW_ZERO" command (TLS command bits) can be used to correct the skew without the list and trim being affected.

Note

When strong sunlight is present, shadows can occur on the reflector that cause limitations of the TLS function (Skew Control). The "Camera_OK" output bit can be used to issue an error message (E4) to the PLC after a parameterized time. The user can set this delay time with the parameter P127.

Note

We recommend that Skew Control should be deactivated via the PLC in the case of the E4 error.

Note

When strong winds are present, the SkewControl TLS function can cause failures. If the system cannot suppress skewing motions within five periods, the crane driver should disable this function because a reliable functionality cannot be guaranteed.

Hydraulic control

The hydraulic control uses the position data of the individual cylinders for

• The automatic travel to the target point and

• The switch-off at limit.

It calculates the cylinder speeds and the associated binary move in/out bits (CYL…_OUT/CYL…_IN, TLS status bits) that are used to control the hydraulics.

If at least one of the speeds is not equal to zero, one of the oil pressure signals is set according to the following principle: If the set speed of at least one hydraulic cylinder exceeds the set speed limit, the output signal "PRESS2" (pressure 2) is activated, otherwise "PRESS1" (pressure 1) (TLS status bits). The oil pressure signals can be switched off with a settable delay.

Confirmation that the zero position has been reached is signaled with the "ZERO" bit (TLS status bits).

The control bits for the skew are generated automatically internally based on the TLS commands. As for the trolley and hoisting gear, the status bits of the slewing gear ("Ready", "Active", "Pos_Completed", etc.) can be used for monitoring the TLS motions.

Permitted residual sway (P198), initial oscillations (P199)

Under some circumstances for small slews, e.g. for the unloading operation, the TLS function can be disruptive for the lowering of containers. Two parameters are present that permit a low residual sway (P198) or initial oscillations (P199); they can be set by the user.



3.4.4 Sway control with TLS control


The control in the "SC Speed Control" AddOn mode is made in this configuration as for Sway Control (see Section 543.4.1.1). The statements concerning the parameter sets also apply here (see Section 544.3).

3.4.4.2 Control of the "TLS Control" AddOn

The control in the "TLS Control" AddOn is made in this configuration as for TLS Control (see Section 543.4.3.1). The statements concerning the parameter sets also apply here (see Section 544.3).


4 Commissioning Software 4 4.1 Preconditions

The following requirements for the commissioning of the AddOn software must be satisfied:

1. All components of the system must be installed, connected, functional and interconnected

2. Installation and start of the CeCOMM diagnostic program (Section 544.4.2) on the commissioning PC.

3. Setting of the IP address of the commissioning PC in accordance with the SIMOTION (same subnet).

4. When a camera is used, the camera measuring system must be operational (SIMOCRANE CenSOR 2.0 documentation).

4.2 Ethernet communication


The connection between the following components is implemented with Ethernet using the TCP/IP network protocol ( 5Fig. 4-1):

• Camera and the Add-on technology in the SIMOTION (1)

• Camera and commissioning tool (2)

• Add-on function in the SIMOTION and the CeCOMM diagnostic tool (3)

SIMOTION C – variant

SIMOTION C 240 PN

Ethernetor PROFINET Ethernet

CenSOR 2.0

(1)(2) (3)

Fig. -4-1: Communication via Ethernet SIMOTION C

Whereas dashed connections ((2) and (3)) are only present during the diagnosis or commissioning, solid connections are always present.

Commissioning Software 4.3 Configuration of the Add-on functions


The continuous communication between the Add-on functions on the SIMOTION and the camera (1) is not performed directly but using FB blocks. The interface is described in more detail in the next section.

4.2.2 Parameter assignment / addressing

For the communication between the components, the IP address of the camera must be made known to the SIMOTION. The camera is delivered with a predefined IP address.

If the IP address of the camera is changed, this new address must be made available to the SIMOTION. The CeCOMM diagnostic software (see Section 544.3) is used for this purpose. After calling the Parameters menu with the "P" key and calling the "I" function, follow the instructions.

When a PROFINET connection is used, the SIMOTION is passed the IP address 0.0.0.0.

Default settings

IP address of the camera 192.168.1.155 Camera port 8500

4.3 Configuration of the Add-on functions The Add-on functions are configured during the commissioning using the CeCOMM diagnostic program (Section 544.4) by setting parameters. These parameters are values and settings that do not change continually during crane travel (such as maximum speed, accelerations, maximum positions, etc.). The parameters are stored in parameter sets. They are loaded at each restart and can be used for the calculations.

Parameter sets

Four parameter sets are provided. The files are named Par0.txt, Par1.txt, Par2.txt and Par3.txt. If no parameter sets are available at the start of the program or if they are faulty, all parameters are set to their default values.

NOTICE

The parameter sets are numbered 1 to 4 in the CeCOMM diagnostic program. Therefore, file Par0.txt contains parameter set 1 and Par3.txt parameter set 4.

If a parameter exceeds the specified limits when it is loaded, an error message is generated and the value of the relevant parameter is set to the default value. The error is only reset after all parameter sets have been loaded successfully.

The current parameter set is defined by control bits in the Common block. All parameter sets can be edited irrespective of which parameter set is switched active by the control bits.

Commissioning Software 4.3 Configuration of the Add-on functions


Switching parameter sets Note

The control response or system configurations can be changed by switching the parameter sets. In conjunction with control elements, the crane driver can select a desired configuration.

Different parameter sets can be used, for example, when different speeds and/or accelerations should be used.

The parameter P101 "Parameter set locked during travel" can be used to prevent the switching of parameter sets during travel.

Input and editing of parameters

To input and edit parameters, the Parameters menu is called from the main menu or another display screen with the "P" key (Section 544.4.6.2). The Parameters menu contains an overview of the parameter groups that can be displayed pagewise in short form with the keys "1", "2", etc.

Parameters which are not set to their defaults are identified by a "+". When "?" and the parameter number are entered, a detailed explanation of the parameter is displayed together with the current, default, minimum and maximum values.

The parameter can be changed with "C" and the parameter number. Only values in the range between the fixed minimum and maximum values can be entered for the parameter.

If acceleration parameters are set to lower than 20, they will be interpreted as times and converted to the corresponding parameter values.

NOTICE

Always use the Parameter menu of the "CeCOMM" diagnostic program to edit the parameter sets. The files can be destroyed when an editor is used.

Note

Detailed information about the parameters is contained in Chapter 5 and the online help.

Saving parameters, effect

Note

Each changed parameter takes effect immediately, but is not stored permanently. Changed parameters should be confirmed with "OK" and then saved permanently with "S" (save all parameter sets and fixed areas). All parameter sets are always saved.

Note

Changes to parameters P100 – P104, P106 and P110 take effect in all parameter sets, otherwise only in the respective, active parameter set.

Commissioning Software 4.4 CeCOMM commissioning software


NOTICE

The semiautomatic commissioning sets parameters only in the current parameter set.

Note

A documentation of all set values can best be created with the Parameter listing ("L"), History call ("F2"), Select (e.g. CTRL+A) and Save ("F4") functions.

Note

All parameters, whose setting during the commissioning is not absolutely necessary and therefore not described explicitly in the appropriate sections, should be left with their default settings and only changed when problems occur.

4.4 CeCOMM commissioning software

4.4.1 Introduction

The diagnostic program is used for the commissioning, parameterization and diagnosis of the sway control systems.

This program can be used for the following tasks:

• Check and change the current parameter settings

• Record curves

• Transfer updates

• Save and load parameter sets

Prerequisite for the diagnosis and commissioning is the Ethernet connection of the laptop/PC with the sway control system using an Ethernet connection.

Note

The following sections describe the principle of the structure and the operation of the diagnostic program. For the diagnosis or commissioning, the displayed menus, functions and dialogs in the function part can vary greatly depending on the connected sway control system.



4.4.2 Installing the software

The CD contains a commissioning and diagnostic program. The installation that can be made on any PC or laptop, and is started from the CD drive by executing the "Setup CeComm.exe" file.

Note

The program can run under the WINDOWS 2000 and WINDOWS XP operating systems. This requires that the user is logged on to the PC as administrator.

The installation program leads you step by step through the whole installation process. After the installation, the diagnostic program is available under "Windows Start Programs".

4.4.3 Parameter assignment / addressing

For the commissioning and diagnosis, the IP address of the commissioning laptop/PC must lie in the same subnet as the SIMOTION.

Note

Any present 'personal firewalls' (e.g. Windows Firewall for Microsoft XP) should be deactivated or exceptions permitted. The correct operation of the "CeCOMM" diagnostic program requires unrestricted access to specific ports (FTP, Telnet).

4.4.4 User interface

General

The diagnostic program consists essentially of four parts:

• Windows menu (Section 4.4.5 5)

• Icons for establishing the communication

• Functions (Sections 4.4.6 to 4.4.11)

• Status bars



Fig. 4-2: General layout

The Windows menu functions are located in the upper area. The icons for establishing the

communication are located below.

After the successful connection to the devices, the following Functions are available on the tabs:

Monitor: Device-dependent display of all diagnostic information, change parameters, display error messages, etc.

File manager (Explorer): User interface for copying, renaming, editing, etc. files

Diagram: User interface for recording, saving and loading curves

Web server: Use the Web server available on the target system

Telnet: Establish connection to the sway control system with Telnet

Effective pendulum length

Tool for determining the parameters for calculating the effective pendulum length (resolution and offset)

Note

Most of the available functions can be operated by clicking a button (e.g. "F2 - History") and also pressing the key (e.g. "F2") shown on the button. The following description only describes the button.

Note

The displayed menus, functions and dialogs in the function part depend on the connected device or system and so can vary greatly.



The Windows status line contains the IP address of the connected device, the interface version and

the version of the sway control system and the loaded *.ini file. The icon can also be used to keep the window in foreground, even when it is not active. Pressing the icon again deactivates this function.

Establishing the communication

After the program start, one of the icons must be used to establish the connection to the devices using the COM or Ethernet interface.

The IP addresses of the attached devices can be set using the Windows "Interface" function. The connection is established in four successive phases:

Phase 1

The application attempts to reach the SIMOTION using the set IP address.

Phase 2

The node can be reached in the network and a connection will be established.

Phase 3

The current version of the application will be loaded.

Phase 4

The language files will be loaded appropriately for the current configuration.

Note

After a sway control system restart (switch-on process, general reset) phases 1, 2 and 3 can take as long as one minute. In this case, to allow the connection to be established correctly, the communication should not be disconnected. If no connection can be established, check the interface settings on the diagnostic PC and in the CeCOMM commissioning tool. The CeCOMM commissioning tool and the sway control system may need to be restarted.



4.4.5 Windows menu functions

4.4.5.1 Windows File menu function

Open

When the connection is established, the software detects automatically the connected hardware (SIMOTION, SIMOCRANE CenSOR, etc.) and loads the associated *.ini file from the program directory.

The "INI" file contains all settings and properties for the diagram (such as data selection, colors, line thicknesses).

If these settings are to be saved and reused with a different name, this can be realized using the "File / Save as" and "File / Load" Windows menu items.

If these *.ini files are deleted unintentionally, new files will be created using the default settings.

Save as

The settings for the diagram can be saved in an *.ini file.

Note

For all changed properties (F8), the properties of the diagram will be saved automatically in the DiagXXX.ini or DiagXXX_engl.ini file in the program directory or the currently set directory and file name.

Reload last chart

This function loads the last recorded chart.

Connect/disconnect network drive

These are the usual Windows Explorer functions for the connection and disconnection of drives.

Properties

This function is only active in the "Explorer" tab and opens the Windows properties window when a file or a folder is selected.

4.4.5.2 Windows View menu function

The Windows "View" menu function can be used to call all functions provided on the tabs.

4.4.5.3 Windows Options menu function

Note

The Windows "Send text file", "Save image content" and "Start cemgr" menu functions are available only when the "Monitor" function (tab) is active.



Save image content

This function is used to save the content of the current screen (e.g. display screen 1 = kinematics) in a text file (*.txt) that can be opened with a simple editor.

Start cemgr

This function is provided for service purposes and serves to start the program in debug mode.

Ping

This function can be used to quickly test whether a connection from the diagnostic tool to the SIMOTION exists. The following screenshot shows a successful connection request.

Fig. 4-3: Ping to SIMOTION

Interface

The IP address of the attached devices can be made known using this function. It is also possible to configure the connection type and the associated required interfaces.

Fig. 4-4: Configuration of the IP address

Language

German and English are currently available. It is possible to switch from one language to the other at any time. The current language of the diagnostic program will also be set on the target system when the connection is made to the target system.

Auto configuration

When this function is activated, the program detects automatically the connected hardware (SIMOTION, SIMOCRANE CenSOR, etc.) and loads the associated *.ini file.

Configuration file

The DiagHPC.ini configuration file will be loaded and can be edited.



Choose root directory

This function is active only in the "Explorer" tab and opens the root directory of the camera.

Set system time

The time of day is not stored permanently on the camera. The time of day is set to zero when the camera is restarted. When the connection is established with the diagnostic tool, the system time of the commissioning PC is transferred automatically to the camera. The "Set system time" function can be used to manually transfer the system time. This option is mainly used for the time stamp when parameter files (Par0.txt…Par3.txt) are saved

4.4.5.4 Windows Calculations menu function

Position parameters

This tool can be used to calibrate the sensor data. The associated measurement data and the required position data are entered. The required conversion factors from the measurement data to the position data are displayed. This requires that two positions are approached with a travel axis. The positions displayed in the controller and the internal positions displayed in the camera are entered at the right-hand side under "Position values" and the left-hand side under "Measured values", respectively, as appropriate for the approached position. "Calculate" fetches the two conversion factors. These conversion factors must be entered manually in the parameter list.

Fig. 4-5: Calculation of position parameters

Speed parameters

The crane manufacturers frequently specify the crane-specific P1 – P5 parameters in units that cannot be used directly in the parameters. This function is used for the simple conversion of the specified crane data into mm/s and mm/s².



Fig. 4-6: Calculation of speed parameters

4.4.5.5 Windows Help menu function

INFO

The version number of the program is displayed under Info.

Help for CeCOMM Note

This function is available only for the commissioning and diagnosis of the camera.

This menu entry provides help for using the CeCOMM diagnostic program.

Load online help

The commissioning help will be uploaded from the associated connected device or system and displayed in HTML format.



4.4.6 Monitors

General information

When the space bar is pressed, all available keyboard commands will be displayed.

Note

The displayed menus, functions and dialogs in the function part depend on the connected sway control system and so can vary greatly.

Fig. 4-7: Monitor - Main menu

To trace the performed diagnostic steps, for copying or for the improved view of scrolling windows (e.g. Parameter Listing), the "F2 - History" button can be used to display all previous steps. When this history function is called, the display screen will have a gray-colored background. After marking the required text using <CTRL>-<A> or <CTRL>-<C>, the "F4 - Save as…" button will be enabled and this selection can be saved with an entered name (see next figure).



Fig. 4-8: Marked text section from the parameter list

The "F3 - Return to monitor" button returns to the monitor function.

The basic monitor functions can be divided into three groups:

• Display screens

• Parameterization menus

• Special functions

4.4.6.1 Monitor display screens

Depending on the target system, different display screens are available.

The display screens are fetched from the main menu using the appropriate keys (e.g. "1" for "Kinematics", 54Bild 4-11).

The "Monitor" function and its subfunctions have a monitor status line in the last line to display information and enter values.



Fig. -4-9: Monitor - Kinematics display screen, sway control system

The "1" to "7" keys can be used to switch arbitrarily between the display screens. Pressing the space bar causes the main menu to be displayed.

In general, the values displayed in the individual screens are self-explanatory because of their labeling and layout.

Some of the values are explained in greater detail below.

Load deflection/angle - "Kinematics [1]" display screen

The load deflection is the deviation of the load from the rest position. It is displayed in the "Kinematics [1]" display screen for the acceleration value (previous figure). The load deflection in the trolley direction is on the left-hand side and is specified in mm. The deviation of the load from the rest position during skew (skew control) is an angle and is specified in cgr (hundredth's of degrees) on the right-hand side.

Effective pendulum length - "Kinematics [1]" display screen

The effective pendulum length is the basis for the calculation model for the prevention of oscillation. It is displayed in the "Kinematics [1]" display screen for oscillation in the trolley direction and the oscillation during the skew (Skew Control) below the laser value (previous figure).

The effective pendulum length for the oscillation in the trolley direction is the distance between the suspension point and the load center of gravity. For the slewing gear or the skew for the TLS (second value), the effective pendulum length is a virtual pendulum length. It is the length with which the skewing motion is eliminated when the same oscillation duration as for the swaying motion is assumed. The swaying duration of the skewing motion is also independent of the load length.



Laser and lanes - "Hoist control [6]" display screen

Fig. 4-10: "Hoist control" display screen, sway control system

The following displays are available for the laser scanner

Laser Measured height above zero.

Count Used for control: Will be increased continually when a new valid value comes from the PLC. Because only the last two places are displayed, it starts at zero again at overflow.

Distance The distance is the position difference of the trolley between two valid heights from the laser scanner. At this distance, the height of the obstacles is set to the higher value.

Laser freq. Display of the refresh rate of the laser scanner (averaged value). The refresh rate n means that a valid value comes from the laser scanner every 2 * n * cycle-time [ms]. The cycle time is displayed in the "Kinematics [1]" display screen.

The selected Lanes for loading and unloading are displayed for the laser values. If only one lane is specified, the other lane receives the same number.

Monitor - logger listing

For a fault analysis, it is important to know under which conditions the phenomenon or unwanted behavior occur. To receive an indication when which input signal changes, the signal sequence of selected input signals is recorded. Such examples are the setting of the basic operation mode, target positions and override.



The "L" key in the "Monitor" function can be used to display the logged signals. The maximum number of entries is 9999. If this number is reached, the first entries will be overwritten.

Fig. 4-11: Monitor - logger listing

Content

1. Column: Sequential number of the entry

2. Column: Time of the event in the format "hh-mm-ss.ms"

3. Column: Name and content of the changed signal

Particularly important signals, such as the basic operation modes, are color-highlighted.

The following functions are available for operating this screen:

H – Home Display the first page

E – Endpos Display the last page

B – Backw Scroll back one page

F – Forw Scroll forward one page

S – Save Save the logged signal sequences in the "Logger.txt" file in the /SWAYCONTROL/ directory



RETURN – Refresh Refresh this page

ESC – Escape Exit this display screen

4.4.6.2 Monitor menus and special functions

General information

The target systems offer various parameterization menus.

The functions described below are examples implemented in this or similar form on all target systems.

The menus and special functions can be called from the main menu and from the display screens. The menus contain various subitems documented in the menu tree (see Appendix) and whose use is largely self-explanatory. The current menu will be displayed after the subitem has been completed. The menus are closed with the ESC key to return to the previous display screen.

Parameters menu

The Parameters menu can be called from the main menu and all display screens with the "P" key ( 54Bild 4-14). All parameters can be displayed, changed, saved and copied in this menu.

Note

Only those parameters are displayed that correspond to the setting of parameter P100 (= access code).

The following access codes are available:

Access code 0 – crane operators, maintenance staff

Access code 1 – commissioning engineers

Access code 2 – service technicians and specially trained commissioning personnel

Access code 3 – development engineers



Fig. 4-12: Monitor - Parameters menu

The digits "1" to "12" can be used to display the parameters as groups. The "1" to "12" keys can be used to switch arbitrarily between the display screens of the parameters. From these display screens it is also possible to execute the functions of the parameter menus.

Note

Whereas the "C – Change parameters" and "F – Search parameters" functions refer to individual parameters, all others apply to the complete parameter set.

C – Change parameters After pressing the "C" key, the parameter number must be entered (e.g. "1" for parameter P1) and closed with <ENTER>. The new value is then entered and confirmed twice with <ENTER>.

Changed parameters are marked with a "+" and a different font color in the displays ("1" … "12").

Note

Each changed parameter takes effect immediately, but is not stored permanently. Changed parameters should be confirmed with "OK" and then saved permanently with "S" (save all parameter sets and fixed areas). All parameter sets are always saved.

D – Set default values The "D" key can be used to delete all previous settings and to load the initial settings.



I – Communication addresses All communications addresses can be set in this menu item.

S – Save all parameter sets and fixed areas This function saves and accepts all changed settings.

N – New parameter/area set This loads a different parameter set. The required number must be entered and confirmed with <ENTER>.

Y – Copy parameter/area set This function can be used to copy all ("A") or only a part (<ENTER>) of the parameters from the loaded parameter set into one of the three other parameter sets. The number of the target parameter set must be entered.

L – Parameter/area listing List all parameters. "F2 - History" can be used to view the list.

R – Reload parameters Load all parameters of the current parameter set. This is useful when a parameter has been changed and the previous version should be restored. If a parameter set is copied into the directory, the parameters must also be reloaded for updating.

F – Search parameters A search term can be entered. All parameters that contain this search term will be listed.

Commissioning menu

The commissioning menu can be called from the main menu and all display screens with the "I" key. All commissioning steps are performed in this menu.

The commissioning steps depend on the associated attached device. A detailed description for the commissioning steps for Sway Control on the SIMOTION is contained in Section 54.6. The commissioning steps for the camera are contained in the SIMOCRANE CenSOR 2.0 documentation.

Monitor special functions

The special functions

E Errors

G Display variable blocked regions

H Errors History

S Shell

V Version information

! Stop diagnosis

X Simulation of the loading

are called from the main menu and from the display screens.



The "Errors" special function lists all currently pending errors. The "?" key and input of the error number (e.g. "12") can be used to display a more detailed description of the error.

Errors marked red are forwarded to the PLC. The errors marked green have the status of a warning and are not forwarded to the PLC.

The "Errors History" special function lists all errors that have occurred previously. All errors marked with an asterisk * are still active.

Note

All errors are listed just once in the "Errors History" screen with the system time of the last occurrence, even if they occurred several times.

The appropriate letter (E, H) can be used to switch between the "Errors" and "Errors History" functions.

The "Display variable blocked regions (G)" function displays the external variables and internally learnt blocked regions.

The "Version information (V)" function displays information about the current version.

The "Shell" function is available only for the diagnosis of the camera and is used to monitor the boot process and to change special settings. The function can be called only when a connection to the camera using the serial interface has been established.

The "Stop diagnosis (!)" special function is provided for service purposes.

All special functions should preferably be closed using the "ESC" key. The last-called display screen is then displayed.

The "Simulation of the loading (X)" special function is used during the commissioning of the hoisting gear to test the correct functioning of the automatic mode. Pressing the "x" key in all display screens simulates the locking of a container and when pressed again, the unlocking. The current status is shown in the status line.

The twistlock simulation can be activated only when both lock bits (LOCKED BIT0 and LOCKED BIT1) have been reset, i.e. when no real container is locked on the spreader.

Warning

If twistlock simulation is used, travel must be performed at an adequate height (> max. container height P108) above the obstacles that actually exist. Otherwise collisions can occur during automatic operation.



4.4.7 File manager

The file manager can be used to edit, copy, rename and delete files. Directories can be created.

Note

The displayed directories in the function part depend on the sway control system and so can vary greatly.

Fig. 4-13: Explorer function

Prerequisite for the correct operation is the correct assignment of the IP address to the connected device in the "Options/interface" Windows menu function.



4.4.8 Diagram – user interface for recording curves

4.4.8.1 General information

The "Diagram" function is a user interface for recording, loading and saving characteristic and signal curves.

Basically there are two diagram types:

• Path/speed time diagram This diagram displays the signal characteristics (speed, path, degree) over time. All curve characteristics of the calculated and actual speeds and paths (upper area) as well as all states of the input/output bits from and to the PLC on the sway control system (lower area) can be tracked (54Bild 4-17, left-hand side)

• X/Y diagram The path characteristics for two axes in the X/Y plane with displayed blocked regions can be monitored (64Bild 4-17, right-hand side).

The recorded measured values are used for both diagram types. F11 or F12 can be used to switch between the diagram types.

Path/speed time diagram X/Y diagram Fig. -4-14: Diagram function

4.4.8.2 Procedure for recording diagrams

The "F2 - Start" button is used to select which axes are affected, and which axes and parameters are to be recorded. The "View diagram" window with the "Axes", "Main values", "Input bits" and "Output bits" tabs appears.



Fig. 4-15: Diagram function, F2 - Start, Axes tab

The following settings can be made in the "Axes" tab:

• Axes – Trolley, hoisting gear, crane or slewing gear (trolley, hoist, skew) The required axes will be activated.

• Recording cycle If the recording takes a long time, the number of values to be recorded per time unit can be reduced. For a "1" setting, a value will be recorded for each sampling time (camera = 70 ms); for a "10" setting, a value will be recorded only every tenth sampling time (camera = 700 ms).

• Delete diagram The diagram will be removed.

• X/Y display This is a supporting function. To display the X/Y diagram, the "position setpoints" and "actual position values" must be recorded. They will be selected automatically when the checkbox is activated.

The recording task is starting with the "F2 - Start" or "F4 - Start trigger" button. When started with the "F4 - Start trigger" button, the recording is performed only when the crane moves, otherwise immediately and permanently. The "View diagram" window closes automatically.

The crane can now be operated so that the interesting states are visible. The recording phase can be monitored online on the screen and starts displaying the signal characteristics over time. It is, however, possible to switch to the X/Y diagram at any time. The recording is completed with the "F3 - Stop" button (next figure).



Fig. 4-16: Diagram function, completing the recording

The following window with the "Resolution" and "Time frame" tabs appears:

Fig. 4-17: Trace dialog window – "Resolution" and "Time frame"

The trace values are displayed as diagram during the "Live recording" with a sampling rate of approximately 100 ms; the digital signals are displayed independently of this accurately timed. In the background, all isochronously received data for tracing is buffered in a temporary file.

After completion of a trace, a dialog window with selectable options opens in order to reload the diagram subsequently. The user now has the possibility to select the required clock rate or, when necessary, specify a specific time interval.

The <File>+<Load last diagram…> menu item contains the same option; the dialog window also appears here. The temporary file is retained until a new trace has been started. This provides the possibility to load the most recent recording into the diagram, even after a restart of CeCOMM.

The "No longer display this window" option causes the suppression of the display of the dialog window after each stop of a trace. With the selection of the above-mentioned menu function, this option can be reactivated at any time. The option is initially always deselected after a CeCOMM restart.

To improve clarity, the number of parameters to be recorded can be restricted. This is done using the "Main values", "Input bits" and "Output bits" tabs of the "View diagram" window.

Note

Prior to the first use of the variables, the "Reloading var-traces" button must be clicked.



The following settings can be made in the "Main values" tab (next figure):

• Values to be transferred Activate all interesting parameters to be displayed as curves in the upper half.

• All ON Select all parameters.

• All OFF Select no parameter.

Fig. 4-18: Diagram function, F2 - Start, Main values tab



The following settings can be made in the "Input bits" and "Output bits" tabs:

Fig. 4-19: Diagram function, F2 - Start, Input bits tab

Fig. 4-20: Diagram function, F2 - Start, Output bits tab

• Bit signals from/to PLC Selection of the bits from and to the PLC displayed in the diagram (lower area).

• All ON Select all parameters.



• All OFF Select no parameter.

• Recording ON If this checkbox is deactivated, the recording of the bits can be completed without losing the settings of the parameters to be selected.

However, it is also possible to record all parameters first and then restrict the recording using the "F7 - View" button.

4.4.8.3 Elements and functionality of the diagram user interface

General information

The user interface displays the signal characteristics with a legend on the right-hand side in which individual or all parameters can be selected. If the user moves the mouse cursor over the curves, the current X- and Y-values will be displayed dynamically in the corners, as shown in the following figure.

Fig. 4-21: Diagram function, display elements

Because of the size relationships, the speed values and the load deflection and the curves for the path are located on the left-hand axis and right-hand axis, respectively, in the path/speed time diagram. The signals are displayed only as numeric values without unit so that the user can arbitrarily assign the curves to the axes. The default assignment of the signals to the axes and the associated unit are described in the following table.



Table 41 Description of the analog signals

Short designation Meaning 3rd axis Unit

Trolley

VSet ext. trolley Trolley set speed specified from the master controller Right mm/s

VSet int. trolley Trolley set speed using the set ramps Left mm/s

VActuator trolley Trolley speed calculated by the oscillation model Left mm/s

VActual trolley Trolley actual speed Left mm/s

Trolley model Load deflection calculated by the model (deviation of the load from the rest position)

Left mm

Trolley camera Load deflection recorded by the camera (deviation of the load from the rest position)

Left mm

SSet trolley Position setpoint, trolley Right mm

SActual trolley Actual position, trolley Right mm

SDelay trolley Position after the set delays Right mm

VDelay trolley Actuator speed after the set delays Left mm/s

P104 Trolley Variable value that depends on the setting in the Parameters menu

Right Variable

Hoisting gear

VSet ext. hoisting gear

Hoisting gear set speed specified from the master controller

Right mm/s

VSet int. hoisting gear

Hoisting gear set speed using the set ramps Left mm/s

VActuator hoisting gear

Hoisting gear speed calculated by the oscillation model Left mm/s

VActual hoisting gear

Hoisting gear actual speed Left mm/s

SSet hoisting gear Hoisting gear set position Right mm

SActual hoisting gear

Hoisting gear actual position Right mm

SDelay hoisting gear

Position after the set delays Right mm

VDelay hoisting gear

Actuator speed after the set delays Left mm/s

P104 Hoist Variable value that depends on the setting in the Parameters menu

Right Variable

Slewing gear

VSet ext. slewing gear

Slewing gear set speed specified from the master controller

Right cgr/s

VSet int. slewing gear

Slewing gear set speed using the set ramps Left cgr/s

VActuator slewing gear

Slewing gear speed calculated by the oscillation model Left cgr/s

VActual slewing Slewing gear actual speed Left cgr/s



Short designation Meaning 3rd axis Unit gear

Slewing gear model Rotation angle calculated by the model (deviation of the load from the zero point)

Left cgr

Slewing gear angle Skewing angle recorded by the camera (deviation of the load from the zero point)

Left cgr

SSet slewing gear Position setpoint, slewing gear Right cgr

SActual slewing gear

Actual position, slewing gear Right cgr

SDelay slewing gear Position after the set delays Right cgr

VDelay slewing gear Actuator speed after the set delays Left cgr/s

P104 Slewing gear Variable value that depends on the setting in the Parameters menu

Right Variable

The states of the input and output bits in the PLC are displayed with a legend on the right-hand side in the path/speed time diagram in the lower area of the diagram user interface; this diagram also allows the selection of a single parameter or all parameters.

Zoom

To provide a detailed display, areas of the diagram can be increased in size. This is done by clicking and dragging with the mouse pointer (from the top left to the bottom right - rectangular form) over the area of interest. If the original state should be restored, drag the rectangle in the opposite direction. The axes can be scrolled and zoomed.

The zoom function for the detailed view can also be used during the recording. Press the space bar to leave the zoom again. The monitoring of the recording continues.

The Zoom In and Zoom Out function is also active in the lower diagram area for displaying the states of the bits.

Ruler

The ruler can be used to permit a more exact tracing of signals (specific bit has been set how does a specific quantity behave at this time) and to determine special points.

It is activated by positioning the mouse cursor on the left-hand screen edge and while keeping the left mouse key pressed, the ruler dragged to the right.



Fig. 4-22: Ruler function – activate ruler

The X value (in the example, 15.02 seconds) of the ruler is now displayed on the left-hand side below the diagram.

The ruler is fixed by pressing the space bar. The first ruler has now been defined; the second ruler that now appears can be moved with the mouse cursor to the required position.

Pressing the CTRL + left mouse key causes the X value of the second point and the difference between the first and the second point to be displayed (see figure below).



Fig. 4-23: Ruler function – second ruler

To deactivate the ruler function again, move the mouse cursor back to the left-hand edge and press the left mouse key.

Longtime tracing

For diagnostic purposes, this function can be used to perform a longtime trace, e.g. over several hours or several days. The function is activated by setting the "Longtime trace" checkbox on the Axes tab (F2 Start Axes Longtime trace).

The trace can be started once all settings have been made (F2-Start). The following screen appears:

Fig. 4-24: Longtime trace active



The laptop screen can be closed. Screensavers also do not interrupt the trace.

Every half hour, a file together with date and time is saved automatically in the "LongTraces" directory.

These files can now be loaded and evaluated. To do this, select "File" "Load longtime trace".

Fig. 4-25: Loading the longtime trace



A file (*.dat format) from the "LongTraces" directory can be evaluated in the following dialog.

Icons

Symbol Short designation Description

Grid lines

A new window appears in which the axes for which the grid lines are to be drawn can be selected (default: time axis).

Measuring points

In the analog curves, all actual measuring points are indicated with a small icon. This makes it possible to check which measuring points produced the curve.

Delete curves

Delete the diagram. If individual elements of the display are to be removed again, this can be realized by deactivating the appropriate checkbox in the legend on the right-hand side.

Start Select which axes and parameters should be traced and

start the trace task.

Stop Stop the trace.

Load file

Load existing "*.dgr" diagram file.

Save file

Save the diagram content (data) in a "*.dgr file".

Print

Print the diagram after selecting the printer and the print preview.

View

Select the displayed parameters and change the characteristics.

Properties

Change the characteristics of the diagram, such as the designation of all parameters and axes, limits and colors.

Help

Function description of the keys for scrolling and zooming in the diagram display.

The icons for operating the X/Y diagram are explained in Section 644.4.9.4.

The functions of selected icons are described in detail in the following sections.



Print, print preview – F6 (Print)

The diagram can be printed using the "F6 - Print" button. After selecting the printer and the printer settings, a print preview appears when the "OK" button is pressed to confirm (following figure). Various details (e.g. print with/without legend) can be set in this print preview. Zooming with the mouse is also possible.

Fig. 4-26: Print, print preview function



View – F7

Pressing the "F7 - View" button opens the "Display measurement series" window (following figure) with the "General" and "Bit signals" tabs that are used to select the displayed parameters and to change the characteristics (color, title, line type and line thickness). A selected parameter can be placed on the left-hand axis or on the right-hand axis. The direction arrow keys (up or down) can be used to change the order of the display.

Fig. 4-27: Diagram function, F7 - View, General tab



Properties – F8

The "F8 - Properties" button can be used to set and change the designation of all parameters and the axes. The limits and the colors can be specified for the background and for individual elements of the diagram.

Fig. 4-28: Diagram function, F8 - Properties, Analog Values tab

Note

For all changed properties (F8), the properties of the diagram will be saved automatically in the DiagXXX.ini or DiagXXX_engl.ini file in the program directory or the currently set directory and file name.

Help – F1

Pressing the "F1 - Help" button opens another window that contains all keyboard commands for scrolling and zooming in the diagram display.

Fig. 4-29: Diagram function, Help



4.4.8.4 X/Y diagram

One of the two buttons can be used to change to the X/Y diagram (next figure). This diagram shows the travel curve for two axes in the X/Y plane, where one axis represents the movement of the trolley and the other axis the path of the hoisting gear. When one of the other buttons (F11 or F12) is pressed, the axes will be interchanged. Activating the same button again changes to the path/speed time diagram.

Fig. 4-30: Diagram function, X/Y representation with blocked regions

The calculated and the actually travelled curve are displayed. The following icons can be used to display additional information.

Icons

Symbol Short designation Description

Interpolation points

Add the curve with the interpolation points used as basis for calculating the travel curve.

Blocked regions

Display all blocked regions (fixed and variable). If the "Cyclical refresh" option is selected, the internally learnt variable blocked regions on the waterside will be updated continually during the crane travel.

Note

The curves drawn in the diagram are always relative to the lower edge of the spreader.



Note

When the spreader is locked with a container, all blocked regions are increased by the value in parameter P108 (maximum container height in mm). If a container is removed , i.e. when both bits "Container locked bit 0 and bit 1" are reset, the blocked region reduces again by this value.

Note

The zero line is drawn at the minimum position for the hoisting gear positioning (P63).

4.4.9 Web server

An integrated Web server can be used to display camera images (only SIMOCRANE CenSOR). In addition, the system time can be set and the diagnostic buffer read.

4.4.10 Telnet

The connection to the camera (only SIMOCRANE CenSOR) can also be established using Telnet. In this case, a connection to the Shell will be established using the Ethernet connection. The Shell is part of the operating system on the camera and permits the interpretation of the entered commands, such as display directories. The Shell is always started automatically.

4.4.11 Effective pendulum length parameters

This tool ("Effective pendulum length" tab) corresponds to the commissioning step 2 of the sway control system and is envisaged for the commissioning of "dummy systems", e.g. to a GSU. Note that the counting at one of the two reversal points begins with 0 (0,1…10).

In two different hoisting heights, the associated effective pendulum lengths are measured, from the known relationship between pendulum length and period duration. Assuming a linear relationship, these two value pairs can be used to establish the relationship between the hoisting height and the effective pendulum length.

It is recommended to be connected online with the system. The values for the two hoisting heights then no longer need to be entered manually and the result, the two parameters, resolution and offset, for calculating the effective pendulum length, can then be transferred to the system. The offline values obviously need to be entered manually.

The effective pendulum length represents a significant quantity for the functionality of the sway control system. The tool can also be used to subsequently check the pendulum length fast and easily. The displayed pendulum length (row 4 in the table) should generally match that currently displayed in screen 1 of the monitor.

Note

Smaller amplitudes suffice, it is only important that the reversal points are still easily recognizable.

Commissioning Software 4.5 Commissioning requirements for AddOn systems


The individual steps in the table are self-explanatory and closed with "F5 - Send values" (following figure). The P60 and P61 parameters are set during the calibration of the hoisting height – trolley. During the calibration of the hoisting height – skew, the P89, P90 (20 ft), P91, P92 (30 ft) or P93, P94 (40 ft) parameters are changed depending on the spreader length.

The integrated stopwatch can also be used individually with "F2 - Start" and "F2 - Stop".

Fig. -4-31: Parameters for determining the effective pendulum length function

4.5 Commissioning requirements for AddOn systems

4.5.1 General requirements, overview

The drive system and all safety functions of the crane, especially switch-off at limit, safety interlocks, EMERGENCY STOP functions and the load monitoring must be commissioned and functional.



DANGER

The commissioning and testing of the Sway Control functions may only be performed by trained personnel who are familiar with the operation of the crane. The regulations of the crane operator must be observed. A further requirement is the successful participation in a commissioning training course held by Siemens AG.

DANGER

All safety functions of the crane must be implemented independently of the sway control system. Measures must be taken to ensure that the crane stops without any adverse affects on persons or goods when a fault occurs.

WARNING

The PLC programmer is required to evaluate the error messages of the sway control system. In a fault situation, the manipulated values of the sway control system may no longer be used. Only the higher-level controller may implement the control of the drives.

The following requirements for the commissioning of the sway control system must be satisfied:

1. All the drives to be controlled and the hoisting gear must be functional

2. All components of the system must be installed, connected, functional and interconnected

3. Preparation of the PLC program (Section 4.5.2)

4. Preparation of the converters (Section 4.5.3)

5. Start of the diagnostic program and establish the connection between the commissioning PC and the sway control system (Section 64.4.4)

6. Setting of the language of the diagnostic program (Section 4.5.5) and the access code (Section 4.5.4)

7. Checking of the communication between the PLC and the sway control system (Section 4.5.6)

4.5.2 Preparing the PLC program

The PLC program must be prepared so that all signals are provided for the sway control system and all output data is processed further (Chapter 3).

Note

The error bits must be evaluated in all circumstances in order to detect malfunctions and to be able to respond appropriately.

4.5.3 Preparing the converters

Converter parameter sets

The converters should have their own parameter set for the sway control function.



The setpoint is supplied continuously by the sway control system. The parameters are set as described in the following sections.

Acceleration and deceleration ramps

The internal converter acceleration and deceleration ramps should be set to approx. 1 s (50 Hz/s).

WARNING

Acceleration and deceleration ramps that are too slow can cause swaying motions!

WARNING

The sway control system can briefly calculate higher accelerations and decelerations than those that occur in normal travel operation – especially when neutralizing large swaying movements.

Initial and final rounding

As the speed characteristic is defined by the sway control system, initial and final rounding functions should be deactivated.

WARNING

Excessive roundings in the converter can cause swaying motions!

Minimum frequency of the converters

In order to be able to eliminate small swaying motions after stopping, the minimum frequency of the converter must be set to 1 Hz or lower.

WARNING

If the minimum frequency is too large, the residual swaying motions may be relatively large and the crane will not or only rarely come to rest!

Speed controller of the converter

The internal speed control of the converter can be activated in order to achieve the best possible control response. In addition to the proportional component, an adequate integral component should also be set. Good results have been achieved for the SIMOVERT MASTERDRIVES with kP = 3..5 and Tn ≤ 200.

Limitation of the speed control signal

Note

Limitations of the actuating signal (e.g. in the converter) can result in the tripping of the following error and therefore should only be intended for safety reasons.

The following error is the path difference between the calculated curve and the curve actually travelled (= set-actual deviation).



4.5.4 Setting the access code

The access code sets the user level and determines the visibility of the individual parameters. The access code is stored in parameter P100.

Note

Only those parameters are displayed that correspond to the setting of parameter P100 (= access code).

Parameter P100 (= access code) should be set to 2 for the commissioning.

The following settings are available:

Access code 0 – crane operators, maintenance staff

Access code 1 – commissioning engineers

Access code 2 – service technicians and specially trained commissioning personnel

Access code 3 – development engineers

The message "No authorization!" appears when an attempt is made to change a parameter that does not correspond to the access code.

4.5.5 Setting the language

The language of the diagnostic program is set via the menu "Options/Language" and saved under parameter P110. German and English are available.

Alternatively the language parameter P110 can be changed via the Parameters menu. The appropriate language file is then automatically opened and read. The screen displays are refreshed, although only the function region in the newly selected language is shown.

4.5.6 Checking of the communication between PLC and SIMOTION

The communication between the PLC and SIMOTION must be checked first. This includes the principle data exchange and the use of the correct data formats and contents.

The CeCOMM program can display various diagnostic screens that allow the communication to be checked. The "PROFIBUS interface" display screen is called from the main menu or another display screen with the "2" key.



Fig. 4-32: Monitor function, "PROFIBUS – Interface" display screen

The current input and output data of the sway control system are shown on this display screen. The data must first be checked for correctness.

Note

The values of the Trolley and Hoist axes are output in mm and the skew in cgr (hundredth's of a degree).

The "State of drive axis" display screen is called with the "3" key (following figure). The command and status bits are displayed here. They should also be checked for correct assignment before the next commissioning step is taken. The color differences in the display of the actual values show which values or states are OK or active (green).

Note

Red display indicates an error or stop in the system, "Not released", "Stop", "Off", etc.

Commissioning Software 4.6 Sway control commissioning


Fig. 4-33: Monitor function, "Status of travel axes" display screen

4.6 Sway control commissioning When all the requirements (Section 654.6) have been satisfied, you can start with the commissioning.

The commissioning of the camera measuring system is performed by setting parameters with the CeCOMM diagnostic program (notes, see Section 654.3).

4.6.1 Functionality of Sway Control

Functionality and characteristics

The sway control system determines the swing angle with the aid of a camera measuring system. The pendulum angle and the distance are used to calculate the load deflection. The reliability of the measuring signal is checked with various algorithms and, if required, corrected. If the measuring signal fails, a mathematical oscillation model is used for the current states.

http://www.siemens.com/motioncontrol/doku



CAUTION

The acceleration and deceleration ramps can vary greatly. They depend on the initial swaying and the pendulum length.

Generally, the sway control system has the following characteristics:

• The oscillation of the load has been eliminated when the stationary speed or standstill is reached

• In positioning functionality, the load only overshoots the target position by a very small amount

The sway control system is configured using parameters (Section 654.3) and can be controlled with the PLC by setting various control bits.

The sway control system calculates speed control values that are forwarded to the drives by the PLC.

Sway control algorithms

As sway control algorithm, the parameter P152 (trolley) can be used either for

• Conventional state feedback or

• Time-optimized control.

The conventional state feedback produces an aperiodic characteristic for the swing angle. The acceleration ramp is smoothed. The acceleration times are approx 1.1 times the natural oscillation duration of the load oscillation. The travel operations are performed with low stressing of the entire crane structure.

The time-optimized control is based on the "Theory of the optimal control". Short deceleration ramps are inserted in the acceleration operation and short acceleration ramps inserted in the deceleration operation. This achieves the quickest possible suppression of a swaying motion. The acceleration and deceleration times depend on the available drive power. The time restrictions of the conventional state feedback do not apply.

Note

The time-optimized control is not appropriate for STS cranes.

Dynamic prelimit switch

Dynamic prelimit switches improve the travel behavior of the crane at the outer position areas.

In contrast to fixed prelimit switches, the axes are braked at various positions. This position depends on the current axis speed. This means an axis traveling at low speed can be braked much later in order to reach the prelimit switch speed at the positions (P24, P27, P64, P68) specified by parameters.

The following figures use two different speeds to illustrate the functionality of the dynamic prelimit switches:

P115: 1 (dynamic limit switches active) P24: 95000 mm (position for trolley PLS speed backwards) P27: 6000 mm (position for trolley PLS speed forwards) P0: 3500 mm/s (maximum actuator speed of the trolley)



Fig. 4-34: Trolley behavior with dynamic prelimit switches at full speed

Fig. 4-35: Trolley behavior with dynamic prelimit switches at half-speed

The figures show clearly the different braking points depending on the speed. For fixed prelimit switches, this point is always at the same trolley position (P115<1).

Although the behavior is similar for hoisting gear (P64, P68), the behavior on the landside and the waterside differ. On the waterside, the lower dynamic prelimit switch does not act in order to allow the immersion in the ship's hold. In this case, the higher-level controller must ensure that no damage can occur to the crane or the ship.

CAUTION

If P115 < 1, ensure that the correct operation of the prelimit switches is guaranteed.

For more details, the behavior of the dynamic prelimit switches in the following figures in comparison with the behavior of fixed prelimit switches is explained:

Behavior for P6 (trolley acceleration setpoint) < P7 (acceleration without sway control / minimum acceleration) and



P115=0

Fig. 4-36: Behavior P6 < P7 for P115 = 0

The crane moves with 50% of the maximum speed to the prelimit switch. The maximum speed is shown white; the actuator speed is shown blue. Two things occur when the prelimit switch is reached:

The trolley is braked to the PLS speed. P6 is used as calculation basis (green curve). The sway control function acts.

The maximum permitted speed is reduced with P7.

If the blue curve (actuator speed) intersects the white curve, it will be limited to its value. It may, however, lie below. If it is desirable to reverse the travel direction in order to counter the sway (the blue curve undershoots the pink curve), the complete maximum speed is temporarily permitted.

(NOTICE! The diagrams have an accuracy of only approx. 100 ms)



Behavior for P6>P7 and P115=0

Fig. 4-37: Behavior P6 > P7 for P115 = 0

In this case, the limitation does not disturb because the ramp is very flat. This allows the effect of the sway control to be seen very accurately. Should the PLS speed be undershot by the actuator speed, the limit value must be reduced immediately because an acceleration above the PLS speed is prohibited.

The fixed prelimit switches are completely independent of the path measuring system and function even when the encoders do not operate reliably or even do not exist. This is often the standard procedure, in particular, for industrial cranes.



Behavior for P115=1

Fig. 4-38: Behavior for P115 = 1

The trolley may continue to run with the speed setpoint. Because the maximum speed is limited to a parameterized position that depends on the distance, this results in the square-root function.

The positions for the prelimit speed (P24, P27) must be set so they lie before the limit switch position or exactly at the limit switch position. This ensures that the trolley drive was braked to the prelimit switch speed when the limit switch is reached.

Because a crane driver does not normally travel to the limit switch without reason, but rather in the extreme case approaches a position near the limit switch, as in the normal travel region, would release or reduce the master controller before reaching the target. This means the crane driver does not notice the dynamic PLS unless the target is very near the limit switch and the crane driver misses the correct moment. In this case, it is limited only when the last possible point is reached. It is, however, possible also in this case to detect that the sway control remains active and the sway caught provided the associated required movement does not violate the limitation (for approx. 28-29 seconds).

Note

If the delay to PLS speed should be sway controlled it is necessary to reduce the setpoint in the PLC.



4.6.2 Commissioning of the sway control system

4.6.2.1 Commissioning steps in the Commissioning menu

Next, the commissioning steps in the Commissioning menu must be performed. This menu is called via the "I" key from the main menu or the display screens (following figure).

Fig. 4-39: Monitor function, Commissioning menu

The commissioning process must be started with the first step and continued step-by-step.

Some parameters of the active parameter set are set automatically in these steps.

WARNING

For this reason, the active parameter set may not be changed during the commissioning.

The successful completion of a commissioning step is identified by a "+". After the commissioning steps have been performed successfully, it is no longer necessary to set these parameters manually.



Note

Individual steps can be omitted depending on the configuration.

Note

The sway control must be switched off during commissioning steps 1 to 3. This is implemented internally and temporarily triggers the error E61.

Setting the configuration and important parameters (commissioning step 0)

In this commissioning step, some of the required parameters are successively called automatically and must be set correctly.

1) P102 Configuration

2) P103 Normalization value

3) P83 Upper limit for sway control

4) P84 Lower limit for sway control

5) P0 Maximum actuator speed, trolley

6) P2 Prelimit switch speed, trolley

7) P7 Acceleration without sway-control / minimum acceleration

8) P6 Set acceleration, trolley

9) P5 Maximum acceleration, trolley

10) P1 Positioning speed, trolley

11) P23 Minimum position for positioning, trolley

12) P28 Maximum position for positioning, trolley

13) P40 Maximum actuator speed, hoisting gear

14) P43 Prelimit switch speed, hoisting gear

15) P51 Set acceleration, hoisting gear

16) P50 Maximum acceleration, hoisting gear

17) P41 Positioning speed, hoisting gear

18) P63 Minimum position for positioning, hoisting gear

19) P69 Maximum position for positioning, hoisting gear



The following figure provides an overview of the use of the speed and acceleration parameters.

Fig. 4-40: Overview of speed control



Set the alignment of the camera (commissioning step 1).

In this commissioning step, the assignment of the directions of motion to the camera orientation is determined and the result saved in parameter P120.

The following basis must be provided prior to the commissioning step:

- Rectify initial oscillation beforehand

- Reflector must always lie within line-of-sight

Note

After starting the commissioning step, the trolley should then be moved when the load is steady. If the SC system causes a swaying motion, this step must be checked.

The diagnostics record the main direction of sway and the sign of the beginning deflection. The assignment of the trolley direction to the camera x or y direction and its sign are determined from this information.

The result can be saved when the sway control is only to be activated for the trolley direction. Otherwise the crane has to be moved so that the sign of the deflection in the crane direction can be determined.



Determining the parameters for calibration of the effective pendulum length (commissioning step 2) Note

Only systems with a camera can perform this automatic commissioning step. For systems without a camera, this step must be performed manually with the tool on the "Effective pendulum length" tab.

Fig. 4-41: Determining the effective pendulum length parameters - TROLLEY (commissioning step 2)

The following options can be selected for this commissioning step:

0 – Reset P80, P81 Parameters P80 and P81 are set to 0 and therefore have no effect.

1 – Basic calibration It is essential that this basic calibration step be performed. Swaying motions are initiated at two different heights. From the swaying measurements, the gain and offset are determined for the conversion of the transmitted hoisting height to an effective pendulum length with correct sign and absolute value. The result is entered in parameters P60 and P61.

This automatic commissioning step was successful when the swaying duration indicated in the tool is roughly identical in each cycle. If this is not the case, the step can be performed manually with the tool on the "Effective pendulum length" tab.

Not the calibrated hoisting height, but the hoisting height taken from the interface is used for the control and positioning of the hoisting gear. This must have increasing values with the increasing height of the load carrying device above the ground.



2 – Dig. hoisting dist. corr. This step is optional. Shifts in the center of gravity that result from the use of different load carrying devices are compensated with the digital effective pendulum length correction. Parameter P80 is written.

3 – Anal. hoisting dist. corr. Note

Before performing step 3, the weight of the load carrying device must be determined and stored in parameter P82.

This step is optional. With the analog effective pendulum length correction, shifts in the center of gravity that result from the load weight can be taken into account. Parameter P81 is written.

Note

In most cases it is sufficient to perform the basic calibration. After being performed successfully, this commissioning step is displayed in green, although the digital and the analog "effective pendulum length correction" have not yet been performed. These steps are optional.

Determining the effective pendulum length parameters - SKEW (commissioning step 3) Note

Only systems with a camera (P102) and activated TLS (P197) can perform this automatic commissioning step.

When the hoisting height is calibrated, the gain and offset are determined for the conversion of the transmitted hoisting height to an effective pendulum length with correct sign and absolute value.

The calibration is performed with two sway measurements at different heights.

A swaying motion must be induced at different heights. The associated effective pendulum lengths and conversion parameters are determined from these motions. Depending on the spreader length, the result is entered in the P89, P90 (20 ft), P91, P92 (30 ft) or P93, P94 (40 ft) parameters.

This commissioning step must be performed separately for each present spreader length. The SPREADER_BIT0 and SPREADER_BIT1 input bits must be set appropriately before the start of the following steps.

2. Move spreader to 20 ft. Perform commissioning step 3. Parameters P89 and P90 are determined.

3. Retract spreader to 30 ft. Perform commissioning step 3. Parameters P91 and P92 are determined.

4. Retract spreader to 40 ft or 45 ft. Perform commissioning step 3. Parameters P93 and P94 (no separate parameters are available for 40 ft or 45 ft) are determined.

This automatic commissioning step was successful when the swaying duration indicated in the tool is roughly identical in each cycle. If this is not the case, the step can be performed manually with the tool on the "Effective pendulum length" tab.

Simulating errors (commissioning step 4)

All error bits of the sway control system can be simulated in this step in order to check the analysis of errors in the PLC.



Determine speed limit (commissioning step 5)

The speed limit can be set automatically in this step when the current actual position value is transferred with the PLC data.

The axes should be moved individually and steadily with constant speed in the BOM Speed Control. If the axis moves with constant speed, this should be confirmed by pressing <ENTER> twice. The maximum actual speed, i.e. the speed limit, produced at the maximum actuating signal is determined from the maximum actuator speed output on the converter and the measured actual speed value.

The determined speed limit can be taken over in the respective parameter (P0 for the trolley or P40 for the hoisting gear) as well as the resulting positioning speed (P1 (trolley) and P41 (hoisting gear)).

Communications addresses (commissioning step 6)

Each device must have its own IP address for communication in the Ethernet network.

NOTICE

The IP address for a device may only be used once within a network.

For the communication between the components, the IP address of the camera must be made known to the SIMOTION. The camera is delivered with a predefined IP address.

For commissioning step 6 "Communications addresses", depending on the deployed hardware and after use of a camera, it is possible to choose between:

• UDP (IP address and port of the camera)

• PROFINET (camera system supports this protocol)

• SIMOTION (IP address, subnet mask, PB address)

The following table shows the associated options for hardware – camera – combinations and the associated selection possibility.

Table 42 Communications addresses selection possibilities

SIMOTION C

With camera Without camera

1 – UDP

2 – PROFINET

3 – SIMOTION

1 – SIMOTION

NOTICE

For the initial commissioning, the SIMOTION (3) must be given the required DP address - even when the default address should be retained.

If the addresses should be changed again later, this can be done after calling the Parameters menu with the "P" key and calling the "I" function (communications addresses).

Saving parameters (commissioning step 7)

All parameter sets are saved.

The commissioning parameters can be copied to the other parameter sets in the Parameters menu.



4.6.2.2 Checking and fine adjustment of the sway control system

The following parameters can be set manually from the Parameters menu of the diagnostic program:

Selection of the control method

The control method (conventional or time-optimized control) is selected via parameter P152.

With the conventional control, the travel behavior is smooth and comfortable for the crane driver. Precise positioning is possible. There is a noticeable counter-response (greater deceleration when the opposite travel direction is specified) with different values for set and maximum acceleration.

If time-optimized control is selected, the drive accelerates and decelerates with set acceleration to the set speed. The deceleration sections integrated in the acceleration operations can be uncomfortable for the crane driver. The time-optimized control algorithms use search algorithms that require a lot of computation time.

Note

The time-optimized control is not appropriate for STS cranes.

Compensating load carrying devices

If different load carrying devices are used, this information must be passed to the control software as the center of gravity and/or the pendulum length changes.

If not already performed semi-automatically in commissioning step 2, the adaptation to the load conditions is performed with the following parameters:

P80 Digital effective pendulum length correction Shifts in the center of gravity that result from the use of different load carrying devices are compensated

P81 Analog effective pendulum length correction Shifts in the center of gravity that result from the load mass are taken into account

P82 Weight of the load carrying device

The effective pendulum length is corrected. It is calculated as follows:

Correction eff. pendulum length = analog correction eff. pendulum length+ digital correction eff. pendulum length

Analog effective pendulum length correction

The value in parameter P81 for the analog effective pendulum length correction acts only when the load (iLoad on DCC_SCCommon) is greater than the weight of the load carrying device (P82). In this case, the value for the load in screen 2 (PROFIBUS interface) of the diagnostic tool is displayed in green, otherwise in red.

Analog correction eff. pendulum length = (load – P82) x P81 |if (load - P82) > 0, otherwise = 0

Digital correction eff. pendulum length

If digital effective pendulum length correction is to be used, the offset must be entered in parameter P80. The command for use is made with the command bit "DigitalLiftCorrection" (bit 18; General command bits). In this case, the value for the load in screen 2 (PROFIBUS interface) of the diagnostic tool is displayed bold.



Digital correction eff. pendulum length = P80 |if DigitalLiftCorrection = 1; otherwise = 0

The following figure provides an overview of the internal processes used to determine the distances for the oscillation model and the camera calibration.

Fig. 4-42: Effective pendulum length correction

Setting the permissible residual sway

The parameters for the residual sway (P169, P170) should only be set as small as required. Values that are too low can result in oscillation after stopping because of dead times.

Setting the gain factor

A gain factor (P85, P86) can be set for the trolley, separately for the acceleration and deceleration phase. Values greater than 1.4 result in aperiodic transient responses, values less than 1.4 to overshoot. Gain factors in the range from 1 to 1.2 represent a compromise between short rise time and slight overshoot. The difference between the gain factors for acceleration and deceleration should not be too large, as the control signal can otherwise change abruptly during the transition to the deceleration phase.



Defining the minimum speed and minimum time

The sway control function is activated only when the activation speed (P146) and sway control switch-on delay (P147) are reached. It is recommended that both parameters be left at zero.

For the activation speed, a hysteresis of ± 5% acts to prevent a continuous connection and disconnection of the sway control system.

Setting the starting delay of the drives

For each axis (P149, P150), the switch-on delay of the frequency converter after releasing the brake can be set.

4.6.3 Commissioning of the positioning

4.6.3.1 Changing the coordinate system

If an automatic positioning is to be commissioned and also the coordinate system of the trolley changed, the position values must be calibrated.

In the "Calculations" window of the "CeCOMM" diagnostic program, two position values of the previous coordinate system and the two associated position values of the new coordinate system must be entered as "Measured value" and in the "Position value" column, respectively.

Fig. 4-43: Calibration of the position values for the trolley

"Calculate" determines the resolution (factor) and the offset for the trolley position sensor; these values must be entered in the P20 and P21 parameters.

4.6.3.2 Position controller setting

The position controllers must be set as shown in the following sequence:

Set position controller (P160, P163) to zero and start the positioning over a longer distance

The setpoint and target positions must be virtually identical at the end. Slight differences result through the deactivated position controller.

Greater deviations might be caused by a maximum control speed error or limits in the drive system. (For localisation of the error, the sway control function can be deactivated by setting the damping factors to zero - only possible with conventional control.)



Set position controller (P160, P163) and gain factors (P85, P86) to default values

All controllers must be set to have a small overshoot. This affects both the speed and the target position. This achieves short rise times.

The value of the position controller should not be greater than 0.5.

The value must be reduced when connection of the speed controller causes an oscillating speed curve and an overshoot at the target position.

Note

An overshoot at the target position often results not from a large position controller value but rather from an incorrectly set limit speed. Consequently, before reducing the position controller value, in controlled operation (position controller is zero or manual operation), a recheck should be made whether for travel at constant speed, the actual speed is nearly equal to the set speed.

The control method can use negative position controller values to switch to target control. In this case, the positioning operation also uses the speed control without position control. The travel curves correspond to those for manual operation. The target control determines only the begin and the exact course of the braking phase. A recommended value for the position controller is -0.7.

The set speed sakv SR Δ⋅⋅⋅= 2 for the target control is determined from the size of the position

control value Rk , the deceleration Sa and the distance from the target sΔ .

A value of -0.7 specifies the time of the beginning the braking so that deceleration is made with 70% of the set acceleration. During the braking phase, the target control has a control reserve of 30%, because the deceleration can be increased to 100% Sa .

4.6.3.3 On-the-fly unloading

The following setting of parameter P152 "Conventional/time-optimized control, trolley" is recommended for on-the-fly unloading:

Table 4-3: P152 setting for on-the-fly unloading

Selection Short designation On-the-fly unloading with const. deflection

On-the-fly unloading with max. deflection

1 Time-optimized control only for BOM Speed Control

OFF OFF

2 Time-optimized control only for automatic control

ON ON

3 On-the-fly unloading permitted ON ON

4 On-the-fly unloading with max. deflection OFF ON

5 Time-optimized control only for stopping OFF OFF

Generally, on-the-fly unloading is only used together with an automatic control (selection 2 = ON).



Selection 3 must always be on for on-the-fly unloading. In this case, the load deflection during travel towards the land and back again remains constant. If the load deviation is not to be constant, but maximum at the time of unloading, then selection 4 must also be switched on. This means:

Selection 3 = ON and 4 = OFF causes a constant load deflection

Selection 3 = ON and 4 = ON causes a maximum load deflection

If the time-optimized control is switched on for one or all basic operation modes (selection 1, 2 or 1 or 2), this behavior of the time-optimum control can be restricted to the stopping procedure (selection 5 = ON).

P152 setting 5 "automatically" satisfies all supplementary conditions:

• The function does not act in manual operation

• The function does not act when "on-the-fly" is selected

This means: Travel is made in the land direction and sway control is activated. For switching over the hopper, "on-the-fly" (FLYING bit) must be deactivated. This causes the setting to start acting. The sway control is "suspended" and is reactivated only for braking. This catches fewer oscillations but some time may be saved.

4.6.3.4 Other settings

The following parameters can be set manually:

Positioning range

The permissible positioning range can be set with the parameters "Minimum position" (P23, P63) and "Maximum position" (P28, P69). The values should be set halfway between the prelimit switch and the limit switch (6following figure). It is not possible to position loads outside these limits.

Fig. -4-44: Permissible positioning range

If a drive axis of the crane enters the range between prelimit switch and limit switch, the axis is braked with at least the ramp with which the crane would brake without sway control (P7).

In the "positioning" mode, error E35 "Starting point in an invalid region" is considered only with regard to the travel movement of the associated axis. When the error is present in the "hoist control" mode, no travel job will be generated for the hoisting gear and trolley axes. In the "positioning" mode, a travel job will be generated for the axis that does not have this error.

Positioning accuracy (P162, P165, P190)

The set positioning accuracy should be as small as necessary and only affects the "Positioning complete" message. Positioning continues while the basic operation mode and the travel signal remain set.

This applies only to position control. The target control brings the axis to the target only with the set accuracy. This means no (further) controlling is performed because the position control is not activated.

In the BOM Hoist Control, the positioning accuracy also affects the status of the direction signals (Travel_F, Travel_B). When during the travel, a single axis for a interpolation point of the trajectory satisfies, the conditions for the "Positioning complete" status bit, it will not be set, but rather the



direction signals of the axis go to 0. In the BOM Hoist control, the "Positioning complete" bits are set concurrently for both axes only when the target position is reached.

Following error (P161, P164)

The following error is the difference between the calculated and the actual position and, when exceeded, initiates a fault.

4.6.4 Commissioning of the hoist control

WARNING

Prerequisite for the commissioning of the hoist control is the successful commissioning of the Sway Control and positioning functions.

In this basic operation mode, the spreader/grab moves on the path curve taking account of blocked regions.

The PLC program must be prepared so that external variable blocked regions can be transferred and/or the learning of the height profile is activated (Chapter 3).

All blocked regions (fixed and variable) are displayed in the diagnostic program, function diagram in the x/y representation.

Defining the limit curve parameters

The clearances to the blocked region can be set as parameters. If a double spreader is used, the width of the blocked region increases in the landside direction. The following figure provides an overview of the effect of the various parameters. Note

When the spreader is locked with a container, all blocked regions are increased by the value in parameter P108 (maximum container height in mm). If a container is removed , i.e. when both bits "Container locked bit 0 and bit 1" are reset, the blocked region reduces again by this value.



Width of obstacles

Travel clearance (P71 / P32)

Hoisting gear offset to the spreader (P107)

Safety clearance hoist (P72)

Calculated travel curve / interpolation points

Safety clearance trolley (P33)

Half spreader width(P106/2)

Safety clearance trolley (P33)

shown blocked regionin CeCOMM, tab „Diagram“

Single spreader Half spreader width (P106/2)

Coupled double spreader Overall width of double spreader (DCC block Common) - Half spreader width (P106/2) Fig. 4-45: Function of the limit curve parameters

Collision protection

A collision protection is activated in the software in the BOM Hoist Control. Based on the current container crane position, it is determined how far the spreader is from a possible obstacle. If this is approached too closely, there is an external reaction via the actuating signals (Section 654.9.4).

Override

The travel speed can be reduced in all basic operation modes using an externally definable override between 0% and 100%.

The speed acceleration occurs with set acceleration for both the hoisting gear (P51) and the trolley drive (P6).

The override acts as limit and can be specified separately for each axis and therefore used, for example, for the software-controlled prelimit switches.

In the BOM Speed Control, the override refers to the maximum speeds P0 (trolley) and P40 (hoisting gear), in the BOM Positioning and BOM Hoist Control it refers to the positioning speed P1 (trolley) and P41 (hoisting gear).

Commissioning Software 4.7 2D-Trajectory commissioning


Laser

The laser values in the "Hoist Control [6]" screen of the CeCOMM commissioning tools (Section 654.4.6.1) should be checked.

Note

Ensure that the laser scanner is refreshed as fast as possible (Laser Freq. ≤ 3) so that the values can be used for calculating the travel curve.

Conditions for validity of the laser values:

• Laser frequency ≤ 3 A valid value comes from the laser scanner at least every three cycles of the SIMOTION

• Position difference of the trolley (distance) between two measured values < 50 cm

If the conditions are not satisfied, the values from the laser and the distance will be ignored. Should the values become invalid, they will be displayed RED, otherwise GREEN.

4.7 2D-Trajectory commissioning Learning the parking position, lashing platform and lanes

The Parking position is learnt by the crane driver traveling to the position and setting the "StoreParkposition" bit (bit 24, General command bits) for learning the position from a control element.

The Parking position is learnt by the crane driver traveling to the position and setting the "StoreIntermediateStop" bit (bit 25, General command bits) for learning the position from a control element.

The Lane positions are also learnt by traveling to the position to be learnt. The "StoreCurrentPosition" value causes the lane number to be assigned to the current position and stored.

The learnt "parking position", "position of the lashing platform" and "position of the lanes" position will be stored in the "TargetPos.txt" file in the /SWAYCONTROL/ directory on the SIMOTION.

Deleting the parking position, lashing platform and lanes

The saved parking position, the position of the lashing platform and the position of the lanes can be removed by deleting the "Zielpos.txt" file in the /SWAYCONTROL/ directory on the SIMOTION. A new file is created when one of these positions is learnt again.

If, for example, only the position of a lane should be deleted, the appropriate row can be deleted with a simple editor (e.g. Notepad). Although the lane is then no longer present in the "Zielpos.txt" file, it remains active in the function until the SIMOTION CPU is restarted (e.g. by with Power OFF and ON). Only then do the changes made to the "Zielpos.txt" file take effect.

Commissioning Software 4.8 TLS Control commissioning


NOTICE

If the "Zielpos.txt" file is edited incorrectly, positioning faults can occur.

Twistlock simulation

Simulation of the loads is possible with the "CeCOMM" diagnostic program. It is used during the commissioning of the hoisting gear to test the correct functioning of the automatic mode.

Pressing the "x" key in all display screens simulates the locking of a container and when pressed again, the unlocking.

The twistlock simulation can be activated only when both lock bits (LOCKED_BIT0 and LOCKED_BIT1) have been reset, i.e. when no real container is locked on the spreader.

WARNING

If twistlock simulation is used, travel must be performed at an adequate height (> max. container height P108) above the obstacles that actually exist. Otherwise collisions can occur during automatic operation.

4.8 TLS Control commissioning Activating TLS Control

All available functions can be activated with the parameter "Use trim/list/skew control" (P197). This calls up the input and output functions and the test commands are available.

Use of the "Trim / List / Skew [7]" display screen on the diagnostic tool for commissioning

This display screen is used for the commissioning and diagnosis of the TLS functions. Input and output signals can be monitored and single TLS commands can be tested.

The display value “Angle” in this screen is the skew angle measured by the camera.



Fig. 4-46: Monitor function, "Trim / List / Skew [7]" display screen



Assignment of the cylinders

The cylinders are designated A, B, C, D and assigned as follows:

A – landside, left

B – waterside, left

C – waterside, right

D – landside, right

The assignment of the positions and output speed is made in the PLC.

Cylinder positions

The positions of the individual cylinders must be set with the parameter "Gain for the TLS cylinder positions" (P187) in such a way that when turning by approx. 1° an offset of 100 mm (50 mm on each side) is measured.

The absolute position is not important at first. A position is saved as zero position for each cylinder (P200 - P203) and all positions in "mm" are then always positions relative to the stored zero position.

The minimum and maximum cylinder positions (P188, P189) also always refer to this zero position.

The permissible angles can be set with the TLS limit values (P194 - P196). According to the above setting of the position values, 250 corresponds to an angle of 2.5°.

TLS speeds

The speed setpoint (P180-P182) is used to approach the zero position as well as for the execution of the TLS commands. If the hydraulic cylinders only have one speed, this must be set there.

The speed value is the change of the internal position values in each time unit. If a time of 2 s is required for trimming 1°, i.e. an offset of 50 mm on each side, then the speed setpoint to be set is 25 mm/s.

The set speed can also be determined in the "Display screen TLS [7]" of the diagnostic tool. To do this, the set speeds are set to the default values and a TLS command (e.g. trim left) initiated. The values displayed as "IN-Speed" are entered as set speeds in the P180-P182 parameters.

Skew control set speed

The electronic skew control uses the internal slewing gear axis in the BOM Positioning. The positioning speed is set with parameter P221 and the maximum permissible speed with P220 . With a rotation of 1°/2s, a value of 50 cgr/s should be set for the positioning speed.

TLS speed limit

With the skew control, a speed greater than the speed setpoint may be required for a short time. The maximum permissible speed of the cylinder (P183) should be set here.

The ratio P183:P180 should correspond to the ratio P220:P221.

Pressure system

Two different pressures have been prepared. The actuator speed for each cylinder is adapted to the pressure conditions. With a low pressure, the proportional valve is opened more than with a high pressure.

The pressure threshold is selected with P184.

If the system requires a minimum pressure, this can be set with P193. As soon as the output signal exceeds the "TLS speed for zero signal" (P186), the output signal is at least the value of parameter P193.

Commissioning Software 4.9 Alarm, error and system messages


Skew Control

The actuator speed of the internal rotary axis can be adapted to the cylinder speed with the parameter P185 "TLS switch-in for skew control".

Output speed

In order that the cylinders are not loaded unnecessarily, the switching threshold for the cylinder activation can be adapted with parameter P186 "TLS speed for zero signal". If the cylinder control signals are less than this value, the output and the direction signals are set to zero.

Under certain circumstances, the same output speed can result in a higher lowering speed than hoisting speed because of the earth's gravitational attraction. In this case, the actuator speed during lowering should be reduced with parameter P191.

Test commands

The following functions are available for testing:

S – Test Skew Control After pressing the "S" key, the setpoint for skew must be entered and applied with <ENTER>. The cylinders then turn to attain the specified skew.

C – Test Cylinder The "C" key can be used to test the correct operation of the individual cylinders. To do this, the cylinder (1..4) and the direction (+ or -) are entered (e.g. the input of "4+" causes cylinder D to extend fully).

N – Save Zero The "N" key causes the current position of the cylinder to be stored as zero position in all parameter files.

T – Test TLS The "T" key can be used to test TLS commands. Possible inputs are:

TL Trim left TR Trim right LW List waterside LL List landside SL Skew left SR Skew right

The cylinders move in the specified direction until they reach the limit value.

R – Reset "R" (Reset) terminates any TLS command that has not yet completed.

Z – Move Zero The "Z" key causes the cylinders to be moved to the zero position.

The cylinders continue to move until the target position is reached while taking account of the positioning accuracy, even when the commands are no longer present. Note

If a TLS command has not completed, this will be done automatically at the next key click with "TLS-Reset".

4.9 Alarm, error and system messages Safety-relevant monitoring operations must operate correctly both with and without sway control and be fail-safe. They must be implemented in the higher-level controller (PLC).



Because parts of the TO monitoring are deactivated during the "Sway Control" basic technology mode (positioning, standstill and following error monitoring), sway control itself must be monitored. The following TO monitoring operations, etc., remain active:

• Maximum speed

• Maximum acceleration

• Jerk

• Encoder fault

The sway control system monitors only what the higher-level controller cannot monitor.

4.9.1 Following error monitoring

The following error is the difference between the calculated curve and the curve actually travelled (= set-actual deviation).

The permitted deviation between the set and actual position during a travel operation in the BOM Positioning and BOM Hoist Control is stored for each axis in the P161 (trolley), P164 (hoisting gear) and P167 (slewing gear) parameters during the commissioning.

If these tolerances are exceeded, the associated axis-related error (E41 – trolley following error, E42 – hoisting gear following error) will be initiated and travel in the "SC Automatic" AddOn mode aborted.

The following error will not be monitored when the value = 0 is set in the parameters.

Work-around: Increase the control reserve, reduce the gain factors, increase the position controller, reduce the brake derivative action time, change the following error.

Note

Limitations of the speed actuating signal (e.g. in the converter) can result in the tripping of the following error and therefore should only be intended for safety reasons.

4.9.2 Velocity monitoring

The velocities of the individual axes are monitored.

A velocity error occurs when the trolley (E50), the hoisting gear (E51) or the slewing gear (E52) are not moving, are moving too fast or in the wrong direction.

This error is triggered when:

• The actuator speed is > 10% of the maximum speed (P0, P40, P220) and the crane is not moving or moving in the wrong direction

• The difference between the actuator speed and the actual speed > 20% of the maximum speed (P0, P40, P220) (e.g. defective drive)

The error appears with a delay of approx. 3 s. The error message is acknowledged when the axis moves.

The causes of these errors can be:

• Defective encoder



• Faulty connection to the drive

• Brake is still closed

The speed is not monitored when the following error parameter of the axis (P161, P164, P167) is set to zero.

Work-around: Check position values and transfer of the actuator speed.

4.9.3 Start sway control monitoring

The warning E65 "Sway control Off (Start)" occurs when the set activation speed (P146) has not yet been attained or the sway control switch-on delay (P147) has not yet expired. This warning is only issued in the BOM Speed Control. For the activation speed, a hysteresis of ± 5% acts to prevent a continuous connection and disconnection of the sway control system.

The sway control start monitoring with the P146, P147 and P148 parameters acts only in the "Speed control" mode.

4.9.4 Collision protection

Monitoring before the automatic start

Note

A travel job is not executed if the current load position or the target position is in a fixed blocked region.

If the actual position is below the limit curve, a travel job is still generated. In this case, hoisting is performed until the hoist position is above the limit curve. The internal sway control is switched off during this phase in order to avoid collisions with adjacent containers.

If a target position below the limit curve is specified, a point is approached that is vertically above the specified target.

Note

With an automatic start close to a stack of containers (obstacle), oscillation of the load can result in an abort of the automatic travel. Here it is essential to avoid an inclined hoisting when picking up a container close to a further row of containers.

Monitoring during automatic operation

A software collision protection is activated in the BOM Hoist Control. The current positions of the hoisting gear and trolley are used to determine how far the spreader is from a possible obstacle. If this is approached too closely, there is a reaction via the actuating signals.

The following protection mechanisms are available:

1. Stopping with sway control outside the limit curve.



2. Reduction of the actuating signal by further approach to the obstacle limit (without consideration of the sway control, only deceleration ramp).

3. Actuating signal is set to zero when the position is in the blocked region. The error message E37 "Actual position in the blocked region" is also generated.

Normally the first protection barrier is effective. The other two protection mechanisms should be considered as additional safety functions.

After setting the travel signal again, the errors are automatically cleared when the error conditions no longer exist.

4.9.5 Application error messages

4.9.5.1 General information

Errors can occur during the operation of an Add-on.

The "DCC_SCCommon" block returns errors with error bits. These errors can be processed in the PLC using the bits set in the "bFault1" and "bFault2" error words. Because several bits can be set at once, more than one error may be present.

NOTICE

The PLC programmer is required to evaluate the error messages of the system. In a fault situation, the manipulated values of the sway control system may no longer be used. The drive control system must be implemented exclusively via the PLC.

During the commissioning or a diagnosis, such errors can be detected and corrected with the CeCOMM diagnostic program.

The currently pending errors are displayed by pressing the "E" key from the main menu or the display screens. The error history can be called via the "H" key (Section 654.4.6.2).

Each error has a number, a title, an error description and remedy information.

Errors that are transferred to the PLC, are identified by an error bit. Errors without error bit should be interpreted as warnings. Both errors and warnings are visible in the "CeCOMM" diagnostic tool.

All errors are self-acknowledging and will be transferred only while they are present.

A detailed description of these errors is found in the following sections:

4.9.5.2 SIMOCRANE CenSOR error list

The error list is contained in the "SIMOCRANE CenSOR2.0" operating instructions on the product CD.

4.9.5.3 AddOn technology error list

Overview

The errors from the sway control system are categorized as follows:

General and severe errors E0 to E19

Error in the limit or prelimit switch area E20 to E29



Error in automatic operation E30 to E49

Other errors 1 E50 to E59

Other errors 2 E60 to E69

The categorization can be adapted specifically for the project by the PLC programmer.

Table 4-4:

Category Meaning

A Display on the CMS, manual and automatic mode permitted

B Display on the CMS, manual mode permitted and automatic mode not permitted

C Display on the CMS, manual and automatic mode not permitted

Brief description

The assignment of the error bits to the error messages in the output data follows:

Table 4-5: Error messages from the sway control system to the PLC

Error Bit no. Brief description Cat.

General and severe errors

E0 - Cycle time too long -

E2 14 Copy protection corrupted C

E3 3 License error A

E4 12 Camera measuring system faulty A

E5 1 Invalid basic operation mode, trolley B

E6 1 Invalid basic operation mode, hoisting gear B

E7 9 Invalid basic operation mode in the limit switch, trolley

B

E8 9 Invalid basic operation mode in the limit switch, hoisting gear

B

E9 - Hoisting height has jumped -

E10 0 Invalid parameter file C

E11 - Invalid parameter value -

E12 - Corrupted language file -

E13 2 Field bus error (only for SIMOTION C) -

E14-E19 - Reserved -

- 20

Input value over- or undershoots the limits of the set value range.

NOTICE

This error is not indicated in the CeCOMM and does not need to be handled by the higher-level controller.

-

Error in the limit or prelimit switch area




E20 - Forward prelimit switch switches incorrectly, trolley

-

E21 - Upper prelimit switch switches incorrectly, hoisting gear

-

E22 - Backward prelimit switch switches incorrectly, trolley

-

E23 - Lower prelimit switch switches incorrectly, hoisting gear

-

E24 - Forward limit switch switches incorrectly, trolley -

E25 - Upper limit switch switches incorrectly, hoisting gear

-

E26 - Backward limit switch switches incorrectly, trolley -

E27 - Lower limit switch switches incorrectly, hoisting gear

-

E28-E29 - Reserved -

Error in automatic operation

E30 31 No path found A

E31 4 Invalid target position, trolley B

E32 4 Invalid target position, hoisting gear B

E33 16 Too many variable blocked regions B

E34 24 Group error abort, hoist control B

E35 17 Starting point in an invalid region B

E36 18 Starting point in variable blocked region A

E37 28 Actual position in blocked region B

E38 25 Target in fixed blocked region B

E39 - -- -

E41 29 Trolley following error B

E42 30 Hoisting gear following error B

E43 - Crane geometry /dynamic response is incorrect -

E44-E49 Reserved -

Other errors 1

E50 11 Trolley speed error B

E51 11 Hoisting gear speed error B

E52 11 Speed error during skew B

E53-E59 Reserved

Other errors 2

E60 15 Load stuck B

E61 7 Sway-control Off (pendulum length) A

E62 6 Start of positioning with too much swaying B

E63 10 Trolley sway-control temporarily reduced B




E64 19 Anti-skew temporarily reduced B

E65 - Sway-control Off (start) -

E66 - Sway-control only when stopping -

E67 - Controlled stop active -

E68 - Internal floating-point data error -

General and severe errors

E0 (Bit -/-) Cycle time too long

The cycle time is greater than 100 ms.

Error type: Warning Remedy: Add the DCC chart to a faster task.

E2 (Bit 14) Copy protection corrupted

The license is damaged or missing. The sway-control function is deactivated.

Error type: Error Remedy: Create and transfer a license key

E3 (Bit 3) License error

A basic operation mode has been selected, but there is no license for this.

Error type: Error Remedy: Reset command bit or purchase license

E4 (Bit 12) Camera measuring system faulty

This may be due to the following causes:

Incorrect commissioning of the camera: Further related information is contained in the product documentation for the SIMOCRANE CenSOR camera measuring system.

The camera-axes assignment (P120) is not correct.

The connection between the controller and SIMOTION C has been interrupted.

The camera is no longer identifying a reflector.

For systems without camera, P102 is not zero.

Error type: Error Remedy: Check the camera, camera settings, communications addresses and connection to the camera, perform commissioning step 2 (set the camera orientation), check the reflector and possibly clean, set P102 = 0 for a system without camera.

E5 (Bit 1) Invalid basic operation mode, trolley



Either multiple basic operation modes are selected simultaneously or unavailable basic operation mode is selected. The error message also appears when the BOM Hoist Control has been selected for only one axis.

Error type: Error Remedy: Check the PLC program, only set one operation mode bit for each travel axis

E6 (Bit 1) Invalid basic operation mode, hoisting gear

Either multiple basic operation modes are selected simultaneously or unavailable basic operation mode is selected. The error message also appears when the BOM Hoist Control has been selected for only one axis.

Error type: Error Remedy: Check the PLC program, only set one operation mode bit for each travel axis

E7 (Bit 9) Invalid basic operation mode in the limit switch, trolley

In the limit switch, only the BOM Speed Control" is permitted at the limit switch for which braking with the maximum ramp is performed in the limit switch region.

Error type: Error Remedy: Activate BOM Speed Control

E8 (Bit 9) Invalid basic operation mode in the limit switch, hoisting gear

In the limit switch, only the BOM Speed Control is permitted at the limit switch for which braking with the maximum ramp is performed in the limit switch region.

Error type: Error Remedy: Activate BOM Speed Control

E9 (Bit -/-) Hoisting height has jumped

The hoisting gear position has jumped to an illegal height (> 10 m).

Error type: Warning Remedy: Reference hoisting height encoder again

E10 (Bit 0) Invalid parameter file

An error has occurred while loading the parameter files. Parameter files are missing or are faulty. The relevant parameter set will be set to default values. The error value (1-4) specifies which parameter set could not be loaded.

Error type: Error Remedy: Check parameters in the parameter menu, save and reload

E11 (Bit -/-) Invalid parameter value

An invalid value [X*10000+P] was found when loading parameter P in parameter set (1-4) from file parX.txt (X:0-3). The value has been set to the default value. The error is only reset after the parameter files have been loaded successfully.



Error type: Warning Remedy: Check parameters in the parameter menu, save and reload

E12 (Bit -/-) Corrupted language file

Lines that are too long or cannot be displayed have been detected during loading of the language file Sprache1.txt.

Error values: 0…199 – Parameter texts 200..300 – Error texts 300..400 – Commissioning texts Error type: Warning Remedy: Correct language file

E13 (Bit 2) Field bus error (only SIMOTION C)

The sway-control could not establish communication to the PLC (General command bits, Bit 13 "watchdog" not set).

Error type: Error Remedy: Check the cables, check the PLC, set bit 13 "watchdog"

E14 – E19 reserved

Error in the limit or prelimit switch area

E20 (Bit -/-) Forward prelimit switch switches incorrectly, trolley

The prelimit switch in the forward direction became active for negative speed or inactive for positive speed.

Error type: Warning Remedy: Exchange forward and backward prelimit switch signals

E21 (Bit -/-) Upper prelimit switch switches incorrectly, hoisting gear

The prelimit switch in the forward direction became active for negative speed or inactive for positive speed.

Error type: Warning Remedy: Exchange upper and lower prelimit switch signals

E22 (Bit -/-) Backward prelimit switch switches incorrectly, trolley

The prelimit switch in the backward direction became active for positive speed or inactive for negative speed.

Error type: Warning Remedy: Exchange forward and backward prelimit switch signals

E23 (Bit -/-) Lower prelimit switch switches incorrectly, hoisting gear



The prelimit switch in the backward direction became active for positive speed or inactive for negative speed.

Error type: Warning Remedy: Exchange upper and lower prelimit switch signals

E24 (Bit -/-) Forward limit switch switches incorrectly, trolley

The limit switch switches for the wrong direction of motion or switched simultaneously with the prelimit switch in the opposite direction.

Error type: Warning Remedy: Exchange forward and backward limit switch signals

E25 (Bit -/-) Upper limit switch switches incorrectly, hoisting gear


Error type: Warning Remedy: Exchange upper and lower limit switch signals

E26 (Bit -/-) Backward limit switch switches incorrectly, trolley


Error type: Warning Remedy: Exchange forward and backward limit switch signals

E27 (Bit -/-) Lower limit switch switches incorrectly, hoisting gear


Error type: Warning Remedy: Exchange upper and lower limit switch signals


Error in automatic operation

E30 (Bit 31) No path found

The hoist control could not find a path between the starting position and the target position.

• For "on-the-fly unloading", the highest point of the calculated travel curve is higher than the target. The automatic does not start.

• Target cannot be reached because there is an obstacle in the way. The automatic starts; the target, however, is placed before the obstacle error category A If the target lies in a fixed blocked region, no travel of the crane is initiated and E38 is issued.



Error type: Error Remedy: Check starting position and target position as well as blocked regions

E31 (Bit 4) Invalid target position, trolley

The target position of the trolley is outside the set limits (P23, P28).

Error type: Error Remedy: Check parameters for limits

E32 (Bit 4) Invalid target position, hoisting gear

The target position of the hoisting gear is outside the set limits (P63, P69).

Error type: Error Remedy: Check parameters for limits

E33 (Bit 16) Too many variable blocked regions

An attempt has been made to transfer more than 200 variable blocked regions.

Error type: Error Remedy: Check PLC program

E34 (Bit 24) Group error abort, hoist control

A travel job in the BOM Hoist Control has been aborted. Refer to other error messages for the exact cause of the error.

Error type: Error Remedy: Evaluate other error messages

E35 (Bit 17) Starting point in an invalid region

The actual position lies outside the limits specified by the parameters P23 and P28 (trolley position) and P63 and P69 (hoisting gear position). In the BOM Positioning, the travel is prevented only for the affected axis. In the BOM Hoist Control, the travel is prevented for both axes.

Error type: Error Remedy: Traverse manually to valid regions. Check limits.

E36 (Bit 18) Starting point in variable blocked region

Only BOM Hoist Control

The actual position is in a variable blocked region at the time a travel operation is started with hoist control. This is no error and so does not cause cancellation and remains set until the range was exited just by raising the hoisting gear.

Error type: Note/warning Remedy:



E37 (Bit 28) Actual position in blocked region


Zero speed: The target position is in a fixed blocked region (parameter)

During travel: The actual position has violated a fixed or variable blocked region. The course has deviated too far from the setpoint.

Error type: Error Remedy: Possibly, manually leave the fixed blocked region (e.g. Silbeamzone), increase safety clearances P33 and P72, increase control reserve, reduce gain factors, increase position controller

E38 (Bit 25) Target in fixed blocked region


The target position is in a fixed blocked region. A travel job is not generated.

Error type: Error Remedy: Check the target position and the fixed blocked region

E41 (Bit 29) Trolley following error

The difference between the actual and the set position is greater than the set permissible following error (P161)

Error type: Error Remedy: Increase the control reserve, reduce the gain factors, increase the position controller, reduce the brake derivative action time, change the following error

E42 (Bit 30) Hoisting gear following error

The difference between the actual and the set position is greater than the set permissible following error (P164)

Error type: Error Remedy: Increase the control reserve, reduce the gain factors, increase the position controller, reduce the brake derivative action time, change the following error

E43 (Bit -/-) Crane geometry /dynamic response is incorrect

Inconclusive value combinations have been determined. Correct functioning cannot be guaranteed.

Error type: Warning Remedy: Check parameters


Other errors 1

E50 (Bit 11) Trolley speed error

The trolley does not move, moves too fast or in an incorrect direction. The error is triggered when:



• The actuator speed is > 10% of the maximum speed (P0) and the crane is not moving or moving in the wrong direction

• The difference between the actuator speed and the actual speed > 20% of the maximum speed (P0) (e.g. defective drive)

The error appears with a delay of approx. 3 s. The error message is acknowledged when the trolley moves.





The error is not signaled when the following error parameter of the axis (P161) is set to zero.

Error type: Error Remedy: Check position values and transfer of the actuator speed

E51 (Bit 11) Hoisting gear speed error

The hoisting gear does not move, moves too fast or in an incorrect direction. The error is triggered when:



The error appears with a delay of approx. 3 s. The error message is acknowledged when the hoisting gear moves.









E52 (Bit 11) Speed error during skew

The slewing gear does not move, moves too fast or in an incorrect direction. The error is triggered when:



The error appears with a delay of approx. 3 s. The error message is acknowledged when the slewing gear moves.








E55 Normalization error

The maximum acceleration corresponds to a normalized speed change less than 1.

Error bit: - Remedy: Use a larger normalization


Other errors 2

E60 (Bit 15) Load stuck

The load has stuck when starting to move.

Error type: Error Remedy: Control crane manually or change P105.

E61 (Bit 7) Sway-control Off (pendulum length)

The sway-control function has been switched off because the pendulum length is not within the specified limits (P83, P84).

Error type: Error Remedy: Check parameters



E62 (Bit 6) Start of positioning with too much swaying

The positioning motion was started when there was too much swaying.

Error type: Error Remedy: Eliminate swaying manually, check parameter P156

E63 (Bit 10) Trolley sway-control temporarily reduced

Because of large swaying motions, the gain factor for trolley has been temporarily significantly reduced for stability reasons.

Error type: Error Remedy: Eliminate swaying manually

E64 (Bit 19) Anti-skew temporarily reduced

Because of large swaying motions, the gain factor for skewing has been temporarily significantly reduced for stability reasons.

Error type: Error Remedy: Eliminate swaying manually

E65 (Bit -/-) Sway-control Off (start)

The set activation speed (P146) has not been reached or the sway-control switch-on delay (P147) has not yet elapsed, in order to start the sway-control function. This warning is only issued in the BOM Speed Control.

Error type: Warning Remedy: -

E66 (Bit -/-) Sway-control only when stopping

The command bit "Sway-control only when stopping" is set.

Error type: Warning Remedy: Reset command bit

E67 (Bit -/-) Controlled stop active

The command bit "Controlled stop" is set.

Error type: Warning Remedy: Reset "Controlled stop" bit



E68 (Bit -/-) Internal floating-point data error

A floating-point error has occurred during calculation.

Error values: 100:SNAN 200:QNAN 300:NINF 400:ND 500:PD 600:PINF 0-9: controller, 10-19: oscillation model, 20-29: VSet, 30-39: oscillation model + offset, 40-49: RT

Error type: Warning Remedy: -

4.9.5.4 CeCOMM diagnostic software

Operating errors in the "Monitor" function are normally displayed in the monitor status line. An example is the "Display screen not assigned" message.

4.9.6 Troubleshooting/FAQs

Table 4-6 Troubleshooting/FAQs

Scenario Possible causes and remedy

After completion of a trolley movement, an excessive residual sway remains.

The actual pendulum length differs greatly from the internally calculated effective pendulum length (screen 01 in the CeCOMM). Recalibrate the hoisting height (commissioning steps 2 and 3). Check the hoisting gear position P169 (permitted residual sway) and possibly set a smaller value.

The load oscillation is increasing. Check acceleration and deceleration ramps of the converter, remove any roundings and check the control parameters of the converter. Set the alignment of the camera (commissioning step 1).

Residual swaying motions are always or occasionally too large.

Check ramps and speed controller of the converter.

Empty main menu (space bar) in the CeCOMM diagnostic tool

License is damaged or missing. Error E2 "Copy protection damaged" is displayed on the "Errors" display screen ("E" key). Check licenses


5 General information 5 5.1 Service and maintenance

5.1.1 Reflector

The reflector must be cleaned regularly depending on the degree of soiling. If the dust content is low, it is sufficient to inspect/clean the reflector once per year. If the dust content is high, however, the reflector must be cleaned at 4-6 weekly intervals. The reflector must be checked for secure mounting as part of the regular crane inspection.

5.1.2 Camera

The front window of the camera protective housing must be inspected and cleaned regularly at the intervals specified in "Reflector". The camera must also be checked for secure mounting. The camera must be recalibrated after a reflector replacement or a rope change.

5.1.3 Spare parts / accessories

Order number Item

6GA7200-0AA01-0AA0 SIMOCRANE SC Integrated: STS/GSU: Basic Control

6GA7200-0AA01-1AA0 SIMOCRANE SC Integrated: STS/GSU: Advanced Control

6GA7200-1AA01-0AA0 SIMOCRANE SC Standalone: STS/GSU: Basic Control 6GA7200-1AA01-1AA0 SIMOCRANE SC Standalone: STS/GSU: Advanced Control

6GA7201-0AA02-0AA0 Reflector 500 mm, active, IR

6GA7201-0AA03-0AA0 Reflector 800mm, active, IR

General information 5.1 Service and maintenance


Order number SIMOCRANE CenSOR camera Camera type: Camera for SIMOTION C/D 6 G A 7 2 0 2 - 1 Replacement camera 6 G A 7 2 0 2 - 0 A A 0 0 0 A A x Camera for SIMOTION C/D: Image sensor resolution SIMOCRANE CenSOR MV440 SR 640x480 pixels 6 G A 7 2 0 2 - 1 A A 1SIMOCRANE CenSOR MV440 HR 1024x768 pixels 6 G A 7 2 0 2 - 1 A A 2SIMOCRANE CenSOR MV440 UR 1600x1200 pixels 6 G A 7 2 0 2 - 1 A A 3 Camera casing Camera casing Stainless steel with flash for outdoor crane 6 G A 7 2 0 2 - x A A 1 xLens protective bus for indoor crane 6 G A 7 2 0 2 - x A A 2 2 0 x Temperature range Temperature range -25° to 50° C (standard) 6 G A 7 2 0 2 - x A A x 0 - x0° to 50° C 6 G A 7 2 0 2 - x A A 2 2 - 0 x Lens Lens focal length 16mm (standard) 6 G A 7 2 0 2 - x A A x x - 0 x25 mm 6 G A 7 2 0 2 - x A A x x - 1 x

5.1.4 AddOn technology parameter list

5.1.4.1 Overview of the parameter list

The parameters for the configuration of the sway-control system are grouped as follows:

Trolley parameters P0 to P39

Hoisting gear parameters P40 to P79

Sway-control parameters P80 to P99

General parameters P100 to P119

Camera/reflector parameters P120 to P139

Travel behavior parameters P140 to P159

Controlled variable parameters P160 to P179

TLS parameters P180 to P219

Slewing gear parameters P220 to P239



Option parameters

Parameters, in which one or more options can be selected, are identified by a "#" in front of the character string. Selected options are specified with the corresponding digit; options that are not selected with a dot ".".

Examples of parameter P152 (conventional/time-optimized control, trolley):

#..... None of the five options has been selected #.23. Options 2 and 3 of five options have been selected #123.5 Options 1, 2, 3 and 5 of five options have been selected

Note

Only the default values are specified for the parameters with selection options, but not the minimum and maximum.

5.1.4.2 Trolley parameters

P0 Maximum actuator speed, trolley

The set value corresponds to the maximum attainable speed. In the higher-level controller (PLC, drive), an actuator value for v_Pos = P103 must correspond to the maximum actuator speed of the trolley (because v_POS = actuator speed [mm/s]*P103 / P0).

Default: 3500 [mm/s] Min: 10 [mm/s] Max: 5000 [mm/s] Access code: 0 Display: Always

Note

After confirmation of the parameter P0, a prompt will be made whether the P1, P7, P6 and P5 parameters should be updated. The updating is appropriate only when the speeds and accelerations dependent on P0 have already been entered and only P0 is adapted again. For this "update", the P1, P7, P6 and P5 parameters are changed in the same ratio as P0.

P1 Positioning speed, trolley

This value (in mm/s) corresponds to the maximum speed in the BOM Positioning and the BOM Hoist Control. In order to allow a slight overshoot, a value of 90% of the maximum actuator speed (P0) should be set. Set manually according to manufacturer or customer specifications. Record in order to check the speed setpoint in Positioning operation.


P2 Prelimit switch speed, trolley

Percentage speed value for P0 within the prelimit switch. With P115 = 0, the speed actuator value is limited to this value if a prelimit switch is triggered. With P115 = 1, this value is used for the dynamic prelimit switches (P24, P27).



Default: 10 [%] Min: 0 [%] Max: 100 [%] Access code: 0 Display: Always

P3 Trolley speed for zero speed signal

If the target position of the trolley has been reached and the actuator speed is less than P3/100*P0, no further direction signal is output. The brake can be closed.


P4 Speed reduction factor for horizontal target point approach

Percentage value of the positioning speed of the trolley (P1). The maximum speed setpoint is reduced by this factor when a horizontal target point approach is performed (VSet=P1*P4/100).


P5 Maximum acceleration, trolley

Acceleration limit in mm/s². The set value corresponds to the maximum drive acceleration/deceleration. The value should be approx. 50..100% above the set acceleration (P6). Input values less than 20 are interpreted as a ramp time.

Set manually according to manufacturer or customer specifications.

Default: 550 [mm/s²] Min: 1 [mm/s²] Max: 2000 [mm/s²] Access code: 0 Display: Always

P6 Set acceleration, trolley

The set acceleration is an internal acceleration variable in mm/s². It acts in all basic operation modes, during both acceleration and deceleration (depending on P115). Input values less than 20 are interpreted as a ramp time. Set manually based on the manufacturer or customer details. The value should be approx. 75% of the maximum acceleration (P5).


P7 Acceleration without sway-control / minimum acceleration

For deactivated sway control, the drive accelerates/brakes with P7 in the BOM Speed Control. Input values < 20 are interpreted as a ramp time. For time-optimized control, P7 acts as set acceleration.




P8 Deceleration gain, trolley

Gain factor for the increase or decrease of the deceleration. The deceleration results from P6 * P8, with countering from P6 * P8 * P142.

Default: 1 Min: 0,5 Max: 5 Access code: 2 Display: Always

P9 Reduction factor for set acceleration, trolley, automatic travel

This parameter can be used to reduce the set acceleration in the BOM Hoist Control. The parameter acts only with time-optimized control.


P10 Acceleration reduction factor for horizontal target point approach

Percentage value of the set acceleration of the trolley (P6). The maximum speed setpoint is reduced by this factor when a horizontal target point approach is performed (ASet = P6*P10/100).


P11 Trolley rounding for operation without sway control

Initial and final rounding of the trolley setpoint. The percentage value is based on the ramp-up time to the maximum speed. The rounding is active when the parameter is greater than zero and the sway control is deactivated.


P12 Smoothing of torque setpoint, trolley

In addition to the control speed, the control acceleration is fed back to the PLC for the torque precontrol of a speed control loop. The smoothing of the torque setpoint can be set with this time constant. If the value is less than 1, the delay element is deactivated.

Default: 350 [ms] Min: 0 [ms] Max: 5000 [ms] Access code: 2 Display: Always

P20 Resolution of position sensor, trolley

Calibration value for the trolley position.

Default: 1 Min: - 100 Max: 100 Access code: 1 Display: Always

P21 Offset of position sensor, trolley

Calibration value for the trolley position.

Default: 0 [mm] Min: - 200000 [mm] Max: 200000 [mm] Access code: 1 Display: Always



P22 Encoder increments per millimeter for trolley

Factor for the conversion of the counted encoder pulses over a distance in mm.

Default: 0 [1/mm] Min: - 500000 [1/mm] Max: 500000 [1/mm] Access code: 2 Display: Always

NOTICE

This parameter is visible in the CeCOMM diagnostic tool, but is not relevant for this product as it is not possible to connect encoders directly to the SIMOTION C 240 PN with PROFINET.

P23 Minimum position for positioning, trolley

Smaller target positions are ignored and error E31 is triggered. Note that the limitation applies to converted target positions with the resolution P20 and the offset P21. If the trolley position in automatic operation lies outside the set limits, error E35 is triggered.


Note

If parameter P23 is changed, the internally learnt obstacles on the waterside are set to the maximum values. Thus, only a new learning travel is necessary. This is also true when a parameter-set switch is made and the parameter sets contain different values for P23.

P24 Position for trolley PLS speed backwards

Position where the trolley must have attained the prelimit switch speed (P2). The position where the trolley is braked depends on the speed (dynamic prelimit switch). The parameter acts only when P115 = 1.


P25 Waiting position, trolley

This parameter specifies the waiting position of the trolley. The trolley waits at this position until the bit "No_WaitingPosition" has been set by the PLC. This function can be used, for example, for container cranes with several trolleys for mutual locking.

Default: 100000 [mm] Min: 0 [mm] Max: 500000 [mm] Access code: 0 Display: Always

P26 Trolley position, start on waterside

Trolley position that corresponds to the start on the waterside. The offset approach (P34) only applies to the waterside.




P27 Position for trolley PLS speed forwards

Position where the trolley must have attained the prelimit switch speed (P2). The position where the trolley is braked depends on the speed (dynamic prelimit switch). The parameter acts only when P115 = 1.


P28 Maximum position for positioning, trolley

Larger target positions are ignored and error E31 is triggered. Note that the limitation applies to converted target positions with the resolution P20 and the offset P21. If the trolley position in automatic operation lies outside the set limits, error E35 is triggered.


Note


P29 Trolley position, end on waterside

Trolley position that corresponds to the end on the waterside. P29 must be set at least half a spreader-width greater than P28.


P30 On-the-fly unloading abort speed

For on-the-fly unloading, the "open grab" signal will be reset once the trolley undershoots the specified speed.

The bit for target switching (CHANGE_TARGET) is also set.

Default: 500 [mm/s] Min: 0 [mm/s] Max: 50000 [mm/s] Access code: 1 Display: Only for GSU (P102, selection 0 = ON)

P31 Distance for opening the grab

For on-the-fly unloading, the "open grab" state bit will be set when the distance between the grab and the target position is smaller than this parameter value.

Default: 1000 [mm] Min: 0 [mm] Max: 50000 [mm] Access code: 1 Display: Only for GSU (P102, selection 0 = ON)



P32 Travel clearance of trolley to limit curve

Travel clearance that should be maintained when travelling around the limit curve in the trolley direction. Minimum travel clearance of the trolley in addition to the safety clearance of the limit curve.


P33 Safety clearance, trolley

Safety clearance to obstacle limit in the trolley direction. This parameter is used to define the safety zone (smart slowdown with stop with sway control). If the target lies within this area, no travel is made there but stops before.


P34 Offset for target point approach

This parameter only applies for target point approaches on the waterside. If the parameter is not equal to zero, a target position is approached that is offset by this value in the trolley direction. The trolley then travels to the target position.


P35 Position offset during unloading

When learning target positions, the value for the trolley is changed by this parameter. The value is limited internally to a spreader width.


P36 Position offset during loading

When learning target positions, the value for the trolley is changed by this parameter. The value is limited internally to a spreader width.




P37 Bay Scanner position offset

Deviation of the laser position from the trolley position. Positive values mean that the Bay Scanner measuring laser is offset by this value from the defined trolley position in the waterside direction.

Default: 5000 [mm] Min: - 10000 [mm] Max: 10000 [mm] Access code: 1 Display: Only for STS (P102, selection 1 = ON)

P38 Time constant for PT1 element

The PT1 element is used to delay and round the actuator signal in order to minimize the relaxation oscillations for time-optimized control. The PT1 element has no effect for value = 0. The larger the value, the faster the rounding.

Default: 0 seconds Access code: 1 Display: Always

P39 Grab frequency (input shaper)

The input shaper can be used to minimize the relaxation oscillations of the grab (double pendulum). The parameter causes a deformation of the converter signal dependent on the specified frequency. The function is disabled for values less than 0.2 Hz.

Default: 0 Hz Min: 0.2 Hz Max: 5 Hz Access code: 1 Display: Always

5.1.4.3 Hoisting gear parameters

P40 Maximum actuator speed, hoisting gear

The set value corresponds to the maximum attainable speed. In the higher-level controller (PLC, drive), an actuator value for v_Pos = P103 must correspond to the maximum actuator speed of the hoisting gear (because v_POS = actuator speed [mm/s] * P103 / P40).


Note

After confirmation of the parameter P40, a prompt will be made whether the P41, P51 and P50 parameters should be updated. The updating is appropriate only when the speeds and accelerations dependent on P40 have already been entered and only P40 has to be adapted again. For this "update", the P41, P51 and P50 parameters are changed in the same ratio as P40.

P41 Positioning speed, hoisting gear

This value (in mm/s) corresponds to the maximum speed in the BOM Positioning and BOM Hoist Control. In order to allow a slight overshoot, a value of 90% of the maximum actuator speed (P40) should be set. Set manually according to manufacturer or customer specifications. Record in order to check the speed setpoint in Positioning operation.




P43 Prelimit switch speed, hoisting gear

Percentage speed value within the prelimit switch. With P115 = 0, the speed actuator value is limited to this value if a prelimit switch is triggered. With P115 = 1, this value is used for the dynamic prelimit switches (P64, P68).


P44 Hoisting speed for zero speed signal

If the target position of the hoisting gear has been reached and the actuator speed is less than P44/100*P40, no further direction signal is output. The brake can be closed.


P45 Hoisting speed reduction

Percentage value of the positioning speed when hoisting (P41). The maximum speed setpoint is reduced by this factor. Acts in the BOM Hoist Control and BOM Positioning. (VSet = P41*P45/100)


P46 Immersion point speed limit

For the transition of the trolley speed from 10% above to 10% below the speed, the current immersion point is set on the waterside. The value refers to the maximum speed of the trolley.


P47 Reduction of speed when raising

Factor for the reduction of the speed until the bit "Slack rope" is no longer set.

Default: 0,1 Min: 0 Max: 1 Access code: 2 Display: Always

NOTICE

If the value = 0 is set, the operation in the BOM Positioning and BOM Hoist control behaves as if the "Slack rope" bit was not set (i.e. despite the set "Slack rope" bit, the trolley drive and the hoisting gear also travel without speed reduction).



P49 Reduction of speed when lowering

Just before putting the load down (P74), the lowering speed is determined from the positioning speed and this reduction factor (P41 * P49).


NOTICE

If value = 0 is set, the output actuator value is also zero. This setting should be avoided.

P50 Maximum acceleration, hoisting gear

Acceleration limit in mm/s². The set value corresponds to the maximum drive acceleration/deceleration. The value should be approx. 50..100% above the set acceleration (P51). Input values less than 20 are interpreted as a ramp time.

Set manually according to manufacturer or customer specifications.


P51 Set acceleration, hoisting gear

The set acceleration is an internal acceleration variable in mm/s². It is effective not only in the acceleration, but also in the deceleration phase. Input values less than 20 are interpreted as a ramp time. Set manually according to manufacturer or customer specifications. The value should be approx. 75% of the maximum acceleration (P50).


P52 Deceleration gain, hoisting gear

Gain factor for the increase or decrease of the deceleration. The deceleration results from P51 * P52, with countering from P51 * P52 * P142. The gain factor acts only in the speed control mode.


P53 Acceleration reduction when hoisting

Percentage value of the set acceleration when hoisting (P51). The set acceleration is reduced by this factor when hoisting. Acts in the BOM Hoist Control and BOM Positioning. (ASet = P51*P53/100)




P54 Hoisting gear rounding

Initial and final rounding of the hoisting gear setpoint. The percentage value is based on the ramp-up time to the maximum speed. The rounding is active when the parameter is greater than zero. It acts only in the speed control mode.


P55 Smoothing of torque setpoint, hoisting gear



P60 Effective pendulum length resolution

Parameter for calculating the effective pendulum length.

Default: - 1 Min: - 100 Max: 100 Access code: 1 Display: Always

P61 Effective pendulum length offset

Parameter for calculating the effective pendulum length.


P62 Encoder increments per millimeter for hoisting rear


Default: 0 [1/mm] Min: - 500000 [1/mm] Max: 500000 [1/mm] Access code: 2 Display: Always

NOTICE




P63 Minimum position for positioning, hoisting gear

Smaller target positions are ignored and error E32 is triggered. If the hoisting position in automatic operation lies outside the set limits, error E35 is triggered.


Note


P64 Position for hoisting gear PLS speed lowering

Position where the hoisting gear must have attained the prelimit switch speed (P43). The position where the hoisting gear is braked depends on the speed (dynamic prelimit switch). The parameter acts only when P115 = 1 and the trolley is located on the landside (see P26).


P65 Hoisting gear waiting position

This parameter specifies the waiting position of the hoist. The hoisting gear waits at this position until the bit "No_WaitingPosition" has been set by the PLC.


P66 Minimum hoisting height, landside

Below the minimum hoisting height on the landside, the "bStart_Auto_OK" state bit is not set. If this bit is used for starting the automatic, a start is not possible. If the state bit is not processed, only the hoisting gear is operated below the minimum hoisting height on the landside at the automatic start, then also the trolley. P66 acts only in the BOM Hoist Control.


P67 Minimum hoisting height waterside

Below the minimum hoisting height on the waterside, only the hoisting gear is operated at the automatic start, then also the trolley. P67 acts only in the BOM Hoist Control.




P68 Position for hoisting gear PLS speed hoisting

Position where the hoisting gear must have attained the prelimit switch speed (P43). The position where the hoisting gear is braked depends on the speed (dynamic prelimit switch). The parameter acts only when P115 = 1.


P69 Maximum position for positioning, hoisting gear

Larger target positions are ignored and error E32 is triggered. If the hoisting position in automatic operation lies outside the set limits, error E35 is triggered.


Note


P70 Safe height on land

An automatic travel on land will always stop above this position. At start in this area, initially only the hoisting gear is operated until the limit is exceeded. P70 acts only in the BOM Hoist Control.

Default: - 100000 [mm] Min: - 100000 [mm] Max: 200000 [mm] Access code: 0 Display: Always

P71 Travel clearance of hoisting gear to limit curve

Travel clearance that should be maintained when travelling around the limit curve in the hoisting gear direction. Minimum travel clearance of the hoist in addition to the safety clearance of the limit curve.


P72 Safety clearance, hoisting gear

Safety clearance above the limit curve. This parameter is used to define the safety zone (smart slowdown). If the target lies within this area, no travel is made there but stops before.


P74 Distance for automatic lowering

As of this distance to the target, lowering is performed with reduced speed (P49).




P75 Horizontal trolley travel to the hopper (only GSU)

Setting of the trolley travel length over the hopper without hoist movement.

The value 1 activates an automatic determination.

Default: 1 [mm] Min: 0 [mm] Max:100000 [mm] Access code: 1 Display: Only GSU

P76 Horizontal trolley travel to the ship (only GSU)

Setting of the trolley travel length over the hopper without hoist movement.

The value 1 activates an automatic determination.

Default: 1 [mm] Min: 0 [mm] Max:100000 [mm] Access code: 1 Display: Only GSU

5.1.4.4 Sway-control parameters

P80 Digital effective pendulum length correction

Correction value for the effective pendulum length for bit "DigitalLiftCorrection" set.

Default: 0 [mm] Min: -10000000 [mm] Max: 10000000 [mm] Access code: 1 Display: Always

P81 Analog effective pendulum length correction

Relationship between load weight and shift in the center of gravity.

Default: 0.02 [mm/kg] Min: -70000 [mm/kg] Max: 70000 [mm/kg] Access code: 1 Display: Always

P82 Weight of the load carrying device

Weight of the load carrying device to determine the shift in the center of gravity. If the load is the same as the weight of the load carrying device, then there is no shift in the center of gravity.

Default: 12500 [kg] Min: -20000 [kg] Max: 20000 [kg] Access code: 0 Display: Always

P83 Upper limit for sway control

For a smaller (effective) pendulum length, the sway control is disabled (E61).


P84 Lower limit for sway control

For a larger (effective) pendulum length, the sway control is disabled (E61).




P85 Gain factor, trolley (braking manual operation, positioning)

Gain factor for the conventional sway control in manual operation for braking and in the BOM Positioning and BOM Hoist Control. Large values result in aperiodic transient responses and low values to overshoot and short rise times.


P86 Gain factor, trolley (acceleration manual operation)

Trolley gain factor for the conventional sway control in manual operation when accelerating. Large values result in aperiodic transient responses and low values to overshoot and short rise times. To achieve fast acceleration, the value should be lower than the sway control factor for deceleration. This parameter has no effect in the BOM Positioning and BOM Hoist Control.


P87 Gain factor for skew (deceleration)

Gain factor for the conventional sway control in all basic operation modes when decelerating. Large values result in aperiodic transient responses and low values to overshoot and short rise times.

Default: 1,2 Min: 0 Max: 10 Access code: 2 Display: Only for TLS (P197, selection 1 = ON)

P88 Gain factor for skew (acceleration)

Gain factor for the conventional sway control in manual operation when accelerating. Large values result in aperiodic transient responses and low values to overshoot and short rise times. To achieve fast acceleration, the value should be lower than the sway control factor for deceleration.

Default: 1 Min: 0 Max: 10 Access code: 2 Display: Only for TLS (P197, selection 1 = ON)

P89 Hoisting height offset for skew control 20 ft

Offset for the conversion of the hoisting position to the effective pendulum length. The value is only used for the anti-skew.

Default: 0 [mm] Min: -200000 [mm] Max: 200000 [mm] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P90 Linear hoisting height factor for skew control 20 ft

Linear gain factor for the conversion of the hoisting position to the effective pendulum length. The value is only used for the anti-skew.

Default: 0,5 Min: -1000 Max: 1000 Access code: 1 Display: Only for TLS (P197, selection 1 = ON)



P91 Hoisting height offset for skew control 30 ft



P92 Linear hoisting height factor for skew control 30 ft



P93 Hoisting height offset for skew control 40/45 ft



P94 Linear hoisting height factor for skew control 40/45 ft



5.1.4.5 General parameters

P100 Access code

Selection:

0 Crane operators, maintenance staff 1 Commissioning engineers 2 Service technicians 3 Developers

Access code for changing parameters.

Default: #1 Access code: 0 Display: Always

P101 Parameter set locked during travel

Selection:

0 The active parameter set can be switched over during travel 1 The active parameter set can only be switched over at standstill




P102 Configuration

Selection:

0 Ship unloader (without camera) 1 STS (with camera)


P103 Normalization value

With this value the set speed v_set (trolley and hoist) will be denormalized and the actuator speed v_Pos and the actuator acceleration a_Pos (trolley and hoist) will be normalized. Because of the limited resolution, values smaller than 1000 can cause function problems, such as, increase of the set accelerations

Default: 32767 Min: 100 Max: 32767 Access code: 1 Display: Always

P104 Diagnostics value

Depending on the set value, the diagnostics variable is assigned 10 and sent to CeCOMM.

0-2 Limit values 3-5 Setpoints 6-8 Actual values 9-11 Control values 12-14 Delayed control values 15-17 Oscillation model 18-21 Camera measurements 26 Set-actual difference (position) each in the order Position-Speed-Acceleration in each case.


P105 Maximum inclined hoisting angle (only STS)

If the inclined hoisting is greater than this angle, error E60 "Load stuck" is triggered. The evaluation is performed by comparing the oscillation model with the camera measurement. The monitoring can be deactivated by setting the parameter to values less than 0,6.

Default: 0 [°] Min: 0 [°] Max: 500000 [°] Access code: 2 Display: Always

P106 Spreader / container / grab width

The obstacles are increased in size by half the width left and right for the travel path calculation and monitoring.


NOTICE

If the parameter is changed, the internal targets are initialized and all the learnt lanes are deleted.



Note

For P106 < 1000 mm, a switchover is made to the MODEL MODE. Because of the different dimensions, smaller safety areas than on the real crane apply.

P107 Hoist offset to the spreader/grab

The limit curve is increased in height by the value of this parameter for the travel path calculation and monitoring. This is useful when the hoisting gear position does not correspond to the lower edge of the spreader/grab.


P108 Maximum container height

The height of the highest possible container. When the bit "Container locked" is set, all obstacles (fixed and variable) are increased by this parameter value.


Note

For P108 < 1000 mm, a switchover is made to the MODEL MODE. Because of the different dimensions, smaller safety areas than on the real crane apply.

P109 Automatic mode

Selection:

1 Automatic travel only to land 2 For travel to land, a lane MUST be specified

This parameter applies only when no external targets are specified.

Default: #.2 Access code: 1 Display: Only for STS (P102, selection 1 = ON)

P110 Language

Selection:

0 German 1 English

This parameter specifies the language used by the diagnostic software.

Independent of the setting of P110 (language) and P100 (access code), the language can also be set with the CeCOMM commissioning software (Windows Options/Language menu function).

Default: 1 Access code: 3 Display: Always



P111 Smoothing factor for actual speeds

This parameter can be used to smooth the determined actual speed. The factor acts on the actual speeds of all axes. Smaller values lead to a stronger smoothing; the maximum value 1.0 causes no smoothing.


P115 Prelimit switch configuration

Deceleration of the trolley and the hoisting gear before the minimum or maximum position to PLS speed. The dynamic prelimit switches (P24, P27, P64, P68) are enabled and disabled.

Meaning:

0 Dynamic prelimit switches deactivated, bits for prelimit switches active 1 Dynamic prelimit switches activated.

Default: #0 Min: 0 Max: 10 Access code: 1 Display: Always

P116 Maximum rotation angle for passive skew control

With passive skew control, the permissible rotation angle of the load after being put down corresponds to this value.

Default: 0 [cgr] Min: 0 [cgr] Max: 10000 [cgr] Access code: 2 Display: Always

P117 Request for encoder synchronization (SIMOTION C)

If the difference of the axis position between the encoder signal and the signal via PROFIBUS is greater than this value, status bit no. 14 of the relevant axis is set and therefore an encoder synchronization requested. As long as this value corresponds to the default value (=0), the bit is not set.


NOTICE




5.1.4.6 Camera/reflector parameters

P120 Assignment of camera axes to drive axes

Selection:

1 Motion up or down corresponds to trolley travel 2 Motion to the left corresponds to the forwards direction 3 Motion up corresponds to the forwards direction

Default: #... Access code: 1 Display: Only for STS (P102, selection 1 = ON)

P121 Delay of camera data, trolley

Delay of the camera signal from the image recording until switching in to the oscillation model.

Default: 0 [ms] Min: 0 [ms] Max: 10000 [ms] Access code: 2 Display: Only for STS (P102, selection 1 = ON)

P122 Camera data delay while skewing

Delay of the camera signal from the image recording until switching in to the oscillation model.

Default: 0 [ms] Min: 0 [ms] Max: 10000 [ms] Access code: 2 Display: Only for STS (P102, selection 1 = ON)

P123 Gain of the camera measuring signal

Value for injecting the camera measuring signal into the internal oscillation model. The camera measurement has no effect when this parameter is set to zero.

Default: 0,03 Min: 0 Max: 1 Access code: 1 Display: Only for STS (P102, selection 1 = ON)

P124 Gain of the camera measuring signal while skewing

Value for injecting the camera measuring signal into the internal oscillation model. The camera measurement has no effect when this parameter is set to zero.

Default: 0,05 Min: 0 Max: 1 Access code: 1 Display: Only for STS (P102, selection 1 = ON) and TLS (P197, selection 1 = ON)



P125 Camera fixed - reflector rotated

Selection:

0 Slewing drive rotates camera and reflector (e.g. trolley slewing gear) 1 Slewing drive rotates reflector, but not the camera (e.g. TLS cylinder)

Mounting of the camera and the reflector with respect to the skew.

Default: #1 Access code: 2 Display: Only for STS (P102, selection 1 = ON)

P126 Upper limit for camera measurement

The camera measurement is deactivated for pendulum lengths shorter than this value.

Default: 0 [mm] Min: 0 [mm] Max: 100000 [mm] Access code: 0 Display: Only for STS (P102, selection 1 = ON)

P127 Tripping time for camera error

Time that elapses before a camera error (E4) is reported to the PLC.

Default: 14 [s] Min: 0 [s] Max: 100 [s] Access code: 1 Display: Always

5.1.4.7 Travel behavior parameters

P140 Transfer time for the actuator speed

Specifies the time required for the transfer of the actuator speed to the drive. It is approximately the sum of the sampling times of the sway control and the PLC.


P141 Suppress opposite direction

As long as this percentage value of the maximum speed is not attained in manual operation, the drive axis is only moved in the direction specified by the crane operator.


P142 Deceleration increase while countering

The deceleration is increased by this value when the speed setpoint and the actual speed have different signs (countering). This parameter acts only for the trolley drive when Sway Control is ON, the conventional control method has been selected (not for time-optimized) and only for the BOM Speed Control.




P143 Acceleration reduction, fine travel

If the speed setpoint and the actual speed equal less than 30% of the maximum speed, the set acceleration is multiplied by this factor. This parameter acts only for the trolley drive when PD is ON, the conventional control type has been selected (not for time-optimized) and only for the BOM Speed Control.

Default: 0,5 Min: 0,001 Max: 1 Access code: 2 Display: Always

P144 Deceleration reduction, fine travel

If the speed setpoint and the actual speed equal less than 30% of the maximum speed, the set acceleration is multiplied by this factor and used as deceleration setpoint. The parameter acts only in the BOM Speed Control and is true only for the trolley.

The parameter does not act for time-optimized travel or when sway control is OFF.

Default: 0,5 Min: 0,001 Max: 1 Access code: 2 Display: Always

P145 Variable acceleration for the time-optimized control

A variable acceleration range can be specified for the time-optimized control. The controller tries to vary the acceleration in such a way that simple ramps result. The acceleration is then in the range (100%-value)*ASet_oPD . (100%+Value)*ASet_oPD or AMax.

With ASet_oPD - Set acceleration without sway control

AMax - Maximum acceleration


P146 Activation speed, sway control

If the absolute value of the speed setpoint is greater than this value, the sway control is activated after expiration of the switch-on delay P147. A hysteresis of ± 5% acts to prevent a continuous connection and disconnection of the sway control. Warning E65 is active as long as the speed has not been reached.


P147 Sway-control switch-on delay

The absolute value of the speed setpoint must be greater than the activation speed P146 at least for this period so that the sway control is activated. Warning E65 is present if this period has not yet elapsed.




P148 Sway-control switch-off delay

The absolute value of the speed setpoint must be less than the activation speed P146 at least for this period so that the sway control is deactivated.


P149 Drive switch-on delay, trolley

Switch-on delay of the drive after the brake has been opened. A dead time of the drive is specified so that the sway control knows this and the behavior for the model can be considered. If the value is less than 1, the delay element is deactivated.

vactuate

Brake closed

vactual

Signal „travelling“

Switch-in delay time

Fig. 5-1: ON delay


P150 Drive switch-on delay, hoisting gear

Switch-on delay of the drive after opening of the brakes. A dead time of the drive is specified so that the sway control knows this and the behavior for the model can be considered. If the value is less than 1, the delay element is deactivated.


P151 Drive switch-on delay during skewing

Switch-on delay of the drive after opening of the brakes. A dead time of the drive is specified so that the sway control knows this and the behavior for the model can be considered. If the value is less than 1, the delay element is deactivated.

Default: 0 [ms] Min: 0 [ms] Max: 1000 [ms] Access code: 2 Display: Only for TLS (P197, selection 1 = ON)



P152 Conventional/time-optimized control, trolley

Selection:

1 Time-optimized control for speed control 2 Time-optimized control for automatic control 3 On-the-fly unloading permitted (only for GSU) 4 On-the-fly unloading with max. deflection (only for GSU) 5 Time-optimized control only for stopping (only for GSU)

If all options are "OFF", the conventional control is always active.

Default: #..... Access code: 1 Display: Always

WARNING

The parameter P152 may be changed only during standstill because otherwise undesired setpoint step changes occur.

P153 Time constant for current rise, trolley

The current rise and therefore the change in acceleration over time are often limited by the converter. In order to take this delay into account when activating the oscillation model and the position control, a first-order delay element has been provided, whose time constant is set with this parameter. If the value is less than 1, the delay element is deactivated.


P154 Time constant for current rise, hoisting gear



P155 Current rise time constant for sway control



P156 Permissible initial sway

Automatic positioning can only be started when the initial sway is less than this parameter. Error E62 is triggered if the initial sway is greater. The value refers to the calculated average load deflection for acceleration operations. If 0% is set as permissible initial sway, then it is possible to start with every initial sway.




5.1.4.8 Controlled variable parameters

P160 Position controller, trolley

P position controller for automatic positioning. Negative values activate a target control instead of the position control. The absolute value of a negative value determines the steepness of the deceleration ramp ADecel=fabs(P160)*P6. The parameter must be set greater than 0 when the time-optimized algorithms are used.

Default: 0,5 Min: -1 Max: 10 Access code: 1 Display: Always

P161 Following error, trolley

Permissible deviation between the set and actual position during a travel operation in the BOM Positioning and BOM Hoist Control. If this value is exceeded, the travel operation is aborted and an error message (E41) generated. If the value = 0 is set, this function is not active.


P162 Positioning accuracy, trolley

Tolerance within which a positioning operation should be completed.


P163 Position controller, hoisting gear

P position controller for automatic positioning. Negative values activate a target control instead of the position control. The absolute value of a negative value determines the steepness of the deceleration ramp ADecel=fabs(P163)*P51.

Default: 0,5 Min: -1 Max: 10 Access code: 1 Display: Always

P164 Following error, hoisting gear

Permissible deviation between the set and actual position during a travel operation in the BOM Positioning and BOM Hoist Control. If this value is exceeded, the travel operation is aborted and an error message (E42) generated.




P165 Positioning accuracy, hoisting gear



P166 Position controller for skewing

P position controller for automatic positioning. Negative values activate a target control instead of the position control. The absolute value of a negative value determines the steepness of the deceleration ramp ADecel=fabs(P166)*P225.


P167 Following error for anti-skew

Permissible deviation between the set and actual position during a travel operation in the BOM Positioning and BOM Hoist Control. If this value is exceeded, the travel operation is aborted.

Default: 3000 [mm] Min: 0 [mm] Max: 500000 [mm] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P168 Positioning accuracy while skewing


Default: 20 [cgr] Min: 1 [cgr] Max: 200 [cgr] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P169 Permissible residual sway

Largest permissible load deflection after completion of a trolley motion. When the load deflection falls below this value, the signal "Sway neutralized" will be set.


P170 Residual sway after time-optimized acceleration

The parameter specifies how large the swaying motion may be after a time-optimized acceleration operation. P169 is always used for stopping.


P171 Quality of the time-optimized control

This parameter specifies the quality of the time-optimized control. Higher quality reduces the acceleration and deceleration times and increases the required CPU time.




5.1.4.9 TLS parameters

P180 Speed setpoint of the TLS cylinders

Cylinder speed when activating trim, list or skew.

Default: 12 [mm/s] Min: 1 [mm/s] Max: 1000 [mm/s] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P183 Maximum speed for TLS cylinders

Maximum cylinder speed that may occur with trim, list, skew and activated skew control.


P184 Speed for pressure 1/2 switchover

The signal for higher pressure is set above this speed.


P185 TLS switch-in for skew control

The manipulated variable determined for the anti-skew is multiplied by this value and switched into the TLS cylinder actuating signals.

Default: 1 Min: -100000 Max: 100000 Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P186 TLS speed for zero signal

If the controller calculates an actuator speed that is less than this value, then zero and no direction is output for the speed.

Default: 15 [%] Min: 0 [%] Max: 75 [%] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P187 Gain for the TLS cylinder positions

Calibration value for the TLS cylinder positions.

Default: 1 Min: 0,0001 Max: 200000 Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P188 Minimum TLS cylinder position

Limit for the TLS cylinder positions.

Default: -10000 [mm] Min: -200000 [mm] Max: 200000 [mm] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)



P189 Maximum TLS cylinder position

Limit for the TLS cylinder positions.


P190 Positioning accuracy of TLS cylinders


Default: 20 [mm] Min: 0.01 [mm] Max: 200000 [mm] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P191 Reduction of lowering actuator speed

The lowering speed of the TLS cylinders can be greater than the hoisting speed by this amount of actuator speed. In this case, the actuator speed for the lowering should be reduced with this parameter.

Default: 100 [%] Min: -100 [%] Max: 100 [%] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P192 Switch-off delay of the pump

The output signal for the pressure control is reduced by this set delay.

Default: 3 [s] Min: 0 [s] Max: 100000 [s] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P193 Minimum pressure, normalized

The hydraulic cylinders start to move as of this output value.


P194 Trim limit

Trim (when List and Skew are set to zero) The cylinders A and B do not exhibit any position difference, similarly, for the cylinders C and D. For the trim action, the cylinders A and B both move in one direction whereas the cylinders C and D both move in the other direction. This produces a difference A-D = B-C. When this difference reaches the value set in P194, the trimming will be interrupted.


P195 List limit

Like trim, B and C, both move in one direction whereas A and D both move in the other direction.




P196 Skew limit

Like trim, A and C, both move in one direction whereas B and D both move in the other direction.


P197 Use trim/list/skew control

Selection:

1 Trim/list/skew control On 2 Use the same positions on the land- and waterside

If the TLS control is to be used, the slewing gear is used in conjunction with the TLS cylinders. It can be specified whether the same TLS positions should apply on the land- and waterside or deviate from each other.

Default: #.. Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P198 Permissible TLS residual sway

Largest permissible load deflection after completion of a cylinder motion. When the load deflection falls below this value, the signal "Sway neutralized" will be set.


P199 TLS initial oscillation

This value must be exceeded in order to start with the sway neutralization.


P200 Zero position of cylinder A

Position that is approached when the command bit "Approach zero position" is set.


P201 Zero position of cylinder B



P202 Zero position of cylinder C





P203 Zero position of cylinder D



P204 Normalization value for TLS cylinders

The parameter contains the normalizing factor for the speeds that are transferred via the fieldbus. If the parameter is set, for example, to 28000, then a speed setpoint of -14000 corresponds to half the negative maximum speed of the cylinders.


5.1.4.10 Slewing gear parameters

P220 Maximum actuator speed while skewing

Speed limit in cgr/s. The set value corresponds to the maximum attainable speed. The maximum speed is the speed attained when sending the normalizing value P204.

Default: 500 [cgr/s] Min: 10 [cgr/s] Max: 4000 [cgr/s] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

Note

After confirmation of the parameter P220, a prompt will be made whether the P221, P226, P225 and P224 parameters should be updated. The updating is appropriate only when the speeds and accelerations dependent on P220 have already been entered and only P220 has to be adapted again. For this "update", the P221, P226, P225 and P224 parameters are changed in the same ratio as P220.

P221 Positioning speed while skewing

This value corresponds to the maximum speed in the BOM Positioning. In order to allow a slight overshoot, a value of 90% of the maximum actuator speed (P220) should be set. Set manually according to manufacturer or customer specifications. Record in order to check the speed setpoint in Positioning operation.

Default: 450 [cgr/s] Min: 10 [cgr/s] Max: 4000 [cgr/s] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P222 Prelimit switch speed while skewing

Percentage speed value within the prelimit switch range.

Default: 10 [%] Min: 0 [%] Max: 100 [%] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)



P223 Speed of rotation for zero speed signal

If the target position of the slewing gear has been reached and the actuator speed is less than P223/100*P220, no further direction signal is output. The brake can be closed.

Default: 3% Default: 3 [%] Min: 0 [%] Max: 75 [%] Access code: 2 Display: Only for TLS (P197, selection 1 = ON)

P224 Maximum acceleration while skewing

Acceleration limit in cgr/s². The set value corresponds to the maximum drive acceleration/deceleration. The value should be approx. 50..100% above the set acceleration (P225). Input values less than 20 are interpreted as ramp time. Set manually according to manufacturer or customer specifications.

Default: 250 [cgr/s²] Min: 0.1 [cgr/s²] Max: 1000 [cgr/s²] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P225 Set acceleration while skewing

The set acceleration is an internal acceleration variable in cgr/s². It is effective not only in the acceleration, but also in the deceleration phase. The set acceleration is achieved for deactivated sway control. Input values less than 20 are interpreted as a ramp time. Set manually according to manufacturer or customer specifications. The value should be approx. 75% of the maximum acceleration (P224).


P226 Acceleration without sway control

When the sway control is deactivated, the drive accelerates and decelerates with the set acceleration value. The value is applied as a minimum deceleration rate when the prelimit switch range is reached. Input values < 20 are interpreted as a ramp time. Set manually according to manufacturer or customer specifications. The drive must be braked with this deceleration from full speed at the prelimit switch down to prelimit switch speed (P222) at the limit switch.


P227 Gain of the deceleration while skewing

Gain factor for the increase or decrease of the deceleration. The deceleration results from P225 * P227, with countering from P225 * P227 * P142.

Default: 1 Min: 0,5 Max: 5 Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P228 Smoothing of torque setpoint while skewing





P229 Resolution of rotation angle sensor

Calibration value for the rotational position.

Default: 1 Min: -100 Max: 100 Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P230 Offset of rotation angle sensor

Calibration value for the rotational position.

Default: 0 [cgr] Min: -100000 [cgr] Max: 100000 [cgr] Access code: 1 Display: Only for TLS (P197, selection 1 = ON)

P231 Encoder increments per millimeter while skewing


Default: 0 [1/mm] Min: -500000 [1/mm] Max: 500000 [1/mm] Access code: 2 Display: Only for TLS (P197, selection 1 = ON)

P232 Minimum position for positioning while skewing

Smaller target positions are ignored. Note that the limitation applies to converted target positions with the resolution P229 and the offset P230.

Default: -5000 [cgr] Min: -200000 [cgr] Max: 200000 [cgr] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P233 Maximum position for positioning while skewing

Larger target positions are ignored. Note that the limitation applies to converted target positions with the resolution P229 and the offset P230.

Default: 5000 [cgr] Min: -200000 [cgr] Max: 200000 [cgr] Access code: 0 Display: Only for TLS (P197, selection 1 = ON)

P239 Commissioning status

Information encoded bit-by-bit about which commissioning steps have been completed successfully.


General information 5.2 Appendix


5.2 Appendix

5.2.1 CeCOMM commissioning software

5.2.1.1 Monitor menu tree

The menu assistance of the screens in the "Monitor" tab is explained using the following table. The display screens (middle column) can be reached from the "main menu" with the keys "1" to "7". The display screens, menus and additional functions listed in the right-hand column can be called from each of these display screens.

1 Display kinematics

2 Display PROFIBUS interface

3 Display status of travel axes

4 Display common bits

5 Display autocheck

6 Display hoist control

7 Display Trim/List/Skew

1 Display kinematics

2 Display PROFIBUS interface

3 Display status of travel axes

4 Display common bits

5 Display autocheck

6 Display hoist control

7 Display Trim/List/Skew

B Fixed blocked regions


I Commissioning menu

P Parameters menu

L Logger

E Error

H Fault history

V Version Info

? Return to main menu

! Stop diagnosis

X Twistlock simulation



Space Return to main menu

ENTER Build a new display

B Fixed blocked regions

1 Display blocked regions

I Add blocked regions

C Change blocked regions

D Delete blocked regions

S Save all sets of parameters/areas

R Reload parameters

F Display interpolation points

ESC Return to last selected display – page 1 to 7


E Error ESC Return to last selected display – page 1 to 7

? Help for selected fault

H Fault history



Any key Return to last selected display – page 1 to 7

H Fault history ESC Return to last selected display – page 1 to 7

E Error

ENTER Return to last selected display – page 1 to 7

I Commissioning menu

0 Set configuration and parameters

1 Set alignment of the camera

2 Calibrate hoist height (TROLLEY)

3 Calibrate hoist height (SKEW CONTROL)

4 Simulate errors

5 Determine speed limit

6 Save all parameters

? Help for selected commissioning step





L Logger H Display first page

E Display last page

B One page backward

F One page forward

S Save logged signal sequences



1,2 Display trolley parameters

3,4 Display hoisting gear parameters

5 Display sway control parameters

6 Display general parameters

7 Display camera parameters

8 Display driveability parameters

9 Display controller parameters

10,11 Display TLS parameters

12 Display skew drives parameters

P Parameters menu

C Change parameters

D Set default values for all sets

F Search parameters

I Communication address

L Parameters/areas listing

N Different parameters/areas set

R Reload parameters

S Save all sets of parameters/areas

Y Copy all sets of parameters/areas

T Title of set of parameters – only camera

? Help for parameters





V Version Info Any key Return to last selected display

! Stop diagnosis Space Restart of diagnosis

X Twistlock simulation

X Stop Twistlock simulation

Fig. 5-2: Monitor menu tree

5.2.2 Bibliography

Ref. 1: PROFIBUS and PROFINET, PROFIdrive Profile Drive Technology PROFIBUS User Organization e. V. Haid-und-Neu-Straße 7, D-76131 Karlsruhe http://www.profibus.com Order No.: 3.172 Version 4.1, May 2006

Ref. 2: SIMOCRANE Basic Technology V2.0 SP1 Operating Instructions SIMOCRANE_Basic_Technologie_1009.pdf, 10/2009 Edition

5.2.3 Abbreviations

BOM: Basic Operation Mode

BT: Basic Technology

BW: Backward

CF: CompactFlash card

CMS: Crane Management System

COP: Crane Operator Panel

CW: Clockwise

CCW: Counter-clockwise

DCC: Drive Control Chart

DN: Down

DS: Double-Spreader

FW: Forward

GSU: Grab Ship Unloader

HO: Hoist

i.e.: (lat. id est) that is to say

IO: Input/Output variables

LS: Landside

LH: Left-hand



MCC: Motion Control Chart

PELV: Protective extra low voltage

PLS: Prelimit switch

PST: Primary setup tool

RH: Right-hand

RMG: Rail-Mounted Gantry Crane

RT: Runtime

SC: Sway control

SELV: Safety extra low voltage

ST: Structured Text

STS: Ship to shore (quayside container) crane

STW: Control word

SW: Software

TLS: Trim/list/skew

TO: Technology Object in SIMOTION; symbol for a moving axis

TR: Trolley

UP: Up

WS: Waterside

ZSW: Status word



5.2.4 Terminology (German/English)

English German English German

Actuator speed Stellgeschwindigkeit Holding gear Haltewerk

Blocked region Sperrbereich i.e. d. h.

BOM Hoist Control

Grundbetriebsart Hubwerksteuerung

Immersion Point Eintauchpunkt

BOM Positioning Grundbetriebsart Positionierung

Input/Output variables

Eingangs- Ausgangsvariablen

BOM Speed Control

Grundbetriebsart Geschwindigkeitssteuerung

Limit curve Grenzkurve

Boom Ausleger Power cycle Aus- und wieder Einschalten

Closing Gear Schließwerk Prelimit switch speed (PLS)

Vorendschaltergeschwindigkeit (VES)

Gantry Fahrwerk Ship-to-shore crane

Containerkran

Gantry - Slave Fahrwerk-Folgeantrieb Slew gear Drehwerk

Grab Ship Unloader

Schiffsentlader Sway control Pendeldämpfungssystem

Higher-Level Controller

Übergeordnete Steuerung Trolley Katzfahrwerk

Hoist Hubwerk



Index Accessories

C240 ................................................................ 70 Alarms................................................................. 220 Basic operating mode......................................... 112

Select......................................................... 89, 91 Speed control ................................................ 113

Bay scanner........................................................ 167 Bay Scanner values

Conversion ................................................... 108 Blocked regions .......................................... 137, 141

Delete ............................................................ 144 External variable.......................................... 142 General features .......................................... 141 Internally learnt variable ................................ 144 Transfer ................................................ 142, 143

Bus cable PROFIBUS ...................................................... 48

Bus connector Connecting to module...................................... 49 Purpose ........................................................... 49 Setting terminating resistor.............................. 49

Bus segment......................................................... 47 C240

STOP............................................................... 56 C240 ambient temperature

Permissible ...................................................... 31 C240 cables

Shielded:Connecting ....................................... 44 C240 clearance distances .................................... 32 C240 components

For PROFIBUS DP subnet .............................. 47 C240 connecting comb......................................... 42 C240 connection values ....................................... 78 C240 current consumption

Rules................................................................ 40 C240 degree of protection .................................... 79 C240 diagnostics

LED display ..................................................... 63 C240 electrical installation

Configuring ...................................................... 39 C240 equipment

Open.................................................................30 C240 fixing bracket

For terminal element ........................................45 C240 front elements ..............................................54

Display of the LEDs..........................................54 C240 heat loss

Rules ................................................................40 C240 insulation test...............................................79 C240 interfaces

Ethernet interface.............................................24 Power supply connection .................................41 PROFIBUS DP interface..................................26

C240 IP 20 ............................................................79 C240 LEDs

5 VDC...............................................................64 BUS1F..............................................................65 BUS2F..............................................................65 MRES...............................................................52 RUN............................................................52, 64 SF.....................................................................64 STOP..........................................................52, 65 STOPU.......................................................52, 64

C240 module Installing..........................................................37 Mounting dimensions .......................................32 Supply ..............................................................41 Transport and storage conditions ....................28

C240 mounting rail Installing..........................................................34 Length ..............................................................33 Protective conductor connection .................36

C240 power supply................................................41 Setting the supply voltage................................44

C240 protection class............................................79 C240 protective conductor connection

On mounting rail ............................................36 C240 safety regulations

EMERGENCY STOP equipment .....................38 C240 shield connecting element ...........................44 C240 slot number

Inserting ..........................................................38



C240 supply voltage ............................................. 39 Setting the power supply ................................. 44

C240 terminal element.......................................... 44 C240 test voltages ................................................ 79 C240 type plate..................................................... 23 CE

Marking ............................................................ 70 Clock

C240 ................................................................ 78 Command bits

General ........................................................... 92 TLS .................................................................. 97

Commissioning 2D-Trajectory ................................................. 211 C240 system requirements.............................. 58 Positioning ..................................................... 211 TLS Control.................................................... 217

Commissioning menu ......................................... 171 Commissioning of C240

Requirements................................................. 57 Commissioning requirements

Sway Control system..................................... 191 Commissioning steps

Sway Control ................................................. 202 Communication

Checking PLC-SIMOTION D ......................... 194 Ethernet ......................................................... 153

Components For PROFIBUS DP subnet .............................. 48

Configuration S7..................................................................... 79 Sway Control system.............................125, 197

Configuring the C240 Electrical installation ........................................ 39

Connecting Bus connector.................................................. 49 C240 power supply .......................................... 41

Content ................................................................... 5 Control method

Selecting ....................................................... 209 Conventional control ...................................197, 209 Cylinder.............................................................. 148 Cylinder positions ............................................... 219 Damping factor

Setting........................................................... 210 Declaration of conformity ...................................... 71 Degree of protection

C240 IP 20....................................................... 79 Deletion

Positions....................................................... 216 Dependency matrix............................................... 19 Device

See node ......................................................... 46 Diagnostic program

Functions....................................................... 160 Diagram.............................................................. 174

Print ............................................................... 186 Properties ...................................................... 188 X/Y display ............................................ 188, 189

Dimensions C240................................................................ 78

Double spreader ................................................. 146 DP slave connections

Number of........................................................ 47 Electrical interference on C240

Protection against............................................ 40 ElectroMagnetic Compatibility .............................. 72 EMC directives ..................................................... 70 EMERGENCY STOP concept

C240................................................................ 38 Error list

Sway Control system..................................... 224 ESD guideline....................................................... 74 Ethernet .............................................................. 153 Ethernet interface

Assignment...................................................... 24 Ethernet subnet .................................................... 50 Exclusion of liability ................................................ 4 FAQ

Sway Control system..................................... 236 Following error monitoring.................................. 221 Functions

Diagnostic program ....................................... 160 Guideline

ESD ................................................................. 74 Highest PROFIBUS-address................................ 46 Hoist control

Activation ..................................................... 121 Hoisting height

Calibrate ........................................................ 206 Hydraulic control .............................................. 150 IEC 1131............................................................... 70 Immersion point................................................ 139 Installation

C240 ................................................................ 34 Installing the C240.............................................. 34

Modules .......................................................... 37 Mounting rail.................................................. 34 Shield connecting element .............................. 45

Integration In S7 project .................................................... 79

Interface Diagnostic program ....................................... 161

Interference



Pulse-shaped................................................... 72 Sinusoidal ........................................................ 73

IP address Camera............................................................ 54 Restoring ......................................................... 56 Sway-control computer.................................... 54

Laser................................................................... 167 Laser scanner ..................................................... 167 Learning

Positions....................................................... 216 Limit curve parameters .................................... 214 List ...................................................................... 149 Load carrying device

Compensate ................................................. 209 Load deflection ................................................... 166 Logic

Travel signal................................................. 108 Micro memory card on C240 ................................ 53 Minimum speed................................................. 211 Minimum time.................................................... 211 Mounting dimensions of modules

C240 ................................................................ 32 Network components ............................................ 48 Nodes ................................................................... 46 Offset Land ........................................................ 138 Offset Water ...................................................... 138 ON delay ............................................................ 211 On-the-fly unloading......................................... 121

Activation ..................................................... 119 Open equipment

C240 ................................................................ 30 Operating mode switchover................................ 134 Operation

Diagnostic program ....................................... 157 Oscillation model

Mathematical ................................................. 196 Override .............................................................. 132 Parameter set ..................................................... 202 Pendulum length

Effective ................................................. 166, 206 Position controller ............................................... 211 Position offset................................................... 137 Positioning

Abort ............................................................. 115 Activation ..................................................... 115

Positioning range................................................ 213 Permissible .................................................... 213

Pressure system................................................. 219 PROFIBUS address.............................................. 46

Highest............................................................. 46 Rules................................................................ 46

PROFIBUS cable.................................................. 48

PROFIBUS cables Rules for laying ................................................48

PROFIBUS DP interface Content............................................................81

PROFIBUS DP subnet Components...............................................47, 48

Protection against electrical interference on C24040 Pulse-shaped interference ....................................72 Radio interference

Emission of.......................................................74 Residual sway

Setting ...........................................................210 Rules for laying

PROFIBUS cables ...........................................48 S7

Configuration....................................................79 Safety of electronic controllers ..............................71 Save position.......................................................216 SC Automatic ......................................................137

Possible settings..........................................137 SC Semiautomatic...............................................141 SC Speed Control .............................. 125, 137, 151

Control............................................................125 End of a travel movement ...........................127 Start of a travel movement ..........................126

Segment ................................................................47 Sinusoidal interference..........................................73 Skew....................................................................149 Skew control

Speed setpoint ...............................................219 Skew Control ............................................ 149, 220 Spare parts

C240.................................................................70 Speed control ......................................................113

Activation ......................................................113 Speed limit

Determine.......................................................208 Status bits

General ..........................................................102 TLS.................................................................107 Trolley, hoisting gear...................................100

Sway Control Activating/deactivating................................128 Basic operating mode ....................................112 Deactivation ..................................................113 Priorities........................................................149 TLS commands ............................................149

Sway Control configurations ...............................125 Sway Control system commissioning

Requirements.................................................191 Sway Control system parameters

Camera and reflector .....................................257



Save............................................................... 209 Trolley ............................................................ 239

Sway-control computer interface description . 81 System overview................................................... 13 Technical data

SIMOTION C240 ............................................. 78 Terminating resistor

Setting on bus connector................................. 49 Time-optimized control ...............................197, 209 TLS

Cylinder.......................................................... 220 Move zero ...................................................... 220 Reset ............................................................. 220 Save zero....................................................... 220 Skew control .................................................. 220 Speed limit ..................................................... 219 Speeds........................................................... 219

Test................................................................ 220 TLS commands................................................. 147 TLS Control ............................................... 147, 151

Activation ..................................................... 147 Trim .................................................................... 149 Twistlock simulation ........................................ 217 UL certification...................................................... 71 Variable blocked regions .................................... 143 Weight

C240................................................................ 78 Windows menu functions

Diagnostic program: ...................................... 160 Wiring

C240................................................................ 38 Zero position

Approach/save .............................................. 149

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