electronic maintenance module for braden planetary hoists product

ELECTRONIC MAINTENANCE MODULE
FOR BRADEN PLANETARY HOISTS
PRODUCT OVERVIEW
USERS GUIDE
PACR WINCH DIVISION
LIT2226-R1
9/2006
Printed in U.S.A.
P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
PHONE (918) 251-8511 FAX (918) 259-1575
www.paccarwinch.com
FOREWORD
The information in this manual is intended to provide the
user with the proper use and operational characteristics of
the optional BRADEN Electronic Maintenance Module
(EMM). It is extremely important that this manual be read in
its entirety and understood.
Some illustrations in this manual may vary from your equipment, or may have some elements removed for clarity.
Please note that this manual is not specific to any particular
hoist. Should you have a question regarding your hoist, the
EMM system or this manual, please contact the BRADEN
Technical Support Department.
Phone:
(918)-251-8511
08:00 to 16:30 hours CST
Monday thru Friday
Fax:
(918)-259-1575
Internet:
winch.service@paccar.com
TABLE OF CONTENTS
WIRING OVERVIEW...............................................
2
GENERAL DESCRIPTION......................................
3
FEATURES..............................................................
3
HOIST CYCLE MONITORING.................................
4
CHARTING...............................................................
5
API CHARTING.............................................
5
HISTORY CHARTING...................................
6
HISTORY.................................................................
7
MAINTENANCE HISTORY......................................
7
API BRAKE TEST HISTORY...................................
8
COMPONENT DESCRIPTION................................
10
ERROR CHECKING................................................
12
COMPONENT INSTALLATION...............................
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harness not
rendered
to scale
BRAKE VALVE CHECK, optional
2-SPEED MOTOR, optional
SPEED PICKUP
PRESSURE TRANSDUCER
Power Supply, 12 VDC
Supply Harness, p/n #106124
Wire Color
Connection Description
White
Blue
Green
Black
Red
Red w/ Black Stripe
Black w/ White Stripe
Orange w/ Black Stripe
Orange
White w/ Black Stripe
Green w/ Black Stripe
Blue w/ Black Stripe
Optional, Active Laptop Connection, serial pin 3 at computer
Optional, Active Laptop Connection, serial pin 2 at computer
Optional, Active Laptop Connection, serial pin 5 at computer
Main Power Supply, negative 12VDC, (-)
Main Power Supply, positive 12VDC, (+)
Thumb Thumper, Positive Feed, (+)
Thumb Thumper, Negative Feed, (-)
Motor Displacement Switch, Provides (+) signal to EMM
Brake Test Switch, Provides (+) signal to EMM
Not Used
Not Used
Not Used
Laptop Computer Connection
2
-Switch
-Switch
Optional
Connections
GENERAL DESCRIPTION
The BRADEN Electronic Maintenance Module (EMM) system is an advanced hoist monitoring option which may be
added to most any Braden planetary hoist. The EMM system provides active load and usage data allowing the user
to plan for preventive maintenance based on the actual hoist
duty cycle.
FEATURES OF THE EMM SYSTEM
• Actual hoist duty cycle monitoring
• Actual hoist operation hours, in accordance with API
specifications
• A complete record of actual hoist use, in hours drum
operation, not just crane engine hours
• Downloadable usage history to laptops or most
handheld PC’s
• 12 or 24-Volt DC operation, for use on most crane
systems
• Optional Brake Test Kit allows ability to perform API
required hoist brake testing from the operator’s station
• Indefinite storage capability of hoist service history –
accessible only with proper access codes (for factory service technicians)
• Tamper-proof information specific to the hoist
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Hoist Duty Cycle Monitoring
The EMM system records the actual loading and speed conditions of the
hoist as it is being used. Actual load and speed conditions are logged
and compared to encoded parameters for the specific hoist, taking into
account torque, motor speed, drum speed and gear geometry, allowing
the system to provide an accurate hoist duty cycle. Knowing the true
duty cycle of the hoist allows the user to better define a preventive maintenance program for the specific unit.
The Duty Cycle Chart, which can be displayed via a PC interface, or on
an optional display unit, plots monthly usage history in one of four categories – Light, Normal, Heavy and Severe - based on actual usage, as
defined above. It also plots a quarterly average usage over the previous
3 month period, providing an accurate accounting of how hard the hoist
is being used over time. The most recent quarterly average usage, or
duty cycle, is indicated at the bottom of the display as:
“Chart indicates = “Light Duty Cycle” (for example)
When performing regular crane inspections (quarterly inspections),
review and download the data from the EMM module. If the quarterly
usage indicates “Heavy” usage or less, no action beyond normal servicing procedures for this specific time period is required. However, if
“Severe” usage is indicated at any time during the period leading to the
current inspection, the hoist MUST be inspected to the next higher level
of service. Also, following inspections should be performed more often
(for example, monthly instead of quarterly) and the EMM data should be
downloaded during these inspections. Continued usage in the “Heavy”
and “Severe” ranges may require shorter time periods between oil
changes and hoist teardowns.
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API – Hours Used Chart
The EMM system will record and display the actual hours of
drum rotation and plot monthly and quarterly usage, as
defined in API (American Petroleum Institute)
Recommended Maintenance Practice RP 2D (latest printing). Per API, usage history is defined as hours of crane use
per month, and is categorized as follows:
0-10 hours / month = Infrequent Usage
10-50 hours / month = Moderate Usage
50-plus hours / month = Heavy Usage
API requires that usage be averaged over quarterly time
periods to define, or classify, the usage. The EMM display
will plot both the monthly hours used and the quarterly, similar to the duty cycle chart, and will display the last quarter
usage per the API designation above.
Please note, that although the API usage chart defines a
time history of usage, the BRADEN Duty Cycle chart will
accurately depict the usage including hoist loading. This
information will provide a much better means to define the
needed maintenance program and intervals, based on actual hoist usage. Heavier loaded hoists will be able to get the
maintenance needed to reduce the possibility of catastrophic failure due to inadequate maintenance cycles, while lesser used hoists can possibly be used for extended periods
between teardowns.
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Winch Life History Chart
The EMM system will record and keep track of the usage
history of the hoist, viewable on this display screen. Data
recorded includes:
•Load Range – 12 load range “buckets” from lightly loaded
conditions to two (2) overload conditions of varying degrees.
These load buckets are specific to the hoist the EMM is
installed on.
•Hours – Actual time used within each of the 12 load
ranges.
•Drum Revs – Actual count of drum rotations within each
load range.
•Average Drum Speed (rpm) – Average hoist drum speed
over the time recorded.
•Total hours of usage and drum rotation count.
“View Mode” options allow the user to switch screen
between Total Winch History, Previous 3-Month Winch
History and Current Month Winch History, allowing monthly
or quarterly reviews of winch usage as required. By utilizing
this option, maintenance supervisors and technicians will be
better able to determine actual service needs of the unit.
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Maintenance History
The EMM system will store and display a history of basic
maintenance performed on the hoist. Braden Authorized
Service Centers and distributors will have protected access
to add to maintenance records of the hoist by entering the
required information on this screen. The date and time will
be entered automatically as a new maintenance record is
added to the file. The technician performing the service can
enter his name, the repair order or work order number, and
a brief description of the work performed at this time, utilizing the entry fields at the bottom of the screen. The “work
performed field is limited to 30 characters
NOTE: Access to the maintenance screen is limited to individuals with the proper permissions and can not be changed
after closing the session. The information entered into the
system should be checked closely before ending this entry.
If an error has been made, or a major element of the repair
was left out, a new record may be entered as an update to
this record. Be sure to enter the same repair / work order
number in the proper location. If the repair / work order
number was originally entered incorrectly, indicate those
changes in the “Work Performed” field.
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API Brake Test History
The EMM system has the capability to allow a brake test to
be performed prior to a lift or during a quarterly inspection.
This can be accomplished by adding the optional Brake Test
Kit to the Maintenance Module. In order to pass the brake
test, the hoist drum must remain stationary during the entire
test.
By activating a toggle switch at the operator’s platform, a
solenoid valve will be energized that will close the oil path to
the hoist static brake cavity keeping the brake fully applied
(the hoist will be powered in the lowering direction against
the fully applied brake). If there is no drum movement, the
test is completed and the test status indicates “NO” under
the Drum Movement column. All values in the table will be
entered automatically once the toggle switch is activated.
The brake valve will remain closed and the hoist will remain
in the brake test mode until the voltage signal has been
removed from the solenoid by deactivating the toggle
switch, opening the valve.
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CAUTION
!
WARNING
!
NOTE: If, in the course of hoist review, a technician
reviews the usage history and finds that a brake test
has recorded “YES”, the brake should be retested manually. If ANY drum movement is noted during this test,
the internal brake assembly and the brake valve should
be disassembled and inspected for wear or other possible failure.
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Component Description
The Braden EMM system contains the following components which must be added to a standard hoist:
• Electronic Control Module (ECM) and wiring harnesses
• Motor adapter and motor shaft adapter
• Pressure transducer and manifold
• Proximity sensor for speed pickup
•Cabling
• Braden “Data Logger” software
• Optional 2-speed motor pickup
• Optional API brake test valve
SPACER BLOCK
FOR
PRESSURE
TRANSDUCER
SPEED SENSOR
SHAFT ADAPTER
MOTOR ADAPTER
The ECM contains the software coding to allow the EMM
system to function and properly interpret the signals allowing it to code the usage history into the ECM memory. The
main harness provides power from either 12VDC or 24VDC
power systems, as specified at the time of order to match
the intended crane power system. An RS-232 adapter harness is available to enable connection to a laptop or
Windows handheld PC for downloading and viewing the history and usage data.
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An adapter flange is installed between the motor and the
hoist motor adapter. This adapter flange contains the port
for installing the proximity switch, or speed sensor. The
motor shaft adapter is installed between the hydraulic motor
shaft and the overrunning brake clutch. The motor shaft
adapter has external teeth from which the speed sensor
picks up and determines the rotational speed of the motor,
or hoist input.
A manifold block is also installed between the hydraulic
motor and brake valve. The manifold has a port for installing
the pressure transducer. This transducer converts the
hydraulic pressure to an electrical signal that can be converted by the ECM to actual hoist load weight, in pounds.
A built-in 2-speed feature allows the EMM system to work
with hoists utilizing 2-speed hydraulic motors. This feature
ensures that as a motor is shifted into high speed range, the
system will have the correct parameters defined and, due to
the speed change in the motor, will not be misinterpreted by
the system as an out of range condition which would create
an error condition in the stored usage history file.
An optional Brake test Kit is also available that allows for
API required brake testing to be completed from the operator’s platform via a toggle switch and a solenoid operated 3way selector valve. By activating the toggle switch at the
operator’s platform, a 12VDC or 24VDC solenoid valve, as
required by the crane power system, will be activated that
will close the oil path to the hoist static brake cavity keeping
the brake fully applied. The hoist will be powered in the lowering direction against the fully applied brake.
If there is no drum movement, the test is completed and the
test status is recorded as “NO” in the ECM history file. If any
drum movement is detected during the brake test, “YES” is
recorded in the history file.
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Error Checking
Self-diagnostic capabilities are built into the EMM system to
advise users/operators whether the system is operating
properly. If an error occurs with either the speed sensor or
the pressure transducer, an indicator LED on the ECM will
notify the operator of the condition.
There are two columns of indicator LED’s on the main module. Under “SYSTEM INFORMATION”, in the left column,
are the following indicators:
Power
Motor – High Speed
Brake Test
Speed Sensor Error
Pressure Sensor Error
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• As long as power to the crane is on and the system connections are
functioning normally, the “Power” indicator LED will glow green. If power
to the hoist is lost, the LED will be off.
• If the hoist is equipped with a 2-speed hydraulic motor and the EMM is
set up for 2-speed motor monitoring, the “Motor – High Speed” indicator
LED will glow green whenever the operator selects high-speed mode.
During normal, low-speed operations, the LED will be off.
• If the operator is performing a brake test, the “Brake Test” indicator
LED will glow green. During normal hoisting operations, the LED will
remain off.
• As the hoist is operated, the speed indicator LED will flash intermittently depending on motor shaft speed. As the motor runs faster, the
LED will flash faster until it reaches a certain point at which it remain lit
solidly. If the speed sensor fails, the LED will not light and will remain
off.
• The pressure indicator will remain off under normal operating conditions. If the pressure sensor fails or an out of range condition is present,
the indicator LED can come on and glow red.
*Note*
When the crane power is on and the hoist is in neutral with no pressure
to the motor, the indicator light will remain lit.
Under “BRADEN DUTY CYCLE”, in the right column, are
the following indicators:
Severe Duty Cycle
Heavy Duty Cycle
Normal Duty Cycle
Light Duty Cycle
If the hoist is operating in either the Heavy, Normal or Light
duty cycle ranges, the indicator LED will glow green, for the
appropriate active working range. If the hoist is operating in
the Severe Duty Cycle range, the LED will glow red. The
proper indicator should be on at all times depending on the
active duty cycle, as long as there is electrical power to the
hoist.
* The active duty cycle consists of the current month, plus the two previous month.
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Electronic Maintenance Module Component Installation
Before installing the EMM components on a used hoist,
make certain the hoist is in suitable condition to allow for full
and proper utilization of the maintenance information to be
logged.
• The hoist MUST be removed from service, disassembled
and inspected as defined in Braden publication PB-308,
“Inspection, Testing, Preventative Maintenance and Special
Operating Instructions for Planetary Hoists”, and the specific
hoist service manual. This pre-installation teardown inspection of the hoist must be done to allow a new baseline to be
established from which new maintenance schedules may be
instituted.
• Install the studs into the motor mounting holes in the hoist
motor adapter. Apply Loc-Tite 272 or equivalent to clean dry
threads prior to inserting the studs.
• Install the EMM motor adapter housing between the hoist
motor adapter and the hydraulic motor.
Install the shaft adapter into the sprag clutch inner race.
• Remove the brake valve from the hydraulic motor, if not
already removed, and install the manifold between the
motor and brake valve using the new capscrews provided.
Position the manifold so the transducer port faces the hoist.
• Install the hydraulic motor to the adapter housing. All motor
plumbing remains as existing. Install the lockwashers and
hex nuts to the studs. Tighten the hex nuts to 110 lb-ft (149
N-m).
• Install the speed sensor into the port in the adapter housing over the shaft adapter. Make certain the shaft is rotated
such that the outer edge of the gear tooth is centered with
the port opening. Carefully run the sensor into the port until
it lightly contacts the gear tooth on the shaft adapter. Then
back the sensor out of the port three (3) complete turns –
approximately 3.0 mm (.12 in.). Tighten the bottom hex nut
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against the housing, then snug the upper jam nut against
the bottom nut to secure the position of the sensor.
• Install the pressure transducer into the manifold port under
the brake valve. Tighten the fitting to 15 lb-ft (20 N-m) maximum.
• Attach the EMM module to the hoist tie plate or base in a
safe location. A safe location is somewhere out of the way,
yet accessible, so that it can not be damaged by personnel
working near the hoist platform during servicing of the
crane.
• Attach the main wiring harness to the module. The connectors on the harness and module are color-matched to aid
installation. Attach the grey harness connector to the grey
module connector – this is the power lead. Attach the black
harness connector to the black module connector – this is
output lead.
• Connect the 12-ft (3.7 m), or optional 25-ft (7.6 m), power
cable to the 12-pin connector lead on the main harness.
• Alternately, locate the EMM module inside the crane
cab in an accessible location, but out of the way of normal crane controls. For this option, new wiring leads
will be required to be fabricated on site to connect
between the EMM module and the sensors on the hoist.
• Once the hoist is installed and all connections are made
and checked, the EMM system is ready to use, or to be set
up. For set up procedures, please refer to Braden publication LIT2271, “Electronic Maintenance Module for Braden
Planetary Hoists – Installation and Set-Up Guide.”
Note: Setting up of the EMM module is performed by authorized
personnel ONLY. This can be Braden Authorized Service Center
personnel, Braden distributor personnel, or PACCAR Winch
Division personnel. Permissions to perform the set-up of the module may only be authorized by PACCAR WinchDivision.
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