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Programmable Logic Controller - PLC / SPS

2006

PLC / SPS FUNCTION


PLC / SPS

Voltage Control Sensor Control Start Engine Stop Engine Start Inter Locks Lubrication Systems Emergency Stop Boarding Lights Service Lights CAN-Bus Communication RS232 Communication Power Supply Via +30

PLC / SPS - COMMUNICATION PORTS


PLC / SPS

RS232 Programming Port ON/OFF LED BUS LED CAN-BUS Input CAN-BUS Output

Configuration Switch

OVERVIEW IN- AND OUTPUTS


PLC / SPS

32 Digital Inputs 2 Analogue Inputs (0-10V) 6 Analogue Inputs (4-20mA) 20 Digital Outputs 4 Analogue Outputs Power supply

DIGITAL INPUTS
(DIESEL ENGINE EXCAVATORS) PLC / SPS

Input Description (German)


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Fahren 2. Stufe auto Fettfass Leer Servo Filter Verschmutzung Counter Dumper Reset Zndung Ein Not Aus Motor Links Start Motor Rechts Start Motor Links Stopp Motor Rechts Stopp Motor Links Idle Motor Rechts Idle Absperrklappe Hydr. lbeh. Links Absperrklappe Hydr. lbeh. Rechts Absperrklappe Hydr. lbeh. Mitte Schmierung Strung Reset lstand Links PVG lstand Rechts PVG Schmierdruck Initiator 2 Schmierdruck Initiator 1 Aufstiegsbeleuchtung Kabinenbeleuchtung Reserve Wartungsbeleuchtung Reserve

Description (English)
Traveling 2nd Gear automatic Grease Empty Servo Filter Contamination Counter Dumper Reset Ignition On Emergency Stop Engine Start LH Engine Start RH Engine Stop LH Engine Stop RH Idle On LH Engine Idle On RH Engine Shut Off Valve Oil Left Shut Off Valve Oil Right Shut Off Valve Oil Middle Grease Fault Reset Oillevel Pumpdrive Gear Box Left Oillevel Pumpdrive Gear Box Right Grease Initiation 2 Grease Initiation 1 Ladder Light Cab Light Reserve Maintenance Light Reserve

Signal Source
(only RH400) S250 or S250.1 S216.2 Clamp 15 S3 - S3.2 (K24) S5 S6 S90 S92 S91 S93 S212 S212.1 S212.2 S106 B136 B137 B336.1 B336 S55 or S56 S35.1 or S35.2 S41 - S43

ANALOGUE INPUTS
(DIESEL ENGINE EXCAVATORS) PLC / SPS

Input Description (German)


57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 Kraftstoff Fllstand linker Tank Kraftstoff Fllstand rechter Tank Schmierdruck Oberwagen Schmierdruck Unterwagen Fettfass Fllstand

Description (English)
Diesel Level Left Diesel Level Right Grease Pressure Uppercarriage Grease Pressure Undercarriage Grease Level

Signal Source
B133 B134 B36 B127 B125

DIGITAL OUTPUTS
(DIESEL ENGINE EXCAVATORS) PLC / SPS

Output
37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

Description (German)
Ultraschall Sensor Klemme 30 Motor Links Start Moror Rechts Start Kraftstoffventil Links Kraftstoffventil Rechts Motor Links Idle Motor Rechts Idle Lampentest Lfter Schaltschrank Schmierung Ein Schmierung Bypassventil Schmierung Umschaltung A-B Drehzahlabsenkung Schmierung Unterwagen Reserve Fettcontainer Voll Aufstiegsbeleuchtung Kabinenbeleuchtung Wartungsbeleuchtung

Description (English) Signal used to operate


US Distance Sensor Supply Plug 30 LH Engine Start RH Engine Start Diesel Valve Left Diesel Valve Right LH Engine Idle RH Engine Idle Lamp Test Fan Electrical Cabinet Grease On Grease Bypass Valve Grease Line Switch A-B Revolutions Reduction Grease Undercarriage Reserve Greasecontainer Full Ladder Light Cab Light Maintenance Light H137.2 - H137.3 K8.2 K2.3 K3.3 K7.1 K7.2 K206 K207 K36 K28.1 K200 K201 K202 K49 K204 K205 K22.1 K199 K25.1

Analogue Outputs are not used!

POWER SUPPLY
(DIESEL ENGINE EXCAVATORS) PLC / SPS

Power Supply via +30 The PLC is supplied directly through the + 30 V battery pole. The voltage supply is activated together with the +15 V control voltage (DE05 activates DA38). The control contact (DA38) activates the relay 8.2 and establishes a self-holding circuit with the + 30 V line. After the +15 V control voltage is disconnected, this contact remains closed until all time stages (Lights etc.) have lapsed before the control system automatically shuts off via contact (DA38).

As soon as the ignition key is switched on or any light switch is pushed, the "POWER" LED indicates the presence of 24V by a green light. Simultaneously the PLC walks through an initialisation period. During this period the "CAN-Bus" LED will flash a few times and finally blinks continuously ON/OFF (orange light).
If the PLC will be switched on by any light switch, the "POWER" LED immediately indicates the presence of 24V by a green light! The self-holding circuit only is present after the PLC walks through the initialisation period. After about 1 2 seconds!

CONTROL VOLTAGE ON
(DIESEL ENGINE EXCAVATORS) PLC / SPS

Colour code for the indication of input and output status LED is OFF LED is ON LED turns ON when... / turns OFF when

Control Voltage ON. Ignition Key Turned On.


Active Input Signals DE05 Power supply ( +15 ) switched ON with key switch DE13 Left shut-off valve on hydr. tank OPEN DE14 Right shut-off valve on hydr. tank OPEN DE15 Centre shut-off valve on hydr. tank OPEN DE19 Grease Initiator 2 is SET (if no Grease Cycle is running)

Active Output Signals DA20 Power supply ( +30 ) switched ON for PLC via this Outlet

Signal changes by Ignition Key Turned On DA07 Lamp Test (ON for 5 seconds)

START LEFT HAND ENGINE


(DIESEL ENGINE EXCAVATORS) PLC / SPS

LED that will not be effected for the following description DE05 Power supply ( +15 ) switched ON with key switch DE13 Left shut-off valve on hydr. tank OPEN DE14 Right shut-off valve on hydr. tank OPEN DE15 Centre shut-off valve on hydr. tank OPEN DE19 Grease Initiator 2 is SET (if no Grease Cycle is running)DA15 DA20 Power supply ( +30 ) switched ON for PLC via this Outlet

Signal changes by turn on the Engine DE07 LH Engine Start Button (as long as Button is engaged!) DA01 LH Engine Start ON DA03 LH Diesel Valve ON

Signal changes after Engine is running (2-4s) DA08 Fan Electrical Cabinet ON DA09 Grease Pump Starts ON DA10 Grease Bypass Valve Open ON

START RIGHT HAND ENGINE


(DIESEL ENGINE EXCAVATORS) PLC / SPS

LED that will not be effected for the following description DE05 Power supply ( +15 ) switched ON with key switch DE13 Left shut-off valve on hydr. tank OPEN DE14 Right shut-off valve on hydr. tank OPEN DE15 Centre shut-off valve on hydr. tank OPEN DE19 Grease Initiator 2 is SET (if no Grease Cycle is running)DA15 DA20 Power supply ( +30 ) switched ON for PLC via this Outlet DA02 LH Diesel Valve ON DA08 Fan Electrical Cabinet ON

LED that will not be effected when Grease System is still running DA09 Grease Pump Starts ON DA10 Grease Bypass Valve Open ON

Signal changes by turn on the Engine DE08 RH Engine Start Button (as long as Button is engaged!) DA02 RH Engine Start ON DA04 RH Diesel Valve ON

ENGINES ARE RUNNING (AFTER FIRST GREASE CYCLE)


(DIESEL ENGINE EXCAVATORS) PLC / SPS

LED that will not be effected for the following description DE05 Power supply ( +15 ) switched ON with key switch DE13 Left shut-off valve on hydr. tank OPEN DE14 Right shut-off valve on hydr. tank OPEN DE15 Centre shut-off valve on hydr. tank OPEN DE19 Grease Initiator 2 is SET (if no Grease Cycle is running) DA20 DA03 DA04 DA08 Power supply ( +30 ) switched ON for PLC via this Outlet LH Diesel Valve RH Diesel Valve Fan Electrical Cabinet

STOP BOTH ENGINES WITHOUT IDLE


(DIESEL ENGINE EXCAVATORS) PLC / SPS

LED that will not be effected for the following description DE05 Power supply ( +15 ) switched ON with key switch DE13 Left shut-off valve on hydr. tank OPEN DE14 Right shut-off valve on hydr. tank OPEN DE15 Centre shut-off valve on hydr. tank OPEN DE19 Grease Initiator 2 is SET (if no Grease Cycle is running) DA20 Power supply ( +30 ) switched ON for SPC via this Outlet

Signal changes by turn off the left hand Engine DE09 LH Motor Stop Button (as long as Button is engaged!) DA03 LH Diesel Valve OFF

Signal changes by turn off the right hand Engine DE10 RH Motor Stop Button (as long as Button is engaged!) DA04 RH Diesel Valve OFF DA08 Fan Electrical Cabinet OFF (after no more running of both engines)

STOP BOTH ENGINES WITH IDLE


(DIESEL ENGINE EXCAVATORS) PLC / SPS

LED that will not be effected for the following description DE13 Left shut-off valve on hydr. tank OPEN DE14 Right shut-off valve on hydr. tank OPEN DE15 Centre shut-off valve on hydr. tank OPEN DE19 Grease Initiator 2 is SET (if no Grease Cycle is running)

Signal changes by turn on Idle Left and Idle Right DE11 LH Engine Idle Button (as long as Button is engaged!) DE12 RH Engine Idle Button (as long as Button is engaged!) DA05 Idle LH Engine ON DA06 Idle RH Engine ON

Signal changes by turn off Ignition key DE05 Power supply ( +15 )

OFF

Signal changes after 5 minutes Idle time DA05 Idle LH Engine DA06 Idle RH Engine DA03 LH Diesel Valve DA04 RH Diesel Valve DA08 Fan Electrical Cabinet DA20 Power supply ( +30 )

OFF OFF OFF OFF OFF (after no more running of both engines) OFF

Everything OFF in the same moment!

EMERGENCY STOP OR ANY UPCOMING FAULT


(DIESEL ENGINE EXCAVATORS) PLC / SPS

LED that will not be effected for the following description DE19 Grease Initiator 2 is SET (if no Grease Cycle is running)
Possible Signal changes by upcoming Faults DE05 Power supply ( +15 ) switched DE06 Emergency Chain DE13 Left shut-off valve on hydr. tank DE14 Right shut-off valve on hydr. tank DE15 Centre shut-off valve on hydr. tank OFF OPEN CLOSED CLOSED CLOSED Light OFF ON OFF OFF OFF

Signal changes after any of above Faults appears DA03 LH Diesel Valve OFF DA04 RH Diesel Valve OFF DA05 Idle LH Engine OFF DA06 Idle RH Engine OFF DA08 Fan Electrical Cabinet OFF (after no more running of both engines)
Possible Signal changes by upcoming Faults without stopping the engines Light DE03 Contamination Filter Servo ON DE17 Oillevel Pumpdrive Gear Box Left ON DE18 Oillevel Pumpdrive Gear Box Right ON

GREASE CYCLE
(DIESEL ENGINE EXCAVATORS) PLC / SPS

LED that will not be effected for the following description DE05 Power supply ( +15 ) switched ON with key switch DE13 Left shut-off valve on hydr. tank OPEN DE14 Right shut-off valve on hydr. tank OPEN DE15 Centre shut-off valve on hydr. tank OPEN DA03 LH Diesel Valve DA04 RH Diesel Valve DA08 Fan Electrical Cabinet DA20 Power supply ( +30 ) switched ON for SPC via this Outlet
Signal changes after Starting Grease Cycle (Line A) DA09 Grease Pump ON DA10 Grease Bypass Valve ON

Signal changes during Line A and Switching to Line B DE19 Grease Initiator 2 OFF (after some seconds) DE20 Grease Initiator 1 ON (after some seconds) DA09 Grease Pump OFF (after 22 seconds) DA11 Grease Line Switch A-B ON (after 4 seconds) DA09 Grease Pump ON
Signal changes during Line B and the Grease Cycle is Finishing DE20 Grease Initiator 1 OFF (after some seconds) DE19 Grease Initiator 2 ON (after some seconds) DA11 Grease Line Switch A-B OFF (after 22 seconds) DA09 Grease Pump OFF DA10 Grease Bypass Valve OFF (after 5 seconds)

GREASE FAULTS
(DIESEL ENGINE EXCAVATORS) PLC / SPS

LED that will not be effected for the following description DE05 Power supply ( +15 ) switched ON with key switch DE13 Left shut-off valve on hydr. tank OPEN DE14 Right shut-off valve on hydr. tank OPEN DE15 Centre shut-off valve on hydr. tank OPEN DA03 LH Diesel Valve DA04 RH Diesel Valve DA08 Fan Electrical Cabinet DA20 Power supply ( +30 ) switched ON for SPC via this Outlet
Signals of Grease System DE19 Grease Initiator 2 DA09 Grease Pump DA10 Grease Bypass Valve

OFF after any Fault arises OFF after any Fault arises (5 Seconds Delay)

Grease System Faults DE02 Grease Empty DE20 Grease Initiator 1 AE3+ AE5+

ON DOES NOT EFFECT (inside of 2 minutes) Grease Pressure (analogue input / no signal) FAULT is indicated if Pressure rises above 350bar Grease Level (analogue input / no signal) FAULT is indicated if Grease Level is lower than 20%

Reset Grease System Faults DE16 Grease Fault Reset (as long as the Button is engaged!) (take effect after pushing for a min. time of 1 Second)

GREASE SYSTEM UNDERCARRIAGE (optional)


(DIESEL ENGINE EXCAVATORS) PLC / SPS

LED that will not be effected for the following description DE05 Power supply ( +15 ) switched ON with key switch DE13 Left shut-off valve on hydr. tank OPEN DE14 Right shut-off valve on hydr. tank OPEN DE15 Centre shut-off valve on hydr. tank OPEN DA03 LH Diesel Valve DA04 RH Diesel Valve DA08 Fan Electrical Cabinet DA20 Power supply ( +30 ) switched ON for SPC via this Outlet
Signals of Grease System DA13 Grease Pump OFF after any Fault arises

Grease System Faults DE02 Grease Empty ON AE4+ Grease Pressure (analogue input / no signal) FAULT is indicated if Pressure rises above 210bar or Does not rise fast enough or Does not reduce fast enough AE5+ Grease Level (analogue input / no signal) FAULT is indicated if Grease Level is lower than 20%
Reset Grease System Faults DE16 Grease Fault Reset (as long as the Button is engaged!) (take effect after pushing for a min. time of 1 Second)

LIGHTS
(DIESEL ENGINE EXCAVATORS) PLC / SPS
LED that will not be effected for the following description DE05 Power supply ( +15 ) switched ON with key switch DE13 Left shut-off valve on hydr. tank OPEN DE14 Right shut-off valve on hydr. tank OPEN DE15 Centre shut-off valve on hydr. tank OPEN DA03 LH Diesel Valve DA04 RH Diesel Valve DA08 Fan Electrical Cabinet DA20 Power supply ( +30 ) switched ON for SPC via this Outlet

Ladder Light DE21 Ladder Light(as long as the Button is engaged!) DA16 Ladder Light ON (for 3 minutes after every Button Push)
Cab Light DE22 DA17

Cab Light (as long as the any Button is engaged!) Cab Light ON (as long as any Cab Light Button is pushed again)

Maintenance Light DE24 Maintenance Light (as long as the any Button is engaged!) DA18 Maintenance Light ON (as long as any Maintenance Light Button is pushed again or as long Ladder Light is ON)

OTHER SIGNALS
(DIESEL ENGINE EXCAVATORS) PLC / SPS
LED that will not be effected for the following description DE05 Power supply ( +15 ) switched ON with key switch DE13 Left shut-off valve on hydr. tank OPEN DE14 Right shut-off valve on hydr. tank OPEN DE15 Centre shut-off valve on hydr. tank OPEN DA03 LH Diesel Valve DA04 RH Diesel Valve DA08 Fan Electrical Cabinet DA20 Power supply ( +30 ) switched ON for SPC via this Outlet nd Travelling 2 Gear auto (only RH400) DE01 Travelling 2nd Gear auto ON (as long as the Button is engaged!) (Signal will be sent via CAN-Bus)

Dumper Counting Reset DE04 Dumper Counting Reset (as long as the Button is engaged!) (Signal will be sent via CAN-Bus) Ultra Sonic Distance Sensor (Boom Stick) DA19 US Sensor (as long as distance is too short) (Signal is received via CAN-BUS)

ON

ON

Reduction of Revolutions DA12 Reduction of Revolutions (as long as the Button is engaged!) (Signal is received via CAN-BUS)

ON

Grease Container Full DA15 Grease Container FULL ON (Grease Container is filled more than 90%)