OPERATING INSTRUCTIONS - ENGLISH Grade-Controller COMBI GRADE G 176 MS

MOBA Mobile Automation AG Kapellenstr. 15 D-65555 Limburg www.moba.de Article number: 10-02-00541 Edition 03/2006

MOBA Mobil Automation GmbH Vor den Eichen 4 - 65604 Elz Telefon 06431/9577-0 - Telefax 06431/9577-77

Index
1.
1.1 1.2 1.3

General information ____________________________________ 3

Rights to changes ______________________________________________ 3 Packaging and storage __________________________________________ 3 Safety measures _______________________________________________ 3

2.
2.1

Introduction ___________________________________________ 6
Advantages and specials ________________________________________ 6

3.
3.1 3.2 3.3 3.4
3.4.1 3.4.2 3.4.3

Mounting _____________________________________________ 7
Dimensions of the device ________________________________________ 7 Mounting of the G 176 MS ________________________________________ 8 Attaching the connecting cable ___________________________________ 8 Attaching the system components ________________________________ 9
Attaching the sensing tube to the sensor arm _______________________________ 9 Attaching the sensing ski to the sensor arm ________________________________ 9 Attaching the sensor arm to the controller _________________________________ 9

4.
4.1 4.2
4.2.1 4.2.2

Operation, working examples and start-up _______________ 10

The control elements ___________________________________________ 10 Mechanical sensing ____________________________________________ 11
Sensing of a stringline _________________________________________________ 11 Sensing of a surface ___________________________________________________ 11

4.3
4.3.1 4.3.2

Ultrasonic sensing _____________________________________________ 12

Sensing of a stringline _________________________________________________ 12 Sensing of a surface ___________________________________________________ 12

4.4
4.4.1 4.4.2

The Handset __________________________________________________ 13

Attaching the handset _________________________________________________ 13 Operation of the handset _______________________________________________ 13

4.5

Start-up ______________________________________________________ 14

5.
5.1 5.2

Maintenance _________________________________________ 15
General information ____________________________________________ 15 Periodic maintenance __________________________________________ 15

6.
6.1 6.2 6.3 6.4 6.5

Connecting plan, specifications and troubleshooting ______ 16

Pin connections _______________________________________________ 16 Block diagram ________________________________________________ 16 Specifications _________________________________________________ 17 Sensitivity tables ______________________________________________ 17 List of failures and troubleshooting _______________________________ 18

7.

Declaration of conformance ____________________________ 20

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1.
1.1

General information
Rights to changes

We try to ensure that these operationg instructions are correct and up to date. In order to maintain our technical leadership, however, it might be necessary, without prior warning, to make changes to the product and to its operation which, under circumstances, do not correspond to the information given here. We accept no liability for disturbances, losses or damages caused thereby.

1.2

Packaging and storage

The product is carefully packed to ensure sufficient protection during shipment. On receipt the packaging and the contents should be inspected for possible damage. Should there be signs of damage the equipment must not be operated !!! Damaged cables and connectors are also a safety risk and must not be used !!! In the event of damage contact your MOBA supplier. The equipment must be protected against humidity and dirt if it is not to be used immediately.

1.3

Safety measures

Warning: Before assembly, setting up and operating the equipment read the operating instructions carefully and fully. Should questions arise, contact your MOBA supplier. Safety precautions: The safety precautions recommended here correspond to basic regulations regarding operation of electrical systems. They can be applied for all applications in conjunction with MOBA equipment. Assembly: Only original MOBA cables may be used. Plugs and sockets must not be removed from the cable as they are protected against humidity and removing them would destroy their protection. Ensure that the safety screw fasteners sit securely on the connectors . Further information about the assembly of the equipment, and the sensors, can be found in the data sheets attached or in these operating instructions.

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Wiring and cabling: The wiring and cabling must be correctly carried out in accordance with these instructions. All supply cables and terminals must be sized according to the current taken. Further, all connections must be made in accordance with VDE regulations or regulations of the area in which the equipment is used. Safety in the event of disturbances: This equipment has been developed and tested for industrial environments. Nevertheless, microprocessor technology requires careful installation. We would therefore like to point out the following which, if not heeded to, can lead to disturbances during the operation later: Pay attention to the correct polarity of the connections Do not exceed (neither too high nor too low) the specified voltage supply range Protect the equipment with a suitable supply fuse Use cables of adequate current and voltage ratings Use the shortest possible cable paths. (Avoid loops) Lay out load, control and signal cables in separate channels where possible Suppress contactor and relay coils Prerequisite for a disturbing sure mode is a good electrical connection between the machine chassis and housing chassis of the units. Connect screened leads to earth at one end only (equipment end) Do not supply other equipment directly from the supply terminals Do not use unused terminals as connections for other equipment

Maximum voltages: Do not exceed the maximum voltages. The maximum voltage between any two circuits isolated from one another, or between any isolated circuit and earth is, unless otherwise stated, limited to its highest input voltage or the supply voltage. The connecting terminals or connectors must be fitted with a suitable fuse. Fuses: The equipment is fitted with electronic fuses which protect it against wrong polarity, voltage transients and overvoltages of short duration. The voltages specified in the technical data may not be exceeded. Configuration:

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The equipment can be configured by the user. It is the responsibility of the user to reconfigure according to the operating conditions of the system. Alarm supervision In complex systems, in which a fault could endanger operating personnel or damage to the system, it is advisable, to use an independent alarm unit. An independent alarm unit provides protection and shut-down of the system in the event of an alarm. In many cases the use of an alarm from within the controller itself does not, because of its dependence on the system, offer adequate protection. Explosive areas The equipment is not designed for use in explosive areas. Fault clearance Before starting to clear faults make sure that all voltages have been disconnected. Defective equipment should be tested in an area which has been especially built for this purpose. Any attempt to remove faults from equipment that is still installed can be dangerous to personnel and to the system itself. Before removing or replacing sensors make sure that the voltage supply has been disconnected. Ask for help Ask your MOBA supplier if you have questions concerning the operation and assembly of the equipment.

Failure to observe the above safety measures can cause breakdown of the equipment or of the system. Damages caused by such negligence are not covered by the manufacturer's guarantee.

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2.
2.1

Introduction
Advantages and specials

The Combi-Grade G 176 MS and the Slope-Controller S 276 M are two fully independently working units which can be run separately but also together as a whole system for the automatic control of level, direction and cross slope. The MOBA levelling system is most commonly used to control the screed position of the finisher, but also works successfully on milling machines, concrete pavers, bulldozers and other construction machines.

The reliable automatic levelling system of MOBA for the control of your road construction machines.

Increasing costs for material and operating time call for precise working at an according capacity per day. The smallest fraction of a centimer during the laying of asphalt, or superfluous extension of the operating time may represent for you the limit between profit and loss. With the MOBA grade controller G 176 MS you made the right choice. All advantages at a glance: Easy handling Safe to false polarity and voltage peaks Supply voltage 10 - 40 V DC Both mechanical and contact-free sensing by ultrasonics

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3.
3.1

Mounting
Dimensions of the device

The dimensions of the G 176 MS

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3.2

Mounting of the G 176 MS

Fastening tube with crank handle

The level controller G 176 MS can be mounted easily and rapidly with simple tools. For this purpouse a fastening tube with a crank handle should be mounted as an extension of the control unit (actuator).

Locking screws

1. 2. 3.

4.

5.

Set the valve switch to the STANDBY position. Loosen the locking screws of the fastening tube. Insert the round centering pivot that is on top of the controllers housing vertically into the fastening tube. Turn the controllers housing so that the operator can see the lamps (front panel of the device against the direction of travel). Lock the controllers centering pivot to the fastening tube with the according locking screws.

Centering pivot

Mounting of the G 176 MS

3.3

Attaching the connecting cable

Set the valve switch to the STANDBY position. Connect the 7 pole socket of the connecting cable to the 7 pole plug of the controller. Connect the 10 pole socket of the connecting cable to the 10 pole device plug of the machine.

To the machine

To the controller

Attaching of the connecting cable

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3.4

Attaching the system components

The system has two different sensors for sensing the reference. The sensing tube is used for sensing the stringline. The sensing ski is used for sensing the ground.

3.4.1

Attaching the sensing tube to the sensor arm

Unscrew the nut at the end of the sensing tube. Insert the end of the sensing tube into the fastening ring of the sensor arm. Lock the sensing tube with the nut.

Attaching of the sensing tube to the sensor arm

3.4.2

Attaching the sensing ski to the sensor arm Remove the locking pin from the pin of the sensing ski; remove the pin. Insert the fastening ring of the sensor arm into the fastener of the ski. Push the pin through the fastener of the ski and the fastening ring of the sensor arm. Lock the pin with the locking pin.
Attaching of the sensing ski to the sensor arm

3.4.3

Attaching the sensor arm to the controller Turn the flat part of the shaft towards the front of the controller. Loosen the locking screw of the sensor arm. Push the sensor arm on the shaft. Lock the sensor arm with the locking screw.
Locking screw

Attaching of the sensor arm to the controller

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4.
4.1

Operation, working examples and start-up

The control elements

Control lamp Valve switch Control lamp

Selector switch

Sensitivity adjustment

Description of the control elements

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4.2
4.2.1

Mechanical sensing
Sensing of a stringline

Switch the selector on the module to the GRADE position. Set the valve switch to the STANDBY position. The sensing tube must be attached to the sensor arm. When attaching the sensor arm take care that the flat side of the shaft is oriented towards the front side of the controller and that the fastening screw of the sensor arm rests on the flat part of the shaft. Set the counterweight of the sensor arm in such a way that the sensor arm presses the sensing tube onto the reference when the controller is set to zero. The zero setting is achieved by positioning the controller by means of the crank handle until the two control lamps go out.

Stringline Direction of travel

Sensing of the stringline

Direction of travel

Sensing with the tube gliding under the stringline

Note: If the tension of the stringline used as reference is too low, it is possible to guide the sensing tube beneath the stringline. For this purpose, the counterweight has to be set in such a way that the sensor arm presses the sensing tube from below against the stingline when the controller is set to zero.

4.2.2

Sensing of a surface

Switch the selector on the module to the GRADE position. Set the valve switch to the STANDBY position. The sensing ski must be attached to the sensor arm. When attaching the sensor arm take care that the flat side of the shaft is oriented towards the front side of the controller and that the fastening screw of the sensor arm rests on the flat part of the shaft. Set the counterweight of the sensor arm in such a way that the sensor Direction of travel arm presses the sensing ski onto the reference when the controller is set to zero. The zero setting is achieved by positioning the controller by means of the crank handle until the two control lamps go out.

Sensing of a surface

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4.3
4.3.1

Ultrasonic sensing
Sensing of a stringline

Switch the selector on the module to the SONIC position. Set the valve switch to the STANDBY position. When operating in the ultrasonic mode, the sensor arm should not be attached to the controller in order to avoid potential damages. The working point is about 30 cm below the sensor head. At this distance the sound lobe has a width of approx. 5 cm. The stringline's diameter has to be at least 3 mm to be indentified as a reference clearly. For sensing the stringline the Combi Grade must be positioned at the vertical of the stringline. It must be ensured that the sound lobe touches the stringline. The zero setting is achieved by positioning the controller by means of the crank handle until the two control lamps go out.

Stringline

Sensing of a stringline with ultrasonics

4.3.2

Sensing of a surface

Switch the selector on the module to the SONIC position. Set the valve switch to the STANDBY position. When operating with the ultrasonic mode, the sensor arm should not be attached to the controller in order to avoid potential damages. The working point is about 30 cm below the sensor head. The zero setting is achieved by positioning the controller by means of the crank handle until the two control lamps go out.

Sensing of a surface with ultrasonics

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4.4
4.4.1

The Handset
Attaching the handset

The Handset has a 6 m long connecting cable. Connect the 5 pole plug of the connecting cable to the 5 pole device socket of the Combi Grade.

Attaching of the Handset

4.4.2

Operation of the handset

The Handset is workind as soon as it is connected to the controller. Turn the knob on the Handset to the mid position. Position the controller by means of the crank handle in such a way that both control lamps are out. Turning the knob allows the working point to be ajusted by +/- 5 cm in the SONIC mode. In the GRADE mode the working point can be adjusted by +/- 4 cm. However the working point should not be adjusted by more than +/ - 2 cm when operating with mechanical sensing, in order to avoid damaging the mechanism and the ultrasonic sensor.

The Handset

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4.5

Start-up

Turning the valve switch to the position ON connects the output of the controller with the according valve. The automatic system is activated. Note: A clockwise rotation of the sensitivity adjustment increases the sensitivity of the controller. A counterclockwise rotation decreases the sensitivity.

Valve switch

The valve switch

Turn the sensitivity button clockwise until the hydraulic system starts to swing. When this is the case, turn the adjuster slowly counterclockwise until the hydraulic system quiets down. A minor readjustment of the device may be necessary after the first operation of the machine because vibrations, temperatures etc. influence the control circuit. No further adjustment should be needed if the readjustment had been done under working conditions.

Sensitivity adjustment

The sensitivity adjustment (loosen the locking ring and adjust by turning the button).

The variation of the working level (adjustment of the working point) has to be done with the Handset. If the user does not have a Handset, he has to carry out this adjustment by means of the crank handle.

The Handset

The crank handle

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5.
5.1

Maintenance
General information

The level controller has been designed for high working safety so that the maintenance needs a minimum of procedures only. The electronic components are mounted in a solid case in order to avoid any mechanical damage.

5.2

Periodic maintenance

Normal repair procedures carried out in the open consist in replacing burned-out lamps and other spare parts that have been located with the troubleshooting. The power supply cables should also be checked regularly in order to detect any damage and dirt. Note: Keep the thread of the plug-connections and of the cable connectors free of any dirt, grease, asphalt or concrete in order to avoid a bad contact. Remove any asphalt or concrete sticking to the sensor arm by means of an appropriate agent and oil the bearing afterwards.

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6.
6.1

Connecting plan, specifications and troubleshooting

Pin connections
1)
7 pole device plug: for the connection to the machine Allocation: A: + supply B: Controller output DOWN C: - supply D: Controller output UP E: free F: free G: free 5 pole device socket: for the connection of the Handset Allocation: A: + supply B: Setpoint C: - supply D: Pot. (+) E: Pot. (-)

1) 2)

2)

Connections on the level controller

6.2

Block diagram
Sensor head

Amplifier

Ref.

Transmitter

Machine Transmitter lower raise Output

The block diagram of the G 176 MS

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6.3

Specifications
10-40 V DC 0.5 amp. approx. (without valves) 3 amp. approx. (current limited) ON/OFF with pulse width modulation (*NPN) 3 Hz approx. +/- 80 mm level difference approx. +/- 50 mm level difference 0.25 mm level difference measured at the sensor arm 1 mm level difference Adjustable from overswinging up to a dead range of 5 mm -10 C to +70 C -25 C to +75 C up to 4g, 10-100 Hz 2.6 kg IP 54

Power supply: Operating current: Current load: Output signal: Frequency: Operating range: Setting range (with Handset): Resolution (synchro-transmitter) Resolution (ultrasonic) Sensitivity: Working temperature range: Storage temperature range: Vibration: Weight: Protection type:

The values given for accuracy and resolution are purely electrical values of the controller. Those actually reached also depend from the construction and type of the machine respectively used and of the operating conditions.

6.4

Sensitivity tables

This is a comparison of the adjustable sensitivity levels with the values for the deadband and the pulse range, hidden behind it. The deadband is given as complete band, the pulse range follows in both directions. Grade
Sensi ti vi ty 1 2 3 4 5 6 7 8 9 10 D eadband + /- 3 ,2 5 m m + /- 3 ,0 0 m m + /- 2 ,7 5 m m + /- 2 ,2 5 m m + /- 2 ,0 0 m m + /- 1 ,2 5 m m + /- 1 ,2 5 m m + /- 0 ,7 5 m m + /- 0 ,2 5 m m < + /- 0 ,2 5 m m Pulse range 2 4 ,5 m m 2 3 ,0 m m 1 9 ,0 m m 1 6 ,0 m m 1 4 ,0 m m 9 ,5 m m 7 ,0 m m 3 ,0 m m 0 ,5 m m < 0 ,5 m m Sensi ti vi ty 1 2 3 4 5 6 7 8 9 10

Sonic
D eadband + /- 2 ,5 0 m m + /- 2 ,2 5 m m + /- 2 ,0 0 m m + /- 2 ,0 0 m m + /- 1 ,7 5 m m + /- 1 ,2 5 m m + /- 1 ,2 5 m m + /- 0 ,5 0 m m + /- 0 ,0 0 m m + /- 0 ,0 0 m m Pulse range 2 0 ,0 m m 1 9 ,0 m m 1 6 ,5 m m 1 3 ,0 m m 11 , 0 m m 7 ,5 m m 5 ,5 m m 3 ,0 m m 1 ,0 m m < 1 ,0 m m

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6.5

List of failures and troubleshooting

The list of failures and troubleshooting indicates all the failures that are the most likely to occur during the operation of the system. It also describes their reasons and the actions to be done in order to eliminate them.
Symptoms: Lamps are not on. Controller does not actuate the valves Possible reasons: No voltage avilable for the controller Controller module faulty Wiring within housing of the controller faulty Lamps work but controller does not actuate the valves Controller module faulty Current cable to the controller faulty Cable damaged Action: Check the wiring to the machine

Replace the module Check the wiring

Replace the module Replace the cable Check the cable with the ohmmeter Check the wiring Replace the lamps Replace the module Replace the module Replace the sensor Replace the lamp

Wiring within the housing faulty Lamps are not on but controller actuates the valves Lamps are burned-out Controller module faulty Hydraulic system works on only one side. One lamp is on (indicates the direction of the movement) Hydraulic system works but only one lampe is on Hydraulic system works but both lamps remain on Sensitivity of the controller cannot be set Zero offset of the controller Controller module faulty Sensor is faulty Lamps are faulty

Controller module faulty

Replace the module

Controller module faulty

Replace the module

Fastening screws of the sensor bearing got loose Controller module faulty Sensor is faulty

Reset the sensor and tighten the screws Replace the module Replace the sensor

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Symptoms: Mechanical sensing works, ultrasonic sensor does not work

Possible reasons: Ultrasonic sensor faulty Interface faulty Wiring within housing of the controller faulty

Action: Replace the ultrasonic sensor Replace the interface Check the wiring

Ultrasonic sensing works, mechanical sensing does not work.

Shaft encoder faulty

Replace the shaft encoder

Wiring within housing of the controller faulty

Chek the wiring

Any control or measurement on the controller should be executed by educated personnel only which has been specially trained for such work.

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7.

Declaration of conformance

Declaration of conformance
to ISO/EC Guide 22 and EN 45014 standards Name of manufacturer: Address of manufacture: MOBA Mobile Automation MOBA Mobile Automation Vor den Eichen 4 D-65604 Elz

The manufacturer declares that the products: Product types: G176 M Combi Grade-System G176 MS 04-15-0001X 04-15-2001X

Model numbers of the components which were tested in a typical system: G176 MS Handset MS 04-15-2001X 04-15-2101X

are designed and manufactured to meet the following standards:

Saftey: EMC: DIN VDE 411, part 1, 0001/10.73 EN 55011 - DIN VDE 0875 T11 (1992), class B ENV 50140 - DIN VDE 847 T3 (1993) criterion A ENV 50140 - DIN VDE 847 (1993), IEC 65A/77B (Sec) 145/110 criterion A EN61000-4-2 (1995), IEC 1000-4-2 (1995), VDE0847 part 4-2 criterion B ENV50141 (1993), E IEC 1000-4-6, E DIN VDE 0843 T6:12/93 EN61000-4-4:1995, IEC 1000-4-4:1995, VDE 0847 part 4-4 criterion B

Performance criteria according to EN 50082 T/2

Additional information: The products meet the EMC-requirements of 89/336/EEC. The products were tested in typical configurations. It is not permitted to take the appliances into service if it is not clarified, that the machine in which this shall be installed is conform to the Council Directive.

Elz, January 11th, 1995

Dipl.-Ing. Markus Wendel Quality manager Page 20