SMSBTS28007/1E

TENSOTRONIC Sp. z o.o.

TYPE TS-280.SB
SAFE LOAD INDICATOR
FOR

SB SERIES PIPE LAYERPIPELAYERS

Rys 6.2 odwrcony

SERVICE MANUALThe Rrepair iInstructions mManual

Januaryuly, 20027

Service Manual

TS-280.SB

TENSOTRONIC

TENSOTRONIC

TS-280.SB

Service Manual

INTRODUCTION
This Service Manualinstructions manual includes the repair procedures for Type TS-280SB Safe
Load Indicators (all versions) as used with Dressta pipe layerpipelayers.
Being familiar with the Operators operating instructions mManual for the respective machine and
with the scaling instructions manualScaling Instructions Manual for the Safe Load Indicator are the
necessary conditions for a correct repair.
Repairs may only be carried out by persons trained and authorised by the manufacturer.
The Manufacturer reserves the right for changes without any obligation to make the same changes
to the products manufactured earlier.
Changes may be made to this Service instructions mManual based upon tests and development
works. Detailed information is available at the manufacturer and authorised distributors.

This Service instructions mManual is the sole property of the manufacturer and must not be published or
copied
in parts or in its entirety without the manufacturers previous written consent.

Service Manual

TS-280.SB

TENSOTRONIC

17

Service Manual

TS-280.SB

TENSOTRONIC

TENSOTRONIC

TS-280.SB

Service Manual

CONTENTS
SB SERIES PIPE LAYERPIPELAYERS................................................................................................................. 1
THE SERVICE MANUALREPAIR INSTRUCTIONS MANUAL .................................................................................. 1
INTRODUCTION ............................................................................................................................................. 433232
CONTENTS ....................................................................................................................................................... 855353
1.

FAILURES OF SIGNALLING ELEMENTS ON THE FRONT PANEL (FIGURE. 1.1) ........... 1177474
1.1.
1.2.
1.3.
1.4.

2.

INCORRECT OUTREACH RADIUS AND LOAD READOUTS. ............................................... 1388585

2.1.
2.2.
2.3.
2.4.
2.5.

3.

SIGNIFICANT DIFFERENCES OF OUTREACH RADIUS READOUTS. ..................................................... 1388585

NO VARIATIONS IN OUTREACH RADIUS READOUTS, STEPWISE RADIUS READOUT VARIATIONS. .... 1499696
ERR 01 OR ERR 02 ERROR MESSAGES (BOOM TOO LOW, OR BOOM TOO HIGH). ............................ 1499696
LOAD READOUT > 0.5 [T] WITH EMPTY HOOKUNLOADED HOOK. ................................................... 1499696
INCORRECT LOAD READOUT WITH LOADED A WEIGHT ON THE HOOK. ................................... 1610107107
MEASURING TRANSDUCERS OR CABLING OUT OF ORDER. ...................................... 1610107107

3.1.
3.2.
3.3.
3.4.
4.

ERR 11 OR ERR 12 ERROR MESSAGE (ANGLE TRANSDUCER SIGNAL TOO HIGH OR TOO LOW).1610107107
ERR 21 OR ERR 22 ERROR MESSAGE (THE LOAD TRANSDUCER SIGNAL TOO LOW OR TOO HIGH).1811118118
ERR 31 OR ERR 32 ERROR MESSAGES (SIGNALS FROM BOTH TRANSDUCERS TOO LOW OR TOO HIGH).
211313101310
ERR 04 ERROR MESSAGE (NO READOUT OF THE INSTALLED BOOM LENGTH) ...................... 211313101310
CONSOLE FAILURES. ........................................................................................................... 211313101310

4.1.
5.

IF ONE OR MORE LAMPS ARE NOT ALIGHT. ...................................................................................... 1177474

ANY OF THE DIODES IN THE % DISPLAY OR IN A KEY CORNER IS NOT ALIGHT. ............................. 1177474
NO REACTION AFTER PRESSING KEYS. ............................................................................................. 1177474
THE LCD (LED) DISPLAY IS PARTLY NOT ALIGHT, BUT READOUTS ARE CORRECT. ..................... 1388585

NO READOUTS. ........................................................................................................................ 211313101310

REPAIR TOOLS AND EQUIPMENT. ................................................................................... 221414111411

6.
THE SAFE LOAD INDICATOR CONNECTION DIAGRAMWIRING DIAGRAM; PC BOARD
VIEWS. .................................................................................................................................................. 231515121512

Service Manual

TS-280.SB

TENSOTRONIC

TENSOTRONIC

10

TS-280.SB

Service Manual

Service Manual

1.

TS-280.SB

TENSOTRONIC

Failures of signalling elements on the front panel (Figure. 1.1)

4
1 processor PC board ,
2 display PC board ,
3 power supply PC board,
4 front panel with keyboard.

Fig. 1.1. Internal view of the console microprocessor controllersole

1.1.
-

If one or more lamps are not alight.

switch the console off,

open the console housing,
check the condition of cables connecting the display PC board / 2 / with the processor PC board
/ 1 / (Figure. 1.1) replace damaged cables,
switch on;

If the lamp is still not alight:

- switch off,
- open the console housing,
- remove the processor PC board / 1 / (Figure. 1.1),
- replace the display PC board / 2 / (Figure 1.1),
- install the processor PC board / 1 / (Figure. 1.1) again,
- close the housing,
- switch on.
1.2.
-

switch the Safe Load Indicator off,

open the housing,
remove the processor PC board,
pull out the display PC board,
replace the faulty diode,
install the PC boards again,
close the housing,
switch the Safe Load Indicator on.

1.3.
-

Any of the diodes in the % display or in a key corner is not alight.

No reaction after pressing keys.

switch the Safe Load Indicator off,

open the Safe Load Indicator housing,

17
11

TENSOTRONIC

TS-280.SB

Service Manual

- check the flat wire band connecting the front panel with the processor PC board / 1 / (Figure 1.1),
-check the flat wire band - processor PC board / 1 / (Figure 1.1) connectionr, clean if necessary,

12

Service Manual

TS-280.SB

TENSOTRONIC

- close the housing,

- switch the Safe Load Indicator on.
If the Safe Load Indicator still does not react after pressing the keys replace the front panel with
keyboard.
1.4.

The LCD (LED) display is partly not alight, but readouts are correct.

- switch the Safe Load Indicator off,

- open the Safe Load Indicator housing,
- check the connection of the processor PC board / 1 / and the display PC board / 2 / (Figure 1.1),
- push the LED display deeper in its socket on the LED display PC board (cold climate version).
If any part of the display is still not alight replace the display / 2 / PC board.

2.

Incorrect outreach radius and load readouts.

2.1.

Significant differences of outreach radius readouts.

2.1.1. Check up the angle transducer.

Lower the boom to the horizontal position, remove the angle transducer cover.
Using a high accuracy voltmeter, check up the following voltages on the KAT2 PC board (Figure
3.1):
- / 1- 4 / - reference voltage to supply the potentiometer: 2.500 [V] 4.100 [V];
- /11 - 9/ - measuring output voltage, with the pendulum remaining pushed to the left stop:
0.0 [V] 0.650[V],
- /11 - 9/ - measuring output voltage, with the pendulum remaining pushed to the right stop:
2.500 [V] 4.100 [V],
- /11 10/ - supply voltage for the KAT2 PC board (Figure. 3.1) and WZM2 PC board
(Figure 3.2) : 12.30[V] 12.80[V].
Compare the measuring results with the data provided by Tensotronic inside of the transducer
housing, on the high accuracy potentiometer.
If the Tensotronic-provided transducer data got lost or are illegible:
- contact the manufacturer and require the data to be sent to you. Please do not forget to include the
transducer s/n (located on the cover).
The transducer can be estimated correct, if the voltage deviations are smaller than 20 mV.
If all the deviations are of a similar value, the reason thereof could rather be the inaccuracy of the
voltmeter applied used for the check up.
If the voltage variations suggest the transducer is out of orderadjustment, it should be replaced:
- lower the boom as low as maximum to get access to the angle transducer,
- switch the Safe Load Indicator off,
- remove the four screws and the transducer cover,
- disconnect cables from terminals 1, 2, 4...11 on the KAT2 PC board (Figure 3.1),
- cut the protective band around the cables, loosen the stuffing boxes on the housing, pull cables
out from the housing,
- remove the four screws attaching the transducer to the boom, dismount the transducer,
- install a new transducer, install the four screws again,
17
13

TENSOTRONIC
-

TS-280.SB

Service Manual

pull the cables through the stuffing boxes into the housing, tighten the stuffing boxes, add
a silicone compound for additional protection,
secure the cables inside of the housing with the protective band,
connect the cables with to the terminals (1, 2, 4...11) on the KAT2 PC board (Figure. 3.1)
according to the diagram in the section 6,
check, whether the angle transducer pendulum is free to move over the full angle; if the
pendulum touches the cables, improve the location of cables inside of the housing,
put a thin coat of silicone compound on the cover edge,
install the cover on the housing, tighten the four screws.

2.1.2 If the radius readoutsoutreach radius readouts vary adequately to the boom movement over
the entire pipe layerpipelayer operating range, but discrepancies are over 7%[%]:
- carry out the angle transducer scaling again according to the scaling instructions, the F 06
program.
2.2. No variations in outreach radius readoutsradius readouts, stepwise radius readout
variations.
If the outreach radius readoutsradius readouts remain constant during the boom operation:
- lower the boom down,
- switch the Safe Load Indicator off,
- remove the angle transducer cover,
-check up whether anything blocks the pendulum, like cables or loose screw; fix the
- failure, check up the operation,
-check, if the coupling pin between the potentiometer and the pendulum is still in its
- place,
- push the pin deeper, secure with a Loctite or Poxipol compound,
- check up whether the pendulum bearings are in their seats,
-push the bearings in their seats, secure with a Loctite or Poxipol compound (between
the outer rings and the seats,
- check up according to item 2.1.1 of the repair Service Manualinstructions manual.

2.3.

Err 01 or Err 02 error messages (boom too low, or boom too high).

The radius readoutsoutreach radius readouts vary during the boom raising, error messages are
displayed: Err 01: the boom raised too low <12o,
Err 02: the boom raised too high >86o;
- check up according to item 2.1.1 of the Service Manualrepair instructions manual.

2.4.

Load readout > 0.5 [t] with empty unloaded hook.

2.4.1. If the load readout (with empty hookunloaded hook) is smaller than 3[%] of the nominal load
for the current radius, the load transducer can be compensated according to the Safe Load Indicator
oOperatingors instructions mManual, section 4.4.

14

Service Manual

TS-280.SB

TENSOTRONIC

2.4.2. If the load readout (with empty unloaded hook) is larger than 3%[%] of the nominal load and
can not be compensated, the following should be done:
- carry out the load transducer scaling (the F 05 program) according to section item 5 of the
scaling instructions manualScaling Instructions Manual,

17
15

TENSOTRONIC

TS-280.SB

Service Manual

if the scaling is not possible, e.g. respective reference weights are missing, the F 19 program should
be executed according to item 7.4 of the scaling instructions manualScaling Instructions Manual.
2.5.

Incorrect load readout with a weight on theloaded hook.

If the nominal load readout (with % readout > 95%[%]) differs more than 5%[%] from QH, the Safe
Load Indicator scaling data can be adjusted. In other cases, e.g. trying to use the Safe Load
Indicator as a weigher, the Safe Load Indicator could get out of adjustment.
First, check up the Safe Load Indicator readout with empty hookunloaded hook according to the
Servicerepair instructions mManual, itemsection 2.4.
Raise the QH reference weight (of an accurately known mass):
for SB-30: 15[t] < QH < 28[t],
for SB-60: 25[t] < QH < 60[t],
for SB-85: 40[t] < QH < 85[t]
for the shortest outreach radius possible and write down the load readout.
According to the scaling instructions manualScaling Instructions Manual, open enter the F 05
program).
If the readout is too small:
- increase the C2 value by 0.2[t] 0.3[t] (or: decrease, if the readout is too large),
- press the F key and check the QH variationreadout.
If the readout is now higher by 0.1[t] 0.2[t], the adjustment can be considered finished.
If the improvement is not satisfactory:
- repeat the adjustment.
After having finished the adjustment, print the data out according to the scaling instructions
manualScaling Instructions Manual and send return them to the manufacturers aAuthorised
Machine dDistributor of the machines.
3.

Measuring transducers or cabling out of order.

3.1.

Err 11 or Err 12 error message (angle transducer signal too high or too low)
(Fig. 3.1.)

16

Service Manual

3
2
1

P
4

LED

5 6 7

8 9 10 11

KAT2
4 2 1

TS-280.SB

TENSOTRONIC

1 - 0 V potentiometer supply voltage

2 signal from potentiometer
3 empty terminal not used
4 - ref. +2.500 - 4.100 [V] potentiometer supply voltage
5 signal from load transducer
6 - +12,30 12,80 [V] load transducer supply voltage
7 - 0V load transducer supply voltage
8 signal from load transducer to controller
9 signal from angle transducer to controller
10 - +12,30 12,80 [V] measuring transducers supply
voltage
11 - 0 [V] measuring transducers supply voltage
B voltage adjustment potentiometer between points 1 and 4
LED for the current loop diagnosis

Figure 3.1. The aAngle tTransducer Wconnection diagramiring Diagram.

17
17

TENSOTRONIC

TS-280.SB

Service Manual

Lower the boom, remove the angle transducer cover.

Check up the power supply voltage on the KAT2 PC board terminals between the white and brown
wires / 10 11 / : the voltage should be 12.30 12.80 [V] DC,
If the voltage is correct:
- check up, if the current loop diagnosis LED on the KAT2 PC board is alight (this LED should
not be alight, if the KAT2 PC board current output is correctly connected with the front
panel).
If the voltage is incorrect (or missing) and/or the current loop diagnosis LED on the KAT2 PC
board is alight:
- check up all the cables and connections between the console and the angle transducer,
- with supply voltage switched off check for any short-circuit to the pipe layer masspipelayer
ground.
If the power supply voltage is correct:
- check up the reference voltage for the angle transducer supply: this should be within 2.500 [V]
4.100 [V] according to data located on the potentiometer.
If the potentiometer supply voltage differs more than 20 [mV]:
- set the voltage with the (B) potentiometer on the KAT2 PC board.
If this is not possible:
- replace the KAT2 PC board.
If both voltages are correct:
- disconnect the potentiometer cables from the KAT2 PC board,
- raise the pendulum to check whether the resistance in points / 1 2 / varies continuously within
1.3 - 0 [k].
If the resistance varies stepwise, or if there are any mechanical obstacles:
- replace the transducer.

3.2.

Err 21 or Err 22 error message (the load transducer signal too low or too high).

-Vout (blue)

WEBridge signal
WE+

+Vout (green)
+12V (brown)
SP (green)

4-20

MT (white)

0V

0V (white)
Uref SP (red)

18

LED
Uzas
ZERO

0V

WZM2
WZM

Uref

LED for the current loop diagnosis

ZERO the SP output signal level adjusting
potentiometer (with empty unloaded
hook)
WZM the WZM2 measuring amplifier gain
adjustment potentiometer
-Vout and +Vout the tensometric bridge
signal
Uz 0V and Uref SP the tensometric
briodge
power supply
+12V and MT the WZM2 amplifier power
supply
SP the measuring amplifier signal output

Service Manual

TS-280.SB

TENSOTRONIC

Figure 3.2. The connection diagramWiring Diagram of the mMeasuring aAmplifier for the lLoad
tTransducer.
(patrz Uz na Rys.)

Lower the boom,

remove the load transducer cover,
check up the cable connections on the WZM2 amplifier PC board,
check the supply voltage on the WZM2 PC board terminals (white wire and brown wire): the
voltage should be within 12.30 12.80 [V] DC.

If the voltage is correct:

-- check up, if the current loop diagnosis LED on the WZM2 PC board is alight (this LED should
not be alight, if the WZM2 PC board current output is correctly connected with the front
panelconsole).
If the voltage is incorrect (or missing) and/or the current loop diagnosis LED on the WZM2 PC
board is alight:
- check up all the cables and connections between the console and the load transducer,
- with supply voltage switched off : check for any short-circuit of the +12 [V] supply voltage or
the SP measuring signal to the pipe layer masspipelayer ground.
If the cables and connections are correct:
- switch the supply voltage off,
- disconnect the load transducer cables from the WZM2 amplifier,
- check up the resistance between the red wire and white wire, and between the green wire and
blue wire (the values should be from approx. 600 up to over 800 and can differ from each
other not more than 1 up to 2 ),
- check the resistance between any of the cables and the transducer body (this should be larger
more than 40 M).
If the resistance between cable pairs varies significantly,
- check up resistance between the cables:
green and white,
green and red,
red and blue,
white and blue.
If a disconnection break in circuit has been found in any of the measurements:
- replace the load transducer and carry out the scaling according to the sScaling iInstructions
mManual, section 5
If the resistance between any of the cables and the transducer body is smaller ss than 40 [M], this
can be caused by moisture; in this case use a hair dryer,
If no results, replace the load transducer and carry out the scaling according to the scaling
instructions manualScaling Instructions Manual, section 5.
17
19

TENSOTRONIC

TS-280.SB

Service Manual

If the resistance value are correct:

- replace the WZM2 amplifier and carry out the scaling according to the sScaling iInstructions
mManual, section 5.

20

Service Manual

3.3.
-

TS-280.SB

TENSOTRONIC

Err 31 or Err 32 error messages (signals from both transducers too low or too high).

Check up the cables as in items 3.1 and 3.2, and then: the KAT2 PC board, the angle transducer
potentiometer, the WZM2 amplifier, the load transducer,
carry out procedures as in items 3.1 and 3.2.

3.4.

Err 04 error message (nNo readout of the installed boom length)

The Err 04 messageNominal load decrease to two [t] regardless the outreach radius means a failure
in the Safe Load Indicator installation: a disconnection break in circuit or missing information,
which of the booms has been installed on the pipe layerpipelayer: L1 or L2.
Check the cabling, +12[V] voltage on pins 5 or 6 of the K1 cable terminal strip.
If +12 [V] voltage is present and the nominal load is still decreased Err 04 message is keeping
displayed:
- replace the console microconsole and move the EPROM and EEPROM chips (Figure 6.2)
accordinglyprocessor controller and pull out both EPROM and EEPROM chips (Fig. 6.2.) from
the damaged console microprocessor controller processor and install them accordingly in a new
one.
The table hereunder presents the boom lengths for SB series pipe layerpipelayers.
SB - 30
6.5
8.5

L1 [m]
L2 [m]

SB - 60
7.3
9.0

4.

Console microprocessor controller failures.

4.1.

No readouts.

SB 85
7.3
8.5

Check if the 24 [V] DC is present on the console (pins 1 and 2 on the male connector).
If the voltage is missing:
check the supply voltage from the pipe layerpipelayer,
- switch the supply off, open the console, check the fuse and internal connections between the PC
boards replace if necessary.

If the 24 [V] DC voltage is present on the PC board:

- check up voltages on the power supply PC board (Figure 6.3):
GND - +12V (expected: 12.3 - 12.8 [V]),
GND - + 5V (expected: 4.9 - 5.25 [V]),
GND - -5 V (expected: -4.9 - -5.25 [V]).
If the voltages are not within the limits as above:
- disconnect the K1 cable from the console and check voltages again.
17
21

TENSOTRONIC

TS-280.SB

Service Manual

If the voltages are still incorrect:

- replace the console microprocessor controller console and move the EPROM and EEPROM
chips (Figure 6.2) accordinglyprocessor and pull out both EPROM and EEPROM chips (Fig.
6.2.) from the damaged console microprocessor controller processor and install them in a new,
- connect the K1 cable,
- check voltages again.
If the voltages are still incorrect despite of what have been done above:
- the failure is outside the console microprocessor controllerconsoleprocessor, so carry out
procedures according to item 3.

If the voltages are correct, but the microprocessor controller console processor does not operate:
- replace the console microprocessor controller console and move the EPROM and EEPROM
chips (Figure 6.2) accordinglyprocessor and pull out both EPROM and EEPROM chips (Fig.
6.2.) from the damaged console microprocessor controller processor and install them
accordingly in a new.

5.

Repair tools and equipment.

-

22

0,5 x 3 screwdriver;
Phillips Ph0 screwdriver;
Phillips PhH1 screwdriver;
Phillips Ph2 screwdriver;
Wrench spannerfor hex sockets, size 4;
Unifversal digital meter, accuracy not worse than 2,5%[%], for:
- Constant voltages up to 100 [V] with accuracy not worse than 0.1 [V];
- Resistance up to 1 [k] with accuracy not worse than 1 [];
- Resistance at least 40 [M] with accuracy not worse than 0,1 [M];
- Circuit continuity with acoustic signal, for resistances below 30 [].

Service Manual

6.

TS-280.SB

TENSOTRONIC

The Safe Load Indicator connection diagramWiring Diagram; PC bBoard vViews.

17
23

TENSOTRONIC

24

TS-280.SB

Service Manual

Service Manual

TS-280.SB

TENSOTRONIC

3
Uref SP (red)
Uz 0V (white)

Z4

MT (white)
SP (green)
+12V (brown)

WZM2

-Vout (blue)
+Vout (green)

SP (green)

KAT2
Uref

MT (white)

4
2
1

Uk

K5

+12V (brown)

Z3

SP (green)
SK (yellow)
+12V (brown)

Uz

K4

MT (white)

2
K3

MT
+12V
SP
SK
65
85
+12V

1
2
3
4
5
6
7

K1

MT
+12V
SP
SK
65

K2

85
+12V

MT
+12V

1
2

SP
SK
65
85
+12V

3
4
5
6
7

B
+24V
19H
19W
PS
WKP

W2

Z2

Z1

W1

1
2
3
4
5
6
7

K6

B
+24V
19H
19W
PS
WKP

Figure 6.1. Connection diagramWiring Diagram of the Safe Load Indicator cComponents.

17
25

TENSOTRONIC

TS-280.SB

Service Manual

1 console microprocessor controller console

2 angle transducer incl. KAT2 measuring amplifier
3 load transducer incl. WZM2 measuring amplifier
K1, K1/2, K2, K3, K4, K5, K6 cables
Z1, Z2, Z3, Z4, Z5 - connectors
D1, D2- grommets
W1 short boom recognition jumper
W2 long boom recognition jumper
J9
C49

C34

R22

C39

R17

U10

Q3
R23

Q2

U6
C26

X3
U5

C48

C51

C40

C47

PIN1

J8

C30

EPROM

U12

C32 C36
U9

D12

BT1

C25

U4

D13
R25

C33 C37

C23
R26

U16

U17

JM6
JM7
JM8
JM9

R21
R24

X2

U15

U11

C42
R18
C24

U13

C29
D14

J7

R29

R28

Q5

TENSOTRONIC
RURA-CPU3 COMP
01.2002

U8
C38

C31

C52B
C52A
C52

J4

C45
R19
C50

C28

C43

C46

X1

C44

U7

C27

C35

C53

R20

EEPROM

R27

U14

C41

Q4
RURA-CPU3 COMP

J9
C49

C34

R22

C39

R17

U10

Q3
R23

Q2

U6
C26

X3
U5

C48

C51

C40

C47

PIN1

J8

C30

EPROM

U12

C32 C36
U9

D12

BT1

C25

U4

D13
R25

C33 C37

C23
R26

U16

U17

JM6
JM7
JM8
JM9

C38

C31

C52B
C52A
C52

U15

X2

U11

C42
R18
C24

U13

C29

J4

R29

R28

Q5

C45
R19
C50

U8
C28

C43

C46

X1

C44

U7

C27

C35

C53

R20

J7

D14

R27

R21
R24

TENSOTRONIC
RURA-CPU3 COMP
01.2002

U14

C41

Q4
RURA-CPU3 COMP

26

EEPROM

Service Manual

TS-280.SB

TENSOTRONIC

EEPROM

EPROM

Figure 6.2. Processor PC boardBoard

17
27

TENSOTRONIC

TS-280.SB

Figure 6.3. Power sSupply PC Boardboard

28

Service Manual