Paltronic 150 Hardware - 2017 - 10 - en PDF

TRAINING
Loader crane
PALTRONIC 150
Hardware
Original training document
2017/10
PALFINGER AG
Franz-Wolfram-Scherer-Straße 24
5020 Salzburg / Austria
www.palfinger.com
Index PALTRONIC 150 Hardware
Index
1 General........................................................................................... 4
1.1 Introduction and handling of this document ..................................... 4
1.2 Validity ............................................................................................ 4
1.3 Symbols in this document ............................................................... 4
2 Hardware........................................................................................ 5
2.1 General........................................................................................... 5
2.2 System specification – Hardware .................................................... 5
2.3 Safety Integrity Level ...................................................................... 5
3 PALTRONIC 150 Hardware ........................................................... 6

3.1 Digital system setup........................................................................ 6
3.2 Main board...................................................................................... 8
3.3 Emergency cut-off loop, push button display................................. 14
3.4 Emergency cut off loop, Push button RC ...................................... 15
3.5 Additional board ............................................................................ 16
3.6 CAN Extension ............................................................................. 16
3.7 Addressing of the CAN bus hardware ........................................... 20
4 Switches and Sensors ................................................................ 29

4.1 Switches and sensors general ...................................................... 29
4.2 Ultrasonic sensor .......................................................................... 29
4.3 Pressure absorber ........................................................................ 30
4.4 Slewing-encoder / angle-encoder /
distance measuring-wire (CAN sensors) 30
4.5 Oil sensor ..................................................................................... 31
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PALTRONIC 150 Hardware General
1 General
1.1 Introduction and handling of this document

This PALFINGER training document is a technical description about systems on a loader
crane. It will be expensed for PALFINGER trainings on loader cranes and should be a
reference book for service and repair work.
These training documents have been produced for PALFINGER service workshops. An
appropriate knowledge about the product and a basic education will be assumed.
1.2 Validity
This training document applies without any time limitation for the described system.
It is possible due to further developments that newer versions of this document are already
available.
The respectively newest edition of this training document and further technical documents
are available on the PALFINGER Extranet in the range PALIPEDIA / service documents.
Registration can be done at https://www.palfinger.com
PALFINGER keeps the right to change the documents at any times without notice.
© Copyright by PALFINGER
Copying (also in Extracts) only after written permission from:
PALFINGER AG
Franz-Wolfram-Scherer-Straße 24
A-5020 Salzburg/Austria
1.3 Symbols in this document

To make the document clearly structured and easily readable, important references,
instructions and risks are highlighted by symbols and special words.
Caution!
Symbol and special word will be used for imminent danger.
If the safety instructions are ignored, acute danger for life exists for the operator and
others.
Attention!
Symbol and special word will be used for imminent danger.
If the safety instructions are ignored, acute danger for life exists for the operator and
others.
Note!
Symbol and special word will be used for a very important note which makes
operation of the machine easier.
4 / 31
Hardware PALTRONIC 150 Hardware
2 Hardware
2.1 General
Depending on the PALFINGER product and the chosen options, PALTRONIC 150 is
composed by different components which are mounted separately or assembled into one
control box. All components are connected to each other under the use of three CAN-Bus
systems.
As a basic principle PALTRONIC 150 is operable in combination with one radio remote
control (Scanreco P3) and a CAN-Bus able control valve (Danfoss PVG32 or Rexroth M4-
12).
The used CAN language is the CAN open protocol.
The specification of the hardware describes the assignment in general. The assignments of
the input and output pins to the signals are done by the software. Further information can be
found in the software specification of the respective PALFINGER product.
2.2 System specification – Hardware

This specification applies to „PALFINGER PALTRONIC 150“control system.
As PALTRONIC 150 is in use for several PALFINGER products with various software
versions, the software specifications differ depending on application and version.
The software-coding is indicating the application and software version of the used
PALTRONIC 150. The software-code is a 4-Byte code. The first two digits indicate the
operating system, the second two digits the product-range and version.
Sample: 001. 3.00
The first part indicates the product-range:
001: Truck crane
002: Railway
003: Lifitng platform
The second part describes the software-version:

3.00: Version 3, Subversion 00
2.3 Safety Integrity Level

The control electronic Platronic 150 reaches “Safety Integrity Level 2” according to IEC
61508. The whole system, including hydraulics, mechanics etc., fulfils the performance level
D according to EN ISO 13849-1 and is therefore licensed to operate working platforms and
workman baskets.
This means that all used components and sensors, fulfilling all given regulations and norms
needed to be allowed for crane operation or passenger transport, without additional safety
systems needed.
5 / 31
PALTRONIC 150 Hardware PALTRONIC 150 Hardware
3 PALTRONIC 150 Hardware
3.1 Digital system setup

3.1.1 CAN-Open general
The CAN- Bus (Controller Area Network) to be among field bus systems. The field bus
replaces parallel wiring bundle with one single Bus-cable and is connects all levels, such as
field-level (encoders, sensors, drives…) and control-level (PALTRONIC 150).
At PALFINGER CAN-Open is used. CAN-Open is a communication protocol based on CAN-

technology utilized for cross-linking within complex devices (PALTRONIC 150, RC, etc.).
During development of the new PALTRONIC 150, special attention has been paid to
component-flexibility, to achieve product-type comprehensive applicability across the
PALFINGER group.
All CAN members get updated every 40ms by the system. Due to the high data-volume
needed, two Bus-systems are used simultaneously at some product-groups (working
platforms):
 C1: Can1: Sensor system (angle/slewing encoder, basket load-cell….)
 C2: Can2: Hydraulic (distributor, radio remote control)
 C3: Can3: Truck Bus
The CAN-Open communication is structured in three domains:
 Service-data-object (SDO) for parameterization: This object is used to exchange

adjustment parameters with each single Bus-component. While initialisation this is
the request for the member identification and the serial number. This is done to
determine if a member has been changed and needs to be synchronised.
 Process-data-object (PDO) for real-time data transport: This is analogue and digital
data, which is gathered by sensors. All current measurement- and reference-values
are exchanged within the CAN-network with this object. For example: the lever
distance, transmitted by the remote control to the PALTRONIC 150, is converted
into a movement and transmitted as a reference-value to the main control valve.
 Network-management-object (NMT) for communication management: To grant a

controlled CAN-Bus process, additional data-objects are defined. These objects
manage and control the communication. NMT-objects are used to switch between
initialisation and operation mode or in case of an error, these objects switch-off all
components.
Objects are data packages which are sent by one CAN-Bus member to one, several or all
CAN-Bus members.
3.1.2 CAN-Bus operation mode
The CAN open system is wired in “bus topology” (all components are connected with the
same transmission medium, = the bus) with terminating resistors (120 Ohm) at the
beginning and at the ending. The transmission of data is done via the signal CAN-H and
CAN-L in combination with GND as data reference potential. The flow of data must be
controlled by an access method (protocol), if all components are using a common Bus-line.
So components of different producers should be compatible with each other. This is called
open Bus-system.
The condition of using two different levels on CAN-H and CAN-L is called dominant
condition. According to the CAN definition the dominant condition corresponds to a logical
zero: When a member writes a logical zero to the bus, it can happen that it overwrites
another member’s logical one.
6 / 31
3.1.3 CAN-Bus signal measurability and error detection

Due to the CAN-Bus mode of operation, the transmitted signals cannot be measured under
the use of common measuring devices (multimeter, oscilloscope, testing lamp…).
The CAN-protocol is able to detect and indicate errors by oneself. There are three
mechanisms implemented at the data level for error detection. Furthermore within the CAN-
protocol are two error detection mechanisms implemented at the BIT-level.
If one of these error detecting mechanisms is responding (detecting an error) at least at one
node, the current communication is interrupted by sending an „Error Flag“. If an error
appears repeatedly this leads to an automatic “switch-off” of the node.
7 / 31
3.2 Main board

The PALTRONIC 150 main board frames the foundation of the system.
It contains all needed connections and functions required for the basic operation.
A) Fuse 3A for main board

B) Main Power
C) Fuse 10A for DV2 relay
D) Digital outputs 09-16 with 3A fuse
E) Digital outputs 01-08 with 3A fuse
F) Analogue inputs
G) AUX RS232
H) Diagnostic RS232
I) Digital inputs
J) CAN bus truck
K) CAN bus hydraulic system
L) CAN bus sensor system
8 / 31
3.2.1 Main board connector pin assignment
A) Fuse 3A CAN bus system

Fuse of the PALTRONIC 150 main board, 3A
B) Main power:
Power supply of the PALTRONIC 150 hardware
+ Power supply „plus“(11-32V), from the vehicle battery or PTO supply, wired
through the emergency cut-off loop
- Power supply „ground“
- Connector ground for ground carry-over to ground supply of digital outputs (D,E)
DV2 Power supply to digital outputs via DV2 - Power supply to digital output
DV2 Power supply to digital outputs via DV2 – not in use
+IN Power supply from the RRC (output DV2 from RC) is forwarded internal via a
relay to the DV2 output at the main power plug.
C) Fuse 10A:
The 10A fuse is wired between +IN and DV2 and acting as the fuse for the relays.
Next to the relay is a green LED which indicates the incoming power at +IN.
D) Digital outputs 09-16

E) Digital outputs 01-08
Each connector is secured by a 3A fuse. The current supply of each connector can be
given by the main board (bridge from DV2 outputs, at main power connector). Meaning that
functions only can be switched by PALTRONIC 150 digital output signals, if a DV2 signal is
given by the RRC.
It is also possible to use an external power supply for the digital outputs. This is used for
functions which are needed to be operated even if no DV2 signal is given from the RRC
(Working light, horn, …).
- Ground, connected to the main power connector (external supply possible)

DV2 Power supply via DV2 from main power connector (external supply possible)
01-16 Digital output signals
Each output is equipped with a LED, to show its activity once it is used (LED 01-
16)
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F/1
F) Analogue input:
The analogue inputs at the PALTRONIC 150 are designated for non-CAN sensors.
The power supply of these sensors is not given by the main board, it must be wired
externally.
01-16 Analogue inputs (signal pins), signal range 4-20mA

- (“-„/pin from connector B)
The signals from the pressure transducers must be between 0,75 and 19,7 mA, if not so
the PALTRONIC 150 gives an error code (broken cable at pressure transducer if the signal
is too low, illogical signal if it is too high).
4mA equals 0 bar, 20mA equals 600 bar (8702 psi) or 1000 bar (14504 psi), depending on
the signal range of the pressure transducer.
If the fly jib is disconnected, a contact must be given. This is done by the blind plug of the
fly jib (resistor loop), if not, an error code is indicated at the PALTRONIC 150. The resistor
in the blind plug results in a 2,75 mA signal.
As redundant sensors are in use (fulfilling SIL2), 2 inputs are needed for each sensor. The
pressure transducers send two independent analogue input signals, 600 bar (8702 psi)
and 1000 bar (14504 psi). Simple sensors, such as the temperature sensor, only require
one input pin.
F/1) Analogue output (not in use at the moment):

The analogue outputs of the PALTRONIC 150 are designed for usage with voltage
or current controlled components, like traction drive at railway machines. For using
them an additional print is needed.
The output signal (mA or V) must be defined before the installation, therefore a
bridge is soldered onto the print by the supplier.
This option is not in use at the moment.
+IN Input signal (external)

mA 0-20 mA output signal
V 0-24 V output signal
- Ground
10 / 31
G) AUX RS232: Intercom for external units (monitor), which can be accessed via RS232
port. Not in use at the moment.
H) Diagnostic RS232: Intercom for diagnostic. Due to the preparation with the various
pins of a serial intercom, the use of modems and other similar units can be realized
in future. The connector is internal wired to a 9-Pin Amphenol connector, so the
diagnostic intercom of the P50, the PALTRONIC 150 and the RRC are alike.
DCD not in use at the moment

RXD Receive data
TXD Transmit data
DTR not in use at the moment
GND Ground
DSR not in use at the moment
RTS not in use at the moment
CTS Prog/Enable
RI not in use at the moment
I) Digital inputs: PALTRONIC 150 can manage 16 digital inputs directly at the main
board. These are labelled with 01-16. All inputs are monitored and activity is
indicated with a green LED, if power is present. Each connector offers eight input
pins and one ground pin. The number of inputs can be increased up to 32 inputs by
using an additional attachment print.
01-16 Digital inputs 01-16 (signal pin)

- Ground (“-„/ pin from connector B)
11 / 31
J) CAN bus truck: CAN bus intercom for the vehicle. This port can be used to combine
more than one PALTRONIC 150 systems with each other. The connector has 3 pins
and only transmits the CAN bus signal.
CA CAN low
CB CAN high
CG CAN ground
K) CAN bus hydraulic: CAN bus intercom for connecting with the control valve and other
actors. This bus is used to link-up any CAN bus able control valves, the RC and any
output extensions (display, digital output extension). The connector has 5 pins and
carries the CAN bus signal and the power.
CA CAN low
CB CAN high
CG CAN ground
+24V Power
- Ground
L) CAN Bus Sensor: CAN bus intercom to the CAN-sensors. This bus is used to link-up
with any CAN-sensors and input extensions (digital-input extension). The connector
has 5 pins and carries the CAN bus signal and the power.
CA CAN low
CB CAN high
CG CAN ground
+24V Power
- Ground
12 / 31
3.2.2 LED’s
1. +24V power supply applied, 3A fuse OK

2. Power supply relay outputs 01-08
4. PALTRONIC is running
5. CPU1 is in RESET-Mode (must be during start-up)
7. DV2 (to dump valve)
8. DV1 (from remote control or steady 24V from key switch)
9. This accumulator is in charge to keep the real-time watch running, when the system
is switched off. This means that date and time are still processed, when no voltage is
applied. Once the PALTRONIC is switched on, this accumulator is charged. It is not
possible to replace this accumulator. If the accumulator breaks down, it has no
influence to the function of the unit. The only effect is that time and date of the error
codes are not correct any more, from this time on. A defective accumulator will be
registered by the PALTRONIC (Error 004.100), but not indicated at the 7 segment
display (to avoid confusing the driver)
13 / 31
3.3 Emergency cut-off loop, push button display

The emergency cut-off loop at the PALTRONIC 150 is wired via the CAN bus connectors of
the display only. It is possible to extend the loop to any other CAN bus plug, not done for the
standard set up of the system.
10. signal from connector 801 (power supply)  to display CAN connector pin 7
11. bridge from pin 7 to pin 6 at the second CAN bus plug of the display (if plug not used)
12. internal connection at the print from pin 6 to emergency cut off plug
13. cut off plug pin 1 wired via mechanical push button to pin 2 at cut off plug
14. Internal connection at the print to CAN bus plug pin 6
15. CAN-Bus plug pin 6 to connector 101
16. Connector 101 to PALTRONIC 150 main board Pin +
Several displays or external emergency cut off buttons can be wired in series if needed.
If any emergency push button at a display is pressed the power supply to the PALTRONIC
150 is interrupted.
14 / 31
3.4 Emergency cut off loop, Push button RC

The emergency cut off button at the RC interrupts the power supply to +IN at the main
board, the main board power supply stays.
Between +IN and DV2 a relay is installed. The red LED “DV2” is lighting once the relays give
signal. This relay forwards the RC’s input signal from +IN to DV2. The relay is monitored by
the two processors. This is indicated with two LED’s. If they are lighting, the processors
activate the relay.
All digital outputs, which are powered by the main power adapter’s DV2 output, are
powered-down, once the emergency button at the RC is pressed.
15 / 31
3.5 Additional board

3.5.1 Additional print for digital inputs (17-32)
Extends the digital inputs by additional 16 pins, all of them are monitored and indicated by
green LED’s.
17 – 24 Digital inputs
25 – 32 Digital inputs
3.6 CAN Extension

3.6.1 Extension for digital inputs (01-16)
Each print is extending the digital outputs by additional 16 outputs. The maximum number of
extension boards being attached simultaneously is four. All inputs are monitored and
indicated by green LED’s.
CAN plug:
CA CAN low signal

CB CAN high Signal
CG CAN ground
+ Power supply for the print
- Ground supply for the print
06 Emergency cut off loop
(+) Signal not used with PALTRONIC 150
01-16 Digital inputs
+ Power supply for the connected user
- Ground supply for the connected user
16 / 31
LED’s:
3.6.2 Additional Display

It is possible to connect up to 4 additional displays.
CAN plug
CA CAN low signal

CB CAN high Signal
CG CAN ground
(+) Signal not in use with PALTRONIC 150
CUT-OFF:
(1) Pin emergency cut off button
(2) Pin emergency cut off button
17 / 31
3.6.3 Extension for digital outputs (01-08)

With this print, additional 8 digital outputs can be added, all outputs are indicated with red
LED’s.
Each output is resilient to 3A, the sum of all outputs must not exceed the usage of 3A
electric current. Maximum 4 of these digital output extensions can be used.
CAN plug:
CA CAN low Signal

CB CAN high Signal
CG CAN ground
(+) Signal not in use with PALTRONIC 150
Output plug:
01-08 Digital outputs

- Ground output for consumer
+Vout External power supply for digital output signals, normally
bridged from +24V. The power supply can also done external, if
a supply without the emergency cut off loop Is wanted.
+24V Power supply from CAN bus plug, used as power supply for
digital outputs (bridge to +Vout)
18 / 31
LED’s:

6. Release of the common power supply for the relays (is on only, once bought CPU’s
released (LD1 and 2 are off)
19 / 31
3.7 Addressing of the CAN bus hardware
A. CAN bus sensor system B. CAN bus hydraulic C. CAN bus truck
1. Digital-input extension 5. Remote control Not in use at the moment.

max 4 prints possible 6. Distributor
7. Digital-output
2. Slewing encoder extension max 2 prints
3. Angle encoder possible
4. Length encoder 8. / 9. Terminal /Display,
max 4 possible
20 / 31
3.7.1 Addressing general

Each member of the CAN bus network requires a unique address, for being able to identify
frames designated to him and to label frames, sent by him, with his signature.
The CAN-Bus address is composed by two digits. The first digit is given by the type of
component, it cannot be changed. It defines the type of component within the CAN bus
network (sensor, input print,…). For systems like the PALTRONIC 150, using several CAN
bus networks, it is common to have identical addresses on differing CAN bus networks
(sensor bus address 41 = input-print, hydraulic bus address 41 = display). Within one CAN
bus network each address must be unique and only used once.
The addressing of a CAN bus component can be realized in several ways. The used method
is given by the component’s producer.
 Pre-programmed address: It is programmed by the producer and not changeable
(e.g. receiver of the RRC).
 Variable programmed address: This is used for similar CAN bus components.
Under the use of certain software the address can be changed (e.g. control valve
Modulee).
78 9 A
 Addressing with a mechanical switch on the print: The adjusting
rang is from 0 to F. The arrow indicates the adjusted digit.
23 6
BC D
45
EF01 Changes are only allowed when the system is shut down.
 Addressing with wiring: For CAN sensors like encoders and load measurement
cells, the definition of the address’ second digit is done under the use of several
addressing wires. The address is composed out of the basic address and hardware
bits. The hardware bits are 4 lines routed with the address-cable for connection.
The installer decides the final address by hardware. The lines are connected to
pull-up resistors. An open line is resulting into an logical 0.
 Inclination sensors are X/Y-angle sensors with a modified software, compared to
angle encoders.
Therefore it is possible, to use the same cable coding like on encoders or length
sensors.
3.7.2 Sensor-Bus
Digital input (addressing with switch on print):
 Digital input print address switch 0  41 (shown address 41)
 Crane stabilizer electronic S-IQ 1  address fix programmed
 Additional stabilizer electronic S-IQ 2  address fix programmed
 Additional front/rear stabilizer electronic S-IQ 3  address fix programmed
CAN sensors (addressing with wiring): Connection: All CAN sensors are connected to the
PALTRONIC 150 bus under use of the same colour connection scheme (Pin 1 –Pin 5). If an
emergency loop exists on the CAN bus plug, it must be bridged. The addressing wires
define the second digit of the address. This is done by connecting the address wires to the
pink ground wire. Different combinations lead to different addresses.
21 / 31
YE
 Wiring:
GR
YE Yellow CANA Data bus Pin 1 BK

GR Green CANB Data bus Pin 2
BK Black CAN Data bus Pin 3 RD
RD Red Plus Data bus Pin 4
BL
BL Blue Minus Data bus Pin 5
WH
BR
 Addressing:
GY
VL
WH White Address bit 0
PN
BR Brown Address bit 1
GR Grey Address bit 2
VL Violet Address bit 3
PN (PK) Pink Address bit Ground
Violet Grey Brown White
Equip-
ment Address Bit3 Bit2 Bit1 Bit0
U205 11 Column slewing X X X X

U206 13 Main Boom - angle encoder X X X -
U207 15 Outer Boom - angle encoder X X - X
U208 17 Ext. Boom – distance encoder X X - -
U209 19 JIB Outer Boom – angle encoder X - X X
U210 1B JIB Ext. Boom - distance encoder X - X -
U215 2F distance encoder outrigger quadrant A - - - -
U216 2D distance encoder outrigger quadrant B - - - X
U218 2B distance encoder outrigger quadrant C - X -
U217 29 distance encoder outrigger quadrant D - X X
U225 31 inclination sensor HPSC-Load X X X X
For addressing, the mentioned wires are connected with ground (= pink wire).
X = Connected with pink, ground
- = not connected
Slewing encoder, Paltronic 150 with S-IQ:

4-pin plug
Equip-
Address
ment
U205 11 Column slewing encoder, ID-Address fix programmed

Paltronic 150 with S-IQ Cable coding not required
22 / 31
Wiring of encoder column slewing Wiring of angle encoder main boom

Address 11 Address 13
23 / 31
3.7.3 Hydraulic bus

Digital outputs (addressing with switch on print):
 Digital output print Address switch 0  51 (shown Address 51)
Display (addressing with switch on print):

 Display address switch 0  40 (shown Address 40)
Radio Remote Control:

 Address fix programmed (cannot be changed)  70 (shown Address 70)
Control valve Modulees:

The system recognises 32 different CAN-Modulees, but only can control 24 under the use of
an analogue signal.
The programming of the address is done via PALDIAG.NET.
shown Address  10 – 2F
24 / 31
Standard configuration CAN-Control valve
Crane with rope winch

1.Module 2.Module 3.Module 4.Module 5.Module 6.Module 7.Module 8.Module
CAN/Paltronic 010 011 012 013 014 015 016 017
adress
Function
add. function
Crane without rope winch

1.Module 2.Module 3.Module 4.Module 5.Module 6.Module 7.Module 8.Module
CAN/Paltronic 010 011 012 013 014 015 016 017
adress
Function
add. function
Standard configuration 2 circuit CAN-Control valve
Crane with Jib

Block 1 Block 2
1.Module 2. Module 3. Module 4. Module 1. Module 2. Module 3. Module 4.
CAN/Paltronic 010 011 012 013 014 015 016
adress
Function
add. function
Crane without jib

Block 1 Block 2
CAN/Paltronic 010 011 012 013 014 015 016
adress
Function
25 / 31
Standard Configuration 2 circuit CAN-Control valve
Crane with Jib but without rope winch

Block 1 Block 2
CAN/Paltronic 010 011 012 013 014 015 016
adress
Function
add. function
Crane without Jib

Block 1 Block 2

CAN/Paltronic 010 011 012 013 014 015 016
adress
Function
Custom Stabilizer:
Custom Stabilizer 1. Module 2. Module

CAN/Paltronic adress 026 027
Function Stabilizer 1 Stabilizer 2
CAN addressing „CUSTOM Functions“:
1. Module 2. Module 3. Module 4. Module 5. Module 6. Module

CAN/Paltronic 018 019 01A 01B 01C 01D
adress
Function
CF1 CF2 CF3 CF4 CF5 CF6
26 / 31
Standard assignment of the stabilizer control valve on the PK200002SH:
Block 1 Front
1. 2. 3. 4. 5. 6. 7. 8.
Module Module Module Module Module Module Module Module
CAN/Paltronic 020 021 022 023 024 025 026 027
adress
Function Stabilizer Stabilizer
1 2
Block 2 Rear
1. 2. 3. 4. 5. 6. 7. 8.
CAN/Paltronic 028 029 02A 02B 02C 02D 02E 02F
adress
Function add.
Stabilizer
(optional)
Standard assignment of the stabilizer control valve on the PK135002TEC; PK165002TEC:
Block 1 Right
1. 2. 3. 4. 5. 6. 7. 8.
Paltronic 020 021 022 023 024 025 026 027
address
Function
Block 2 Left
1. 2. 3. 4. 5. 6. 7. 8.
Paltronic 028 029 02A 02B 02C 02D 02E 02F
address
Function
27 / 31
View Danfoss CAN-Control valve
3.7.4 Truck bus

It is designated to access the CAN bus network of the truck or it can also be used to link
together with several PALTRONIC 150 systems.
28 / 31
Switches and Sensors PALTRONIC 150 Hardware
4 Switches and Sensors
4.1 Switches and sensors general

For being operational, PALTRONIC 150 needs information about the current situation. This
information is provided by switches and sensors and can be given, depending on the
information, in analogue or digital form.
4.2 Ultrasonic sensor

The ultrasonic sensor is delivered pre-adjusted, according to PALFINGER specifications.
This is valid for sensors mounted on new cranes and spare parts.
The sensors operating voltage = 10 – 30VDC
Adjusting of switching points:

The ultrasonic sensor comes with two teachable outputs with corresponding switching
points. These are adjusted by applying –UB or +UB to the teaching input. The power must
be applied at least for 1 second. While performing the teaching procedure, a LED indicates if
the sensor recognized the voltage. At –UB switching point A1 and at +UB switching point A2
is adjusted.
There are five modes adjustable.
The teaching of the switching areas is only possible immediately after applying the main
power to the switch. A time lock secures the parameters against unintentional changes, 5
min. after the last teaching procedure was done. If readjustments need to be changed, it is
needed to switch OFF and ON main power.
1. Brown = +UB
2. White = Teaching input
3. Blue = -UB
4. Black = Signal output
5. Grey = Synchronisation
29 / 31
PALTRONIC 150 Hardware Switches and Sensors
4.3 Pressure absorber

The used pressure absorbers of the PALTRONIC 150 also fulfil SIL2 and can be operated
with 12VDC and 24VDC power supply. The used measuring technology detects the
pressure with a hermetical welded thin-film measuring cell. The pressure absorber’s signal
must be between 0,75mA and 19,7mA at the PALTRONIC.
Connector: circular connector M12x1 4poles
Pin 1: VCC
Pin 2: Signal 2 (1000 bar, 14504 psi)
Pin 3: GND
Pin 4: Signal 1 (600 bar, 8702 psi)
4.4 Slewing-encoder / angle-encoder / distance measuring-wire (CAN

sensors)
Angle encoders are used to measure angle and distance positions and deliver the
measurement results as an electrical output signal.
For angle detection, the used sensors have two redundant systems with identical
construction. The evaluation of the given data is done by the PALTRONIC 150. Due to this
design, safety level SIL2 is achieved. The data output is realized via a CAN open safety
protocol. The angle detecting sensor is working with a „Hall-effect“ based sensor and is
equipped with a down streamed interpolator (the „Hall-effect“ appears at an electrical
conductor under power, if the conductor is in a magnetic field). The measuring system
detects the position of a magnet and determines the angle. The magnetic detection can be
designed very robust and is suitable for critical and ruff conditions.
For absolute position encoders, the correct sensing of the angular position is also possible
after a power cut out when the shaft starts to spin again. This is possible because the shaft
position is given as an absolute value.
30 / 31
Switches and Sensors PALTRONIC 150 Hardware
4.5 Oil sensor

The oil level detection is based on a capacitive measuring principal. Under the use of an
electro conductive plate and an aluminium tube, a condenser is formed. Based on the oil
level the volume of the remaining air is changing between the measuring electrodes. The
resulting capacity change is detected, processed and forwarded by the microcontroller.
The analogue temperature output can be used to get the oil temperature within a range of
-40°C ... +125°C. For this area an output signal from 2V to 10V (4mA – 20mA) can be
generated.
The sensors operating voltage = 12 – 36VDC
1. green = power „+“

2. yellow = temperature
3. violet = level
4. black = ground “-“
31 / 31

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TRAINING

Original training document

3 PALTRONIC 150 Hardware ........................................................... 6

4 Switches and Sensors ................................................................ 29

1.1 Introduction and handling of this document

1.3 Symbols in this document

2.2 System specification – Hardware

The second part describes the software-version:

2.3 Safety Integrity Level

3 PALTRONIC 150 Hardware

3.1 Digital system setup

At PALFINGER CAN-Open is used. CAN-Open is a communication protocol based on CAN-

The CAN-Open communication is structured in three domains:

 Service-data-object (SDO) for parameterization: This object is used to exchange

 Network-management-object (NMT) for communication management: To grant a

3.1.3 CAN-Bus signal measurability and error detection

3.2 Main board

A) Fuse 3A for main board

3.2.1 Main board connector pin assignment

A) Fuse 3A CAN bus system

D) Digital outputs 09-16

- Ground, connected to the main power connector (external supply possible)

01-16 Analogue inputs (signal pins), signal range 4-20mA

F/1) Analogue output (not in use at the moment):

+IN Input signal (external)

DCD not in use at the moment

01-16 Digital inputs 01-16 (signal pin)

1. +24V power supply applied, 3A fuse OK

3.3 Emergency cut-off loop, push button display

3.4 Emergency cut off loop, Push button RC

3.5 Additional board

3.6 CAN Extension

CA CAN low signal

3.6.2 Additional Display

CA CAN low signal

3.6.3 Extension for digital outputs (01-08)

CA CAN low Signal

01-08 Digital outputs

1. CPU2 is in RESET-Mode (must be during start-up)

3.7 Addressing of the CAN bus hardware

1. Digital-input extension 5. Remote control Not in use at the moment.

3.7.1 Addressing general

YE Yellow CANA Data bus Pin 1 BK

Violet Grey Brown White

U205 11 Column slewing X X X X

Slewing encoder, Paltronic 150 with S-IQ:

U205 11 Column slewing encoder, ID-Address fix programmed

Wiring of encoder column slewing Wiring of angle encoder main boom

3.7.3 Hydraulic bus

Display (addressing with switch on print):

Radio Remote Control:

Control valve Modulees:

Standard configuration CAN-Control valve

Crane with rope winch

Crane without rope winch

Standard configuration 2 circuit CAN-Control valve

Crane with Jib

Crane without jib

Standard Configuration 2 circuit CAN-Control valve

Crane with Jib but without rope winch

Crane without Jib

1.Module 2. Module 3. Module 4. Module 1. Module 2. Module 3. Module 4.

Custom Stabilizer 1. Module 2. Module