prolec ltd., 25 benson road, nuffield industrial estate ... piling monitor prolec ltd., 25 benson...

PM1 Piling Mast Monitor

Issue E (560375-000) July 2012

Prolec Ltd., 25 Benson Road, Nuffield Industrial Estate, Poole, Dorset, England BH17 0GB

PM1 Piling Monitor Installation and Operation Guide


Issue E (560375-000) July 2012


Issue E (560375-000) July 2012

Piling Mast Monitor

Installation and Operation Guide Contents Section Title Page No. 1 System Components 4 2 Installation 5 2.1 Display 5 2.2 Display – Power 5 2.3 Sensor 6 2.4 Offset Calibration 7 2.5 Average Adjust 9 2.6 Calibration Reset 11 2.7 Switch Sensor type 12 3 Operation 13 4 Maintenance 14


Issue E (560375-000) July 2012

The Piling Monitor consists of the following components : 1 TS3 Dual Axis Tilt Sensor – Mounted on the vibration hammer 2 Display – A computer controlled unit giving visual indication in the form of a cross indicating proximity to target angle and an X Y angle display. 3 Sensor Cable – 6 way connector 4 Power Cable – 3 way connector Wire No. 1 = +10V to +30V dc Wire No. 2 = 0V 5 CAN Cable terminator 6 Sensor Mounting Plate

1 System Components

Display

Sensor CAN Cable

Power

The sensor orientation shown will operate as per the diagram on the display. As the sensor is pitched forwards, then Y increases posi-tively. As the sensor rolls right then X increases positively.

Y Axis

AS7 – Dual Axis Sensor

Mounting Plate

Terminator – Must be fitted, provides correct termination resistance for cable and environmentally seals connector

CAN Connector and cable

X Axis


Issue E (560375-000) July 2012

The display can be fitted to any convenient surface inside the machine cab ensuring that the operator has convenient access to the pushbuttons and a direct view of the LED cross and angle displays. A ball joint fitting is provided and should be used in conjunction with a suitable mounting bracket – this will have to be determined / fabricated by the installer as each application and machine type may be different. The sensor and power cables are fitted to two different connector types, misconnection is not possible. Try to mount the unit in a position that avoids vulnerable long cable runs inside the cab. When routing the cable to the display try to use existing cable looms, and make sure any holes drilled for routing purposes are properly deburred and grommeted.

2 Installation

2.1 Display

2.2 Display – Power

The display operates from +10V to +30V dc and is suitable for nearly all machine types. The Display is fused and protected against reverse voltage connection and transient voltage spikes. The cable terminations are : Cable No. 1 = +V Cable No. 2 = Gnd Grn / yellow = Not connected When connecting the power cable it is recommended that an in line fuse of 1A minimum is used to protect the machine supply in case of the power cable short circuiting. Choose a suitable +V point inside the machine fuse box avoiding a noisy +V supply such as wiper mo-tors and ensure that a good earth contact is made for the Gnd wire.

Display

Sensor

Ground Wire No. 2

+V Wire No. 1

In Line Fuse


Issue E (560375-000) July 2012

The tilt sensor is mounted on the top of the vibrating pile hammer. The sensor should be mounted away as far as possible from moving parts like rams or hoses, and away from any potential danger caused by the material being handled. The sensor connects to the display via the 8m cable provided. The cable is very rugged, but has a length of hose fitted for extra protection and should be located around any part that may be moving / bending or be in an exposed position. The sensor orientation is shown below – plan view.

The sensor fits inside the bracket and is located via two pins which stops incorrect orienta-tion of the sensor in the bracket. The bracket is welded to the hammer. NOTE : THE SENSOR MUST NOT BE FITTED INSIDE THE BRACKET WHEN ANY WELDING TAKES PLACE. THE DISPLAY MUST NOT BE CONNECTED TO THE SENSOR OR THE POWER SUPPLY WHEN ANY WELDING TAKES PLACE. IT IS RECOMMENDED THAT NO PROLEC EQUIPMENT IS FITTED WHEN WELDING TAKES PLACE TO AVOID ANY DAMAGE THAT MAY ACCIDENTALLY OCCUR. Observe the machine manufacturers recommendations regarding welding before commenc-ing.

2.3 Sensor

CAN Connector and cable

X Axis

Y Axis

Terminator

Orientation Pins

The sensor monitors tilt (pitch and roll) and therefore sits flat on the top of the equipment to be measured.


Issue E (560375-000) July 2012

2.4 Offset Calibration

After installation of the sensor it may be necessary to calibrate for any offsets in the sensor outputs due to the sensor mounting not being level.

Set Button

Row 1

Row 2

Row 3

Row 4

Top plate

Offset Calibration Procedure 1 Remove the top plate and gasket by remove the 4 securing screws using a 4mm Hex key.

2 Switch the power to the unit on. 3 Change the PCB mounted switch from position 0 to position 1. A small screwdriver or pot trimmer is required for this operation.

4 Set the main equipment so that the sensor is at the required horizontal or vertical level.


Issue E (560375-000) July 2012

5 Press the Set Button. The LEDs will illuminate in the sequence of Row 1, Row 2, Row 3, Row 4. The X Y LEDs will each set to 00. The centre LED will illuminate. The sensor offsets have been calibrated and the offset data stored in the Display non volatile memory. 6 Return the PCB switch to position 0.

7 Test the calibration of the equipment level / horizontal. Reset zero postion if necessary. 8 Switch the power to the unit off. 9 If no other setting are required refit the top plate and gasket. Procedure Ends

If the offset requires re adjusting then repeat the above procedure. Note : If the display is changed then the offset calibration will be required with the new display.


Issue E (560375-000) July 2012

2.5 Average Adjust

After installation of the sensor it may be necessary to adjust the amount of averaging of the sensor information. If the sensor is installed on a ‘noisy’ vibrating piece it may appear on the display as random LED illumination and the numerical values rapidly changing. If this is the case the reading can be averaged and the amount of ‘noise’ reduced.

Average Adjust Procedure 1 Remove the top plate and gasket by remove the 4 securing screws using a 4mm Hex key.

2 Switch the power to the unit on. 3 Change the PCB mounted switch from position 0 to position 3.

A small screwdriver or pot trimmer is required for this operation.


Issue E (560375-000) July 2012

4 Press the Set Button. The Numerical display will show the current average level (the default is 1).

5 Set to the desired level. The maximum of 9 will provide the most stable of readings,

but this will cause the display to ‘slow down’ in operation due to the averaging procedure. Hence there is a trade off in display response and display noise. The discretion of the installer is required to obtain the optimum system performance.

6 Return the PCB switch to position 0.

7 Test the new averaging settings readjust if necessary. 8 Switch the power to the unit off. 9 If no other setting are required refit the top plate and gasket. Procedure Ends


Issue E (560375-000) July 2012

2.6 Calibration Reset

If the system calibration data is in an unknown state , it may be necessary to reset the cali-bration values. This removes any offset calibration values and resets the averaging to 1.

Calibration Reset Procedure 1 Remove the top plate and gasket by remove the 4 securing screws using a 4mm Hex key.


4 Press the Set Button. The system is now reset. 6 Return the PCB switch to position 0.

8 Switch the power to the unit off. 9 If no other setting are required refit the top plate and gasket. Procedure Ends


Issue E (560375-000) July 2012

2.6 Sensor Type Switching

The AS-7 Sensor type can be switched between AS7 Pitch & Roll to AS7 Tilting bucket, this allows the PM1 to be connected to an existing CAN bus and use a Tilting Bucket sensor. Note:- That this option is only available from software version V1.02 or higher.

Calibration Reset Procedure 1 Remove the top plate and gasket by remove the 4 securing screws using a 4mm Hex key.


4 Press the Set Button. Pressing the Set Button will now select the AS-7 sensor types. AS-7 Pitch and Roll Sensor or AS-7 Tilting Bucket Sensor 6 Return the PCB switch to position 0. 8 Switch the power to the unit off. 9 If no other setting are required refit the top plate and gasket. 9 Procedure Ends


Issue E (560375-000) July 2012

3 Operation

Monitor Operation The LEDs indicate the X and Y position detected by the sensor at the top of the mast. The actual angle measured by the sensor at the top of the mast is displayed via the 7 segment displays. When the sensor is at 0º and the SET function is not in use then the centre LED (or Target LED) is illuminated. Zoom Function The LED cross has three selectable increments of 1º, 5º and 10º. These increments are se-lected using the ZOOM button. An LED indicator refers to which ZOOM is selected. Vertical Pile Driving When driving a pile vertically both displays can be used for guidance. The SET button must not be pressed – the SET LED will be off if this is the case. Inclined Pile Driving The monitor allows a pile to be driven at an angle other than 0º. To set a mast angle manoeuvre the mast until it is at the required X and Y angles and press the SET button. This causes : 1) The Angle displays freeze at the set angle 2) The target LED is set to the angle displayed. The ZOOM function will still operate. Any deviation from the set angle will be shown on the LED cross. 3) The SET LED is illuminated. Pressing the SET button again releases the display, switches off the SET LED and returns the target LED to 0º.

Set Button

Zoom Button


Issue E (560375-000) July 2012

4 Maintenance

The Piling Mast Monitor has been designed with ease of maintenance in mind. There are no moving parts. Maintenance is restricted to periodical checking of cable routing / chafing and general fixing / sealing verification. The sensor installations are by their nature in exposed positions so checks for damaged cable runs and physical sensor damage are important. The display and sensor are each protected by an internal resettable fuse mounted on the computer board. Any power cable runs that become short circuit due to chafing will blow the recommended in line fuse.


Issue E (560375-000) July 2012


Issue E (560375-000) July 2012

Prolec Ltd., 25 Benson Road, Nuffield Industrial Estate, Poole, Dorset, England BH17 0GB

PROLEC LTD

25 BENSON ROAD NUFFIELD INDUSTRIAL ESTATE

POOLE, DORSET

ENGLAND, BH17 0GB

560648-000 Issue 1 - Feb 2010

+44 (0)1202 681190

+44 (0)1202 677909

[email protected]

prolec ltd., 25 benson road, nuffield industrial estate ... piling monitor prolec ltd., 25 benson...

Documents