DS1201 PDF

DS 120
Programmable Switching Amplifier

Configuration Manager
Operating Manual
Edition 4/2002 Rev. 1.30/1.31
Order No.:
414677 - 24 120 19 0001e
All rights reserved

Warranty
We reserve the right to make design changes or technical modifications to the product
under description without prior notification.
We reserve the right to amend this operating manual without prior notification.
PAT GmbH can accept no liability for any technical or printing errors or deficiencies in
this operating manual. In addition, PAT GmbH cannot be made liable for any damage
directly or indirectly resulting from the use of the operating manual.
Copying restriction
This operating manual and the examples provided for the product under description
constitute protected information that is subject to the law of copyright. All rights are
protected under the law. This operating manual may not be copied in whole or in part or
otherwise reproduced without the prior consent of PAT GmbH.
Trademarks
The use of generic names, trade names and trademarks etc. in this documentation
cannot be taken to mean that such names are not protected by trademark and brand
protection legislation and therefore open to use by anyone, even if this is not expressly
stated.
Attention
We hereby make express reference to the fact that any parts or accessories not
supplied by us have not been tested or released by us. The installation and/or use of
such products may therefore have a negative effect on the design properties of your
device and thus impair active and/or passive safety. No liability can be accepted for
damage caused by the use of spare parts and accessories manufactured by third
parties.
PAT GmbH
Hertzstrae 32-34
D-76275 Ettlingen
Telephone:
Facsimile:
Customer service:
E-mail :
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+49 (0) 7243 709-0

+49 (0) 7243 709-222
+49 (0) 7243 709-113
pat.ettlingen@pat-group.net
2002 PAT GmbH D-76275 Ettlingen Hertzstr. 32 - 34 ++49 (0) 7243 709-0 FAX ++49 (0) 7243 709-222
Email: pat.ettlingen@pat-group.net Edition 4/2002 Rev. 1.30/1.31
Please note:
The DS 120 can be supplied in a calibrated condition ex works if required.
Adaptation of the system on site can only be carried out as described
below using a PC.
Safety Instructions
The user can change the functionality or relevant data of this product.
Therefore the user takes the full responsibility by himself.
PAT GmbH cannot admit any liability.
These adjustment instructions are to be regarded as exemplary instructions. For special applications please contact
PAT GmbH
Hertzstrae 32-34
D-76275 Ettlingen
Phone +49 (0) 7243 709-0
Fax
+49 (0) 7243-113
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Contents
About this Manual
DS 120 General Introduction
List of Hardware Components
Basic functions
Connecting the DS 120 to the PC
Installation of the DS 120 software
Operation of the DS 120 software
Views and applications of the individual menus
Opening a file
Producing or modifying a configuration file
File menu item
Menu item Basic Adjustments
Programming the basic functions
Analog Input module
Switching points module
Calculation module
Configuration of the analog output
Enhanced functions
Programming the enhanced functions
Curve module
LC - Display module (optional)
"Switch" module
Lifetime counter (optional) module
RS422 interface module
"Harbour display"
"Snagload" module
Analog input alignment
System menu
Data type; Compatibility with older versions
System Errors
Preventive Maintenance
Specifications
Abbreviations and their Meaning
Appendix
A Solder Bridge Diagram/Tables
B Solder Bridge Diagram Overview
C Connection Diagram
5
8
9
11
15
16
18
19
21
22
23
26
31
31
34
37
39
45
49
49
52
55
57
59
61
63
67
69
70
73
75
80
81
82
83
83
84
85
Customized information (optional)

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About this Manual

This document is a constituent part of the system supplied by:
PAT GmbH
In this documentation you will find information on starting-up, operating and
maintaining the system.
The Safety Information chapter tells you how warning information and symbols
are used in this manual. You will also find information on the intended use of the
system and the qualifications needed by the operatives.
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Safety Information
Warning Information and Symbols
The following designations and symbols are used in the operating manual to
indicate information that is especially important:
This symbol refers to dangers involved in the activity under description that
could possibly result in injury to personnel.
Here your attention is drawn to dangers which could pose a threat to property,
e.g. damage to the equipment or the environment.
The hand with the pointing finger refers you to sections providing additional
information and tips.
This sign points out a possible loss of warranty cover.
Make sure you read all the safety information in this documentation and comply
with this information when using the system.
Always keep these instructions in a safe place. Issue a copy to everyone
who needs one.
The system may no longer be operated if the device is damaged. It should
be disconnected from the mains. The device must be protected against
damp, liquids and dust, in particular, for as long as it is damaged.
Always use mild detergents when cleaning the device. Solvent-containing,
aggressive and abrasive detergents may not be used.
On disposal of the device, the electronic assemblies must be disposed of
as special waste in accordance with local regulations.
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Intended Use
This system is built to recognised safety standards. However, the improper use
of the device can endanger the life and limb of the user or of other persons and
may result in damage to the equipment or other items.
It may be used only for the intended purpose and must be in perfect technical
condition.
Faults that represent a potential safety risk must be remedied immediately.
This system is designed solely for the tasks described in this documentation. It
may not be used for any other purpose. With the aid of the sensors installed on
the equipment being used, the system compares the values measured against
the preset default values. It may not be used for any other purpose.
Your attention is directed to the fact that this system is, and shall not be, a
substitute for good operator judgement or experience with regard to equipment
procedures. Responsibility for safe equipment operation and any consequences
arising therefrom shall remain solely with the operator.
The manufacturer can accept no liability for damage or injury caused by
improper or impermissible use of the system. The user alone bears the risk.
Requirements for Operating Personnel

Only appropriately trained personnel should operate this system, i.e. persons
who:
-
are familiar with the procedures for starting up and operating the system;
have read and understood the documentation or have received the necessary training or instruction;
know the accident-prevention regulations.
7 / 85
DS 120 General Introduction

Basic Schematic
P-System
Machine
control
DS 120
The principle use of a programmable switching amplifier (PSA) is to monitor

machinery or equipment. With the aid of sensors the machine status and/or
important ambient data is transmitted to the PSA by means of analog signals.
The PSA converts these signals into physical variables for further processing.
These physical variables can then be used to carry out various functions
(comparisons, calculations etc.). The PSA makes available relay contacts,
analog output voltages and interfaces as outputs, which can be installed directly
in the machine control.
List of Basic and Extended Functions
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Setting of switching points for an overload protection device

Calculation of physical variables
Configuration of analog outputs
Enabling of various functions via digital inputs
Relay option
Curve processing
Information via LC display
Communication with external devices (RS422/RS485 interfaces)
Switch function
Snagload monitoring
Lifetime counting
List of Hardware Components

Analog Signal Inputs
The DS 120 features a maximum of 8 analog inputs for the connection of PAT
sensors as well as those made by other manufacturers. Voltage signals of
between 0 VDC and +8 VDC can be connected. The device can also process
current signals of between 4 mA and 20 mA.
All input signals are user-scalable for further processing. Sensors with different
rated loads can also be hooked up and processed.
By scaling we mean the assignment of an input voltage (sensor) to a numerical
load value e.g in tonnes.
If, for instance, a load value of 0 - 10 tonnes is to be used with an output voltage
of 2.5 7.5 VDC, the system can be told the corresponding assignment via a
special function.
All subsequent processing operations then refer only to the numerical load
signal.
Analog Signal Outputs

The DS 120 features a maximum of 12 analog signal outputs, of which 4 can be
assigned and scaled at will.
For the first eight analog outputs the signal (1:1), usually 2.5 VDC to 7.5 VDC,
is made directly available at the terminal strip by a decoupling amplifier.
The four additional user-programmable outputs can refer to a free scaled value,
e.g. an individual load, a half-load or a total load, and lie in the voltage range
0 10 VDC. Optionally, the outputs can also be in the current range 4 20 mA.
The outputs are made available by a 12 bit D/A converter.
Depending on the application, scale intervals of between 0.1% and 0.025 % can
be achieved. List of hardware componentry
9 / 85
Digital control input

A maximum of 8 optoelectronic coupler control inputs are available for binary
signals. These can be potential-free contacts such as roller switches or proximity switches.
All inputs can process signals between 0VDC and 30VDC.
Relay output
The DS 120 is supplied as a standard with 8 output relays. Optionally, a
supplementary card can be equipped with 8 additional relays.
Each relay has a potential-free change-over contact that is lead through by
means of a 3-pole screw-type terminal.
The maximum connectable trip line cross section amounts to 2.5mm. The
relays comply with insulation group "C" according to VDE 0100 and switch
250VAC / 8A / 2KVA or 30VDC / 5A.
The switching time of the relays is mainly determined by the number of connected sensory mechanisms (reading cylce minimum 10ms). If, for instance, 2
sensors are used, the minimum switched-off time amounts to 20ms.
All relays have a LED status indicator.
10 / 85
Basic functions
Setting Switching Points, Illustrated by an Overload
Control Unit
Machine
control
DS 120
A DS 120 is intended to measure a load and shut down a relay in case of

overloading. With a load of 0-10t the output signal of the load sensor is 2.57.5V.
Programming has been divided into individual software modules in order to
achieve highest possible complexity and flexibility of the DS 120 system and a
simultaneous clear structure and simple handling.
Only those modules need to be programmed that are necessary for a certain
function. At the same time modules that have already been programmed can be
re-used again and again.
To begin with the sensor signal must be converted into a physical actual
variable in order to realize an overload function. This task is taken on by an
analog to digital transformer, which supplies a number between 0 and 4095.
The signal is now scaled to 0-10.0t (see software module "Analog input" page
31).
After activating a switch function, entering a limiting value and selecting a relay,
(see software module "Switching points" page 34) the system executes the
overload function.
For instance, if a limiting value of 7.5t has been entered, the relay will be closed
at a load below 7,5t. If the load is increased to more than 7,5t, the relay will be
opened.
As a result, machine functions can be shut down.
11 / 85
Individual and Total Loads Processing with the Help

of the Calculation Module
Machine
control
DS 120
If, for instance, the overload of a load total of 2 sensors is to be monitored, one
should proceed as follows: Analog input "1" is already programmed and can
thus be used. Analog input "2" is programmed in the same way as input "1" .
The output of both "Analog Input" modules can now be used directly in order
to trigger switching points (individual monitoring). They can, however, also be
switched simultaneously to a further software module, i.e. "Calculations" in
order to calculate the load total. This load total can then also be monitored
(compound monitoring). In addition to a summation as shown in this example,
the "Calculations" software module can also carry out other mathematical
operations such as subtraction, determination of the highest or lowest value,
etc.
At this point, one is able to recognise the variable structure of the system with
its combination possibilities, as the load total can also serve as input for further
software modules.
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Controlling a machine PLC via analog output

DS 120
The load total is to be provided as an analog output signal of, for example,
0... 10VDC.
For this purpose select "Alignment" (DA/ Align) on the menu bar. As the
calculation of the load total is already available, the required benchmark figures
can be adapted and adjusted, e.g. 0... 20t and 0... 10VDC.
In addition to this, a current of 4 to 20mA can also be emitted as an output
signal (see menu item "Alignment" (DA/ Align) page 39).
Please observe the hardware setting. If necessary, see the solder bridge
plan in the addendum.
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Activation of functions via digital inputs

Individual modules can be activated or deactivated via digital inputs.
PSV 3/1 Win
Relay adjustment 1
AD-converter
Terminal
Analog input 1
2,5V-7,5V
Sensors
Limit 1
0 - 4095
Terminal
floating
Digital
contacts
Signals
DS 120
Hardware
Software
This type of isolation can be used in the following modules:

SWITCHING POINT
(see page 34)
RELAYS
(see page 44)
CURVES
(see page 45 and 49)
DISPLAY DESIGN
RS485 INTERFACE
RS422 INTERFACE
The "Switch" module offers a very varied possibility of controlling signal

courses via digital input (see page 55)
The voltage level for logic "High" is >10VDC.
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Connecting the DS 120 to the PC

The PC is connected to one of the serial interfaces (COM1 / COM2) using the
supplied cable. When doing so the DS 120 must be de-energized.
Connect the supplied hardlock component to the parallel interface (for
USB design to the USB port) after installation of the software.
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Installation of the DS 120 software

1. Start WINDOWS.
2. Place the CD-Rom in the CD-ROM drive.
3. Read the "readme"-file first.
4. If the installation starts automatically, please follow the instructions on the
screen. Otherwise use Windows- Explorer to access the CD-ROM drive,
open the CD-Rom and start installation by double clicking on SETUP.EXE
5. Now follow the instructions on the screen.
6. Once installation has been carried out, connect your PC and the PSA using
the supplied link cable. Plug the 25 pole plug on the link cable into the appropriate 25 pole socket on the PSA base board. Connect the other end to
the COM1 interface (COM-N port) of your PC according to the configuration.
7. Now connect the hardlock (available for the parallel or USB port according to customers requirements) to the appropriate connection on
your computer.
8. Installation is now completed.
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Switching on DS 120
Once DS 120 has been switched on, the following will appear on the screen for
approx. "2" seconds:
PAT GmbH
#118292
The equipment will carry out a self-check. Once this has been completed, either
the display design module pre-programmed display will appear in the DS 120
display (see Design Display Module, page 52) or:
SYSTEM
D-INPUTS
:DS 120
:
This standard display consists of the system name and the information on the
condition of the digital input.
The equipment is now operative and can be programmed.
DS 120 is now ready and can be programmed. To avoid unwanted overwriting
of data, safe the existing configuration on your PC harddisk.
"Data Read"
"Save As"
17 / 85
Operation of the DS 120 software

Once the software has been started, the main menu can be accessed.
View: DS 120 main menu
Menu "File"
Menu "Module"
Menu "Alignment"
Menu "System"
Menu "View"
Comprehensive
help can be found
here
Status bar:
If "Offline" is displayed in the right half of the status bar
DS 120 is not connected.
"Online" indicates recognition of DS 120 equipment.
In the "online direct" mode, any data change will be written directly into DS 120,
(see pages 26 and 28). In the "online indirect" mode, data changes will only be
written into DS 120, when "write data " in menu "System" has been clicked on.
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Views and applications of the individual menus

"File" menu
see page 23
"Module" menu
see page 31
"Alignment" menu
see page 69
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"System" menu
see page 70
"View" menu
see page 18
20 / 85
Opening a file
A configuration must initially be loaded onto the PC if you wish to begin with the
programming of the modules. You may either:
-
load an existing configuration from the hard disk

or disk ("File / Open" menu)
or
produce a new configuration ("File / New" menu)

or
read out the configuration of a connected DS 120

("System / Read Data" menu)
This data are subsequently available for configuration changes. Menu item
"Module......." is selected for this purpose.
DS 120 goes into calibration mode during programming, i.e. as soon as a
module has been selected. All relays are shut down and the following appears
on the DS 120 display:
SYSTEM
CALIBRATION
21 / 85
Producing or modifying a configuration file

A configuration file can also be produced offline, i.e. DS 120 not connected. The
produced configuration is loaded into the equipment using the "System / Write
Data" menu.
The new configuration is saved using "Save" (corresponds to the disk symbol
on the menu bar
), or by selecting the "File / Save As" menu. If necessary, the name of the configuration file can be altered on your PC.
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File menu item
New
This is used to produce a new file.
Insert your 6-digit Access code here. This is found on a yellow card supplied
with every piece of DS 120 equipment.
The data type can be selected. It is recommended to confirm the file type shown
by the program. The file type must be adapted to the respective software
version if you wish to program a DS 120 using an earlier software version.
23 / 85
The appropriate file type for the software version can be recognized when data
are read out of the DS 120 ("Read Data" in the "System" menu) and "Information" opened in "Basic Adjustment" in the "File" menu.
Detailed information on file types can be found in chapter "Data type; compatibility with older versions". (See page 73).
Open
This lists the existing bin files in the active directory that can be opened.
Close
Closes the active file without saving.
Save
Saves the active file on the hard disk using the same name.
Save as...
Saves the file on the hard disk and offers the possibility of using a new name.
Before saving of a datafile, the checkroutine will be activated.
(see page 25 " Check data record")
Print...
Prints off the produced configuration.
Printer setting...
Used to select the printer, paper format, etc.
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Check data record

Checks the produced configuration for plausibility and errors. Appropriate
information is provided if configurations are faulty.
We strongly recommend checking a new or altered configuration before this is
loaded into DS 120 using "Write Data" in the "System" menu.
Important notice
If you have used digital inputs to control modules (e.g. in the switch module),
the system will check whether both conditions (on and off) have been considered.
If e.g. a switching point is only active, when digital input 1 is closed, then
another switching point must become active when digital input 1 is open. This is
strongly recommended in order to have a definitive action of DS 120 under all
conditions.
When the data check finds that only one condition of a digital input has been
considered, a warning message "used digital inputs not fully programmed" will
appear together with the afflicted module.
If not all constellations of digital inputs can be considered in DS 120, then it is
mandatory to check which constellations of digital inputs can come in reality and
at least consider those in order to be sure to program the wanted reaction of DS
120. Only thereafter the configuration may be written into DS 120.
Generally, the user has to exercise proper care when using digital inputs
because of the need to really consider any constellation. Please also read the
Safety Instruction on page 3.
Quit
Used to quit the program.
25 / 85
Menu item Basic Adjustments

Communication dialog box
This is where the PC interface can be selected to which the DS 120 is to be
connected.
Interface selection
The current interface is displayed and a new selection can now be made. The
program memorizes the adjustment and selects this automatically when the
program is re-started. It is therefore only necessary to carry out this adjustment
once.
Online mode
A direct connection is produced to the DS 120 system if the online mode is
activated and the OK button operated. The access number must normally be
entered before the Online status is displayed in the lower right section of the
screen. The system connection can be disconnected in the same way (offline
mode).
It is possible to process data online when in online mode ("Online direct", see
page 28) or to alter data in DS 120 after using the Write data command,
"Online indirect".
It is necessary to be in online mode in order to communicate with DS 120 (read
/ write data). The access code is to be entered for this purpose (see page 30).
Conversion will be offered if the program determines differences in the data
type between DS 120 and the configuration file.
Detailed information on data types can be found in chapter "Data type; compatibility with older versions". (See page 73).
26 / 85
Information dialog box

This is where important system data are displayed.
The left-hand "WinDS120" column refers to the data record currently being
processed by the computer. If the DS 120 is connected and in online mode this
data will also be displayed.
Access Code
The 6-digit data record code number on the PC and on DS 120 must be
identical in online mode.
There is the possibility of changing the code number on the PC data record in
offline mode. The access code of the DS 120 to be programmed must be
entered in order to use a produced data record on several items of DS 120
equipment.
The code number of a connected DS 120 cannot be altered.
Data type
In this case it should also be observed that the data type of the data record in
the PC complies with the connected DS 120. The current data type is "7". If a
DS 120 is to be programmed with data type "<7", this must be entered appropriately when re-producing a data record (see page 23). It is to be observed that
all DS 120 functions and modules may possibly not be available.
Detailed information on data types can be found in chapter "Data type; compatibility with older versions". (See page 73).
27 / 85
Checksum
Each level of the configuration file has a specific checksum that also changes
following every configuration alteration. If one is in "Online direct" mode, the
WinPsa and DS 120 system checksums must be identical, as every alteration to
the configuration is also accepted by DS 120.
This field is purely a display field and makes configuration file alterations directly
visible.
Last alteration using Dongle SN

The dongle serial number is shown here, with which the last alterations were
made to the DS 120 data.
General dialog box

This is where the options for communication with the DS 120 system can be
adjusted.
Process Data Online

As soon as a module is completed with "Accept" and "Ok", altered data are
saved directly in the DS 120 system using the Process Data Online option.
This approach is practical if only individual data are to be altered.
28 / 85
This option is only then permissible if the system data and the current
data are identical. Otherwise, an information message will appear and the
option cannot be activated.
Relay release in calibration mode

All relays normally move to safe condition (relay drop-out) after changing to
calibration mode. This option can be used, for example, during alignment to
move all relays to unsafe condition (relay pick-up).
This option is only to be used by PAT service staff for service purposes
and is not activated on the standard Hardlock.
29 / 85
Access Code
The access code is to be entered to protect against data alteration by unauthorised persons in order to go into online mode.
The access number is provided on a separate card when the system is supplied.
Access is gained to this dialog box as soon as you go into online mode using
Basic Adjustment / Communication.
Insert the 6-digit number here.
Caution
There is no possibility of controlling the system or making
alterations using a PC if an access code is forgotten or lost.
A correction can only be made by
PAT GmbH Customer Service
Entry of the access code is also necessary if a new data record is to be produced. (See page 23)
30 / 85
Programming the basic functions

The programming of the basic functions is explained using the examples shown
on page 11 (Basic Functions). The appropriate sensors are to be connected to
the respective analog channels in compliance with the connection plan.
Setting switching points

This example is used to describe the programming of the analog input and
setting the switching points using the "Module menu item.
Analog Input module

The DS 120 is adjusted to the sensors connected to its input using this module.
Production of a new data record normally commences using this module.
Input - Name
Analog input Channel 1 is configured here (in the example).
(Channels 1 to 8 can be selected independently )
Sensor type
The output of the physical value for the sensor must be selected here, e.g.
Load (t). Further entries can only be made after this has been carried out.
31 / 85
Curve correction
If a "0 is entered in the "Curve Correction enter field, the input signal is not
corrected. A curve can be activated by entering a curve number between 1...16.
Please ensure that the curve type (see page 49) is selected correctly.
Filter functions
This function serves to smooth slightly unsteady sensor signals. The input
signal is not filtered if "0" is entered here. The input signal is recorded and the
mean taken arithmetically for a period of 1 sec. if, for instance, 1000 ms is
entered before being provided to the system. It should be observed that shut
down relative to this sensor input can also only take place after 1 sec.
Transformer
This display is used on the one hand to check whether or not the transformer
circuit is working and on the other hand to determine which values are to serve
as limiting values in order to check for cable break or short circuit respectively.
The current signal emitted from the sensor is shown as a number between 0
and 4095 (cable short circuit / cable parting, see page 33)
Entry is not possible here as this is purely a display function for service
purposes.
Actual variable
Entry is not possible here as this is purely a display function for service purposes. The current load is displayed along with the correct dimension. The
alignment function and accuracy can be checked, e.g. with another test weight.
32 / 85
Cable short circuit / Cable parting

Appropriate limiting values are to be entered in order to monitor a sensor for
cable break or cable short circuit. These refer to the transformer values. If
these are fallen short of (short circuit) or exceeded (cable break), the appropriate monitoring relay shuts down.
We recommend the following reference input:
Standard values of normal sensory analysis for cable

break and cable short circuit
Caution: Observe hardware setting, see solder bridge plan
Sensor output :
2.5-7.5V
4-20mA
Setting short circuit :
1000 = 2.0VDC
250 = 2mA
Setting cable break :
4000 = 8.0VDC
2750 = 22mA
DS 120 is designed as a standard for sensors with voltage output. Hardware alterations are to be carried out in accordance with the solder bridge
plan (see addendum) for sensors with current output.
Monitoring relay
The relay number can be entered here if the sensor monitoring is to trigger a
relay. Otherwise, all relays will shut down in case of an error. If a relay is
selected, only this relay will shut down. It is possible to place several sensor
monitors on one relay here.
The cable short circuit must be pending for at least "1 second" before the
relay switches.
Accept, OK, Cancel

Once the Analog Input module has been programmed in full, the data can be
confirmed using Accept. Further analog input can be programmed following
this, beginning with the entry of the channel number. In order to program other
modules, exit analog input using OK.
Return to the main menu without altering data up until then by using Cancel .
33 / 85
Switching points module

Switching point - Name
It is possible to set 16 different switching points. Enter the desired number of
the respective switching point in the Switching point-Name box.
Switching point - Type

Maximum is selected for an overload function and Minimum for an underload function. Not used will appear if the function has not yet been released.
Switching point - Reference

The value to be monitored is shown here. The program offers a list of all
programmed, relevant modules so far. The module output to be monitored can
be selected from this list. If none of these modules have been programmed so
far, "No Data" will appear in the display. In this case one of these modules
must first be programmed before continuing with "Switching Points".
34 / 85
Limit value - Constant

A static limiting value can be entered here, e.g. 10t.
Limit value - Variable

The output of one of the other previously programmed modules can also be
selected here as a limiting value instead of a constant value. This enables
dynamic load / load comparisons.
Limit value - Dynamic

A time interval-related limiting value can be entered here. If "0" is entered, this
function is not activated. If, for example, "0.5t" is entered, it is checked whether
there has been a change in load of more than "0.5t" within a certain period of
time. If so, the allocated relay shuts down. This therefore monitors any increase
in load. The period of time is determined by the minimal switched-off time. This
can be calculated by multiplying the number of programmed analog inputs by
10 ms.
Relay
The number of the relay to be shut down when a limiting value is exceeded is to
be entered.
The Switching Point of several modules can be placed on one relay.
However, this should be avoided so that the cut-offs remain clear. It is
recommended to keep switchpoint name and relais the same number.
Hysteresis
The hysteresis value of the relay can be entered directly in 0.1% stages here.
"0" means that there is no switching hysteresis.
Delay - off
The delay in shut down can be entered directly in "0.1 second" stages. "0"
means that there is no delay in shut down.
It is advised to use this function with proper care considering legal requirements.
35 / 85
Delay - on
The delay re-connection can be entered directly in "0.1 second" stages. "0"
means that there is no delay in re-connection.
Release via digital input

(Also see page 14)
Programmed switching points can be activated by assigning logical levels
(+12V for high, 0V for low) to the digital input of the DS 120. The following
sub-menu is opened after clicking on Digital Input Release:
Indication of the
digital inputs to
be queried
Enter which of the

specified digital
inputs need to be
high in order to
activate the
switching point
In the above example, the switching point is only activated when digital inputs 2
and 6 are high and input 5 low".
If an entry is not made on the table, the switching point is always active.
Important instructions for the use of digital inputs (see page 25).
Accept, OK, Cancel

The module programming is confirmed here analogous to the procedure
described on page 33. Quit the module using either OK or Cancel.
36 / 85
Calculation module
There is the possibility of programming 16 different calculation modules.

Choose the module number.
Choose between:
-Addition
-Subtraction
-Multiplication
-Division
-Min (determination of the smallest value of the selected parameters)
-Max (determination of the greatest value of the selected parameters)
-Multiplication of a parameter by a constant value.
The dimension of the parameter is preserved.
37 / 85
Available parameters
The program lists all previously programmed modules whose output value can
be used for calculation.
Mark the parameter to be used in the calculation and click on Add. As a
result, this (parameter) is accepted in the list of selected parameters. Use
Remove to delete a parameter again.
Constant parameter
If you have selected multiplication by a constant parameter, this is entered here.
Result
Finally, the calculated value can be displayed along with its dimension and
checked. This function is for service purposes and is only available during
online operation.
Accept, OK, Cancel

Please observe
-
Only parameters of the same dimension can be processed using

addition, subtraction, minimize and maximize.
For "Multiplication" and "Division"
only a maximum of 2 parameters can be processed.
the result is always further processed as a dimensionless value.
parameters of "kg" or "lb" dimension can only be further

processed with other dimensionless parameters or parameters of
the same dimension.
The program follows algorithm for subtraction:

-
38 / 85
Selected parameter 1 -(total of the other selected parameters)
Configuration of the analog output

D/A Alignment
Also see Controlling a machine PLC via analog output (see page 13).
Select the DA Alignment module via Alignment in the main menu.
It is necessary to switch to Online mode in order to adjust this module, i.e.
connect the DS 120 to the PC (see page 26).
However, contrary to the adjustment of the analog input, it is not necessary to
load the sensors with appropriate test loads.
Select one of the 4 available analog outputs.

There is the possibility of programming 16 different modules. Modules with
access to the same output channel must be released via digital inputs in such a
way that they do not interfere with each other.
39 / 85
DAC - Type
The type of analog output is laid down here. "mV limited" is selected if the
analog output is to supply a voltage and if this voltage is to be limited to the
respective minimum or maximum value when exceeding or falling short of the
reference value. "mV unlimited" is selected if, on the other hand, the voltage is
to continue in a linear fashion. The same applies to current output in compliance
with "mA limited" and "mA unlimited".
DS 120 is supplied as a standard with current outputs.
Appropriate solder bridge connection is to be observed. If the function has not
been released, "Not used" will appear.
Actual value(Minimum/ Maximum)

The benchmark figures of the reference value are entered here that lay down
which numerical value (e.g. load) is to be released for which output voltage or
output current. The entered data will become active when clicking on "accept".
Output value (Minimum / Maximum)

Finally, the benchmark figures of the output voltage or output current that are
allocated to the respective actual measurable variables are entered numerically.
The dimension complies with the entry made at DAC Type. Due to component
tolerances it must be assumed that the exact entered value is not at the output
(check using a multimeter on the analog outputs see connection plan
For fine tuning click on "Start" and then on the arrow buttons.
Start
DAC value
This is purely a display function. The direct DA transformer value of this output
is indicated. This value is always to be found in a range between "0" and
"4095". This display is used on the one hand to check whether or not the
transformer circuit is working and on the other hand to determine which output
voltage or current is released at which value.
40 / 85
Curve correction (also see page 45)

An analog output correction curve is now entered. If "0" is entered, the output
signal is not corrected and follows the respective actual measurable variable in
a linear fashion. A curve can be activated by entering a curve number between
1...16.
Control via digital inputs is carried out analogous to the procedure described on
page 36.
Accept, OK, Cancel

41 / 85
"General" dialog box

The value of the respective analog output to be accepted in DS 120 nonoperative mode can be set here.
DAC Mode
There is "Non Operative Mode if the DS 120 starts up (program start) following
connection of the supply voltage, during calibration and in the case of an error.
DAC Channel
Select the desired channel (1...4).
DAC Dimension
Choose mV or mA depending on the position of the solder bridges.
Output
Set the required voltage or current value for the respective Non-Operative
Mode here.
42 / 85
Alignment / Correction
Fine alignment of the set value.
DAC value
This is purely a display function. The direct DA transformer value of this output
is indicated. This value is always to be found in a range between "0" and
"4095". This display is used on the one hand to check whether or not the
transformer circuit is working and on the other hand to determine which output
voltage or current is released at which value.
Accept, OK, Cancel

43 / 85
Relay module
Using this module one is able to switch a relay directly dependent upon the
condition of one or more digital inputs.
Insert the number of the desired relay here.

Note: As a standard, the DS 120 has 8 relays, (16 with supplementary
card). On the standard design, selection of a relay number greater than
8 will have no effect.
Digital input control is carried out analogous to the procedure described on
page 36.
Accept, OK, Cancel

44 / 85
Enhanced functions
Further functions can be used in addition to the basic functions that have been
described.
Curve module:
(Angle)
Kurvenverarbeitung
Curve
0 - 90
Ausgangswerte
Output values
0 -10 m
Eingangswerte
Input values
Using the DS 120 it is possible to process various curves. It is, for instance,
possible to correct non-linear analog input and output signals.
Any desired output values can be allocated to the variable values on the input
side of the module using the "Curve Processing" module. This allocation is
carried out via 16 support points (pairs of values).
This module is required, for instance, for the correction of non-linear sensors.
However, angle values, for instance, can also be converted into lengths (also
see Programming the enhanced functions page 49)
45 / 85
"LC-Display" module (optional)
Switching
Point
The optional DS 120 system display can be programmed as required in normal

working mode. It is possible to superimpose text as well as to also present all
system parameters (also see LC-Display Module " Page 52)
"Switch" module
The switch module allows selection of the output signals from various modules
that are connected to the input of the switch module. The signal from the
selected module is forwarded to the output without any alteration being made.
Selection is made dependent on the respective constellation of the digital
inputs. ("Switch" module page 55)
Forwarding to
next module
Signals from
various modules
Digital Input
46 / 85
"Snagload" module
This module is used especially to detect sudden increases in load, caused for
instance by interlocking of the load if the load is suddenly blocked during lifting.
In order to do this, the system memorizes the current load value. If this load
suddenly rises by more than a prescribed percentage rate, the relay shuts down
in order to protect the crane and the load against damage.
(Snagload module page 67)
Lifetime counter module (optional)
The DS 120 system can also be fitted with up to 4 lifetime counter by means of
an additional board (option) (also see "Lifetime counter" module page 57).
47 / 85
External display equipment can be connected via the RS422 interface (e.g. a
large figure display) (also see "RS422 Interface" module page 59).
Switching points
Curves
External ST9 series display equipment can be connected via the RS485
interface (also see "RS485 Interface"module page 61).
48 / 85
Programming the enhanced functions

Curve module
Curve - Name
There is the possibility of entering up to 16 different curves, each with 16 points.
To begin with select the number of the curve to be entered.
3 different kinds of curves can be produced. It is possible, for instance, to

produce completely new variables, i.e. if, for example, one wishes to produce a
radius dependent on an angle, this can be realized with the help of a curve. This
radius can then be used quite normally in the system in order, for example, to
switch a relay or control an analog output.
It is also possible to correct non-linear analog input and output signals.
Curve - Type
This shows what the curve is to be used for:
The measured value is the most important type of curve. It is selected in
order to allocate values from one of the previously programmed modules to any
desired output values. At the same time, dimension alteration is also possible.
49 / 85
"Analog Input" is selected in order to change the characteristics of a sensor

connected to the input. The reference to the desired analog input is shown in
the Analog Input module as this curve can be selected here (see page 31).
Analog output is selected in order to adapt the output signal to the characteristics of a consumer attached at this point.
X-axis
Where the "Measured variable" type of curve is concerned, the input values
are determined to which the curve is to refer. When making this selection the
dimension is determined simultaneously. The program provides the list of all
previously programmed modules that can be used as X-values.
If the "Analog Input" or "Analog Output" type of curve has been selected, no
entry needs to be made.
Y-parameter for output values
X-parameter for input values
Y-axis
Where the "Measured Variable" type of curve is concerned, the dimensions
are determined for the Y-parameter.
If the "Analog Input" or "Analog Output" type of curve has been selected, no
entry needs to be made, as these curves do not require a dimension.
50 / 85
X-parameter / Y-parameter
The entry of the actual curve parameters is now carried out. It is determined
which output value is to be created for which input value (e.g. 10 corresponds
to 29m). The distances between 2 points can be entered as desired. For this
reason, linear curve courses can be realized with only 2 pairs of values. Nonlinear courses require the necessary number of pairs of values for that purpose.
Up to 16 pairs can be entered. The dimensions of the X and Y-values are
entered correctly dependent on the previous data.
Add new line / Remove line(s)

Pairs of values can be inserted or deleted using the "Add new line" and
"Remove line(s)" buttons.
The worksheet can also be imported from EXCEL by copying appropriately marked worksheets from EXCEL and then inserting these in the
upper left input area by simultaneously pressing "CTRL" and "V".
Chart
This is used to visualize the entered curve. Worksheet alterations are shown
immediately in the graphics.
Use "Close" to close the graphic presentation.
Enable
Digital input control is carried out analogous to the procedure described on
page 36. However, this function is only available if the curve module is used in
connection with the analog input or output.
Accept, OK, Cancel

51 / 85
LC - Display module (optional)

Up to 4 different presentations can be programmed on the optional display. If
more than 1 LC - display module is programmed, they must be released via
digital inputs in such a way that they do not interfere with each other.
The DS 120 display can be programmed as required in normal working mode. It

is possible to superimpose text as well as to also present system parameters. If
a system has not yet been programmed or re-initialized, the system name will
always appear in the upper line (L-1) and information on the digital inputs in the
lower line (L-2).
SYSTEM
D-INPUTS
:DS 120
:
Display - Name
Select the number of the desired display module here.
52 / 85
Number of parameters
The number of the values to be presented is now entered. If, for instance, 4
loads are to be displayed, a 4 should be entered here. The following entries for
the individual parameters refer to this entry, i.e. there are also only 4 entry
possibilities. It is only possible to send a maximum of 8 values to the display. If
necessary, the entered value must be confirmed here using "Accept" in order to
open all further entry fields.
Select Parameters
Select the number here of the parameter to be specified in the block on the
right.
Type of parameter
To begin with the system must be informed of the type of parameter, e.g.
"Analog Input", "Calculations", "Switching Points" etc., in order to enable
output of all parameters available from DS 120.
The parameter type "Switch Input" has a special status. This does not supply
a numerical value on the display. Instead it provides information on the module
just selected by the "Switch" module.
Number of Parameters
Once the type of parameter has been selected, the entry as to which parameter
it should be is still missing. If for instance the "Analog Input " type of parameter is chosen, this is now followed by "1" for analog input 1, 2 for analog input
2, etc.
Format
The next step is to enter the type of presentation or the format of the output. In
order to simplify entry, a selection can be made from a list showing various
formats. This list closely follows EXCEL format instructions (#### for no digits
after the decimal point, #.### for 3 digits after the decimal point, etc.).
If the "Switch - Input" parameter has been selected, this point is of no relevance.
page 36.
53 / 85
Offset (Positioning in the DS 120 LC-Display ):

The so-called offset is now entered. This value indicates at which point in the
display the parameter should appear, beginning with the upper left corner,
equivalent to "0", lower right corner to "39". If, for example, a value is to appear
in the center of line 2 (L-2), "30" should be entered.
0
20
30
19
39
Text line 1 / Text line 2:

Text for both lines can be entered here. Text with a maximum of 20 characters
can be entered per line. In case the text and a parameter to be displayed have
the same position on the display, only the display value will be superimposed at
the position concerned.
Confirm the entry of each parameter field using Accept.
Accept, OK, Cancel

54 / 85
"Switch" module
The switch module allows selection of the output signals from various modules
that are connected to the input of the switch module. The signal from the
selected module is forwarded to the output without any alteration being made.
Forwarding to
next module
Signals of various
modules
Digital Input
The incoming signals can come from various modules: analog input module,
calculation module, curve module or other switch modules. The output of the
switch module can be used as input for other modules with the exception of
analog inputs.
Selection of the input signal to be forwarded is made using the digital inputs of
the DS 120. Up to 16 modules can be connected to the input of the switch
module.
55 / 85
Switch Name
Up to 8 switch modules are available. Choose between 1 and 8.
Inserting or removing available parameters

There is a list of all modules that have already been configured. Choose the
modules that are to be used as input signal of the switch module and add them
to the selection of parameters by using the Add field. Up to 16 modules can
be connected to the inputs of the switch module and thus also be available.
Modules selected in error can be deleted by using the Remove field.
Selected parameters, digital inputs, closed

Mark the appropriate modules in the selection list. Determine the configuration
of the 8 digital inputs from which the modules are to be forwarded. Please
check that every module has a different configuration.
Please note: In case there are constellations of the digital inputs which are not
in the table, the system will remain in its present condition until a known
constellation is at the digital inputs.
Accept, OK, Cancel

56 / 85
Lifetime counter (optional) module
Counter - Name
Using an additional board (option) the DS 120 can be fitted with up to 4 lifetime
counter. Choose the appropriate counter here.
Counter - Type
A resolution can be selected between "0.01h" and "0.1h".
Counter - Reference
Counter reference value. This value serves only as reference for the counter.
57 / 85
Reference - Maximum
Maximum reference value. This value can be entered numerically. It represents
100% of the reference value and is used to carry out appropriate counter
control.
Digital Input to Activate

Digital input used. This is where the digital input to be used for counter release
is determined. Entry is binary.
page 36.
Further information concerning the lifetime counter

The operating hours of the machine (e.g. crane winch) are dependent on the
loading and will be calculated according to VBG8/FEM9.755.
Integrated electromechanical counter

The microprocessor will generate a counting pulse every 36 seconds (equal to
1/100 h) when the machine is 100% loaded. Therefore, the counter can display
max 9999,99 hours. the counter can not be reset. Since the counter does not
have a decimal point, the displayed value must be divided by 100, i.e. 000001 =
1/100 hours.
58 / 85
Display - Name
The KRGER large numeric display can be connected to the DS 120 system as
external display equipment using the RS422 interface. Using the control
system up to 4 different values can be displayed via digital inputs with up to 4
entry modules. Select the appropriate module number here.
Parameter Type
In order to enable the output of all parameters provided by DS 120, the system
must initially be informed of the type of parameter. This could be "Analog
Input", "Calculation ", "Curve Processing", etc. values.
Parameter Number
Enter the number of the selected module type here.
Enable large display

Activate the entry of further data by marking this field.
59 / 85
Parameter Format
The next step is to enter the type of presentation or the format of the output. In
order to simplify entry, a selection can be made from a list showing various
formats. This list closely follows EXCEL format instructions (#### for no places
after the decimal point, #.### for 3 places after the decimal point, etc.).
Digital input tare key

The digital input to be used for the connection of a tare key is determined here.
The entry is binary. Only the currently displayed values are set to zero. These,
however, remain stored until new tare or final tare is carried out.
Accept, OK, Cancel

60 / 85
Type of equipment
Up to 4 ST9 series external display devices or the harbour crane display can be
connected to the DS 120 system using the RS485 interface. Select one of the
two possibilities and click on Edit.
Please note that both, the ST9 and the harbour crane display, show error
messages during programming. The wanted display appears as soon as the
connection between PC and DS 120 is interrupted (offline mode).
ST9 displays
If you have chosen this possibility, the following will appear on the screen:
61 / 85
ST9 - Name
Up to 4 external ST9 series display devices can be connected. Using up to 16
entry modules, up to 4x4 operating methods can thus be realized with digital
inputs via the control unit. Select the appropriate module number.
Device Address
The address of the device to be connected is set here. Addresses 8... 11 are
available. It should be ensured that the same address is set on the ST9 display
equipment.
Number of Parameters
The number of the values to be processed is now entered. If, for instance, 4
loads are to be displayed, the figure 4 is to be entered. The following entries of
the individual parameters refer to this entry, i.e. there are also only 4 subsequent entry possibilities. A maximum of 8 values can be transmitted to the
display.
Available Parameters, type of parameters, parameter number

Beginning with "Parameter 1 specify the output values from the modules that
you wish to transfer via the RS485 interface.
page 36.
Accept, OK, Cancel

62 / 85
"Harbour display"
General
If you select this possibility, the following will appear on the screen:
To begin with, click on Enable harbour display in the General dialog box
and select from which modules the values for load (upper digital display) and
radius (lower digital display) come from. The number of digits after the decimal
point can be selected using "Format".
The analog loadmoment display as well as the optional analog windspeed
display are directly driven by the analog outputs of DS 120. A voltage of 1 V
results to a full deflection of the pointer. See also page 39.
63 / 85
Overview harbour crane display
LED/push button 1 free programmable, recommended, prewarning wind

LED/push button 2 free programmable, recommended, prewarning wind
LED/push button 3 free programmable
LED/push button 4 free programmable
LED/push button 5 free programmable, recommended, prewarning load
moment
LED/push button 6 free programmable, recommended, shut off load moment
LED/push button 7 Tare load
64 / 85
Lights and horn
The lights and the horn of the harbour crane display are triggered by the DS
120 switching point modules (however with the exception of the lower right
green tare light). Every light and the horn can be allocated to one or more
switching point modules.
An entry must also be made as to whether the light is to blink or illuminate
statically. The criteria for the lamp selected in the left field will then be visible in
the right field. By using the "Available Parameters", "Add" and "Remove"
fields, the settings are made for the respective lamp.
As far as the horn is concerned, an entry must be made as to whether this is to
be acknowledged (using any display key) or not .
65 / 85
Key allocation
There is the possibility of controlling the DS 120 via its digital inputs by using
the harbour crane display keys. If one or more entries are made in the digital
inputs table for the respective key, this means that by pressing the key once the
indicated digital input switches to high. The input is unset if the key is pressed
again.
Note that key 7 (Tare) cannot be used for this function.
Accept, OK, Cancel

66 / 85
"Snagload" module
This module recognizes any sudden load increase, which, for example, can
happen if the load interlocks. The system memorizes the actual weight load. If
the weight suddenly exceeds a previously determined percentage rate, the relay
shuts down in order to protect the crane and the load.
Principle of the module

After the DS 120 has been switched on, the indicated relay remains shut down
until the actual load on the hook is lower than the defined restload or a signal
appears on the acknowledge digital input.
If the actual load is lower than the restload (e.g. after placing the load on the
ground) or the acknowledge signal is pressed, the relay is connected and the
crane is ready to function.
The measurement cycle starts up after a signal goes to the digital input brake,
as soon as the brakes are released. The start delay time indicates the period
of time the system allows for load fluctuations to settle down after lifting the load
before commencing with measurement.
67 / 85
Following this, the load is measured in a defined measurement time within the
fluctuation width (measurement value). The measurement result is taken as
the reference value. If the system suddenly measures a load that is greater than
the reference load + the proportional increase in load, the relay will be shut
down. It remains switched off until either the actual load falls below the reference load (e.g. by placing the load on the ground), or the acknowledge signal is
pressed.
A maximum load fluctuation can be defined in order to avoid incorrect reference
value measurements. If the load rises above this maximum value during the
measurement period, a reference value will not be determined.
A new measurement cycle commences after the load has been deposited and
the brake released.
Snagload - Name
Select the number of the desired module.
Snagload - Type
Choose "Maximum" in order to detect a sudden overload.
Snagload Reference
Select the module that contains the load information.
Control via digital inputs

The module can be activated or deactivated via digital inputs. Procedure as
described on page 36.
Accept, OK, Cancel

68 / 85
Analog input alignment

Analog output alignment has already been described on page 39, see Configuration of the analog outputs.
Select A/D-Alignment in the Alignment main menu item.
The alignment (transformation into a physical value) of the sensors is carried

out using this menu item.
Select the channel to be aligned.
It is absolutely necessary for the sensors to be connected and that they
can be loaded using a calibrated test weight. Work must be carried out
online, i.e. DS 120 connected.
To begin with, minimum alignment of the load is carried out, normally 0.0t (no
load on the hook). This value is confirmed using Accept. The AD transformer
value determined during setting is used for control and documentation purposes. Maximum alignment of the load is carried out after this (e.g. 10.0t test
weight). This value is also confirmed using Accept. In order to carry out
alignment of the maximum load as exactly as possible, a test weight of at least
2/3 of the maximum crane load should be used. If the difference between min
and max is smaller than 500 converter digits, the system will display an error
message. In this case you have to increase the testload. If alignment is completed successfully, the measured data are confirmed by clicking on the
Alignment field. Use OK to return to the main menu.
Important: The alignment data will not be stored in the Configuration Manager,
but directly in DS 120. That means that every new programmed DS 120
needs to be aligned once.
69 / 85
System menu
In addition to the choice of programmable modules, DS 120 also has several

control commands and menus at its disposal that are described below.
Checksum
The checksum of the data content of the memory ICs is set using "Checksum". This is always necessary if data have been altered. This can be the
case when changing a control program or a data IC and also when changing
the contents of the control data not carried out using the adjustment modules.
This procedure is carried out automatically after selection of one of the memory
ICs, "data control" for the control data or " EPROM program" for the system
control program. Following completion, it is imperative that a "re-start" is
carried out in order to re-start the system.
Error
If an error has occurred, the red error LED on the system will illuminate or blink.
By using the error function it can be determined which error has occurred. This
is displayed in the form of an error code.
If the system is working properly, No error will be displayed. In all other cases
the appropriate error code will appear. The system error code table can be used
to determine the error that has occurred. It is then possible to find and rectify
the error as soon as possible.
Re-start
This is always only then necessary if, for example, changes have been made to
the system or if it has been necessary to set the checksum. A re-start is also
practical in order to put the system into basic condition or to allow alterations to
take effect.
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Version
The "Version" menu can be used to determine the control program with which
the DS 120 system operates. Use "OK to quit this menu level. This function is
only effective in online mode.
Initializing
The DS 120 system can be completely adjusted without auxiliary devices by
simply using the PC and the configuration manager. Basic initializing of the
system is necessary if unprogrammed memory components are also used.
Even if data are altered unintentionally, which could lead to a malfunction,
initializing can rectify the fault.
If this function is called up, the question will be raised whether initializing
really is to be carried out. If this is confirmed using "Y", all programming
data will be deleted and basic programming carried out.
71 / 85
Read data
The existing configuration of a connected DS 120 can be read out using this
menu item.
For this purpose, go into online mode using File, Basic Adjustments and
Communication (see page 26).
Write data
The configuration produced on the PC is written in DS 120 using this menu
program.
It is also necessary to go into online mode for this function (see above). As a
result the configuration data in the equipment will be overwritten in full. The
program will ask for confirmation in advance for safety reasons.
Prior to write the data into DS 120, the data check routine will become active
(see page 25).
72 / 85
Data type; Compatibility with older versions

In order to guarantee perfect communication between DS 120 and the configuration manager it must be observed that the data type is identical.
Every version of the DS 120 control program can only process one certain data
type (e.g. Version 2.24 processes data type 2).
Control Program
Version
(internal DS 120
software)
Data type Configuration

Manager
Version
Remarks
2.10, 2.11, 2.12,

2.13, 2.20, 2.24,
2.27
1.00, 1.01
Standard up until February

2002
2.22
1.21
Special version
2.23
1.21
Special version
2.25
1.25
Special version
2.30
1.30 / 1.31
Standard as from February

2002
The configuration managers are compatible in downward order, i.e. the

1.30 version of the configuration manager processes all data types from 2
to 7; the 1.01 configuration manager only processes data type 2.
If an older version file is read in by the configuration manager, the data type is
recognized immediately and automatically adjusted.
When establishing a new configuration file the data type is always defined by
the user. On this occasion the program offers the highest possible data type,
e.g. the 1.25 configuration manager offers type 6. This highest possible data
type includes all software features of the respective configuration manager.
However, if the configuration file is intended for a DS 120 that has an older
version of the control program, e.g. 2.20, data type 2 must be set.
On the other hand, newer versions of the DS 120 control program (e.g. 2.30)
can only be programmed with a configuration manager in control of data type 7
belonging to this version and not with an older configuration manager (e.g.
1.01).
73 / 85
"File" and "Basic adjustments are used to see the type of configuration data
in the "Information" dialog box. "System" and "Version are used to see the
DS 120 control program version.
With the 1.30 configuration manager there is the possibility of converting the
data type of a configuration file that has already been produced, e.g. from type
2 to type 7.
Conversion in an upward direction, thus for example from 2 to 7, is not critical,
because data type 7 includes all the functions that were possible for type 2.
Conversion in a downward direction, thus for example from 7 to 2, can lead to
loss of data. In this case, all new modules and functions that were not available
on data type 2 will be deleted. The configuration file must be adapted by the
user.
Support is offered by the check routine (see pages 23 and 25).
74 / 85
System Errors
System errors can be initiated by defective components or incorrect assembly.
The error message is indicated in code form on the device's display.
SYSTEM ERROR
CODE: FE00
System error code table
Internal system errors
1040
Division by zero
1042
Control program checksum
1100
Data program error
1101
Data program checksum
1160
Control program changed
1162
Data program changed
DS 120 analog input module data programming error

1200
Table address
121C
Number of modules
121D
Module length
121E
Module starting address
1220
Parameter : Curve processing
1221
: Filter
1222
: Cable short-circuit
1223
: Cable break
1224
: N-MIN (converter data)
1225
: N-MAX (converter data)
1226
: Dynamic area converter data too small
1227
: Control relay
Calculation module
1201
Table address
1228
Number of modules
1229
Module length
122A
75 / 85
122B
Parameter : TYPE
122C
: number of parameters
122D
: incorrect parameter type
122E
: incorrect parameter number
122F
: unequal dimensions
LC DISPLAY module
1202
Table address
1230
Number of modules
1231
Module length
1232
1233
Parameter : parameter type
1234
: parameter number
1235
: parameter offset
1236
: parameter format
SWITCHING POINTS module
1203
Table address
1240
Number of modules
1241
Module length
1242
1243
Parameter : switching point type
1244
: switching point reference
1245
: limit value constant
1246
: relay
1247
: Delay off
1248
: Delay on
1249
: Dimension not same

RELAY module
76 / 85
1204
Table address
1250
Number of modules
1251
Module length
1252
Analog outputs (D/A alignment)

1205
Table address
1260
Number of modules
1261
Module length
1262
1263
Parameter : TYPE
1264
: DAC channel
1265
: DAC reference
1266
: curve correction
Curve module
1206
Table address
1270
Number of modules
1271
Module length
1272
1273
Parameter : TYPE
1274
1275
: x-axis
1276
: y-axis
Lifetime counter module
1207
Table address
1280
Number of modules
1281
Module length
1282
1283
Parameter : counter type
1284
: counter reference
1208
Table address
1290
Number of modules
1291
Module length
1292
1293
Parameter : device address
77 / 85
1294
1295
: parameter type
1296
: parameter number
1209
Table address
12A0
Number of modules
12A1
Module length
12A2
12A3
Parameter : TYPE
12A4
Not used
12A5
: parameter format
12A6
: parameter type
12A7
: parameter number
Switch Module
120A
Table address
12C0
Number of modules
12C1
Module length
12C2
Standard address of the modules
12C3
Number of parameters
12C4
Parameter : TYPE
12C5
: Dimensions not the same

Snagload Module
78 / 85
120B
Table address
12D0
Number of modules
12D1
Module length
12D2
Standard address of the modules
12D3
Parameter : Switch - type
12D4
: Switch - reference
12D5
: Start time
12D6
: Measurement time
12D7
: Measurement value
12D8
: Relay
Analog Output (D/A-Alignment) Expansion

120C
Table address
12E0
Number of modules
12E1
Module length
12E2
Start address of the modules
12E3
Start address of the modules (expansion)
12E4
Parameter : Mode
12E5
: Output value
12E6
: Output transformer value

Harbour Display Module
120D
Table address
12F0
Number of modules
12F1
Module length
12F2
Start address of the modules
12F3
Harbour display used
12F4
Parameter : Load Type
12F5
: Radius - Type
12F6
: Format information
12F7
: Horn information
Special Modules
1300
Table address
1310
Number of modules
1311
Module length
1312

Hardware fault
F000
+12VDC fault
F001
A/D converter fault
FE00
Cable short-circuit analog input 1
FE01
FE02
FE03
FE04
FE05
79 / 85
FE06
FE07
FE10
Cable break analog input 1
FE11
FE12
FE13
FE14
FE15
FE16
FE17
Preventive Maintenance
The PAT DS 120 Programmable Switching Amplifier consists of electronic,
electrical and electromechanical components.
Maintenance work may be carried out on the system only by service personnel
of the company
PAT GmbH,
by personnel authorised by the manufacturer or by personnel trained by PAT
GmbH.
As even minor damage can significantly impair the efficiency of the device or
even put it out of operation, the operator must ensure that the device is fully
operational before the start of work each day.
80 / 85
Specifications
Operating voltage:
Primary fuse:
Secondary fuse:
Power input:
Supply voltage for external
consumer unit:
Working temperature range:
Degree of protection:
Relative humidity:
Analog inputs:
Digital inputs:
Relay outputs:
Analog outputs:
Interfaces:
Switching points:
ON, OFF delay:

Operating point hysteresis:
Lifetime counter:
System configuration:
System monitoring:
48/115/230 VAC, 12/24 VDC

48 VAC/0.8 AT- 115 VAC/0.25 AT, 230 VAC/
0.1AT
1.0 AT
approx. 250 mA (DC secondary)
12 VDC, max. 0.6 A
-25 C - +70 C
IP 65
max. 95%/40 C, non-cond.
max. 8 analog inputs, either 2.5 7.5 VDC
or 4 20 mA
max. 8 digital optoelectronic coupler inputs
(not isolated),
10 30 VDC
standard = 8, optional max. 16 (with additional board),1 changeover contact, contact
load 250 VAC/8 A/2 kVA or 30 VDC/5 A
8 analog signal outputs (for the 8 analog
inputs) through 1:1 decoupling amplifier, 4
user-scaleable outputs 0 10 VDC/
4 20 mA, (12 bit resolution)
1x RS232 for connection of a PC,
1x RS232/1x RS485/ 1x RS422
user-programmable switching points for
overload, underload and offset load values
for individual, half and total loads
separately user-programmable in 0.1 s steps
up to 10 s
user-programmable in 0.1 % steps up to
100%
max. 4 electromechanical, no-reset 6-digit
controllers (with additional board), scale interval 0.01 h, registration of elapsed full-load
hours in accordance with FEM9.755
the configuration manager consists of the
Windows program Win DS 120 on CD
ROM, hardlock key with connecting cable
power ON test, watchdog timer, operating
voltage control, sensor cabling control
81 / 85
Abbreviations and their Meaning

German
Abbreviation English
Control Modules
AIN
Analog input
Analogeingnge
CALC
Calculation
Berechnungen
CURVE
Curve control
Kurvenverarbeitung
DAC
Digital-to-analog
converter
Analogausgnge
DISPLAY
Display design
LC- Display
LIMIT
Switching points
Schaltpunkte
LTC
Lifetime counter
Lebensdauerzhler
RELAY
Relay control
Relaisanpassung
RS422
RS422 interface
Schnittstelle RS422
RS485
RS485 interface
Schnittstelle RS485
Control Menus
82 / 85
CHECKSUM Checksum
Berechnung von. Checksummen
EEPROM
EEPROM control
Datensteuerung
ERRORS
System errors
Systemfehler
OFF
OFF
Ausschalten PSION
RESET
System reset
System zurcksetzen
VERSION
Display version
Version Steuerprogramm
INIT
System initialisation
Systeminitialisierung
Appendix
A Solder Bridge Diagram/Tables
83 / 85
B Solder Bridge Diagram Overview
84 / 85
- 5VDC-
K9 - K16
OPTION
C Connection Diagram
85 / 85

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DS 120

Programmable Switching Amplifier

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+49 (0) 7243 709-0

Customized information (optional)

About this Manual

Requirements for Operating Personnel

know the accident-prevention regulations.

DS 120 General Introduction

The principle use of a programmable switching amplifier (PSA) is to monitor

List of Basic and Extended Functions

Setting of switching points for an overload protection device

List of Hardware Components

Analog Signal Outputs

Digital control input

A DS 120 is intended to measure a load and shut down a relay in case of

Individual and Total Loads Processing with the Help

Controlling a machine PLC via analog output

Activation of functions via digital inputs

This type of isolation can be used in the following modules:

(see page 34)

(see page 44)

(see page 45 and 49)

(see page 46 and 52)

(see page 48 and 61)

(see page 48 and 59)

The "Switch" module offers a very varied possibility of controlling signal

Connecting the DS 120 to the PC

Installation of the DS 120 software

Operation of the DS 120 software

Views and applications of the individual menus

load an existing configuration from the hard disk

produce a new configuration ("File / New" menu)

read out the configuration of a connected DS 120

Producing or modifying a configuration file

File menu item

Check data record

Menu item Basic Adjustments

Information dialog box

Last alteration using Dongle SN

General dialog box

Process Data Online

Relay release in calibration mode

Insert the 6-digit number here.

Programming the basic functions

Setting switching points

Analog Input module

Cable short circuit / Cable parting

Standard values of normal sensory analysis for cable

Setting short circuit :

Setting cable break :

Accept, OK, Cancel

Switching points module

Switching point - Type

Switching point - Reference

Limit value - Constant

Limit value - Variable

Limit value - Dynamic

Release via digital input

Enter which of the

Accept, OK, Cancel

There is the possibility of programming 16 different calculation modules.