device description

EN

warnings and safety instructions

part 1/2
Load Monitor RPU

Contents
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.2
1.3
1.3.1
1.3.2
1.3.3
1.3.4
1.4
1.4.1
1.4.2

safety hints ........................................................ ... page

symbols ................................................................ page
further, important hints ......................................... page
intended use ......................................................... page
inappropriate use .................................................. page
description ............................................................ page
special features of the Load Monitor .............. ...... page
features .............. .................................................. page
safety and internal tests (up to softwear 4)........... page
safety and internal tests (from softwear 5)............ page
permanent tests during running ........................... page
description of function .......................................... page
temperature control .............................................. page
operating hours counter ....................................... page

2 Motor management

2.1
2.2

inching operation .................................................. page 6

hoisting/slow hoist ................................................ page 6

3 Device configuration

in part 2/2

1 further hints / features of the

Load Monitor

4 Errors and warnings

5 Electrical connection

6 Mechanical data

7 Technical data

4.1
4.2

3
3
3
4
4
4
4
4
5
5
5
5
5
5

warnings ............................................................... page 7

errors and additional risks .................................... page 8

5.1
block circuit diagram ............................................. page 9
5.2
inputs .................................................................... page 10
5.2.1 operating voltage .................................................. page 10
5.2.2 control switch inputs ............................................. page 10
5.2.3.1 RPU load sensor inputs .............. ......................... page 10
5.2.3.2 connection to measurement-amplifier MV35/36 ... page 11
5.2.4 temperature inputs 1 and 2 .............................. page 11
5.3
output ................................................................... page 12
5.3.1 contact elements for lifting and lowering .............. page 12
5.3.2 -err and option relays ........................................ . page 12
5.3.3 -right and left relays ............................................ page 12
6.1
6.2
6.3
6.4
6.5

dimensions ...........................................................
methods of attachment .........................................
lead connection ....................................................
rating plate ............................................................
terminal assignment .............................................

page 13
page 13
page 13
page 13
page 14

7.1
7.2

technical data ....................................................... page 15

categories of safety .............................................. page 15

page 2 / 15

1 further hints
1.1 Safety hints

In the instruction, the safety hints are subdivided, according the

likelihood of the danger and the feasibility of the appearance. The
described arrangements of the avoidance of the dangers are absolutely
to respect.

1.1.1

symbols

This symbol is warning from an immediately threatening danger for the

health and the life of persons. The disobey of this warning hints cause
heavy injury, also with death results.

danger
This symbol is warning from a possible dangerous situation for the
health and the life of persons. The disobey of this warning hints may
cause heavy injury, also with death results.

warning
This symbol is warning from possible dangerous situation for the
health of persons or from damage of property or damage caused to
the environment. The disobey of this warning hints may cause injury,
or damage of property or damage caused to environment.

attention

Specific symbol:
Warning of electrical voltage
Covers like front lids and cover plates, which are signed with this symbol,
may only be opened by a qualified electrician or authorised person.
A touch of parts, which are energized, can lead to immediately dead.

1.1.2 further, important hints

The wire rope hoist/chain hoist may only put in operation, if its
appropriateness has been ascertained.
maintenance work may only realized at the unloaded crane.
the line connector has been switched off and has been safeguarded
against resetting by mistake.
the regulations of the accident prevention regulations have to been
observed.
for the repairing, you have to use exclusive genuine spare parts,
otherwise the warranty expires.
dont take changing and alterations.
additionally fittings needs the permission of the manufacturer.
the electrical connection and the electrical operation may only be
executed by a qualified electrician
the warranty expires, if the assembly, the handling, the checking
and the maintenance does not happen. For operating of other
persons than those, we have instructed, we dont take any warranty.

page 3 / 15

1 further hints
The commissioning of this component is not till then allowed, if it is
ascertained, that the construction or the device, in which the
component was build in, meets the requirements of the EC
machinery directive.
1.1.3 intended use
as extensive defined in this device description
application in electrical circuits for wire rope- and chain hoists
1.1.4 inappropriate use
application in explosive area without explosion proof housing
to bridge the inputs of the load sensors with a resistor
application with conveyance of passengers
to cut loose of loads
technological changes at overload cut-off
is this product part of a machine, the marketing authorisation
holder has to take guarantee, that the product equates to the special
instructions of the case of application

Intervention in the control or further controls requires the

authorization of the manufacturer. For failure malfunction at
unauthorized engagement in the control, the manufacturer meets no
warranty.

danger

Hint:

definition "instructed persons":

An "instructed person" is a qualified person with the
necessary qualification, constitutive on theoretical and practical
knowledge of hoists, for the in the manual specified necessary
operations. This person has to estimate the safety of the
construction in dependence of the individual case.
Instructed persons with the authority, to deal with specific
maintenance to our products, are service assemblymen of the
manufacturer and well skilled, with certificate designated
assemblymen.

The main language of the original text shall be the official,

authoritative version. These translations were provided for
better understanding. Only the language version, which was
published in the original, is valid. Therefore check your
translation with the original language version of the publication.

1.2 Description

The Load Monitor is a programmable control, evaluation and

switching device for single or dual-speed motors. The load
monitor can be optimally adapted to the application of
controlling a hoist motor and provides a compact overall
solution. It provides the basis for safe working and long
service life. With the Load Monitor, Harrington Hoists sets a
high safety standard for hoists and hoist systems.

page 4 / 15

1 further hints
1.3 Special features of the
Load Monitor

1.3.1 features
constant overload protection
temperature control of hoist and travel motors
registration of operating hours
crane test can be activated by pressing a button
motor-specific data for controlling the motor are stored in a table.
The motors are assigned by means of the rotary switch S1
(see table 2.3).
1.3.2 safety and internal tests (up to software version 4)
After power on the device, an internal test cycle runs up for 4
seconds. This will be finalized, when the user operates lift or
lower for the first time. At this process, the message system
error will be displayed temporarily. No movement will be happen,
and the LEDs II and III are flashing up shortly, to display the test
run. This will additionally displayed via the relay "-option".
(see point 5.3.2)
If the display of the device will not be receipt, an error occurs. (see
chapter 4.2)
After a renewed start (up/down), the device will be ready for action.

1.3.3 safety and internal tests (from software version 5)

After power on the device, an internal test cycle runs up for 4
seconds. During this time, all LED are always luminously, to test
them.
The tests have been completed, when all LED will be off, only the
green one is always luminously.
If there will be an error during this tests, the according error-code
will be displayed. (see chapter 4.2).
If there will be no error, the device is ready for action.
1.3.4 permanent tests during running
(from software version 4)
The RPU performs because for reasons of safety also during
operation further tests, to conform the framework of existing
legislation. Further, the internal relay circuit in the device will be
proved by every selection of movement. This test could possibly
be disturbed under difficult conditions and the hoist would stop its
movement. This can be notified to a superior control via the relay
"-option". (See point 5.3.2)

1.4 Description of function

1.4.1 Temperature control

Monitoring the temperature control of the hoist motor is standard. If
a PTC thermistor reacts this is displayed by LEDs on the Load
Monitor and the load cannot be moved again until the hoist motor
has cooled off.
In addition, the "err" relay is switched and as an option, the error
can be displayed via the relay contact "option". The travel motor
temperature "2" is also monitored. The motor PTC thermistors are
evaluated via the relay contacts "left" / "right".

page 5 / 15

2 Motor management / 3 Device configuration

1.4.2 Operating hours counter
The Load Monitor registers the total operating hours. They are
displayed on the operating hours counter mounted on the front of
the device.
In standard version, only the main hoist operating hours are
registered, however the device can be adjusted to register main
hoist including slow hoist operating hours by setting S2 and S4
following the special functions table.

2.1 Inching operation

Inching operation has a damaging effect on the electrical and

mechanical components of a hoist. Apart from rapid temperature
rise in the motor and excessive wear on the contacts, inching
operation also leads to premature wear on the brake.
2.1.1 Slow speed disabling time off/on
After the slow motor speed has been switched off, it cannot be
switched on again until the programmed disabling time has elapsed
(prevention of inching operation at slow motor speed). The setting
depends on the motor (see part II, table 3.1)
2.1.2 Fast speed disabling time off/on
After the fast motor speed has been switched off, it cannot be
switched on again until the programmed disabling time has elapsed
(prevention of inching operation at fast motor speed.) During the
disabling time only the slow motor speed is available. The setting
depends on the motor (see part II, table 3.1).
2.1.3 Disabling time for change of direction up/down
When the motor is switched off, the opposite direction of rotation of
the motor cannot be switched on until the programmed disabling
time has elapsed. (Prevention in rapid changes of direction of
rotation). The setting depends on the motor (see part II, table 3.1).
Rapid changes of direction (reversing) also have a damaging effect
on motor temperature rise and wear.

warning
2.2 Hoisting / slow speed1

2.2.1 Starting at slow speed

To reduce the load on the hoist, from hoist motor size H71 starting
is at slow speed. The starting time at slow speed depends on the
motor, see allocation table, point 2.1.

2.2.2 Braking at slow speed

To reduce the load on the brake, after the fast speed has been
switched off slow speed is briefly switched on. The activation time
depends on the motor (see table 2.3).

3 device configuration

in part 2/2
page 6 / 15

4 Errors and warnings

Warnings of this Load Monitor (RPU) represent a concrete
danger, therefore you have to be react immediately. This is
necessary, because the warnings dont bring automatically
about, that hoist movement will be appropriate restricted.

4.1 Warnings

warning
The warning is indicated by three (flashing) LEDs on the front of
the Load Monitor.
light half: blinking
light full: always luminously

Specification of warning

Elimination

Load Monitor RPU is in

crane test-mode

press button S5
switch Load Monitor off/on

temperature input 2 has

Recognized over temperature

check connection,
let the motor cool down,
check PTC sensor

outside the permissible cut-off band:

+8-20% of the parameterized
threshold

adjust cut-off threshold

cut-off threshold exceeded, wished

follow device description
cut-off point is bigger than 19,5mA.
This is not possible, to parameterize.

cut-off threshold under-run

adjust cut-off threshold
cut-off point is less than 9,0mA.
This is not possible, to parameterize.

RPUis functional
stand by display

The functions of the Load Monitor are not restricted when a

warning is displayed!

page 7 / 15

4 Errors and warnings

4.2 Errors and additional risks

danger

light half: blinking

light full: always luminously

Various conditions may arise in the system load sensor - PTC

thermistor Load Monitor. If the load sensor value can no longer be
ascertained, e.g. if a cable breaks, the Load Monitor must indicate this
condition. Conditions which no longer ensure correct functioning of the
hoist are designated errors. These can be recognised immediately in
that the hoist is no longer available in upwards direction. Lowering
motions however are still permitted after errors have been detected.
(Except in the case of over temperature).
In addition to the red LED, the corresponding error code is displayed
by three LEDs on the front of the Load Monitor (continuously light).
Apart from the error display, it is possible to indicate the error
display via external signal generator. The relay err" marks all
errors. For the relay opt, further states can be tuned.
Error specification
sensor error
sensor current
less then 3.2mA
or bigger than
24mA

Cause
break in connecting
cable,
sensor supply faulty,
sensor faulty

Elimination
check sensor
connection,
check sensor current,
check sensor supply,

overload

load too heavy,

cut-off threshold
too high

set down overload,

correct cut-off
threshold

over temperature

hoist motor too hot

PTC thermistor faulty

let hoist motor cool

down, check
PTC thermistors

control error

lifting and lowering

control wired
activated simultaneouslyincorrectly

system error

no control current at
terminal 6,
internal error

switch Load Monitor

on/off

no error

restart, processorand relay test

wait, till internal test

is over

sensor-error

sec. controller has a too

high sensor-current.
restart the device, if
error occurs again,
change the device

system error
1-times
4-times

timeout, problems at
internal interface

Load Monitor faulty

no control voltage,
fuse faulty,
Load Monitor faulty

check voltage,
check fuse,
replace Load Monitor
page 8 / 15

5 Electrical connection
5.1 block circuit diagram

for the second

sensor connection,
use the RPU 2

RPU

page 9 / 15

5 Electrical connection
5.2.1 Operating voltage
The operating voltage for the Load Monitor had to be connect to the
terminals 1 (L) and 2 (N). The rated value of the supply voltage
must correspond to that given on the device rating plate (operating
voltage). The permissible deviations from the rated value (voltage
tolerances) must not be exceeded on any account.

5.2 Inputs

For AC operating voltage terminal 1 (L) and 2 (N)

For 24DC operating voltage (L = +) and (N = ground)
Caution: Do not connect wrongly!
Rated voltage as per device rating plate (230, 110, 48, 42 VAC
and 24 VDC).
Voltage tolerance -10/+15% of rated value, 50-60 Hz
Power absorbed max. 9 VA
Suitable for continuous operation

3
up

4
own

5.2.2 Control switch inputs

The hoisting and lowering functions of the control pendant are
connected to terminals 3, 4 and 5. Terminal 3 is the input for slow
hoist up, terminal 4 for slow hoist down and terminal 5 for main
hoisting speed. All common control switches used in hoisting
technology can be connected. The control voltage must correspond
to the operating voltage of the Load Monitor (see device rating
plate). Interference voltages in the leads to the inputs are
suppressed by capacitors integrated into the Load Monitor at the
control inputs.

5
fast

sensor

PE

19
UBS

20 21 22
GD I1+ I1-

24
UB

5.2.3.1 RPU load sensor inputs

2-wire load sensors with a 4...20 mA signal can be connected to the
Load Monitor. To do so, a jumper must be placed between
terminals 20 (GND) and 22 (l1-). The load sensor is then connected
to terminals 21 (l1+) and 19 (UBS). The input resistance between
terminals 21 and 22 is 39.2 .The load signals should display an
approximately linear response characteristic. The load sensor
signal must be 4.0 mA when the hoist is unloaded. This ensures
that the RPU will reliably detect a broken wire to the load sensor.

If the load sensor is not supplied via the Load Monitor the mass of
the external voltage supply must be connected to terminal 20.

page 10 / 15

5 Electrical connection
Supply to load sensors:
Two voltages are available for supplying load sensors or 4...20 mA
amplifiers:

19
UBS

20
GD

24
UB

15 VDC 5%, 50mA controlled via terminals 19 (UBS) and

20 (GD, mass)
24 VDC, 50mA via terminals 24 (UB) and 20 (GD).

5.2.3.2 Connection measurement-amplifier MV35/36

Will the measurement amplifier MV35 or MV36 be constituted at
the RPU, it will have to be supplied with a separate power supply
unit (PSU).
The reason is, that the current consumption (50...80mA) of these
measurement amplifier is higher, as the RPU can deliver
and depends on the strain gauge and the justification of these unit.
The RPU delivers max. 50mA.

Temperature sensor of hoist motor

16

17
1

5.2.4 Temperature inputs 1 and 2

The hoist motor temperature sensor is connected to terminals 16
and 17 at temperature input 1. If the hoist motor does not have
temperature sensors, terminals 16 and 17 must be connected by a
resistance of 300 . The values of the temperature sensors to be
connected must meet
DIN 44 080. A high-ohm input resistance or a short-circuit are
recognized as a temperature error and all outputs (7...10) are
switched off. The hoist can then no longer be moved.
After the motor has cooled off the error is automatically
acknowledged by the Load Monitor and hoist motions permitted
again.

second temperature sensor

One or more further temperature sensors can be connected to
terminals 25, 26 at temperature input 2 as temperature prewarning. The values of the temperature sensors to be connected
must meet DIN 44 080. A high-ohm input resistance is recognized
as over temperature and treated as a warning by the Load Monitor.
After the motor has cooled off the warning is automatically
acknowledged by the Load Monitor.

25

26
2

page 11 / 15

5 Electrical connection
5.3 Outputs

5.3.1 Contact elements for lifting and lowering

the control voltage for the hoisting and lowering contactors is
connected to terminal 6.
terminal 7 is the output for contactor "slow up".
terminal 8 is the output for contactor "fast up".
terminal 9 is the output for contactor "slow down"
terminal 10 is the output for contactor "fast down".

rated breaking capacity of relays:

250 VAC, 5 A, operating mode AC1

5.3.2 "-err" and "-option" relays

The "-err" relay, terminals 27 and 28, and the "-option" relay,
terminals 29 and 30, are intended for transmitting error signals. The
contacts can be changed from normally open to normally closed.
This is done in the "special functions" mode, described under table
3.4.2. special functions in Part 2/2.
"Sensor error", "overload" or "over-temperature" or as from
software version 4 (type label SLE21-1-(c1)-X40), a miscarriage of
the internal test by hoist movement selection, can be allocated to
the -option relay. As standard, the relay -option is
parameterized as normally open. It will open, if the internal test will
miscarriage, at selection of the hoist movement.
rated breaking capacity of relays:
250 VAC, 5 A, operating mode AC1

5.3.3 "-right" and "-left" relays

The potential-free relays "-right" and "-left" open when activated
by 2.
rated breaking capacity of relays:
250 VAC, 2 A, operating mode AC1

page 12 / 15

6 Mechanical data
6.1 Dimensions

100 x 110 x 75 mm (W x H x D)

6.2 Methods of attachment

clipped onto 35 mm top-hat rail (EN 50022-35)

screwed onto base of housing (M4) with slides (option)

6.3 Lead connection

30 box terminals with captive plus-minus screws

per box terminal: 1 x 4 mm solid or 1 x 2.5 mm flexible with
sleeve DIN 46 228 or 2 x 1.5 mm flexible, with sleeve DIN 46 228

6.4 Rating plate

The type designation is to take out of the rating plate. The hardware
and software state is also readable.

SLE 2 1 1 - ( b 1 ) 1 1 0
temperature range
software version
hardware version
reference to other
safety standards
device alternatives
number of sensor inputs
submitted category to
EN 954
device: SLE = RPU

page 13 / 15

mains - L

mains - N

main hoist up

main hoist down input

main hoist fast input

voltage up/down input

output slow up control

output fast up

output slow down

option relay

error relay

temperature sensor
e.g. travel motor

+24 DC sensor supply

load sensor
connection

mass for sensor and DC input

+15 DC sensor supply

hoist motor
temperature sensor

6.5 Terminal assignment

output - fast down

relay for travel motor

right

relay for
travel motor left

6 Mechanical data

page 14 / 15

7 Technical data
7.1 Technical data
RPU
input power
temperature range
operation
storage
type of protection
EMC

< 9 VA
-20C ... + 55C (standard)
-40C ... + 70C (optional)
-40C ... + 70C
IP 20 EN 60 529
EN 61000-6-3 (2001)
EN 61000-6-2 (2001-10)
potential-free
max. 1500 DIN VDE 0660-302 (DIN EN 60947-8)
2800 ...3500 Ohm
1650 Ohm
250V / 5 A/2A
500 VA
< 10 mA
Box terminals for max. 2x1.5 mm with sleeve
Top-hat rail to EN 50022 TS35 or with screws
0.5 kg
filed in electronics R&D

temperature inputs
- maximum total cold resistance
- response resistance
- maximum release resistance
relay outputs
contact inputs
connection terminals
attachment
weight
software
LED display

Pwr
Err
III
II
I

coded error numbers

operating voltages
-10 ... + 15%, 50/60 Hz

24 VDC 300mA
24 VAC 300mA
42 VAC 170mA
48 VAC 150mA
110/120 VAC 70mA
230 VAC 30mA

sensor supply UB (24)

UBS (19)

24 VDC
15 VDC switched from Load Monitor
total < 50 mA, short-circuit resistant
R in = 39.2 Ohm; 0 ... 25 mA

sensor inputs(analog)
or
analog section

7.2 Safety categories

2-wire
4-wire
accuracy
resolution

2 %, 1LSB of final value

8 bits (0.1mA)

The RPU meets safety category 2 in acc. with EN 954-1 with the
mono sensor as device.
As the RPU is only single-channel the system as a whole can
only meet category 1.
RPU meet performance level c in acc. with EN ISO 13849-1 and
SIL 1 in acc. with EN IEC 62061.
RPU is certified for 110/120V UL.

page 15 / 15