User Manual: Index

LAB3 Basket Levelling and load control (CAT3/PL d)
LAB3_e Ver.4.11 - 08/07/2019
USER MANUAL
Index
1 SAFETY NOTES FOR THE USER ................................................................................................................................. 2
1.1 PRECAUTIONS .................................................................................................................................................... 2
1.2 CHECKS AND MAINTENANCE .................................................................................................................................... 2
1.3 VOID THE WARRANTY ............................................................................................................................................ 2
2 CONFORMITY ......................................................................................................................................................... 3
3 TECHNICAL DATA ................................................................................................................................................... 4
4 HOW TO IDENTIFY YOUR DEVICE ............................................................................................................................. 5
5 OPERATING LOGIC.................................................................................................................................................. 5
6 ORDERING INFORMATION ....................................................................................................................................... 6
7 MECHANICAL FITTING ............................................................................................................................................. 7
8 ELECTRICAL CONNECTIONS ..................................................................................................................................... 7
8.1 ELECTRICAL PROTECTIONS ...................................................................................................................................... 7
8.2 SETUP ............................................................................................................................................................. 7
8.3 CIRCUIT BOARD MAP............................................................................................................................................. 8
8.4 ELECTRICAL CONNECTIONS FOR LEVELLING .................................................................................................................. 9
8.5 ELECTRICAL CONNECTIONS FOR BASKET LOAD CONTROL ................................................................................................. 12
9 CALIBRATION ....................................................................................................................................................... 13
9.1 BASKET LOAD CONTROL CALIBRATION ...................................................................................................................... 14
9.2 PLUG & PLAY CALIBRATION ................................................................................................................................... 15
9.3 MANUAL CALIBRATION......................................................................................................................................... 15
9.4 ADAPTIVE CALIBRATION ....................................................................................................................................... 16
10 OPTIONAL FUNCTIONS ...................................................................................................................................... 23
10.1 BASKET ROTATION ............................................................................................................................................. 23
10.2 MANUAL LEVELLING ............................................................................................................................................ 24
11 ERRORS DIAGNOSTIC AND TROUBLESHOOTING ................................................................................................... 25
11.1 LEDS VISUALIZATION ......................................................................................................................................... 25
11.2 ERROR CODES .................................................................................................................................................. 26
12 TROUBLESHOOTING .......................................................................................................................................... 28
12.1 HOW TO MEASURE A TRANSDUCER SIGNAL ................................................................................................................. 28
12.2 HOW TO CHECK THE TRANSDUCERS WIRING HARNESS ................................................................................................... 28
12.3 CALIBRATION NOT CORRECTLY STORED ..................................................................................................................... 29
12.4 ZERO CHECK FAILED ........................................................................................................................................... 29
12.5 ERROR ON SAFETY OUTPUT RELAY ........................................................................................................................... 29
12.6 ERROR ON DIGITAL INPUTS CHECK .......................................................................................................................... 29
13 WASTE DISPOSAL ............................................................................................................................................. 29
BPE Srl, Campagnola Emilia (RE), Italy www.bpe.it Tel. +39 0522 662357, Fax +39 0522 653740 1/29
LAB3_e Ver.4.11 - 08/07/2019
1 Safety notes for the user

i This manual is NOT intended for the end user
It is for machine manufacturer skilled personnel only
It is compulsory to fully read the present manual and its addendums (if provided) before start system installation
BPE SRL shall not be liable for damage resulting from improper use of the present device or from
non-observance of the instructions written in this manual

The information in this document is subject to change without notice. BPE SRL shall not be liable for errors
contained herein for incidental or consequential damages in connection with the furnishing, performance or
use of this manual
1.1 Precautions
• It is compulsory to connect device power supply wires directly to the battery.
• Cut off power supply before every device check or replacement.
• Do not weld on machine structure before removing power supply (both positive and negative connections) and removing device from vehicle
frame or possible connections towards vehicle frame.
• Provide suitable mechanical protections for connection wires, paying particular attention for external transducers (when provided).
• Do not place device or cabling close to sources of heat, electromagnetic interferences or power transmissions.
• Do not directly touch the device with flushing or degreaser fluids under pressure.
• Do not hole or drop the device shell or its box (when provided).
• Seal the box and/or the panel who contains the electronic board, to reveal any not authorized access or tampering.
1.2 Checks and maintenance

A correctly mounted system will not need special maintenance through its operative life.
In this chapter you can find some checks for system functionality. Due to the safety functions of the system, if these checks are not carried out it can
be very dangerous for the operator.
Assembly checks
With a digital tester made this checks:
• Angle transducer: the voltage difference between White and Black of the angle transducer wires must increase when the boom rise
• Strain gauge transducer: the voltage difference between the strain gauge transducer Yellow and Black wires, between the rest and the alarm
position, must be in the range 2÷7 mV.
After assembly checks

When you assemble the system for the first time you must made some checks:
• Check the power supply to verify it is correct (range and noise absence).
• Check the device shell and (when provided) the box lock and gland clamp.
• Check the device shut down through main power supply switch.
• Check that the electrical connection with machine structure follow the instructions of the tables in the “Safety - Conformity” chapter.
Ordinary maintenance to be made at the beginning of every duty cycle

• Visual check device shell or its box (when provided) and connection wires.
• Check of power supply to verify it is correct.
• Check of the equipment correct operation, by simulating a locked condition and correspondent rearming.
Extraordinary maintenance
Made by skilled workers. Ask BPE Srl or its reseller/or importer. Extraordinary maintenance is considered to be everything that is not described in
ordinary maintenance and in procedure of device installation. Warning: only skilled operators are allowed to make this type of maintenance;
sanction: loss of every responsibility by BPE Srl.
1.3 Void the warranty

Any hardware modifications, changes, tampering or unauthorized uses of the product will void the warranty. Disassembly and reverse-engineering
are strictly forbidden.
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2 Conformity
The system meets the following directives:
• CE Conformity: 2004/108/CE EMC

in accordance with technical standards:
EN 61000-6-2 - Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial environments
EN 61000-6-4 - Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission standard for industrial environments
Case of vehicle frame electrically connected to battery negative

Box Kind of electrical connection to the frame
Metal, supplied by BPE • Electrically connect the box to the frame
Case of vehicle frame electrically NOT connected to battery negative

Box Kind of electrical connection to the frame
Metal, supplied by BPE • Electrically connect the box to the battery negative
• Electrically insulate the box from the frame
The system is manufactured to comply Category 3 (EN 954-1) and PL d (EN 13849-1) for levelling function
!
according
to the following conditions:
 use of safety outputs J5.3/J5.4 and J5.13/J5.14
basket load control

!
The system is manufactured to comply Category 3 (EN 954-1) and PL d (EN 13849-1) for
according to the following conditions:
 transducers doubling (see chapter “Operating logic”)
 use of safety output J5.23/J5.35
• RoHS Directive: 2011/65/UE

The products detailed in this document comply with the RoHS (Restriction of use of certain Hazardous Substances in
Electrical and Electronic Equipment) directive 2002/95/EC.
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3 Technical data
BPE Electronics reserves the right to modify the technical data anytime, without advise
Fig.3.1: Board dimensions with 35 poles connector Fig.3.2: Dimensions of standard box
Fig.3.3: Closed box photo Fig.3.4: Open box photo
Power supply from 9 to 33 VDC ●

Digital inputs 3 ●
Analogue inputs 1 + 2 differential Protected against short circuits or bad manoeuvres.
Digital outputs 3 + 2 positives Imax = 1A. Imax = 2A if activated separately.
Protected against short circuits.
Digital safety outputs 2 + 1 with polarized relay Imax = 2A. Protected against short circuits.
Proportional outputs 2 PWM with current drive or ON/OFF with 3A or analogue for one Danfoss™ module
Connections RS-232 serial port CAN bus on request
Operating temperature from -40 to +70 °C ●
Standard protection grade IP 66 Inside BPE standard box
Difference threshold for double channel systems

The typical values for the difference threshold between the two channels are shown in the following table(1):
Kind of transducers Difference (Δ) Notes
Load transducers 10% of maximum load -
Tilt transducers 3° -
(1)
These typical values are shown for example purpose only, they may change with the application on the custom machine and must
be arranged with the customer
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4 How to identify your device

The following photo shows how to find the board identification label and an example of an identification label on the board
• Part number (P/N): this code identify the device hardware and firmware type
• Serial number (S/N): this code identify the single and unique device and its firmware version
Fig. 1.2: LAB3 part number label
Fig. 1.1: Identification label on the board box Fig. 1.3: LAB3 internal serial number label
5 Operating logic
The LAB3 electronic board works as basket levelling system with the option of basket load control. The levelling sensors are
embedded on the electronic board. External, optional, transducers are:
• Double channel strain gauge transducers set for load control function
• One or two angle transducers on basket boom (optional, not compulsory for levelling function)
The transducers must be correctly fitted according to installation instructions.

The LAB3 electronic board operating logic is the following:
• Basket levelling: When a tilt condition is detected the system start to work and put again the basket in horizontal
position. When the tilt is higher than 10° the system enters alarm condition.
• Basket load control: When the load is higher than the stored alarm level, the system enters alarm condition. It is
available a pre-alarm level.
The operating modes are coded as following:

• ”L” = Levelling control only
• ”W” = Basket overload control only
• ”LW” = Both levelling and basket overload control
i The levelling and the basket load control safety outputs are fully independent. For example: if the basket load control
safety output opens (for overload or transducer error) the machine can continue to level. It is the machine manufacturer
that can choose, with the correct electrical wiring harness, to stop levelling in case of overload.
 On every power on the board makes a short integrity check. During the check the safety outputs are disabled
The system is simply set by push buttons or can be fully configured with the BPEterminal software.
In case of replacement of components of the system, these parts must be original parts by BPE.
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6 Ordering information
Ordering information sample:
_L P 1 _N PL_33 NOT Mxy

Operating Output Connection JIB Safety CAN Special
mode signal type angle level operating
mode
Operating mode
_ L Levelling only function
_ W Basket load control only function
L W Levelling and basket load control functions
Output signal
P PWM outputs to drive PWM proportional solenoid valves
D Danfoss™ outputs to drive Danfoss™ solenoid valves
F ON/OFF outputs to drive ON/OFF solenoid valves
Connection type
1 Electrical connection with 35 poles standard connector
JIB angle
_ N Jib angle not used
_ A Only one jib angle is used
2 A Two jib angles are used
Category level
C A T W L Safety level for weight (W) and levelling (L)
N O T 0 0 Without any safety level
P L _ W L Performance level for weight (W) and levelling (L)
CAN bus connection

N O T Without CAN bus connection
C A N With CAN Open bus connection
Special operating mode

M x y Operating mode code “xy”. For special custom versions only
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7 Mechanical fitting
i Factory default: the LAB3 is shipped pre-configured to be perfectly mounted in horizontal position as
show in the drawing on the right. If you choose another position it is compulsory to change its
orientation
BPEterminal is required to change LAB3 orientation

Configuration→Orientation  For Load Control function only,
LAB3 orientation is not required
Horizontal positions Vertical positions
Fig. 7.1: Available mounting positions for the LAB3
8 Electrical connections
8.1 Electrical protections
The board runs a non stop autocheck to find any breakdown, failure or damage. If any problem is found, the board goes into the
alarm condition. The board is protected against:
• polarity reversal
• transducers cable breakaway, damage or short circuit (the board goes into alarm condition)
• digital safety and proportional outputs short circuit (when that condition is detected, the board goes in alarm condition)
The slave microcontroller runs a non stop check of board functions.
8.2 Setup
Cabling has to be realized so as to warrant a correct wiring insulation of all parts accessible from operator.
Installation has to be made without wires having radius of curvature too small and without machine moving cause crushes or
tractions.
The cables properties must be function of the custom application.
Minimum suggested characteristics

2
Power supply: 1,00 mm
Connections: standard RS-232
2
Digital input: 0,5 mm
2 2
Digital and proportional outputs: 0,5 mm for low power outputs, 0,75 mm for high power outputs (see chapter “Technical features”)
Analogue input: see the connected transducer specific manual
! The electrical wiring harness must by comply to:

EN 60204-1 Safety of machinery. Electrical equipment of machines. General requirements.
Excepting special cases, the above cables are not supplied by BPE.
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8.3 Circuit board map
Fig. 8.3.1: Board map – external connector version
Fig. 8.3.2: 35 poles J5 external connector layout
Upper layer connectors Jumper

J2.1 Secondary microcontroller programmation JP3 CAN bus termination
J3.1 RS-232 serial connection
J4.1 Main microcontroller programmation
LEDs
D8 Green
Lower layer connectors D9 Red
[J4] Ground connection (Faston type) D10 Yellow
J5 External multi functions connector D18 Green. Shows that the board is electrically supplied
Connections to the shield

Mh1 Metallized fixing hole n. 1
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8.4 Electrical connections for levelling

!
To give the power supply to the electronic board (connector J5 pin 1 e 2) , connect it directly to the battery. All positive inputs
must be connected to service positives only, do not connect them directly to the battery. Do not use service positives to
power supply external devices.
Power supply
Pole Meaning Notes
1 Main positive power supply Must be directly connect to the power supply
2 Main negative power supply Must be directly connect to the power supply
CAN bus
15 CAN L ●
16 CAN H ●
PWM and ON/OFF solenoid valves

24 Levelling output n. 1 (LO1) For proportional or on/off solenoid valves. Imax=3A
25 Levelling output n. 2 (LO2) For proportional or on/off solenoid valves. Imax=3A
26 Negative output for levelling solenoid valve For proportional or on/off solenoid valves. Imax=3A
Never connect it to negative power supply!
Fig. 8.4.1: How to connect PWM and ON/OFF solenoid valves
Danfoss™ solenoid valves

24 Positive from Danfoss™ From Danfoss™ supply voltage
25 Signal To Danfoss™ signal voltage
26 Negative from Danfoss™ From Danfoss™ supply voltage
+
+
Fig. 8.4.2: How to connect Danfoss™ solenoid valves
i The Danfoss™ negative feed-back must be connected to terminal 26, otherwise the LAB3 cannot work properly
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Category 3 | PL d outputs
! Use these outputs to automatically stop the machine when over tilted
Single mode
(1)
3 Polarized safety relay IMAX = 2 A. The output switches (the contact opens) when the angle tilt is higher than ±10°
4 ±10° levelling safety stop ()
(1)
It is not possible to connect the two outputs in series.
Intervention angle is user configurable from 0 to 10 degrees. It is not possible to set angles greater than 10 degrees.
Double mode
(1)
3 Polarized safety relay IMAX = 2 A. The output switches (the contact opens) when the angle tilt is higher than +10°
4 +10° levelling safety stop ()
(1)
13 Polarized safety relay IMAX = 2 A. The output switches (the contact opens) when the angle tilt is higher than -10°
14 -10° levelling safety stop ()
(1)
It is not possible to connect the two outputs in series.
Intervention angle is user configurable from 0 to 10 degrees. It is not possible to set angles greater than 10 degrees.
Fig. 8.4.3: How to connect ±10° safety outputs for single and double mode (J5.13/J5.14 not available for single mode)
JIB angle connections

(1)
18 Analogue input for angle transducer Connect it to the jib angle transducer signal output
(1)
19 Analogue input for angle transducer Connect it to the jib angle transducer signal output
30 Negative power supply for transducers Connect it to the jib angle transducer negative power supply
31 Positive power supply for transducers (+5 VDC) Connect it to the jib angle transducer positive power supply
(1)
Also in case of single channel angle transducer, connect the angular signal to both inputs: 18 and 19
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Hydraulic pre-selection, tilt signalling, basket rotation
If basket rotation function is disabled:

(2)
27 Output for hydraulic power pre-selection (Output n. 3) IMAX = 1 A . It is not disabled over 10º
(3)
28 Output for tilted signalling () (Output n. 2) IMAX = 1 A
(3)
29 Output for tilted signalling () (Output n. 1) IMAX = 1 A
(2)
Some different customization are available and user configurable
(3)
Intervention angle and logical levels are user configurable
If basket rotation function is enabled (OPTIONAL):

(2)
27 Output for hydraulic power pre-selection (Output n. 3) IMAX = 1 A . It is not disabled over 10º
(3)
28 Output for basket rotation hydraulic diverter (Output n. 2) IMAX = 1 A
(3)
29 Output for tilted signalling () and () (Output n. 1) IMAX = 1 A
(2)
(3)
If basket rotation function is enabled (OPTIONAL) and hydraulic pre-selection disabled:

(2)
27 Output for basket rotation hydraulic diverter (Output n. 3) IMAX = 1 A . It is not disabled over 10º
(3)
28 Output for tilted signalling () (Output n. 2) IMAX = 1 A
(3)
29 Output for tilted signalling () (Output n. 1) IMAX = 1 A
(2)
(3)
Manual levelling and basket rotation
i These optional functions and the two alarm levels for load limitation cannot be available at the same
time
5 Digital input for manual levelling activation Connect the other end to pin 22 service positive
6 Digital input for manual levelling or basket rotation: Connect the other end to pin 22 service positive
start movement on direction B
12 Digital input for manual levelling or basket rotation: Connect the other end to pin 22 service positive
start movement on direction A
17 Digital input for manual levelling or basket rotation: Connect the other end to battery positive
person present signal
22 Service positive For safety logical functions (WQ)
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8.5 Electrical connections for basket load control

!
To give the power supply to the electronic board (connector J5 pin 1 e 2) , connect it directly to the battery. All positive inputs
must be connected to service positives only, do not connect them directly to the battery. Do not use service positives to
power supply external devices.
Power supply
Pole Meaning Notes
1 Main positive power supply Must be directly connect to the power supply
2 Main negative power supply Must be directly connect to the power supply
CAN bus
15 CAN L ●
16 CAN H ●
Category 3 | PL d outputs
! Use these outputs to automatically stop the machine when overloaded
23 Polarized relay safety output: to the solenoid valve IMAX = 2 A. The output switches when the load on the basket is higher than
35 Polarized relay safety output: from power supply allowed level
Strain gauge connections

7 Negative power supply for strain gauge transducers +0 VDC Black or Blue Channel 2
8 Positive power supply for strain gauge transducers +5 VDC Red or Brown Channel 2
20 Input for strain gauge transducers signal S2+ White Channel 2
21 Input for strain gauge transducers signal S2- Yellow or Green Channel 2
9 Negative power supply for strain gauge transducers +0 VDC Black or Blue Channel 1
10 Positive power supply for strain gauge transducers +5 VDC Red or Brown Channel 1
32 Input for strain gauge transducers signal S1+ White Channel 1
33 Input for strain gauge transducers signal S1- Yellow or Green Channel 1
Signalling outputs
11 Signalling output for basket load alarm (OUT5). IMAX = 1 A
34 Signalling output for basket load pre-alarm (OUT4). IMAX = 1 A
Alarm level selection

(1)
12 Digital input for alarm level selection Connected the other end to a positive
(1)
17 Digital input for alarm level selection Connected the other end to a positive
22 ● ●
(1)
It is compulsory to use both input at the same time.
Fig. 8.5.1: Example of an electrical connection for wires J5.35 (IN) and J5.23 (OUT)
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9 Calibration
The LAB3 levelling function can be configured in three ways: «Plug & Play», «Manual or fine» and «Adaptive».
Plug & Play The LAB3 is factory configured to work with the wider type of machines. If mounted as previously stated, it is ready to start to
level. See «Plug & Play» chapter for understand the factory configuration.
Manual/fine For a full fine tune of LAB3 system you can use the manual/fine calibration through the BPEterminal software
Adaptive The semi-automatic adaptive calibration is used for special machines or in case of jib angle transducer
The LAB3 load control function calibration is always «Full manual».
•
!
The basket load calibration (when available) must be stored before the levelling calibration
• Never start levelling calibration if load calibration is not over and vice versa
• During calibration never cut off power supply to the LAB3 so as not to lose data storage
• Carry out the after assembly checks, if you have not completed them, as shown in chapter “Checks and maintenance”
• See “Error visualizations” chapter to check which errors disable calibration procedure
• The calibration procedure is function of the board properties. Check “How to identify your board” chapter, to know
what functions are enabled for your board
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9.1 Basket load control calibration

With the basket load limitation calibration procedure is always possible to set up two independent alarm levels. If you need to use
only one level, you must set up also the second one, at the same level of the first one.
Fig. 9.1.1.a: «Alarm Level 1». Bigger load selection.

J5.12 and J5.17 connected to J5.22
Fig. 9.1.1.b: «Alarm Level 2». Smaller load selection.

J5.12 and J5.17 not connected to J5.22
LEDs key to symbols OFF ON Blinking
Let’s now look at the setting procedure:
Begin 1. Power on the board. The LEDs will blink

for a while; after they will go off.
2. If green LED (D8) or yellow LED (D10) are blink, see chapter “Errors visualizations”.
Calibration start 3. Press SW1 push button for NOT more than 3 seconds: yellow LED (D10) will go
ON and red LED (D9) will blink.
Transducers Zero 4. Press SW2 push button: red LED (D9) will become brighter during push button
pressure.
Alarm level 1 5. Put the system in alarm condition with load 1. Press SW3 push button: green LED
(D8) will power on during push button pressure
Change curve 6. Press SW1 push button to select the other curve: green LED (D8) will become
brighter during push button pressure
Alarm level 2 7. Put the system in alarm condition with load 2. Press SW3 push button: green LED
(D8) will power on during push button pressure
Calibration end 8. Press SW1 push button to exit from calibration. Red LED (D9) will power on: come
back from alarm condition and check that red LED (D9) power off
9. Power off the board.
10. Power on the system and check its right working: put the system in its alarm condition and check that the red LED (D9)
power on and the deactivation of safety alarm output.
Notes
The evaluation of the alarm condition (overloading) is competence of the machine builder and must be
forecasted all the depreciatory (adverse) conditions: dynamics, atmospheric, machine positioning etc.
Shortcuts(*) to store
 transducers zero only:
alarm level 1 only:
alarm level 2 only:
SW1 + SW2 + SW1 + SW1
SW1 + SW3 + SW1 + SW1
SW1 + SW1 + SW3 + SW1
(*)
To be used only after you have stored a full valid calibration!
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9.2 Plug & Play calibration

The LAB3 is shipped pre-calibrated to work with the wider type of machines.
Factory configuration
• Mounting position: horizontal
i The LAB3 must be mounted perfectly horizontal.
Otherwise is compulsory to store again the relative zero
• Dead zone: ±0.5 degrees
For PWM systems For Danfoss™ systems

• minimum current: 280 mA • minimum voltage: 2.5% of VIN (it means from 52.5% to 75% and
• maximum current at 10 degrees: 880 mA from 47.5% to 25% of VIN)
• LO1 closing, LO2 opening • maximum voltage at 10 degrees: 25% or 75% of VIN (neutral=50%)
• A-port closing, B-port opening
For a new system it is ALWAYS compulsory to correctly store the zero, also if cloned
i from an old one
If something is to fine calibrate, see following chapter “Manual calibration”.
9.3 Manual calibration

LAB3 manual calibration is available through the BPEterminal software. It is used to adjust the standard Plug & Play
calibration or to fine set the LAB3 on your machine. See BPEterminal documentation for software and hardware requirements.
See chapter “Circuit Board map” to identify RS-232 serial port internal connector J3.1.
Ask BPE Electronics for the special cable and (if necessary) the supported USB to serial adapter.
i For LAB3 with jib angle transducer is compulsory to execute part of the adaptive calibration.
Ask BPE Srl to have more details about calibration procedure for your system
!
System evaluation (lead the basket tilt over ±10 degrees and check that system stops) is pertinence of the
original equipment manufacturer and it has to include all the pejorative (adverse) conditions: dynamics,
atmospheric, machine positioning etc.
× Do NOT go onto the basket during calibration!

Let’s now look at the manual calibration procedure:
1. Check that all configuration parameters are correctly set for your system and your machine configuration. See all tabs under
the BPEterminal “Configuration” tab (Setup, Orientation, Levelling, I/O etc.).
2. Go to “Manual Calibration” tab:
a. Press “Read” push button to read present LAB configuration.
b. Press “Draw plot” push button if you want to start to draw the “angle”, “set point current” and “real solenoid
current” plot (suggested).
c. Put the basket in its zero position (horizontal), wait until any vibration in gone and press “Basket zero” push
button to store the basket zero inside the LAB3. The yellow LED will blink few times.
d. Put zero inside the “Tilt Gain” fields for Basket Opening and Basket Closing and press “Send” push button.
e. Change “Minimum Current” fields for Basket Opening and Basket Closing (see your solenoid valves manual to
see what is the minimum current for your system), press “Send” push button and try the machine. Change these
values until the machine works well at the minimum possible speed. Remember to press “Send” push button every
time you change the values inside the fields.
f. Change “Tilt Gain” fields for Basket Opening and Basket Closing and press “Send” push button and try the
machine. Change these values until the machine works well at the maximum possible speed. Remember to press
“Send” push button every time you change the values inside the fields.
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9.4 Adaptive calibration

× Do NOT go onto the basket during calibration!
i Remove any load from the basket and enable all hydraulic movements
Phase 1: Orientation
This first phase is compulsory for the board to define its orientation. Let’s now look at the orientation procedure:
Begin 1. Check that the LAB3 board is correctly fit (see chapter “Mechanical fitting”).
2. Check that the LAB3 board is correctly fit (see chapter “Mechanical fitting”).
3. Check LEDs blinks: if the LAB3 has some errors the calibration cannot be done. See “LED visualization” chapter for errors
that inhibit calibration.
!
5. Connect J5.1 to J5.3 and J5.1 to J5.13. These connections bypass the safety outputs! All movements are
allowed!!! BE CAREFUL!!!
It is correct to have three LED yellow blinks in this case
6. Power on the board.

7. Put the basket in horizontal position, as shown in the following drawing: the jib must not be at the end of its end-of-stroke
but around the middle of its working range.
Fig. 9.4.1: Put the basket in horizontal position and in the middle of its working range
Phase 1 start 8. Press SW1 push button for more than 3 seconds to start the calibration.
9. Release the push button: the green LED D8 and red LED D9 start blinking even
faster for 8 seconds and after that still blinking fast.
! Stay away from the machine during this phase!
10. After 8 seconds the machine starts to move. i Be careful! This phase can last some minutes
Phase 1 end 11. The board automatically ends orientation phase. If the board gets any error during data
acquisition, all three LEDs stay on until the board is powered off. In this case, please check the following:
a. The electronic board fitting must be correct as shown in chapter “Mechanical fitting”
b. The hydraulic system must work correctly and in the correct direction
c. The electronic board must not have transducers or category errors (check it with ERROR command or reboot the
board and check if green or yellow LEDs blink)
i It is normal to have 7 green LED blinks at the end of phase 1
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Phase 2: Levelling zero (and jib angle zero when available)
i Before starting this phase it is compulsory to successfully finish the previous phases
Let’s now look at the levelling procedure:
Begin 1. Power on the board.
2. Put the basket horizontal.
3. If the system has the jib angle transducer, put also the jib exactly vertical; otherwise you can skip this step and directly go to
next one.
Fig. 9.4.2: Horizontal basket.

And vertical jib (if the system use the angle transducer).
Phase 2 start 4. Press push buttons SW1+SW2 for more than 3 seconds to start the calibration.
5. Release the push buttons: yellow LED D10 powers on and not blinking.
Levelling zero 6. Check that the machine is not oscillating. Gently press push button SW2 without making any
machine oscillation.
7. After 5 seconds from push button pressure, the board stores the zero and powers off yellow LED D10 for one second. If the
board gets any error during data acquisition, all three LEDs power on until the board is powered off.
Angle transducer zero 8. Skip this point if you do not use the angle transducer!Otherwise press SW3 push button without
causing any oscillation of the machine. After 5 seconds from push button pressure the board stores
the zero and powers off yellow LED D10 for one second. If the board gets any error during data
acquisition, all three LEDs power on until the board is powered off.
Phase 2 end 9. Press push button SW1 to exit. Yellow LED D10 powers off.
LAB3_e Ver.4.11 - 08/07/2019
Phase 3: Auto calibration
During this phase the system automatically finds the minimum currents necessary to move the basket. Let’s now look at the auto
calibration procedure:
Begin 1. Power on the board.
2. Tilt the jib and put the basket in the middle of its working range (Fig. 10.2.3.1).
Phase 3 start 3. Press the three push buttons SW1+SW2+SW3 for more than 3 seconds to start the calibration.
Fig. 9.4.3: How to set the basket in the middle of its working range, with tilted boom.
4. Release push buttons: red LED D9 and yellow LED D10 stay on.
5. Only if you have the jib angle transducer. Move away from the machine and put the jib horizontally (Fig. 9.2.3.2). BE
CAREFUL: do not move any machine part until the end of this phase.
6. When the jib will be horizontal (if the system has the jib angle transducer) the green
LED D8 and red LED D9 start to blinking even faster for 8 seconds. The machine
will start to move automatically.
! Stay away from the machine during this phase!

7. The three LEDs will go steady on.
Fig. 9.4.4: Put the jib horizontally
LAB3_e Ver.4.11 - 08/07/2019
8. The board automatically ends auto calibration phase. If the board gets any error during data acquisition, all three LEDs
stay on until the board is powered off. In this case, please check the following:
a. The electronic board fitting must be correct as shown in chapter “Mechanical fitting”
b. The hydraulic system must work correctly and in the correct direction
c. The electronic board must not have transducers or category errors (check it with ERROR command or reboot the
board and check if green or yellow LEDs blink)
8. The system will do some full rotations for the whole working range. After some
minutes the system will stop horizontally and will start levelling.
i If basket stops for more than 10 minutes, power off the board and start again the auto calibration procedure
9. If the basket stops horizontally, lower the boom until ground and check the system levelling function (also if it is not perfect)
i If system does not level the basket, , power off the board and start again the auto calibration procedure
10. If the system levels correctly, phase 3 is ended and the system goes automatically to next phase. The seven green LED blinks
will disappear.
Phase 3 end
LAB3_e Ver.4.11 - 08/07/2019
Phase 4: System advanced calibration
The advanced calibration is function of the machine working speed. The machine is a:
if the boom or jib speed is

Fast machine higher than 2 degrees per second
Slow machine lower than 2 degrees per second
Select the correct calibration for your machine and its working speed.
Fast machines calibration

Let’s now look at the calibration procedure::

2. Remove the connections between J5.1/J5.3 and J5.1/J5.13
! REMOVE CONNECTIONS BETWEEN J5.1/J5.3 AND J5.1/J5.13

4. Press SW3 push button for more than 3 seconds to start the calibration.
5. Release the push button: the system starts phase 4 initial calibration and the three LEDs will power on and off some times.
6. Move 5 times the boom for its whole working area, using the lower possible speed.
7. Move 5 times the boom for its whole working area, using the higher possible speed.
8. Move 5 times the boom for its whole working area, using the lower possible speed.
9. Move 5 times the boom for its whole working area, using the higher possible speed.
10. After these 20 cycles the system is ready for use. Check it. If it doesn’t work correctly, repeat from point 6.
13. Check the systems and its right working.
! The system evaluation (lead the basket tilt over ±10 degrees and check that system stops) is pertinence of
the original equipment manufacturer and it has to include all the pejorative (adverse) conditions: dynamics,
atmospheric, machine positioning etc.
i To break, stop or cancel the procedure, press SW3 push button
LAB3_e Ver.4.11 - 08/07/2019
Slow machines calibration

The slow machines calibration needs the use of the BPE Terminal on a PC connected via an RS-232 serial port to the LAB3
internal connector J13.1 (it is inside the board box and it is necessary to remove the box top, see chapter “Board map” to identify
J3.1 connector). Ask BPE Electronics for the special cable and (if necessary) the supported USB to serial adapter.
Let’s now look at the calibration procedure:
! REMOVE CONNECTIONS BETWEEN J5.1/J5.3 AND J5.1/J5.13
2. Connect the PC or other serial device to J3.1 connector.
4. The serial connection with the board is necessary to set the KC1 and KC2 parameters (system tilt gain) during the basket
opening and closing movements.
Fig. 9.4.5: Basket closing movement, used to level during jib descent. Fig. 9.4.6: Basket opening movement, used to level during jib rise.
The following table shows the meaning for KC1 and KC2 parameters, according on how the LAB3 electronic board is mounted on
the basket:
KC1 and KC2 parameters meaning, according with mounting options
KC1 is the system gain during basket closing movement (jib descent)
KC2 is the system gain during basket opening movement (jib rise)
KC1 is the system gain during basket opening movement (jib rise)
KC2 is the system gain during basket closing movement (jib descent)
Fig. 9.4.7
KC1 is the system gain used when the basket tilt from (levelling) zero position is positive, KC2 is the gain when the tilt is
negative. The basket tilt can be read from RS-232 serial port with the ANGREL command.
LAB3_e Ver.4.11 - 08/07/2019
The KC1 and KC2 standard value is 10000 and their range is from 1000 to 28000. Values near to high range value means that
the system is more sensible and reactive.
To change the KC1 and KC2 parameters values as required, use the following syntax:
KC1=[value]<Enter>
KC2=[value]<Enter>
for example:
KC1=1150<Enter>
KC2=760<Enter>
5. Change the KC1 and KC2 parameters values until you are satisfied of system working.
8. Check the system and its right working.
! The system evaluation (lead the basket tilt over ±10 degrees and check that system stops) is pertinence of
the original equipment manufacturer and it has to include all the pejorative (adverse)
conditions: dynamics, atmospheric, machine positioning etc.
LAB3_e Ver.4.11 - 08/07/2019
10 Optional functions
These optional functions are optional and require the use of the following digital inputs.
If the load limitation function uses the double alarm level, the selection inputs are not available for the optional functionalities.
Therefore, the optional functionalities are available only when the load limitation uses one single alarm level.
10.1 Basket rotation

The used inputs are the following:
Pin Function Notes

5 Manual levelling activation Connect the other end to pin 22 service positive
6 Basket rotation: start movement on direction B Connect the other end to pin 22 service positive
12 Basket rotation: start movement on direction A Connect the other end to pin 22 service positive
17 Basket rotation: person present signal Connect the other end to a battery positive
The used outputs are the following:
Pin Function Notes

Hydraulic power pre-selection (Output n. 3) IMAX = 1 A.
27
Or Basket rotation hydraulic diverter
Basket rotation hydraulic diverter (Output n. 2) IMAX = 1 A.
28
Or Output for tilted signalling ()
Tilted signalling () and () (Output n. 1) IMAX = 1 A.
29
Or Output for tilted signalling ()
Levelling output n. 1 (LO1) For proportional or on/off solenoid valves. Imax=3A
24
Or Positive from Danfoss™ From Danfoss™ supply voltage
25
Or Signal to Danfoss™ To Danfoss™ signal voltage
Negative output for levelling solenoid valve For proportional or on/off solenoid valves. Imax=3A
26
Or Negative from Danfoss™ From Danfoss™ supply voltage
The input at pin 5, the manual levelling activation, must always be OFF in order to operate the basket rotation.
The basket rotation can be started when the levelling function is not active, that means the basket must not be tilted.
During the basket rotation, if the basket tilt becomes higher than the maximum allowed value (default: 6 degrees), the rotation is
stopped and the levelling is performed.
The basket rotation is operated through the same proportional output used for the levelling function, and an output (pin 28 or 27)
is used for a hydraulic diverter meant to carry the oil to the rotation actuator. Optionally the hydraulic pre-selection output can be
activated also during the basket rotation.
The operator must activate first the Person present signal (pin 17) and then the Direction A switch (pin 12) or Direction B switch
(pin 6).
The input for the Person present signal (pin 17) must not be activated during power on.
LAB3_e Ver.4.11 - 08/07/2019
10.2 Manual levelling

The inputs used are the following:
Pin Function Notes

5 Manual levelling activation Connect the other end to the service positive at pin 22
6 Manual levelling: start movement on direction B Connect the other end to the service positive at pin 22
12 Manual levelling: start movement on direction A Connect the other end to the service positive at pin 22
17 Manual levelling: person present signal Connect the other end to a battery positive
The outputs used are the following:
Pin Function Notes

Hydraulic power pre-selection (Output n. 3) IMAX = 1 A.
27
Or Basket rotation hydraulic diverter
Basket rotation hydraulic diverter (Output n. 2) IMAX = 1 A.
28
Or Output for tilted signalling ()
Tilted signalling () and () (Output n. 1) IMAX = 1 A.
29
Or Output for tilted signalling ()
24
Or Positive from Danfoss™ From Danfoss™ supply voltage
25
Or Signal to Danfoss™ To Danfoss™ signal voltage
Negative output for levelling solenoid valve For proportional or on/off solenoid valves. Imax=3A
26
Or Negative from Danfoss™ From Danfoss™ supply voltage
The manual levelling can always be operated.
Each direction is allowed when the movement reduces the basket tilt, or when the movement increases the basket tilt up to a
maximum allowed value (default: 6 degrees).
The manual levelling function does not alter or modify the PL d outputs operation.
The manual levelling is activated by activating the Manual levelling activation input. This input must be set when all the other
inputs are not activated.
Then, the operator must activate first the Person present signal (pin 17) and then the Direction A switch (pin 12) or Direction B
switch (pin 6).
The input for the Person present signal (pin 17) must not be activated during power on.
LAB3_e Ver.4.11 - 08/07/2019
11 Errors diagnostic and troubleshooting

11.1 LEDs visualization
Transducers errors – green LED (D8)
Blinks Meaning Troubleshooting Levelling Load
Calibration Calibration
- No error ● - -
1 Internal accelerometer error Ask BPE Srl no no
2 Jib angle transducer error Check transducer signal and its electrical wiring
no phase 3, 4 yes
harness
3 Internal temperature error Ask BPE Srl no no
4 Load transducer error Check transducer signal and its electrical wiring
yes no
harness
5 Load transducers error: under zero Check transducer signal and its electrical wiring
yes yes
harness
6 Basket load control calibration not correctly stored Store again the load calibration yes yes
7 Levelling calibration not correctly stored or Levelling calibration not yet finished or
yes yes
levelling stopped via BPEterminal “STOP” button press BPEterminal “START” button
Category errors – yellow LED (D10)

- No error ● - -
1 Internal communication error Check for power supply greater than +9 VDC no no
Ask BPE Srl
2 Internal safety error Ask BPE Srl no no
3 Safety relay error Check if you have removed temporary electrical yes yes
connections between J5.1 and J5.3/ J5.13/J5.19.
4 Digital inputs check error Check electrical wiring harness. Wrong use of service no no
Small over current on PWM output positive. Check free-wheel on solenoid valves
5 CRC memory error Ask BPE Srl yes yes
6 Embedded angle sensor check error Try to store again the levelling zero. Ask BPE Srl no phase 3, 4 yes
7 Load cross check error Check transducer signal and its electrical wiring yes yes
harness
8 Jib angle cross check error Check transducer signal and its electrical wiring no phase 3, 4 yes
harness
9 Temperature check error Ask BPE Srl yes yes
For all yellow LED errors, remove the error cause and power off/power on the LAB3 to reset error condition
Various errors – All three LEDs (DD8/D9/D10)

ON fixed for Big over current on PWM output Check electrical wiring harness no no
10 seconds
ON After failed calibration: calibration error Check calibration. Do it again no no
ON During board power on: wrong board box Check board box orientation no no
orientation
LAB3_e Ver.4.11 - 08/07/2019
11.2 Error codes

The LAB3 board has two microcontrollers: main and secondary, each one with its own table errors.
Transducers errors for main and secondary micro controller

N Error Possible reason Possible solution
0 Internal error Tilt transducer 1 (X axis) ● Signal too low Ask BPE Srl
1 Internal error Tilt transducer 1 (X axis) ● Signal too high Ask BPE Srl
2 Internal error Tilt transducer 2 (Y axis) ● Signal too low Ask BPE Srl
3 Internal error Tilt transducer 2 (Y axis) ● Signal too high Ask BPE Srl
4 Jib angle transducer Signal too low Check the transducer electrical wiring harness.
Replace the transducer
5 Jib angle transducer Signal too high Check the transducer electrical wiring harness.
6 Internal error Temperature transducer ● Signal too low Ask BPE Srl
7 Internal error Temperature transducer ● Signal too high Ask BPE Srl
8 Strain gauge transducer (S1+) Signal too low Check the transducer electrical wiring harness.
9 Strain gauge transducer (S1+) Signal too high Check the transducer electrical wiring harness.
10 Strain gauge transducer (S1-) Signal too low Check the transducer electrical wiring harness.
11 Strain gauge transducer (S1-) Signal too high Check the transducer electrical wiring harness.
12 Signal from transducer lower than Frame or transducer deformation. Put the machine in normal working condition. Check the
minimum value (under zero) Broken transducer, signal loss. transducer electrical wiring harness. Replace the
transducer
13 Load calibration not correctly stored or Power supply failure during calibration. See chapter “Troubleshooting”
not finished Errors during calibration Make again the load calibration procedure
14 Internal error Wrong factory calibration ● Not correctly stored Ask BPE Srl
Transducers errors for main micro controller

15 Level calibration not correctly stored or Power supply failure during calibration. See chapter “Troubleshooting”
not finished or levelling stopped via Errors during calibration Make again the level calibration procedure
BPEterminal “STOP” button Use of BPEterminal “STOP” button Press BPEterminal “START” button
Transducers errors for secondary micro controller

15 None ● ●
LAB3_e Ver.4.11 - 08/07/2019
For all yellow LED errors, remove the error cause and power off/power on the LAB3 to reset error condition
Category errors for main micro controller

0 None ● ●
1 Internal error ● Main micro communication error Ask BPE Srl
2 Transducers electrical wiring harness Electrical wiring harness problems, broken strain Check the transducer electrical wiring harness. For strain gauge
(main micro controller) Fault injection gauge transducer internal problems transducers check the internal resistors
3 Safety relay error Wrong electrical wiring harness Check if you have removed temporary electrical connections
(main micro controller) User mistake during calibration between J5.1 and J5.3/ J5.13/J5.19.
Internal error Ask BPE Srl
4 Digital inputs check failure Wrong electrical connection on almost one digital input Check that all digital inputs are connected to service positives
(main micro controller) and that they are not directly connected to battery positive
5 Internal error ● CRC EEPROM Ask BPE Srl
6 Internal error ● CRC RAM Ask BPE Srl
7 Internal error ● CRC firmware Ask BPE Srl
8 Internal error ● ALU error Ask BPE Srl
9 Internal error ● CRC RAM/EEPROM difference Ask BPE Srl
10 Not used Not used Not used
11 Internal error ● Secondary communication error Ask BPE Srl
12 Internal error ● Main accelerometer difference error Ask BPE Srl
13 Internal error ● Secondary accelerometer. difference error Ask BPE Srl
14 Different signals from strain gauge Transducers signal loss, broken transducers or not Check the transducer electrical wiring harness. Check that both
transducers (main micro controller) correctly working. signals increase or decrease at the same time.
Wrong transducers electrical wiring harness Replace the transducer/transducers that not work correctly
15 Different signals from strain gauge Transducers signal loss, broken transducers or not Check the transducer electrical wiring harness. Check that both
transducers (slave micro controller) correctly working. signals increase or decrease at the same time.
16 Different signals from angle Transducers signal loss, broken transducers or not Check the transducer electrical wiring harness. Check that both
transducers (main micro controller) correctly working. signals increase or decrease at the same time.
transducers (slave micro controller) correctly working. signals increase or decrease at the same time.
18 Internal error ● Main temperature difference error Ask BPE Srl
19 Internal error ● Secondary temp. difference error Ask BPE Srl
20 Not used Not used Not used
(slave micro controller) gauge transducer, internal problems transducers check the internal resistors
22 Internal error ● Main time-out fault injection Ask BPE Srl
23 Internal error ● Secondary time-out fault injection Ask BPE Srl
(secondary micro) User mistake during calibration between J5.1 and J5.3/ J5.13/J5.19.
41 Digital inputs check (secondary micro) Wrong electrical connection on almost one digital input Check that all digital inputs are connected to service positives
and that they are not directly connected to battery positive
98 PWM outputs over current Wrong/broken electrical wiring harness Check PWM outputs electrical wiring harness
Power off/power on the board to reset the error
99 PWM outputs short circuit Wrong/broken electrical wiring harness Check PWM outputs electrical wiring harness
Category errors for secondary micro controller

0 None ● ●
1 Internal error ● Main micro communication error Ask BPE Srl
(main micro controller) gauge transducer transducers check the internal resistors
Internal error Internal error Fault injection Ask BPE Srl
11 Internal error ● Fault injection (secondary) Ask BPE Srl
13 Internal error ● Accelerometer difference Ask BPE Srl
15 Different signals from load transducers Transducers signal loss, broken transducers or not Check the transducer electrical wiring harness. Check that both
(slave micro controller) correctly working. signals increase or decrease at the same time. Replace the
Wrong transducers electrical wiring harness transducer/transducers that not work correctly
transducers (slave micro controller) correctly working. signals increase or decrease at the same time. Replace the
Wrong transducers electrical wiring harness transducer/transducers that not work correctly
19 Internal error ● Temperature difference Ask BPE Srl
(slave micro controller) gauge transducer, internal problems transducers check the internal resistors
(secondary micro) User mistake during calibration between J5.1 and J5.3/ J5.13/J5.19.
41 Digital inputs check failure (slave Wrong electrical connection on almost one digital input Check that all digital inputs are connected to service positives
micro controller) and that they are not directly connected to battery positive
LAB3_e Ver.4.11 - 08/07/2019
12 Troubleshooting
12.1 How to measure a transducer signal
1.1.1. Strain gauge transducers
1. Disconnect the signals wires from the terminal block/connector.
2. Keep connected the transducer power supply to terminal block/connector.
3. Use a 20 VDC scale set tester, connect the black rod on terminal block negative power supply pole and the red one to signal
wire
4. Do the same for both signal wires
5. Set the tester on mV scale and measure the voltage across the two wires (black rod connected to “S-“ wire, red rod connected
to “S+” wire)
1.1.2. Voltage pressure or amplified strain gauge transducers

1. Disconnect the signals wires from the terminal block/connector.
2. Keep connected the transducer power supply to terminal block/connector.
3. Use a 20 VDC scale set tester, connect the black rod on terminal block negative power supply pole and the red one to signal
wire.
1.1.3. Current pressure transducers

1. Disconnect the signals wires from the terminal block/connector
2. Keep connected the transducer power supply to terminal block/connector
3. Use a mA scale set tester, connect the black rod on terminal block where was connected the signal wire and the red rod to the
signal wire.
12.2 How to check the transducers wiring harness

With a digital tester, set on Ohm scale, check for short circuits or electrical leak between wires and body. For strain gauge
transducers, see their manual.
1.1.4. Signal from transducer too low or too high

Check that:
1. Is not present a short circuit, or a leak, between the signal wire and shield or negative power supply (signal too low).
2. Is not present a short circuit, or a leak, between the signal wire and positive power supply (signal too high).
3. For angle transducer check that the signal range is inside {0.50 ÷ 4.50} VDC and that the signal do not decrease for increasing
angle (transducer fit in the reverse way).
4. For current pressure transducer that the signal range is inside {4 ÷ 20} mA.
5. For voltage pressure transducer that the signal range is inside {0.5 ÷ 4.0} VDC.
1.1.5. Transducer cross check error

This error happens when the difference between the signals, from a couple of transducers in same channel of a Category 3 system,
is higher than allowed. Check that:
1. Transducers wiring harness has not any signal leak
2. For angle transducers both signals must decrease and increase at the same time
3. Transducers signals must be almost equal when the error happens and inside the allowed range (see chapter “Signal
from transducer too low or too high).
4. If, after the replacement of on transducer, the problem is still present, mount again the old transducer and try to change the
other one. If, again, the problem is not solved, try to change both transducers. If the error still present with new transducers,
check the electrical wiring harness.
1.1.6. Signal lower than allowed (under zero)

This error happens when the board get a signal from transducers lower than the minimum value set during calibration. These
controls are available to protect the machine and may be of different type. For a first installation, check with BPE Srl your own
under zero configuration management. For an already installed machine, check that:
1. The transducer is not moved from original position, deformed, broken and that it is fitted in the correct way as stated in its
specific manual
2. The frame is not deformed
3. The electrical wiring harness are in good conditions and without any ground leak
4. If nothing solves the problem, call the machine builder and ask the instructions on how to make again the system zero
LAB3_e Ver.4.11 - 08/07/2019
12.3 Calibration not correctly stored

1.1.7. Load calibration error
This error happens when the board loses power supply during calibration or the user does not follow the correct push buttons
sequence during calibration procedure. The only way to solve this problem is to do again the full calibration procedure.
1.1.8. Level calibration error

With the BPEterminal software, go to “Manual calibration” tab:
1. Press “Read” button (blue one)
2. Press “Move” button (red one)
3. Press “Send” button (magenta one)
12.4 Zero check failed

In case of systems without double transducers it is necessary to have activated a special position (zero or another point) check to
verify the signal in that position. Every time the system comes back to that position the control checks that the transducer value is
equal to stored value for that point. If this error happens, check that:
1. The transducer was not moved from original position
2. The micro switch is mounted and correctly working for that point
3. The wiring harness is not damaged or wrong
12.5 Error on safety output relay

This error happens when the electrical wiring harness on safety output J4 or J5 (function of board version) is wrong. Check that:
1. The electrical connection polarity must be as shown in the parameter “Electrical connections”
2. The output does not get back currents from solenoid valves
3. The relays changes status powering on and off the board
12.6 Error on digital inputs check

For enhanced safety, the electronic board uses, for some control functions, special positives (called “service positive”). This error
happens when positives from battery are used instead the special service positives. Check that:
1. All the electronic board inputs must be connected to service positive and not to the battery positive
13 Waste disposal
The disposal of the system described in this manual must be in accordance with current laws of the country where the disposal
will be done.
Manufacturer’s Recycling Information

WEEE Mark (European Directive 2012/19/UE)
Within the European Union
EU-wide legislation, as implemented in each Member State, requires that waste electrical and electronic products carrying the mark (left) must be disposed of separately from normal household waste. This includes electrical
accessories, such as signal cables or power cords. When you need to dispose of this BPE Electronics products, please follow the guidance of your local authority. The mark on electrical and electronic products only applies
to the current European Union Member States.
Outside the European Union
If you wish to dispose of used electrical and electronic products outside the European Union, please contact your local authority so as to comply with the correct disposal method.

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LAB3 Basket Levelling and load control (CAT3/PL d)

LAB3_e Ver.4.11 - 08/07/2019

LAB3_e Ver.4.11 - 08/07/2019

1 Safety notes for the user

1.2 Checks and maintenance

After assembly checks

Ordinary maintenance to be made at the beginning of every duty cycle

1.3 Void the warranty

LAB3_e Ver.4.11 - 08/07/2019

• CE Conformity: 2004/108/CE EMC

Case of vehicle frame electrically connected to battery negative

Case of vehicle frame electrically NOT connected to battery negative

basket load control

• RoHS Directive: 2011/65/UE

LAB3_e Ver.4.11 - 08/07/2019

Fig.3.3: Closed box photo Fig.3.4: Open box photo

Power supply from 9 to 33 VDC ●

Difference threshold for double channel systems

LAB3_e Ver.4.11 - 08/07/2019

4 How to identify your device

Fig. 1.2: LAB3 part number label

The transducers must be correctly fitted according to installation instructions.

The operating modes are coded as following:

LAB3_e Ver.4.11 - 08/07/2019

_L P 1 _N PL_33 NOT Mxy

CAN bus connection

Special operating mode

LAB3_e Ver.4.11 - 08/07/2019

BPEterminal is required to change LAB3 orientation

Horizontal positions Vertical positions

Fig. 7.1: Available mounting positions for the LAB3

Minimum suggested characteristics

! The electrical wiring harness must by comply to:

LAB3_e Ver.4.11 - 08/07/2019

8.3 Circuit board map

Fig. 8.3.1: Board map – external connector version

Fig. 8.3.2: 35 poles J5 external connector layout

Upper layer connectors Jumper

Connections to the shield

LAB3_e Ver.4.11 - 08/07/2019

8.4 Electrical connections for levelling

PWM and ON/OFF solenoid valves

Fig. 8.4.1: How to connect PWM and ON/OFF solenoid valves

Danfoss™ solenoid valves

Fig. 8.4.2: How to connect Danfoss™ solenoid valves

LAB3_e Ver.4.11 - 08/07/2019

JIB angle connections

LAB3_e Ver.4.11 - 08/07/2019

Hydraulic pre-selection, tilt signalling, basket rotation

If basket rotation function is disabled:

If basket rotation function is enabled (OPTIONAL):

If basket rotation function is enabled (OPTIONAL) and hydraulic pre-selection disabled:

Manual levelling and basket rotation

LAB3_e Ver.4.11 - 08/07/2019

8.5 Electrical connections for basket load control

! Use these outputs to automatically stop the machine when overloaded

Strain gauge connections

Alarm level selection

LAB3_e Ver.4.11 - 08/07/2019

The LAB3 load control function calibration is always «Full manual».

LAB3_e Ver.4.11 - 08/07/2019

9.1 Basket load control calibration

Fig. 9.1.1.a: «Alarm Level 1». Bigger load selection.