Neuenfelder Maschinenfabrik

Hamburg

Training

BASIC - NMF- Crane

Hydraulic
Electric

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AGENDA

NMF Crane Training

Part - 1 Part - 2
08:00 Welcome to NMF 08:00 Focus on Electrics
08:45 NMF Company Tour 09:30 Breakfast
09:30 Breakfast 10:00 Focus on Electrics
10:00 Introduction 12:30 Lunch
11:00 Question & Answer Game 13:30 Troubleshooting
12:30 Lunch 15:00 Sharing of Experiences
13:30 Focus on Hydraulics 16:00 End of Training
16:00 Day Ends

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Inhalt

Part - 1 Part - 2

1. Introduction 1. Key Concepts in Electrics

Neuenfelder Maschinenfabrik a) System overview

2. Crane Construction 2. Crane Electrics

a) Main components a) Electronic components
b) Practical examples with the switch box

3. Key Concepts in Hydraulics

a) Symbols 3. Troubleshooting
b) Open/closed hydraulic systems a) In case…
b) Operating Sauer-Danfoss pumps manually
4. Crane Hydraulics c) Operating Rexroth pumps manually
a) Crane system d) Operating the brake manually
b) Pumps e) In case…
c) Motors f) In case…
d) Hydraulic switches

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Part 1

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1. Introduction

Neuenfelder Maschinenfabrik

• Founded in 1960

• Deck cranes with

1 -700 t load capacity

• Worldwide service

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2. Crane Construction

The outreach is always defined from

center of crane to center of hook.

Outreach

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a) Main components

Slewing Ring

The slewing ring connects the foundation

of the crane to the crane housing.

Slewing ring

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Hoisting and Luffing Winches

The winches have modular gearboxes and
are fixed to the crane housing.
They are powered by one or more
hydraulic motors.

Winch with gearbox and brake unit

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Slewing gears
The slewing gears are bolted to the
foundation plate of the crane.

The pinion of the slewing gear hooks into the

fixed gear of the slewing gear, thereby
transmitting the slewing motion to the crane.

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Pump Units

A pump unit consists of an electric motor,

a pump drive unit and three hydraulic pumps.

The electric motor powers the pumps via the Electric motor
pump drive unit.

Pump drive unit

Pumps

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Hydraulic Oil Coolers

The hydraulic oil cooler cools the

hydraulic oil in the system.

It starts up when the oil temperature

reaches 40°C.

The heated air exits through a vent flap

in the outer wall, which opens when the
hydraulic pump is switched on. This
prevents heat from building up in the
interior of the crane.

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Gear Oil Cooler

The gear oil cooler cools the gear oil in the

drive unit.

It starts up when the oil temperature

reaches 20°C.

The oil filter needs to be changed in

accordance with the maintenance cycle.

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Slack rope switch

The slack rope switch detects reduced tension

in the hoisting rope.

If the rope begins to sag, the crane can only be

operated in „hoisting“ mode.

This prevents the rope from possibly jumping

out of the grooves.

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Limit Switches

Limit switches are mounted on each winch.

A variable number of accompanying cams

register the current location and position
of the jib (luffing winch) and the hook
(hoisting winch).

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Cabin

Load indicator

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3. Key Concepts in Hydraulics

a) Symbols

Two-way flow

2/2 control valve

One port blocked, one open
Normal position: open (B →A)

Three ports connected, one blocked 4/2 control valve

Normal position: open (B,A →P,T)

All ports connected (bypass)

4/3 control valve

Normal position: middle pos., closed (B,T,P,A)

Two ports connected, two blocked

4/3 control valve

Normal position: middle pos., bypass (P →T)
Two-way flow, one port blocked closed (A,B)

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b) Open/Closed Hydraulic Systems

Open Circuit

Features that typify an open circuit system:

• Intake lines – large diameter, short length
• Control valves – flow-dependent nominal widths
• Filter/cooler – flow-dependent cross-sections/frame sizes
• Container sizes – a multiple of the max. pump flow volume in liters
• Pump positioning – next to or under the tank
• Drive speeds – limited by intake height
• Load support via valves on return lines

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Closed Circuit

Features that typify a closed circuit system:

• Control valves – small nominal widths for pilot control
• Filter/cooler – small flow cross-sections/frame sizes
• Container size – small, adapted only to auxiliary and system volume pumps
• Drive speeds – high thresholds via supply
• Positioning/mounting position – as needed/can be placed freely
• Drive – fully reversible via the null position
• Load support – via the drive motor
• Recovery of brake energy

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4. Crane Hydraulics
a) Crane System

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Oil cooler

Flushing valve
Pump unit

Discharging valve

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Closed circuit system

with main pump on zero displacement

26

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Closed circuit system

with main pump activated

26

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Sauer-Danfoss
b) Pumps

Pump functioning:
As the drive shaft turns, the motion is passed to the cylinder via
Rexroth
the gears.
As this happens, the pistons perform a stroke movement in
accordance with the angle of the swash plate (slider plate).
The fluid is feed to the pump at its low-pressure side (inlet) and is
fed by the piston into the system at the high-pressure side (outlet).

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c) Motors

In contrast to pump functioning, the

pressure oil here is fed to the inlet. Axial piston motor

The pistons perform a stroke movement,

which is transformed into a rotary motion
by the piston joint on the drive flange.

The cylinder moves with the pistons, and

drive torque is generated at the drive
shaft.

The exiting fluid returns to the sytem.

Bent axis motor
This can take place using both the axial
piston and bent axis principles.

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d) Hydraulic Switches

Pressure switches Transmitter /

and feed pressure brake control
switches

The crane has a number of pressure switches (the The transmitter (pressure transducer) is a key component of
exact number depends on the number of load steps the brake control system.
and special functions). It measures the pressure in the working pressure line of the
hydraulic system and transforms it into a current.
They serve to monitor the working pressure for This current serves as an analogue input signal for the PLC
maximum permissible working and feed pressures. and is analyzing accordingly.

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Feed pressure switch and

pressure switch

Transmitter / brake control

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Examples of solenoid valves

3.8 Solenoid for hoisting gear brake

4.6 Solenoid for luffing gear brake
5.5 Solenoid for slewing gear brake
2.2 Solenoid for the bypass

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Part 2

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1. Key Concepts in Electrics

a) System overview
Fault Card

11

12

10 08

09

Overspeed
Sensor

06

05

07

01

02

03
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2. Crane Electrics
a) Electronic components – Programmable logic controller (NEW)
00
The programmable logic controller (XC100/XC200) is a central computer
that controls and monitors the entire crane.
All sensors (e.g. electronic pressure switches, slack rope switches, etc.)
converge at the digital and analog inputs, and are analysed by the
programmable logic controller (PLC).
The PLC transmits the appropriate reaction for the actuators
(e.g. valves, pilot lamps, etc.) via the digital outputs.

• RUN/STOP (1) and SF (general error) LEDs show the CPU’s operating state.
• RUN/STOP switch (2)
• Multimedia card MMC (3) serves as the mass storage device.
• A type 1/2 AA (3.6 V) lithium battery is used as a back-up to prevent loss of volatile data (4)
• Communication between the SPS and the programming device (laptop) takes place via the
CPU’s ETH232 programming interface (5).
• The CAN interface (6) is a fieldbus that can be used to connect additional sensors and
actuators (e.g. a bus coupler with digital inputs and outputs).
• The LEDs (7) show the signal status for the inputs and outputs.
• The 18-pole terminal block is located behind the front cover on the right side of the CPU (8).
This is used to connect the CPU power supply and the local inputs/outputs, as well as the
sensors and actuators.

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Programmable logic controller (Old)

00 .1

Reset button
• This is the old PLC-system (PS4). Battery case
Master switch
The first of this units is the Master
and all follow units are the slaves.

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Load measurement system DMSA 04 / Load measuring pin

01 Load measuring pin

1.The load measuring pin (A) is integrated into the hoisting winch.
The winch contains an apparatus that exerts force
(pressure) on the pin when a load is present.
When inserting the pin into the winch, it is important to
position it carefully (see type plate), because the pin can only
detect pressure on one side. Depending on the force
exerted upon it, the load measuring pin emits a current
signal via the electronic connection (B).

The load measurement system consists of:

(1) Power unit card: Supply voltage 230V/50-60Hz
(2) Loadmaster card: Control electronics with display (6),
entry buttons (7) and an RS-232 connection (8) for use with a laptop.
(3) Fuse card: Safety fuses to protect the electronics,
with a LED display (4) and key switch operation.
The plug-in rack with connection terminals: (9) supply /
(10)display / (11) PLC inputs / (12) PLC outputs /
(13)load measuring pin / (14) potentiometer and heeling sensor

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Load measurement system DMSA 03 (old)

01 .1
DMSA 03

This is an old kind to install the measuring cell.

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Display
02 The crane operator’s cabin has an optional digital display.
This display is connected to the DMSA04 (terminal block (10)) with an RS-485 cable.
The DMSA04 sends data directly to the display.

The following items may be displayed:

1) Shows the currently selected load step (e.g. loadstep 5)

1) Shows parameter mode or "out of service", depending on key switch setting

1) Shows overload, when the calibrated values are exceeded

1) Shows load measuring pin error, if the DMSA04 is not receiving data from the load measuring pin

2) Shows the maximum permissible load for the selected load step

3) Shows the current load on the hook

4) Shows the current jib outreach position (only with Automatic mode/potentiometer at jib base)

5) Shows the current degree of heeling

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Current regulator card SRK 04 (new)

03 The current regulator card (SRK) is controlled via the
potentiometers in the control lever located in the cabin.
The SRK’s outputs control the variable solenoid valves
(control module) in the corresponding pumps by means
of PWM (pulse-width modulation) signals.

1: Display: Shows the operating mode.

SINGLE: The pump is operated in asynchronous mode (individual operation).

SLAVE: The pump is operated in synchronous mode; it is synchronised to another (master) pump.

MASTER: The pump is operated in synchronous mode; it provides synchronisation data to
another (slave) pump.
2: Display: Shows the output current value (PWM output I1) for Pump 1.
3: Display: Shows the output current value (PWM output I2) for Pump 2.
4: Display: Shows the direction of control.

UP: The PWM outputs for “hoisting” are supplied with current.

DOWN: The PWM outputs for “lowering” are supplied with current.
5: Buttons for entering parameters.

The SRK should only be parameterised, after consulting with NMF, by
authorised trained personnel.
6: RS-232 interface for entering parameters.

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Current regulator card SRK 04 (new)

03 .1

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Control levers / Master controller

04

When the control lever is moved, a potentiometer (2) is activated.

This potentiometer reproduces the exact position of the control lever
by changing the resistance value. The current regulator card processes
and analyses this change in resistance.
A so-called side contact (1) also closes when the control lever is moved.
The control lever has two side contacts, one for each direction.
The hoisting gear control lever, for example, has a side contact for
hoisting and a side contact for lowering.
The side contacts are connected with the PLC, and tell the
PLC when the hoisting or lowering functions are activated.
The PLC links these binary input signals in the PLC program.

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Limit switch
05 The gear cam limit switch consists of a drive shaft (A), a gearbox (B), a selector
shaft with cam disc (D) and the switching contacts (C).
The drive shaft (A), which is connected to the crane winch, drives the gearbox (A).
The gearbox part and selector part are fixed to one another by means of a shaft.
The rotation direction of the last part of the gear is transmitted to the selector shaft (D).
The gearbox transforms the drive shaft’s usable range of revolutions (e.g. 51) into a selector shaft revolution (D).
The cam disc attached to this, with 20° to 180° stopping cams for activating the contacts,
can be adjusted continuously and independently of one another.

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Over speed sensor

06

The IH510 is built in as a front end assembly or into the limit switches
for the hoisting gear, jib gear or auxiliary hoisting gear. It has a fixed
mechanical connection with the winch. The rotary encoder emits short,
fast pulses during rotation. This can be up to 2500 pulses per revolution
(depending on the type). It generates three output signals; however,
only one of these output signals (channel A) is processed in the crane.

The rotation speed is derived from number of pulses counted per time period.
This rotation speed is used to monitor the speed within the individual load steps.
There is a fixed value (max. value) for each load step. If this maximum value
is exceeded, an overspeed alarm is issued. The brake engages, and optical
and acoustic alarms are set off.
The alarm can be switched off using the RESET button in the switch box.

When triggered, a “hoisting gear / jib overspeed” fault message

is sent to the fault indicator card

The fault message must be acknowledged using the RESET button

When triggered, the brake engages and crane movement is disabled

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Slack rope switch

07

Proximity switches protect the hoisting gear and auxiliary

hoisting gear ropes against slack rope conditions.

The moment a rope begins to slacken toward the crane

column so that the rope threatens to jump out of the grooves,
the inductive proximity switch is actuated by a pre-stressed rocker.
The resulting signal is an input signal for the PLC and is linked there.
It is linked in such a way that it is no longer possible
to lower the hoisting gear.

1: Rocker that switches the inductive proximity switch to "ON"

if slack rope occurs (4: the LED on the switch lights up)

2: Inductive proximity switch

3: Rope guide

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Emergency stop
08

The crane has emergency stop relays in case the

crane gets out of control. The crane usually has four
emergency stop switches.
They are located in the following places:

Cabin

Switch box

Access ladder

Crane access ladder on deck (via an extra relay)

The emergency stop switches need to be normally

open (NO, wire break) that snap into place and
remain closed when activated.
The emergency stop switches are wired in a
so-called safety chain, i.e. following one another
serially on one emergency stop relay.

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Pressure switch / Feed pressure switch

09

The switching point of the pressure switch is set to the maximum The switching point of the feed pressure switch is set to approx. 20 bar.
permissible value for the current load step. When overload The first feed pressure switch is located on the lowering side of the
conditions occur for a given load step, the pressure switch is hoisting gear working circuit. The second feed pressure switch is
deactivated and the PLC no longer receives an input signal located on the luffing down side of the jib working circuit, and the
from that pressure switch, which enables the PLC to detect third is located at the oil filter assembly.
hydraulic overload. In case of overload, the brake engages When a hose rupture causes the system pressure to fall below 20 bar,
immediately, or if engaged, cannot be released. the NC contact opens and the PLC shuts the crane down.
An optical alarm is set off. Optical and acoustic alarms are set off.
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Transmitter / Brake control system

10
The hoisting gear (3.20) and the jib (4.20) each have a transmitter that controls the brake.
The transmitter controls the brake control system. When a load is to be raised or lowered, the hydraulic system
first needs to generate pressure that corresponds to that load. When this pressure is reached, the brake is released.
This prevents the load from sagging.

The transmitter constantly measures the current pressure in the working

line of the hydraulic system. Each time one of the crane functions is stopped (hoisting/lowering the hoisting gear,
luffing the jib), the pressure value that immediately precedes the engagement of the brake is saved in the PLC.

In order for the brake to be released, the hydraulic system needs to achieve the most recently saved pressure.

There is, however, one exception here. When the operator engages the brake,
it will open when the pressure in the
hydraulic system reaches 250 bar. The reason for this is that the
brake engages immediately when e.g. the emergency stop switch is activated,
resulting in very high pressure in the hydraulic system. If the operator engages
the brake again under these conditions, extremely high pressure would be needed
to release the brake. In order to avoid this, the brake is released
when the pressure is greater than 250 bar.

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Oil temperature / Tank heating

11

The crane has two separate cooling circuits. These are the cooling circuit for the drive unit (gear unit) and the
cooling circuit for the hydraulic system. The drive unit, which powers the pumps, is on the drive shaft of the main unit.
The gear oil cooler is responsible for cooling the drive unit and the oil cooler is responsible for cooling the hydraulic system.
Three temperature values are important for the entire hydraulic system:

20 degrees Celsius in the hydraulic system.

At up to 20 degrees Celsius, the tank heating is switched on.
From 20 degrees Celsius in the hydraulic system, the gear oil cooler
or coolers are switched on.

40 degrees Celsius in the hydraulic system.

From 40 degrees Celsius in the hydraulic system, the oil coolers are switched on.

85 degrees Celsius in the hydraulic system.

From 85 degrees Celsius in the hydraulic system, optical and acoustic alarms are set off.
The hoisting, jib and slewing functions are disabled. Once the temperature drops
below 85 degrees Celsius in the hydraulic system, the hoisting, jib and slewing functions are re-enabled.

85 degrees Celsius in the drive unit.

From 85 degrees Celsius in the drive unit, optical and acoustic alarms are set off.

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Fault Card, interference pilot print card (SMK)

12
The Fault card can display 16 different Faults.
The Faults can be cross checked on a diagram
inside the switchboard.

DMSA

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3. Troubleshooting
a) In case… • Check emergency stop switches
• Check emergency stop relays
• Check motor protection system
• Check oil levels
• Crane does not start • Check the PLC
• Check feed pressure switches
• Check gear oil cooler (over 20°C)

• Operate pump manually

- Requires brake to be opened manually,
(see 3.d)
• No motion • Check control lever • Call NMF support
For some/all functions • Check current regulator card
• Check limit switches
• Check the PLC

• Operate pump manually

- Leave the brake closed, and monitor
max. pump pressures (see 3.b,c)
• Check load step / limit switches
• Slow motion • Check pump controls
For some/all functions - To do this, connect the el. plug from another
pump to the malfunctioning pump, and check
whether it works. (see 3.b,c).

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3. Troubleshooting
b) Manual operation (Sauer-Danfoss)

Should a pump generate pressure

when it is not activated electronically
or manually, its zero position of the
control module can be adjusted.

See adjustment screw – zero

position.

Elec. plug

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c) Manual operation (Rexroth)

Elec. plug

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d) Operating the brake manually

Solenoid valve

Activate the solenoid valve

manually using a screwdriver.

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e) In case …

• Not possible to switch • Check Outreach

into a loadstep. (center of crane to
• Call NMF support
center of hook)
• Check limit switch

Note:
The jib position is measured “step-wise” via the limit switches.
Load steps can only be within their permissible range (the jib must be
within the corresponding outreach range) by using the load step key
switch.

Example:
Crane with load steps 90t (4.0-20.0m) /
45t (4.0-26.0m) / 22t (4.0-30.0m)

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f) In case …

• Hook gets not • Jib doesn`t

High enough. go deeper.

• Check • Check
outreach / load- outreach / load-
step step, height of
• if necessary – hook
move jib a bit • if necessary –
higher. move hook a bit
down

• Call NMF support

Example: Hook adjustment

(hook/jib anti-collision)
Crane with load steps 90t (4.0-20.0m)
/ 45t (4.0-26.0m) / 22t (4.0-30.0m)

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4. Exchange of Experiences

Requests
Comments
Suggestions

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