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Airline Hydraulics Functional Specification NBOC MLV Hydraulics

System V1.0 05/07/2024

1) Summary This is the summary for the project. Throughout this document referenced inputs, outputs and parameters/variables are shaded to make them easier to identify.

2) Reference Documentation 08-20010-DOC-06 V6.doc

3) I/O Summary This section provides an overview of the inputs and outputs to the control system from the operator and field devices. This summarizes the inputs and outputs by type, more details will be provided in later sections.

3.1) Base Station These I/O are connected directly to the base station and the main control box.

3.1.1) Digital Inputs Electric Motor ON Boom Elevation Pin 1 Ext Boom Elevation Pin 1 Ret Boom Elevation Pin 2 Ext Boom Elevation Pin 2 Ret Boom Linear Pin 1 Ext Boom Linear Pin 1 Ret Boom Linear Pin 2 Ext Boom Linear Pin 2 Ret Boom Elevation Up Overtravel Boom Elevation Down Overtravel Boom Linear Extend Overtravel Boom Linear Retract Overtravel

3.1.2) Analog Inputs Boom Elevation Angle Boom Linear String Pot Hyd Oil Pressure Hyd Oil Temp Oil Level

3.1.3) CAN Bus Inputs from Powertech PTI-30SI These inputs are over J1939 can bus connection to the generator provided by vendor. These are the values to be read by the control system over that CAN connection.

Generator Engine Oil Pressure Generator Engine Temp Generator Power Output

3.1.4) Digital Outputs Boom Elevation Pin Cyl Solenoid Boom Linear Pin Cyl Solenoid Electric Motor ON Contactor Warm Up Circuit Solenoid

3.1.5) PWM Outputs Boom Elevation Up Coil (150Hz, 12 Ohm) Boom Elevation Down Coil (150Hz, 12 Ohm) Boom Linear Extend Coil (150Hz, 12 Ohm) Boom Linear Retract Coil (150Hz, 12 Ohm)

3.2 Wireless Transmitter

These I/O reside on the wireless controller module for use remotely by the operator.

3.2.1) Digital Inputs Boom Elevation Pin Cyl Retract Switch Boom Linear Pin Cyl Retract Switch Warm Up Circuit ON Switch Electric Motor ON Switch

3.2.2) Analog Inputs Boom Elevation Joystick (+ Values for Up, - Values for Down) Boom Extension Joystick (+ Values for Extend, - Values for Retract)

3.2.3) Visual Display Indicators Hyd Oil High Temp Indicator Hyd Oil Low Temp Indicator Hyd Oil Low Level Indicator Electric Motor ON Indicator Boom Elevation Pin 1 Ext Indicator Boom Elevation Pin 1 Ret Indicator Boom Elevation Pin 2 Ext Indicator Boom Elevation Pin 2 Ret Indicator Boom Linear Pin 1 Ext Indicator Boom Linear Pin 1 Ret Indicator

Boom Linear Pin 2 Ext Indicator Boom Linear Pin 2 Ret Indicator System Warning Indicator System Alarm Indicator

3.2.4 Visual Display Outputs

Hyd Oil Pressure Hyd Oil Temp Boom Elevation Angle Boom Linear Extension Calculated Boom Height Calculated Boom Extension Generator Engine Oil Pressure Generator Engine Coolant Temp Generator Power Output System Alarm Message

3.3) Safety Inputs Base Push/Pull E-Stop Transmitter Push/Pull E-Stop Base Reset

4) Major Control System Components

4.1) System Controller – BRH R917A13301 (Rexroth BODAS RC27-18/40)

4.2) Wireless Transmitter – Hetronic Nova XL 4.3

4.3) Wireless Reciever – Hetronic RX ES-CAN-HL

4A) Hydraulic System Components

Electric Motor Power: 20HP 230/460V 1,750 RPM Voltage: 230/460V Speed: 1,750 RPM Device: Weg 02018ET3E256TC-W22 Description: Prime Mover for Hydraulic System

Hydraulic Pump Power: Variable Displacement Axial Piston Pump – 4.33 cu.in./rev Control: Load Sense with Pressure Cut-off Speed: 1,750 RPM Device: Bosch Rexroth A AA10VSO 71 DFR /31R-VKC92N00 Description: System Pump for Hydraulic System

Motor/Pump Adapter Material: Steel Device: PD1-G250-A2-R01 Description: Adapter to connect A10VSO71 pump to 256TC Frame Electric Motor

Drive Coupling Magnaloy M300 Coupling Set with M300, INSERT, HYTREL (-65F to +300F) Description: Coupling to connect A10VSO71 pump to 256TC Frame Electric Motor

Pressure Filter Pressure: 6,090 psi Rated Max Flow: 63 GPM Micron Rating: 10 Micron Beta Ratio > 200 Bypass Rating: 6 bar Device: Bosch Rexroth DF ON 240TE10A1.0/12B6

Return Filter Pressure: 360 psi Rated Max Flow: 87 GPM Micron Rating: 10 Micron Beta Ratio > 200 Bypass Rating: 3 bar Device: Bosch Rexroth RF ON 330VE10B1.0/12

5) Base Input Details

Hyd Oil Low Level Input Type: Analog Signal Type: 20-4mA Device: Temposonics LLE G 0024U A110 1 A 70 S Cable: PHOENIX 1683374 (SAC-5P-10,0-PUR/M12FS) Description: The voltage drops below a set value when the oil level in the tank is too low for the system to function.

Boom Elevation Pin 1 Ext Input Type: Digital Input Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This signal is triggered when the pin cylinder reaches it’s extended position.

Boom Elevation Pin 1 Ret Input Type: Digital Input Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This signal is triggered when the pin cylinder reaches it’s retracted position.

Boom Elevation Pin 2 Ext Input Type: Digital Input Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This signal is triggered when the pin cylinder reaches it’s extended position.

Boom Elevation Pin 2 Ret Input Type: Digital Input Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This signal is triggered when the pin cylinder reaches it’s retracted position.

Boom Linear Pin 1 Ext Input Type: Digital Input Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This signal is triggered when the pin cylinder reaches it’s extended position.

Boom Linear Pin 1 Ret Input Type: Digital Input Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This signal is triggered when the pin cylinder reaches it’s retracted position.

Boom Linear Pin 2 Ext

Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This signal is triggered when the pin cylinder reaches it’s extended position.

Boom Linear Pin 2 Ret Input Type: Digital Input Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This signal is triggered when the pin cylinder reaches it’s retracted position.

Boom Elevation Up Overtravel Input Type: Digital Input Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This switch indicates an overtravel of the boom elevation cylinder. The NC function also indicates an issue with wire break or other sensor failure.

Boom Elevation Down Overtravel Input Type: Digital Input Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This switch indicates an overtravel of the boom elevation cylinder. The NC function also indicates an issue with wire break or other sensor failure.

Boom Linear Extend Overtravel Input Type: Digital Input Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This switch indicates an overtravel of the boom elevation cylinder. The NC function also indicates an issue with wire break or other sensor failure.

Boom Linear Retract Overtravel

Signal Type: 24VDC Dry Contact Device: Schmersal 131118496 (TR 330-11Y-1903) Cable: PHOENIX 1501728 (SAC-5P-100,0-PUR/SH-0,34 - Cable reel) Description: This switch indicates an overtravel of the boom elevation cylinder. The NC function also indicates an issue with wire break or other sensor failure.

Boom Elevation Angle Input Type: Analog Input Signal Type: 4-20mA Device: HYDAC 925009 (HAT 1236-C01-360L-P01-V106-M01-S2PD-000) Cable: PHOENIX 1683002 (SAC-4P-10,0-PUR/M12FS) Description: This device directly reads boom elevation angle as a raw value. Needs to be scaled and offset to provide system value in degrees.

Boom Linear String Pot Input Type: Analog Input Signal Type: 4-20mA Device: TURCK DW8000-135-116-7ASALWL-H1151 Cable: PHOENIX 1683002 (SAC-4P-10,0-PUR/M12FS) Description: This device directly reads linear boom extension as a raw value. Needs to be scaled and offset to provide system value in inches.

Hyd Oil Pressure Input Type: Analog Input Signal Type: 4-20mA Device: HYDAC 922821 (HDA 8466-A-2000-000) Cable: PHOENIX 1683002 (SAC-4P-10,0-PUR/M12FS) Description: This device directly reads oil pressure as a raw value. Needs to be scaled to provide system value in PSI.

Hyd Oil Temp Input Type: Analog Input Signal Type: 4-20mA Device: HYDAC 923567 (HTT 828K-A-012-011) Cable: PHOENIX 1415002 (SAC-3P-DTMS/10,0-PUR) Description: This device directly reads linear boom extension as a raw value. Needs to be scaled to provide system value in degrees.

6) Base Output Details

Boom Elevation Pin Cyl Solenoid Output Type: 24VDC Solenoid Contact Device: REXROTH SQMQE008-008W29KQQ Cable: PHOENIX 1410731 (SAC-2P-10,0-PUR/DTFS-1L) Description: This valve drives the retraction of both boom elevation pin cylinders. These cylinders are single acting, spring extend.

Boom Linear Pin Cyl Solenoid Output Type: 24VDC Solenoid Contact Device: REXROTH SQMQE008-008W29KQQ Cable: PHOENIX 1410731 (SAC-2P-10,0-PUR/DTFS-1L) Description: This valve drives the retraction of both boom linear pin cylinders. These cylinders are single acting, spring extend.

Electric Motor ON Contactor Output Type: 24VDC Solenoid Contact Device: Motor Starter Contactor Description: This output closes the main hydraulic motor contactor and brings the hydraulic system online.

Warm Up Circuit Solenoid Output Type: 24VDC Solenoid Contact Device: REXROTH SQMQQ019-019W29KA034A034 Cable: PHOENIX 1410731 (SAC-2P-10,0-PUR/DTFS-1L) Description: This valve diverts oil over an orifice to generate heat in the hydraulic oil.

Boom Elevation Up Coil Output Type: PWM Output, 150Hz, 12 Ohm Device: REXROTH SQMQQ038-015W29KQQ Cable: PHOENIX 1410731 (SAC-2P-10,0-PUR/DTFS-1L) Description: This PWM output drives the “UP” coil on the boom elevation proportional valve.

Boom Elevation Down Coil Output Type: PWM Output, 150Hz, 12 Ohm Device: REXROTH SQMQQ038-015W29KQQ Cable: PHOENIX 1410731 (SAC-2P-10,0-PUR/DTFS-1L) Description: This PWM output drives the “Down” coil on the boom elevation proportional valve.

Boom Linear Extend Coil Output Type: PWM Output, 150Hz, 12 Ohm Device: REXROTH SQMQQ038-015W29KQQ Cable: PHOENIX 1410731 (SAC-2P-10,0-PUR/DTFS-1L) Description: This PWM output drives the “Extend” coil on the boom linear proportional valve.

Boom Linear Retract Coil Output Type: PWM Output, 150Hz, 12 Ohm Device: REXROTH SQMQQ038-015W29KQQ Cable: PHOENIX 1410731 (SAC-2P-10,0-PUR/DTFS-1L) Description: This PWM output drives the “Retract” coil on the boom linear proportional valve.

7) J1939 CAN Communication to Powertech Generators PTI-30SI

Generator Engine Oil Pressure

PGN: 65263

Offset: 3.0 Length: 1.0 Scaling: 4 kPa/bit, 0 kPa offset

Generator Engine Coolant Temp

PGN: 65262

Offset: 0.0 Length: 1.0 Scaling: 1 DegC/bit, -40 DegC offset

Generator Percent Load at Current Speed

PGN: 61443

Offset: 2.0 Length: 1.0 Scaling: 1%/bit, 0% offset

8) Remote Transmitter Inputs

Boom Elevation Pin Cyl Retract Switch Input Type: Digital Device: Toggle Switch Description: This input device triggers the operation of the Boom Elevation Pin Cyl Solenoid device.

When this switch is activated the solenoid is activated, when deactivated the controlled solenoid is off.

Boom Linear Pin Cyl Retract Switch Input Type: Digital Device: Toggle Switch Description: This input device triggers the operation of the Boom Linear Pin Cyl Solenoid device. When this switch is activated the solenoid is activated, when deactivated the controlled solenoid is off.

Warm Up Circuit ON Switch Input Type: Digital Device: Toggle Switch Description: This input device triggers the operation of the Warm Up Circuit Solenoid device. When this switch is activated the solenoid is activated, when deactivated the controlled solenoid is off.

Electric Motor ON Switch Input Type: Digital Device: Toggle Switch Description: This input device triggers the operation of the Electric Motor ON Contactor device. When this switch is activated the contactor is closed, when deactivated the contactor is deactivated.

Boom Elevation Joystick (+ Travel) Input Type: Analog Linear Input Device: Positive Travel on Y-Axis Joystick Calibration: 6-point calibration Description: This joystick controls the Boom Elevation Up Coil PWM output. The 6-point calibration parameters allow the end user to construct a linear or complex operation profile or add deadband at the center travel of the joystick.

Boom Elevation Joystick (- Travel) Input Type: Analog Linear Input Device: Negative Travel on Y-Axis Joystick Calibration: 6-point calibration Description: This joystick controls the Boom Elevation Down Coil PWM output. The 6-point calibration parameters allow the end user to construct a linear or complex operation profile or add deadband at the center travel of the joystick.

Boom Extension Joystick (+ Travel) Input Type: Analog Linear Input Device: Negative Travel on Y-Axis Joystick Calibration: 6-point calibration Description: This joystick controls the Boom Linear Extend Coil PWM output. The 6-point calibration parameters allow the end user to construct a linear or complex operation profile or add deadband at the center travel of the joystick.

Boom Extension Joystick (- Travel) Input Type: Analog Linear Input Device: Negative Travel on Y-Axis Joystick Calibration: 6-point calibration Description: This joystick controls the Boom Linear Retract Coil PWM output. The 6-point calibration parameters allow the end user to construct a linear or complex operation profile or add deadband at the center travel of the joystick.

8) Remote Transmitter Display Outputs

Hyd Oil High Temp Indicator Output Type: Digital Device: Display Indicator Light Description: The controller will compare the scaled Hyd Oil Temp value to a warning threshold parameter. The indicator will be illuminated if the scaled value is above this setpoint.

Hyd Oil Low Temp Indicator Output Type: Digital Device: Display Indicator Light Description: The controller will compare the scaled Hyd Oil Temp value to a threshold parameter. The indicator will be illuminated if the scaled value is below this setpoint.

Hyd Oil Low Level Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if the Hyd Oil Low Level input is inactive.

Electric Motor ON Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if the Electric Motor ON input is active.

Boom Elevation Pin 1 Ext Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if the Boom Elevation Pin 1 Ext input is active.

Boom Elevation Pin 1 Ret Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if the Boom Elevation Pin 1 Ret input is active.

Boom Elevation Pin 2 Ext Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if the Boom Elevation Pin 2 Ext input is active.

Boom Elevation Pin 2 Ret Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if the Boom Elevation Pin 2 Ret input is active.

Boom Linear Pin 1 Ext Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if the Boom Linear Pin 1 Ext input is active.

Boom Linear Pin 1 Ret Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if the Boom Linear Pin 1 Ret input is active.

Boom Linear Pin 2 Ext Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if the Boom Linear Pin 2 Ext input is active.

Boom Linear Pin 2 Ret Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if the Boom Linear Pin 2 Ret input is active.

System Alarm Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if there is an active system alarm condition.

System Warning Indicator Output Type: Digital Device: Display Indicator Light Description: The indicator will be illuminated if there is an active system warning condition.

Hyd Oil Pressure Output Type: Numeric Device: Display Text String Format: #### Units: Pounds per Square Inch (PSI) Description: The scaled value of the Hyd Oil Pressure transducer will be displayed, rounded to the nearest full PSI.

Hyd Oil Temp Output Type: Numeric Device: Display Text String Format: ###.# Units: Degrees Celsius (DegC) Description: The scaled value of the Hyd Oil Temp transducer will be displayed, rounded to the nearest 1/10 DegC.

Boom Elevation Angle Output Type: Numeric Device: Display Text String Format: ##.# Units: Angular Degrees (Deg) Description: The scaled value of the Boom Elevation Angle transducer will be displayed, rounded to the nearest 1/10 Deg. This will operate in the positive 0-90 degree range.

Boom Linear Extension Output Type: Numeric Device: Display Text String Format: ###.# Units: Linear Feet (Ft) Description: The scaled value of the Boom Linear String Pot transducer will be displayed, rounded to the nearest 1/10 Ft.

Calculated Boom Height Output Type: Numeric Device: Display Text String Format: ###.# Units: Linear Feet (Ft) Description: The scaled value of the Boom Elevation Angle transducer and the Boom Linear String Pot transducer will be used to calculate the boom height from the pivot pin. A parameter for Ground to Pivot Pin height will be added to this value and displayed, rounded to the nearest 1/10 Ft.

Calculated Boom Extension Output Type: Numeric Device: Display Text String Format: +/- ###.# Units: Linear Feet (Ft) Description: The scaled value of the Boom Elevation Angle transducer and the Boom Linear String Pot transducer will be used to calculate the boom linear extension along the long axis of the vehicle from the pivot pin. A parameter for Boom Tip to Pivot Pin offset will be added to this value and displayed, rounded to the nearest 1/10 Ft. Based on boom angle and extension this dimension could possibly be in the positive or negative direction. Negative would indicate the boom is currently above the vehicle.

Generator Engine Oil Pressure Output Type: Numeric Device: Display Text String Format: ###.# Units: Pounds per Square Inch (PSI) Description: The converted kPa value of the Generator Engine Oil Pressure J1939 value will be displayed, rounded to the nearest 1/10 PSI.

Generator Engine Coolant Temp Output Type: Numeric Device: Display Text String Format: ###.# Units: Degrees Celsius (DegC) Description: The offset value of the Generator Engine Coolant Temp J1939 value will be displayed, rounded to the nearest 1/10 DegC.

Generator Power Output Output Type: Numeric Device: Display Text String Format: ###.# Units: Percent (%) Description: The value of the Generator Percent Load at Current Speed J1939 value will be displayed, rounded to the nearest 1/10 %.

System Alarm Message Output Type: Text Device: Display Text String Format: ASCII String Units: N/A Description: If there is an active system warning or alarm the description of that warning or alarm will be displayed in this line of text.

9) Safety Function

There are three operator inputs to the safety system. The Base Push/Pull E-Stop and the Base Reset reside on the control cabinet, while the Transmitter Push/Pull E-Stop resides on the NOVA XL 4.3 transmitter unit. The Hetronic RX ES-CAN-HL receiver has a pair of safety rated outputs that are controlled by the Transmitter Push/Pull E-Stop button. These outputs are on when the Transmitter Push/Pull E-Stop button is inactive.

The control cabinet houses a safety relay that receives the dual channel inputs from the Base Push/Pull E-Stop button and the dual channel outputs from the Hetronic RX ES-CAN-HL receiver. When either of these signals interrupted the controller opens the redundant power relay and drops the outputs to Inhibit Input 1 and Inhibit Input 2 on the BODAS RC27-18/40 controller. Without 24VDC on these inputs all power is removed from the outputs on the controller.

To recover from this E-Stop condition both the Base Push/Pull E-Stop and the Transmitter Push/Pull E-Stop buttons must be pulled out, indicating it safe to resume operation. The operator must push the Base Reset button to allow the safety relay to assess the e-stop circuit for faults and re-apply power to the BODAS controller inhibit inputs.

Upon initial power up the operator must also follow all procedures related to recovering from e-stop to put the system into a ready to operate state.

10) System Function The system functions detailed below assume the generator is running, the safety system is reset and the system is in a ready to operate state.

10.1) Electric Motor Operation The electric motor provides power to the HPU to drive all hydraulic functions of the system. To bring the electric motor online the operator would toggle the Electric Motor ON Switch on the wireless transmitter. The base controller will energize the Electric Motor ON Contactor to start the electric motor. An auxiliary set of contacts on the contactor will energize the Electric Motor ON base input, which illuminates the Electric Motor ON Indicator on the wireless transmitter display.

The Electric Motor ON input is a permissive that allows the hydraulic solenoids and PWM coils to operate.

10.2) Warm Up Circuit Operation If the hydraulic oil is not up to temperature the warm up circuit can be engaged to add head to the oil by bleeding it over an orifice. The operator would toggle the Warm Up Circuit ON Switch on the wireless transmitter. The base controller will energize the Warm Up Circuit Solenoid to allow oil flow through the orifice circuit. The rest of the system may be operated while the warm up circuit is in operation.

10.3) Boom Elevation Motion This section covers the necessary operations to allow the boom to elevate up or down.

10.3.1) Boom Elevation Pin Cylinder Retraction There are two independent lock pins that need to be fully retracted before the main hydraulic cylinder can operate at full speed. These valves are single acting, spring extend, controlled by a single solenoid valve. The operator would toggle the Boom Elevation Pin Cyl Retract Switch on the wireless transmitter to the RETRACT position, and the base controller would energize the Boom Elevation Pin Cyl Solenoid valve. When the pin cylinders have fully retracted, and the Boom Elevation Pin 1 Ret and Boom Elevation Pin 2 Ret inputs are active the operator will see illumination of Boom Elevation Pin 1 Ret Indicator and Boom Elevation Pin 2 Ret Indicator on the wireless transmitter display. If the pins are in an intermediate position no indicators will be illuminated on the display until they are in the fully retracted position.

10.3.2) Boom Elevation Up The upward boom elevation is controlled by the Boom Elevation Joystick when moved in the positive direction. This joystick has y-axis “fore/aft” motion only, with no lateral x-axis “side to side” movement. The joystick travel to PWM output is mapped using the 6-point calibration method using the following parameter combinations. The mapping is interpolated when operating in between control points and is written to a control value ELE_PWM_P_ACTUAL as a PWM percentage.

(ELE _JOY_P_0 / ELE _PWM_P_0) (ELE _JOY_P_1 / ELE _PWM_P_1) (ELE _JOY_P_2 / ELE _PWM_P_2) (ELE _JOY_P_3 / ELE _PWM_P_3) (ELE _JOY_P_4 / ELE _PWM_P_4) (ELE _JOY_P_5 / ELE _PWM_P_5)

This is an example of calibration curves that can be built using these parameters.

To elevate the boom up, the Electric Motor ON input must be active. If the Boom Elevation Pin 1 Ret and Boom Elevation Pin 2 Ret inputs are not both active then the ELE_PWM_P_ACTUAL value will be capped by the ELE_PWM_P_CAP parameter, limiting the speed that the boom can elevate until the pins have retracted. This function is necessary due to the single acting spring extend nature of the pins; the load may need to be taken off the boom before they will move. If the scaled value of the Boom Elevation Angle input exceeds the ELE_ANGLE_P_MAX parameter, the ELE_PWM_P_ACTUAL value will be capped to a value of 0 (zero.) The ELE_PWM_P_ACTUAL value will be capped to a value of 0 (zero) if the Boom Elevation Up Overtravel input is not active, this prevents any motion past the overtravel sensor.

To compensate for the different bore areas in the telescopic cylinder two additional parameter sets are available for use. ELE_PWM_STG2_CAP, ELE_ANGLE_STG2 and ELE_PWM_STG3_CAP, ELE_ANGLE_STG3 are setpoints for maximum PWM and boom elevation angle. When ELE_ANGLE_STG2 is exceeded the maximum value of ELE_PWM_P_ACTUAL is capped at ELE_PWM_STG2_CAP. When

ELE_ANGLE_STG3 is exceeded the maximum value of ELE_PWM_P_ACTUAL is capped at

ELE_PWM_STG3_CAP.

10.3.3) Boom Elevation Down The downward boom Elevation is controlled by the Boom Elevation Joystick when moved in the negative direction. This joystick has y-axis “fore/aft” motion only, with no lateral x-axis “side to side” movement. The joystick travel to PWM output is mapped using the 6-point calibration method using the following parameter combinations. The mapping is interpolated when operating in between control points and is written to a control value ELE_PWM_N_ACTUAL as a PWM percentage.

(ELE _JOY_N_0 / ELE _PWM_N_0) (ELE _JOY_N_1 / ELE _PWM_N_1) (ELE _JOY_N_2 / ELE _PWM_N_2) (ELE _JOY_N_3 / ELE _PWM_N_3) (ELE _JOY_N_4 / ELE _PWM_N_4) (ELE _JOY_N_5 / ELE _PWM_N_5)

This is an example of calibration curves that can be built using these parameters.

To elevate the boom down, the Electric Motor ON input must be active. If the Boom Elevation Pin 1 Ret and Boom Elevation Pin 2 Ret inputs are not both active then the ELE _PWM_N_ACTUAL value will be capped by the ELE _PWM_N_CAP parameter, limiting the speed that the boom can elevate until the pins have retracted. This function is necessary due to the single acting spring extend nature of the pins; the load may need to be taken off the boom before they will move. If the scaled value of the Boom Elevation Angle input falls below the ELE _ANGLE_N_MAX parameter, the ELE _PWM_N_ACTUAL value will be capped to a value of 0 (zero.) The ELE _PWM_N_ACTUAL value will be capped to a value of 0 (zero) if the Boom Elevation Down Overtravel input is not active, this prevents any motion past the overtravel sensor.

10.3.4) Boom Elevation Pin Cylinder Extension There are two independent lock pins that need to be fully extended to mechanically lock the load so that it won’t move when hydraulic control is removed. These valves are single acting, spring extend, controlled by a single solenoid valve. The operator would toggle the Boom Elevation Pin Cyl Retract Switch on the wireless transmitter to the EXTEND position, and the base controller would de-energize the Boom Elevation Pin Cyl Solenoid valve. When the pin cylinders have fully extended, and the Boom Elevation Pin 1 Ext and Boom Elevation Pin 2 Ext inputs are active the operator will see illumination of Boom Elevation Pin 1 Ext Indicator and Boom Elevation Pin 2 Ext Indicator on the wireless transmitter display. If the pins are in an intermediate position no indicators will be illuminated on the display until they are in the fully retracted position.

10.4) Boom Linear Motion This section covers the necessary operations to allow the boom to extend and retract.

10.4.1) Boom Linear Pin Cylinder Retraction There are two independent lock pins that need to be fully retracted before the main hydraulic cylinder can operate at full speed. These valves are single acting, spring extend, controlled by a single solenoid valve. The operator would toggle the Boom Linear Pin Cyl Retract Switch on the wireless transmitter to the RETRACT position, and the base controller would energize the Boom Linear Pin Cyl Solenoid valve. When the pin cylinders have fully retracted, and the Boom Linear Pin 1 Ret and Boom Linear Pin 2 Ret inputs are active the operator will see illumination of Boom Linear Pin 1 Ret Indicator and Boom Linear Pin 2 Ret Indicator on the wireless transmitter display. If the pins are in an intermediate position no indicators will be illuminated on the display until they are in the fully retracted position.

10.4.2) Boom Extend Out The outward boom extension is controlled by the Boom Linear Joystick when moved in the positive direction. This joystick has y-axis “fore/aft” motion only, with no lateral x-axis “side to side” movement. The joystick travel to PWM output is mapped using the 6-point calibration method using the following parameter combinations. The mapping is interpolated when operating in between control points and is written to a control value LIN_PWM_P_ACTUAL as a PWM percentage.

(LIN _JOY_P_0 / LIN _PWM_P_0) (LIN _JOY_P_1 / LIN _PWM_P_1) (LIN _JOY_P_2 / LIN _PWM_P_2) (LIN _JOY_P_3 / LIN _PWM_P_3) (LIN _JOY_P_4 / LIN _PWM_P_4) (LIN _JOY_P_5 / LIN _PWM_P_5)

This is an example of calibration curves that can be built using these parameters.

To elevate the boom up, the Electric Motor ON input must be active. If the Boom Linear Pin 1 Ret and Boom Linear Pin 2 Ret inputs are not both active then the LIN _PWM_P_ACTUAL value will be capped by the LIN _PWM_P_CAP parameter, limiting the speed that the boom can extend until the pins have retracted. This function is necessary due to the single acting spring extend nature of the pins; the load may need to be taken off the boom before they will move. If the scaled value of the Boom Linear String Pot input exceeds the LIN_DIST_P_MAX parameter, the LIN_PWM_P_ACTUAL value will be capped to a value of 0 (zero.) The LIN_PWM_P_ACTUAL value will be capped to a value of 0 (zero) if the Boom Linear Extend Overtravel input is not active, this prevents any motion past the overtravel sensor.

To compensate for the different bore areas in the telescopic cylinder two additional parameter sets are available for use. LIN _PWM_STG2_CAP, LIN _ DIST _STG2 and LIN _PWM_STG3_CAP, LIN _ DIST

_STG3 are setpoints for maximum PWM and boom elevation angle. When LIN _ DIST _STG2 is exceeded the maximum value of LIN _PWM_P_ACTUAL is capped at LIN _PWM_STG2_CAP. When LIN _ DIST _STG3 is exceeded the maximum value of LIN _PWM_P_ACTUAL is capped at LIN _PWM_STG3_CAP.

10.4.3) Boom Retract In The inward boom retraction is controlled by the Boom Linear Joystick when moved in the negative direction. This joystick has y-axis “fore/aft” motion only, with no lateral x-axis “side to side” movement. The joystick travel to PWM output is mapped using the 6-point calibration method using the following parameter combinations. The mapping is interpolated when operating in between control points and is written to a control value LIN_PWM_N_ACTUAL as a PWM percentage.

(LIN _JOY_N_0 / LIN _PWM_N_0) (LIN _JOY_N_1 / LIN _PWM_N_1) (LIN _JOY_N_2 / LIN _PWM_N_2) (LIN _JOY_N_3 / LIN _PWM_N_3) (LIN _JOY_N_4 / LIN _PWM_N_4) (LIN _JOY_N_5 / LIN _PWM_N_5)

This is an example of calibration curves that can be built using these parameters.

To retract the boom in, the Electric Motor ON input must be active. If the Boom Linear Pin 1 Ret and Boom Linear Pin 2 Ret inputs are not both active then the LIN _PWM_N_ACTUAL value will be capped by the LIN _PWM_N_CAP parameter, limiting the speed that the boom can retract until the pins have retracted. This function is necessary due to the single acting spring extend nature of the pins; the load may need to be taken off the boom before they will move. If the scaled value of the Boom Linear String Pot input falls below the LIN_DIST_N_MAX parameter, the LIN_PWM_N_ACTUAL value will be capped to a value of 0 (zero.) The LIN_PWM_N_ACTUAL value will be capped to a value of 0 (zero) if the Boom Linear Retract Overtravel input is not active, this prevents any motion past the overtravel sensor.

10.4.4) Boom Linear Pin Cylinder Extension There are two independent lock pins that need to be fully extended to mechanically lock the load so that it won’t move when hydraulic control is removed. These valves are single acting, spring extend, controlled by a single solenoid valve. The operator would toggle the Boom Linear Pin Cyl Retract Switch on the wireless transmitter to the EXTEND position, and the base controller would de-energize the Boom Linear Pin Cyl Solenoid valve. When the pin cylinders have fully extended, and the Boom Linear Pin 1 Ext and Boom Linear Pin 2 Ext inputs are active the operator will see illumination of Boom Linear Pin 1 Ext Indicator and Boom Linear Pin 2 Ext Indicator on the wireless transmitter display. If the pins are in an intermediate position no indicators will be illuminated on the display until they are in the fully retracted position.

11) Alarm Conditions

These are operational conditions that will cause the system to shut down all outputs and alert the operator. These are critical failures and the system shutdown will prevent component damage. The Base Reset input can be used to clear these alarms and resume operation.

11.1) Hydraulic Oil Low Level Alarm If the Hyd Oil Low Level input is inactive it indicates the oil level in the system has fallen critically low. All outputs will be deactivated until the oil level is above the critical level. The System Alarm Indicator will be illuminated and the System Alarm Message will read “HYD OIL LOW LEVEL ALARM” on the remote transmitter screen.

11.2) Hydraulic Oil High Temperature Alarm The controller will compare the scaled Hyd Oil Temp value to a High Oil Temp Alarm threshold parameter. All outputs will be deactivated until the oil temperature is under the critical level. The System Alarm Indicator will be illuminated and the System Alarm Message will read “HYD OIL HIGH TEMP ALARM” on the remote transmitter screen.

11.3) Boom Elevation Pin Cyl Solenoid Alarm When the controller actuates the Boom Elevation Pin Cyl Solenoid output there is current consumption feedback to the controller. If an open circuit is detected the System Alarm Indicator will be illuminated and the System Alarm Message will read “BOOM ELE PIN SOL ALARM” on the remote transmitter screen.

11.4) Boom Linear Pin Cyl Solenoid Alarm When the controller actuates the Boom Linear Pin Cyl Solenoid output there is current consumption feedback to the controller. If an open circuit is detected the System Alarm Indicator will be illuminated and the System Alarm Message will read “BOOM LIN PIN SOL ALARM” on the remote transmitter screen.

11.5) Electric Motor ON Contactor Alarm When the controller actuates the Electric Motor ON Contactor output there is current consumption feedback to the controller to detect an open circuit. A watchdog timer is also started when the output is activated and if this timer expires before the controller receives the Electric Motor ON input as alarm is also indicated. If an open circuit is detected or the watchdog timer elapses the System Alarm Indicator will be illuminated and the System Alarm Message will read “ELEC MOTOR ALARM” on the remote transmitter screen.

11.6) Warm Up Circuit Solenoid Alarm When the controller actuates the Warm Up Circuit Solenoid output there is current consumption feedback to the controller. If an open circuit is detected the System Alarm Indicator will be illuminated and the System Alarm Message will read “WARM UP SOL ALARM” on the remote transmitter screen.

11.7) Boom Elevation Up Coil Alarm When the controller actuates the Boom Elevation Up Coil PWM output there is current consumption feedback to the controller. If an open circuit is detected the System Alarm Indicator will be illuminated and the System Alarm Message will read “BOOM ELE UP PWM ALARM” on the remote transmitter screen.

11.8) Boom Elevation Down Coil Alarm When the controller actuates the Boom Elevation Down Coil PWM output there is current consumption feedback to the controller. If an open circuit is detected the System Alarm Indicator will be illuminated and the System Alarm Message will read “BOOM ELE DN PWM ALARM” on the remote transmitter screen.

11.9) Boom Linear Extend Coil Alarm When the controller actuates the Boom Linear Extend Coil PWM output there is current consumption feedback to the controller. If an open circuit is detected the System Alarm Indicator will be illuminated and the System Alarm Message will read “BOOM LIN EXT PWM ALARM” on the remote transmitter screen.

11.10) Boom Linear Retract Coil Alarm When the controller actuates the Boom Linear Retract Coil PWM output there is current consumption feedback to the controller. If an open circuit is detected the System Alarm Indicator will be illuminated and the System Alarm Message will read “BOOM LIN RET PWM ALARM” on the remote transmitter screen.

11.11) Boom Elevation Angle Sensor Alarm The controller expects to see a 4-20mA input value for the Boom Elevation Angle input sensor. If the input value falls outside of this range the System Alarm Indicator will be illuminated and the System Alarm Message will read “ELE ANG SENS ALARM” on the remote transmitter screen.

11.12) Boom Linear String Pot Sensor Alarm The controller expects to see a 4-20mA input value for the Boom Linear String Pot input sensor.

If the input value falls outside of this range the System Alarm Indicator will be illuminated and the System Alarm Message will read “LIN EXT SENS ALARM” on the remote transmitter screen.

11.13) Hyd Oil Pressure Sensor Alarm The controller expects to see a 4-20mA input value for the Hyd Oil Pressure input sensor. If the input value falls outside of this range the System Alarm Indicator will be illuminated and the System Alarm Message will read “HYD PSI SENS ALARM” on the remote transmitter screen.

11.14) Hyd Oil Temp Sensor Alarm The controller expects to see a 4-20mA input value for the Hyd Oil Temp input sensor. If the input value falls outside of this range the System Alarm Indicator will be illuminated and the System Alarm Message will read “HYD TEMP SENS ALARM” on the remote transmitter screen.

12) Warning Conditions

These are sub-optimal operational conditions that are detected while the system is in operation.

These are conditions that do not warrant a shutdown of the system, but the operator is notified while that condition exists.

12.1) Hydraulic Oil High Temperature Warning The controller will compare the scaled Hyd Oil Temp value to a High Oil Temp Warn threshold parameter. The System Warning Indicator will be illuminated, and the System Alarm Message will read “HYD OIL HIGH TEMP WARN” on the remote transmitter screen.

12.2) Hydraulic Oil Low Temperature Warning The controller will compare the scaled Hyd Oil Temp value to a Low Oil Temp Warn threshold parameter. The System Warning Indicator will be illuminated, and the System Alarm Message will read “HYD OIL LOW TEMP WARN” on the remote transmitter screen.