WIKA PAT-Hirschmann

iFLEX5 / Expert Console

Lattice Boom Cranes

Installation and Calibration Manual

NOTICE
SkyAzúl makes no warranty of any kind with regard to this material, including, but not limited to, the
implied warranties of merchantability and/or its fitness for a particular purpose.

SkyAzúl will not be liable for errors contained in this manual or for incidental or consequential
damages in connection with the furnishing, performance, or use of this manual. This document
contains proprietary information, which is protected by copyright, and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another language without
the prior written consent of SkyAzúl.

SkyAzúl reserves proprietary rights to all drawings, photos and the data contained therein. The
drawings, photos and data are confidential and cannot be used or reproduced without the written
consent of SkyAzúl. The drawings and/or photos are subject to technical modification without prior
notice.

All information in this document is subject to change without notice.

SkyAzúl, Inc.
16 Walnut Street
Middletown, MD 21769
Fax 301-371-0029
[email protected]

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Service Manual, iFLEX5 / Expert Console

TABLE OF CONTENTS

1 GENERAL INFORMATION ................................................................................................. 1

2 WARNINGS......................................................................................................................... 1
3 SYSTEM DESCRIPTION .................................................................................................... 2
4 CENTRAL UNIT INSTALLATION ........................................................................................ 3
5 JUNCTION BOX INSTALLATION ....................................................................................... 4
6 CONSOLE INSTALLATION................................................................................................. 5
6.1 LIGHTBAR CONNECTION ................................................................................................................ 6
6.2 PRS40 (WINDSPEED OPTION) ........................................................................................................ 6

7 DRAWINGS AND SCHEMATICS........................................................................................ 7

7.1 ELECTRICAL WIRING - LINE RIDER SYSTEM (PAGE 1) ...................................................................... 7
7.2 ELECTRICAL WIRING - LINE RIDER SYSTEM (PAGE 2) ...................................................................... 8
7.3 ELECTRICAL WIRING - LINE RIDER SYSTEM (PAGE 3) ...................................................................... 9
7.4 ELECTRICAL WIRING – LINE RIDER SYSTEM (PAGE 4) ................................................................... 10
7.5 ELECTRICAL WIRING - LINE RIDER SYSTEM (PAGE 5) .................................................................... 11
7.6 ELECTRICAL WIRING - LINE RIDER SYSTEM (PAGE 6) .................................................................... 12

8 Quick calibration reference ................................................................................................ 13

8.1 MAIN LINERIDER .......................................................................................................................... 14
8.2 AUXILIARY LINERIDER .................................................................................................................. 14
8.3 FUNCTION X: CUTOFF TEST ......................................................................................................... 15

9 iFLASH .............................................................................................................................. 15
9.1 IFLASH PC INTRODUCTION ......................................................................................................... 15
9.2 SYSTEM PREREQUISITES ............................................................................................................. 15
9.3 PROGRAM MENU.......................................................................................................................... 16

10 CALIBRATION INFORMATION SHEET............................................................................ 21

RECOMMENDED TOOLS
Installation: Calibration:
• drill • laptop
• screw Drivers • null modem cable
• self-tapping screws • iFlash
• wrenches • level
• tape measure
• known test weights

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General Information 1

1 GENERAL INFORMATION
The iFlex5 system has been designed to provide the crane operator with the essential information required to
operate the machine within its design parameters.

Using different sensing devices, the iFlex5 system monitors various crane functions and provides the operator
with a continuous reading of the crane’s capacity. The readings continuously change as the crane moves
through the motions needed to make the lift.

The iFlex5 system provides the operator with information regarding the angle of the boom, working radius, rated
load and the total calculated weight being lifted by the crane.

If non permitted conditions are approached, the iFlex5 will warn the operator by sounding an audible alarm,
lighting a warning light and locking out those functions that may aggravate the crane’s condition.

Refer to operator’s manual 050-650-190-201 for console operating instructions.

2 WARNINGS
The Rated Capacity Limiter (RCL) has been designed to provide the crane operator with the essential
information required to operate the machine within its design parameters.

Using different sensing devices, the Rated Capacity Limiter monitors various crane functions and provides the
operator with a continuous reading of the crane’s capacity. The readings continuously change as the crane
moves through the motions needed to make the lift.

The RCL provides the operator with information regarding the angle of the boom, working radius, rated load and
the total calculated weight being lifted by the crane.

If non permitted conditions are approached, the Rated Capacity Limiter will warn the operator by sounding an
audible alarm, lighting a warning light and locking out those functions that may aggravate the crane’s condition.

The device is not, and shall not, be a substitute for good operator judgment, experience and use of accepted
safe crane operating procedures.

The responsibility for the safe crane operation shall remain with the crane operator who shall ensure that all
warnings and instructions supplied are fully understood and observed.

Prior to operating the crane, the operator must carefully and thoroughly read and understand the information in
this manual to ensure that he knows the operation and limitations of indicator and crane.

Proper functioning depends upon proper daily inspection and observance of the operating instructions set forth
in this manual. Refer to Section Pre-Operation Inspection and Calibration Verification of the operator’s manual.

The RCL can only work correctly, if all adjustments have been properly set. For correct adjustment,
the operator has to answer thoroughly and correctly all questions asked during the setup procedure
in accordance with the real rigging state of the crane. To prevent material damage and serious or
even fatal accidents, the correct adjustment of the RCL has to be ensured before starting the crane
operation.

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3 SYSTEM DESCRIPTION
The iFlex5 consists of a central microprocessor unit, operating console, angle sensor, line riders, and
anti-two block switches.
The system operates on the principle of reference/real comparison. The real value, resulting from the
load measurement is compared with the reference data, stored in the central processor memory and
evaluated in the microprocessor. When limits are reached, an overload warning signal is generated at
the operator’s console. At the same time, the aggravating crane movements, such as hoist up and boom
down, will be stopped.
The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity and
dimensions are stored in memory chips in the central processor unit. This data is the reference
information used to calculate the operating conditions.
The boom angle is measured by the angle sensor, mounted in the boom base. The cable reel cable
serves as an electrical conductor for the anti two-block switches and line rider signals.
The hoist load is measured by line riders mounted on top of the boom, close to the tip.
The interactive user guidance considerably simplifies the input of operating modes as well as the
setting of geometry limit values. Please refer to the iScout / Expert Console operator’s manual for the
operation of the system.

The System consists of the following main components:

1. Central Unit
2. Cable for crane power
3. Cable to cable reel
4. Cable Reel
5. Junction box
6. A2B switch with weight
7. Cable to main line rider
8. Main line rider (Tensiometer)
9. Dummy Plug
10. Dummy Plug
11. Cable to main boom angle sensor
12. Main boom angle sensor
13. Operator’s console with cable
14. Internal light bar
15. Cable for slewing sensor or proximity switch
16. Slewing sensor or proximity switch
17. Junction box
18. Dummy Plug

Fig. 1: Components of the iFlex5 system

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4 CENTRAL UNIT INSTALLATION

• Disconnect all cable assemblies from central

unit.
• Remove existing central unit from wall of
operator’s cab. (it may be necessary for an
additional person outside the cab to hold the
head of the screw tight while loosening the nuts
from inside the cab).

• Fasten iFlex5 central unit to wall, using the

same mounting hardware from previous
installation.
• Ensure the central unit is mounted with the
wiring harness connector located on the top of
the box and bypass key is easily accessible by
the crane operator.
• Firmly attach 70-pin wiring harness to central
unit connector.

LIGHTBAR

CENTRAL UNIT

JUNCTION BOX
CONSOLE

MOUNTING
ARM

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5 JUNCTION BOX INSTALLATION

• Locate best suited position for installation of junction box, ensuring cables from central unit
wiring harness and console will adequately reach all adjoining junction box connectors.

Figure 1: Located on outside wall of cab, behind operator.

Figure 2: Located on inside wall of cab, behind operator’s chair and above the Operators and Parts
Manual.

• Securely fasten junction box assembly to wall.

• Route cables previously removed from central unit and connect to junction box.

ANGLE SENSOR CONSOLE

SLEW SENSOR /
PROX. SWITCH

LINKBELT RELAY BOX

WIRING HARNESS
BOOM TIP
JUNCTION BOX

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6 CONSOLE INSTALLATION
• Remove existing console and disconnect cables.
• Route newly supplied console cable from junction box
assembly to the control panel and through the access
hole of console cover (mounting plate).
• Securely connect console power cable to back of console.
• Fasten the console cover (mounting plate) to the control
panel.
• Mount console by inserting the console mounting ball into
the mounting arm, and tighten securely.

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6.1 Lightbar Connection

• If the lightbar option is being used, an additional lightbar
adapter cable must be purchased. (031-300-060-520)
• Route lightbar cable through access hole of console cover
(mounting plate).
• Connect adapter cable between already existing lightbar
cable and connection located on back of iScout console.
• Securely fasten the console cover (mounting plate) to the
control panel. Plate may be installed with cable access
hole towards the top, limiting the length of cable visible on
outside of panel.
• Mount console by inserting the console mounting ball into
the mounting arm, and tighten securely.

6.2 PRS40 (windspeed option)

• If the Windspeed monitor is an option, disconnect the

PRS40 wiring (power / antenna) and remove the
mounting arm from its’ base.
• Remove the base from the plate, and reinstall on the
bottom side of the mounting plate.
• Connect previously removed cables.
• Attach the console mounting arm to its’ base.
• Rotate the mounting arm of the iScout console to the
left, allowing visibility of the crane gauges.

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7 DRAWINGS AND SCHEMATICS

For reference information, Drawing 1 is the central unit wiring and Drawing 2 is the console and boom
wiring. There are 2 different system drawings; slewing sensor 24V, and proximity sensor 12V, each
have drawings 1 thru 5.

7.1 Electrical Wiring - Line Rider System (page 1)

DRAWING 1. Electrical Wiring For iFlex5 Central Unit (+12/24V),console, and lightbar.

CENTRAL PROCESSING UNIT

GRAPHIC
DISPLAY
CONSOLE
CAN-BUS CABLING

LIGHT BAR
INTERNAL

PG13.5
12' 10 X 0.5 SS

PG13.5
12' 7 X 0.5 SS

PG11

12' 4 X 0.5 SS

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7.2 Electrical Wiring - Line Rider System (page 2)

DRAWING 2. Internal Wiring For Central Junction Box Assembly (SLEW OPTION).

7-3 87 LUFFER RELAY 7-4

30
87A
14-10
85 (LUFF SW FROM REEL)
86

7 - 1 / 14 - 5 (A2B/FORCE) + Ub + UB 5
1 1
3 - 1 (ANG) / 4 - 1 (SLEW) + Ub + UB 1 6
2 2
14 - 4 / 14 -11 (FORCE) + Ub
3 3
Lockout RLY COM 7
7 - 6 GND
4 4
7 - 2 GND GND 4
5 5
14 - 13 / 14 -14 GND 2
TO CABLE REEL (REEL) GND 6 6
14 - 3 2
7 7 10 X 0.5 SS
3-3/4-4 PG13.5
(ANG/SLEW) GND 8 8
9 9 TO CCU 12'
2 n/c
10 10
11 3 n/c
11
Area Definition 8
12 12
4-2 Slew 1 9
13 13
4-3 Slew 2 Yel/Grn (7)
14 14
TO POWER / RELAY 1
15 15
14 - 2 Force Main Boom 3
16 16
14 - 7 Force Jib 4 PG13.5 7 X 0.5 SS
17 17
3-2 Angle Main Boom 5
18 18
14 -12 Angle Jib 6 TO CCU 12'
19 19 1
14 - 6 A2B (7)
20 20 n/c
Yel/Grn
14-9
(LUFF SW TO REEL) 21 21
TO SLEW BOX
22 22
23 23
3 n/c
4 n/c
PG11 4 X 0.5 SS

POWER EXPERT 12'

CRANE POWER CONSOLE
7-5 O/L RELAY 7 - 6 GND
87
30
87A
10-1 GND
86 85
Overload / Error

JUNCTION BOX
(BEHIND CAB)

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7.3 Electrical Wiring - Line Rider System (page 3)

DRAWING 3. Internal Wiring For Central Junction Box Assembly (PROX. SWITCH OPTION).

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7.4 Electrical Wiring – Line Rider System (page 4)

DRAWING 4. Electrical Wiring For Luffing Boom – top section.

SLEW/GEAR BOX ASSY

(031-300-060-169)

D
C
B
A
4
3
2
1
PROXIMITY SWITCH OPT.

4
3
2
1
D
C
B
A
D
C
B
A
LUFFING BOOM A A 1 1 A A
ANGLE SENSOR B B 2 2 B B
(031-300-060-320) C C 3 3 C C
TO CABLE REEL

A A 1 1 A A
B B 2 2 B B
C C 3 3 C C
D D 4 4 D D
E E 5 5 E E TO POWER / RELAY
F F 6 6 F F
CABLE REEL G G 7 7 G G
(031-300-100-424) H H 8 8 H H
325 FT J J 9 9 J J
TO SLEW BOX
K K 10 10 K K OR PROX. SWITCH
L L 11 11 L L
M M 12 12 M M
N N 13 13 N N
P P 14 14 P P TO ANGLE SENSOR
A
B
C
D
E
F
G

WIRES ARE LABELED

AS SHOWN
A
B
C
D
E
F
G
1
2
3
4
5
6
7

F5 +24V POWER

E7 GROUND

F3b +24V LUFFER

804 LB #804

953 LB #953

E8 GROUND

NOT CONNECTED 7

CONNECT TO HSC WIRE

HARNESS LOCATED
INSIDE OF UPPER FRAME
NEAR BOOM FOOT
(RIGHT SIDE)

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7.5 Electrical Wiring - Line Rider System (page 5)

DRAWING 5. Electrical Wiring For Luffing Boom – top section.

LIMIT SWITCH
ALIGN

W12

LIMIT SWITCH LIMIT SWITCH

LIVEMAST 1 2 BACKSTOP

1 2
W12 W12
2 1

A A 1
LUFFING JIB
ANGLE SENSOR B B 2
CABLE ASSY
(064-206-060-004) C C 3 (031-300-060-242)

CABLE ASSY
(031-300-060-579)
CABLE REEL BOOM JUNCTION BOX
(031-300-100-446)
(031-300-100-501)

D D 4
C C 3
B B 2
A A 1

B B 2
A A 1
200 FT
BY-PASS CONNECTOR
(031-300-100-444)
A A 1
B B 2
A A 1
B B 2
(031-300-100-508) C C 3
CABLE ASSY D D 4
E E 5
1 A A F F 6
2 B B G G 7
3 C C
4 D D
1 A A 1
5 E E
2 B B 2
3 C C 3
4 D D 4
5 E E 5
6 F F 6
7 G G 7 TO CABLE REEL
8 H H 8
1 A A
9 J J 9
2 B B
10 K K 10
11 L L 11
12 M M 12
13 N N 13
14 P P 14
15
16
1 A A
2 B B

1 A A
2 B B
3 C C
4 D D
5 E E

CABLE ASSY
(031-300-060-176) BY-PASS CONNECTOR
(WHEN AUX LINERIDER
NOT IS USE)
BY-PASS CONNECTOR
1 A
2 B

(USED W/ NO MIDFALL ATB

1 A
2 B
3 C
4 D
5 E

(031-300-100-532)
(031-300-060-232)
CABLE ASSY
(CABLE INTEGRAL (031-300-060-176)
W/ ATB SWITCH)

1 A A 1 A A
MAIN HOIST
2 B B LINE RIDER 2 B B AUX HOIST
LINE RIDER
3 C C (048-500-060-035) 3 C C (048-500-060-035)
4 D D 4 D D

AUX HOIST ATB SWITCH

LOCATED IN LUFFING BOOM
(031-300-100-507)

W8

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7.6 Electrical Wiring - Line Rider System (page 6)

DRAWING 6. Electrical Wiring For Luffing Jib Base Section, Jib Top Section and 30’ Fixed Jib
Section.

BOOM JUNCTION BOX

(031-300-100-446)
LUFFING JIB
BASE SECTION BOOM
JUNCTION BOX
1 A A
A A 1 CABLE ASSY
LUFFING JIB (031-300-060-242) 2 B B
B B 2
ANGLE SENSOR 3 C C
(064-206-060-004) C C 3
4 D D

CABLE ASSY
A A 1 (031-300-100-508) 1 A A
B B 2 2 B B

CABLE REEL
(031-300-100-501)
LUFFING JIB 200 FT

TOP SECTION 30-FT. FIXED JIB

TOP SECTION
MAIN HOIST ATB SWITCH
LOCATED IN LUFF JIB TOP
(031-300-100-507) BY-PASS CONNECTOR
(USED WHEN FIXED JIB
NOT IN USE) AUX HOIST ATB SWITCH
W8 (031-300-100-444) LOCATED IN FIXED JIB
(031-300-100-507)
(CABLE INTEGRAL A 1
W/ ATB SWITCH) B 2
W8
C 3
2 B B D 4
A A 1
1 A A E 5 (CABLE INTEGRAL
B B 2 W/ ATB SWITCH)
F 6
G 7
BY-PASS CONNECTOR
2 B B (031-300-060-232)
1 A A A A 1
A A 2
B B 3

1
2
3
4
5

7
6
5
4
3
2
1
B B 2
BY-PASS CONNECTOR
A
B
C
D
E

G
F
E
D
C
B
A
C C 3 CABLE ASSY
(031-300-100-532) (031-300-100-421)
A
B
C
D
E

G
F
E
D
C
B
A
D D 4
E E 5
F F 6
JUNCTION BOX 1 2 1 2 3 4 S
LUFF JIB TOP SECT G G 7
(031-300-100-535) 1 2 3 4 5 6 S

JUNCTION BOX
FIXED JIB TOP SECT
(031-300-100-522)

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8 Quick calibration reference

Warning: Switch power off when installing or removing components to the central unit/console
Note: If the desired display can not be achieved the problem could be; wrong software, bad
transducer, angle set wrong or bad sensor. Do not continue with further calibration until
you have contacted Hirschmann ECS.

1. Connect PC to the Console, Power ON.

2. Go to Load then Flashloader upload. Browse to location of the files to be uploaded C/:PAT/IScout.
Upload CAG_20080219.brn, D4_v306.brn and linkbelt_can_n1.brn.
3. After uploading these files, go to Tools then Copy to Eeprom then Copy All Configurations to
Eeprom. Copy all files. Ensure correct software is used, correct software should come from
Hirschmann ECS or PAT approved source.
4. Power OFF disconnect the PC from the IScout console.
5. Connect PC/laptop to IFLEX central unit using null modem cable.
6. Power up PC and open IFLASH software go to Program then Terminal.
7. Power ON, There will be text in the Terminal window assuring you are connected to the system.
8. Go to Load then Flashloader upload. Browse to location of the files to be uploaded. Example:
C/:PAT/IFLEX. Upload C3a_v304.brn, LMLGv11.brn and linkbelt_can_n2.brn. After uploading
these files.
9. Go to Tools then Copy to Eeprom then Copy All Configurations to Eeprom. Copy all files. Ensure
correct software is used, correct software should come from Hirschmann ECS or PAT approved
source.
10. Power OFF, then Power ON.
11. Go to Load then Flashloader upload. Browse to location of the TLK and DATA files to be
uploaded Ensure correct software is used, correct software should come from Hirschmann ECS
or PAT approved source and should be for the Crane model and serial number. Upload these
filesYou will see software information in the Terminal window.
12. Acquire a test data sheet and fill in the crane model, S/N, date and the SN’s of PAT components
etc.,
13. Mechanically zero the angle and slew angle sensors
14. Zero lineriders and slew angle sensors through the console. Directions are in the iSCOUT
Operator’s Manual page 51 using the ACCESS CODE “67676”.
15. Verify Area of Definition is switching properly. Record on Calibration Information Sheet (pg. 9).
16. From the Terminal window PRESS "T" then "Y" to initialize the data. This will eliminate E:57 also.
17. PRESS "O" then "User code [699]", then DAY, MONTH, YEAR, CRANE NO. the last 5 digits of
the crane serial number.
18. Boom crane to the test load.
19. MAIN LINE RIDER CALIBRATION get main block weight with main linerider block only. PRESS
“W” then “25” then Enter a +/or – value to get proper block weight indication. Press “K” to exit
back to the main screen. Then ”W” again to get to Serial Eeprom menu.
20. Pick a known load with main linerider block only. PRESS “W” then “11” then enter a +/or – value
to get proper load + rigging + block indication. Note: Do not operate crane out of the load chart
for the model crane being calibrated.
21. Repeat steps 19 and 20 (if necessary).
22. After load has been calibrated verify load and radius indications at two spots high angle and low
angle. Record information on the Calibration information sheet. If any indications cannot be
calibrated to SAE recommendations contact Hirschmann ECS.

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23. AUXILIARY LINE RIDER CALIBRATION get main block weight with aux. linerider block only.
PRESS “W” then “26” then enter a +/or – value to get proper block weight indication. Press “K” to
exit back to the main screen. Then ”W” again to get to Serial Eeprom menu.
24. Pick a known load with aux. linerider block only. PRESS “W” then “12” then enter a +/or – value
to get proper load + rigging + block indication. Note: Do not operate crane out of the load chart
for the model crane being calibrated.
25. Repeat steps 23 and 24 (if necessary).
26. After load has been calibrated verify load and radius indications at two spots high angle and low
angle. Record information on the Calibration information sheet (pg. 9). If any indications cannot be
calibrated to SAE recommendations contact Hirschmann ECS.
27. Perform a cutoff test with a load on the Load Chart. Record information on the Calibration
information sheet. If the load display is good and the cutoff is 90% to 100%. Use “X” function to
determine cutoff %(pg. 3). If the cutoff is not correct contact Hirschmann ECS.
28. SAVE CALIBRATION information. Go to Load then Flashloader download. Select parameterfile
for download process Browse to location of the download_ser_EEPROM.adr file. Browse to
location where calibration information is stored name the file Crane Model_Serial
Number,Version_ serial_eeprom.brn and save.

8.1 Main Linerider

User Inputs IFLASH Terminal Display Remarks

OM= XXXX,LS= XX.XX

inside LS, MB-V= X
PRESS "W" ADDRESS NR. 25 Hook weight load Change this
value until load display is correct
Note: Start with a +/- 10.
PRESS "K" OM= XXXX,LS= XX.XX PRESS "K" to exit
inside LS, MB-V= X
PRESS "W" ADDRESS NR. 11 Hook weight+ rigging + known load
Change this value until load display
is correct
Note: Start with a +/- 100.

8.2 Auxiliary Linerider

User Inputs IFLASH Terminal Display Remarks

OM= XXXX,LS= XX.XX

inside LS, MB-V= X
PRESS "W" ADDRESS NR. 26 Hook weight load Change this
value until load display is correct
Note: Start with a +/- 10.
PRESS "K" OM= XXXX,LS= XX.XX PRESS "K" to exit
inside LS, MB-V= X
PRESS "W" ADDRESS NR. 12 Hook weight+ rigging + known load
Change this value until load display
is correct
Note: Start with a +/- 100.

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8.3 Function X: Cutoff test

User Input Hand Terminal Display

PRESS "X" Enter measured

radius or "ENTER"
Enter measured radius, Press RAT LOAD = XXXX
"ENTER“ ACT LOAD = XXXX
Enter actual load. Press RAT R/A = XXXX The cutoff percent will be shown
ENTER CUTOFF = XXXX on the hand terminal. Record
this on the test sheet.
PRESS "K" OM= XXXX,LS= XX.XX PRESS "K" to exit
inside LS, MB-V= X

9 iFLASH

9.1 iFLASH PC introduction

iFLASH PC supports the user in the terminal, uploading, and downloading BRN files.:

iFLASH PC is a program for Microsoft Windows operating systems as of Windows 98. The user and
control system primarily communicate via a terminal program by using a serial interface. Within the
terminal program, basic functions can be executed using the menu selection. Furthermore, iFLASH
PC supports the user with additional dialogs for easy operation of the system, especially when
exchanging data.

iFLASH PC is a software toolbox used for configuration, start-up and service of PAT devices with
RTOS operating systems such as iFLEX5, DS85, SLI, ECIS and ¼" VGA console.

9.2 System prerequisites

To install iFLASH PC on a PC, the following conditions should be satisfied:

• PC min. 486 / 100 MHz

• Operating systems:
o Windows 98 or higher
o Windows NT4 with Service Pack 6
o Windows 2000 or higher
• Memory:
o 15 MB free memory on hard disk
o min. 32 MB RAM
• Graphics:
o VGA graphic card
o Resolution 800 x 600 (1024 x 768 recommended).
• RS232 interface

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9.3 Program menu

The Menu program contains the actual work functions for exchanging data with iFLEX5.
These are:

9.3.1 Terminal
The terminal window is the communication center for the system. All outgoing messages from the
system are shown in this window, allowing for troubleshooting system inputs, output, and sensors.

9.3.2 Flash loader upload

This dialog is used to transfer data (BRN files) into the Flash storage of the system. There are 3
different file types system, data, and TLK that will be uploaded for operation. Upload one or all three
files as necessary to update your system. Note: Only upload files received from PAT America. System
software is the operating software, which calculates and displays the system function. Data software is
crane dimensional data, which include measurements of boom, sheaves offset, and hoist position.
TLK software is the load charts. Both data and TLK software are required for the system software to
operate.
To upload, proceed as follows:

1. Initiate the upload process by selecting Flash loader upload from the Program Menu

2. Choose the open folder icon, to browse for location of software on PC.

folder icon

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3. Select directory of where the software is stored in from the “look in” box.

4. Highlight the software file you choose to upload. Ensure that file extension reads .BRN and press
Open. The following is an explanation of the software file names:

• System software: DGCTvXXX.brn (example: DGCTv10H.brn, where DGCT is the

software designation, v is for version and 10H is the version number)
• Data software: DXXXXXXXX.brn,
the file name begins with a D and
then is followed by 6 to 9 digits, the
crane model number and 2 digits.
(example D22101c00.brn)
• TLK software: TXXXXXXXX.brn,
the file name begins with a T and
then is followed by 6 to 9 digits, the
crane model number and 2 digits.
The 2 digits are; 00 – main boom,
10 – fixed jib, and 20 – tele jib..
(example T22101c00.brn)

5. After the correct file is selected, press the “Start Upload” Icon.

Start upload
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18 Service Manual, iFLEX5 / Expert Console

6. Ensure the parameters correspond with the settings below before proceeding, and select “OK”.

7. At this point, the upload process will begin.

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8. After file successfully transferred, as indicated in the Status bar. Select the “EXIT” icon.

Exit

If necessary, this process will need to be completed for each of the three file system, data, and TLK.
If there is a transfer failure you will get an error message in the status bar, retry the procedure or
contact PAT service.

9.3.3 Flash loader download

This dialog is used to transfer data from the flash memory of the iFLEX5 onto the PC.
A download is executed as follows:

1. Initiate the upload process by selecting Flash loader upload from the Program Pull-down Menu.

2. “Generate BRN file” will already be selected.

3. Select “Keep BIN file”, it will now have a check make by it as shown.
4. Choose the open folder icon to “select parameterfile for download process” and browse for file
location. The following software files must be given to you from Hirschmann ECS in order to down
load the Data (download_ser_EEPROM.adr).

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5. Choose the open folder icon to “select filename for received data”. Name the file as follows:
Crane Model plus Serial number last 5 digits (XXXXX) and revision #(00,01,02…). (example
HC238_8979900_ser_EEPROM.brn).
6. Select “Start Download” to begin down load. The progress bar will increase in blue as the
precentage.

folder icon

folder icon

Start download

If there is a transfer failure you will get an error message in the status bar, retry the procedure or
contact PAT service.

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10 CALIBRATION INFORMATION SHEET

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

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SkyAzúl, Inc.
16 Walnut Street
Middletown, MD 21769
Phone 301-371-6126
Fax 301-371-0029
www.skyazul.com [email protected]

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126