DD

Preface
System Description
1
Software Engineering for
2
SIMOCRANE Sway Control on the
SIMOTION D
Add-on Sway Control SIMATIC S7

3
Configuration
Commissioning AddOn
Software
4
Operating Instructions
General information
5
valid for:
Hardware:
- SIMOTION D435 as of Firmware V4.1.4.1
- SINAMICS as of Firmware V2.5.1
- CenSOR M as of Board Revision V-MHPC-251D
Image sensor: Omnivision 7120 Revision 1.0
Operating System: WIN 32 CE3.0
Software:
- SCOUT V4.1.4.1
- SIMATIC CFC V7.0.1.5
- SIMOCRANE as of Version V1.0
- JAVA as of Version V1.0.0.10
- Sway Control as of Version V2.0
- CenSOR M as of Version V1.5.0.10
- CeCOMM as of Version V4.4.1.12
05/2010 Edition
V1.02-E
Safety guidelines
This manual contains information which you should observe in order to ensure your own personal safety,
as well as to avoid material damage. Notices referring to your personal safety are highlighted in the
manual by a safety alert symbol; notices referring to property damage only have no safety alert symbol,
Depending on the hazard level, warnings are displayed in descending order as follows.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a warning triangle indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without safety alert symbol indicates that property damage may result if proper precautions are not
taken.
CAUTION
indicates that an unwanted result or state may occur if the relevant instruction is not observed.
In the event of a number of levels of danger prevailing simultaneously, the warning corresponding to the
highest level of danger is always used. A warning with a safety alert symbol indicating possible personal
injury may also include a warning relating to material damage.
Note
Routines or advice for the efficient use of the device and the software optimization.
Qualified personnel
The relevant device/system may only be set up and operated in conjunction with this documentation. A
device/system must only be commissioned and operated by qualified personnel. For the purpose of the
safety information in this documentation, a “qualified person” is someone who is authorized to energize,
ground, and tag device, systems, and circuits in accordance with established safety procedures. A further
requirement is the successful completion of a commissioning training course of the Siemens.
Proper use
Note the following:
WARNING
The device may only be used for the applications described in the catalog and the technical description,
and only in conjunction with equipment or components from other manufacturers which have been
approved or recommended by Siemens. Correct transport, storage, installation and assembly, as well as
careful operation and maintenance, are required to ensure that the product operates safely and without
faults.
Siemens AG Copyright © Siemens AG 2010

Automation and Drives Subject to change
P.O. Box 48 48
80437 Nuernberg
Germany
WARNING
The electronic sway control system is an aid during the transport of loads with almost complete
elimination of swaying movements. The crane driver is still responsible for monitoring movements of the
load on the crane and for switching off the system should any hazardous situations occur.
If the sway control system fails, the crane operator must ensure that the crane is stopped without any
injury to persons or damage to objects. The functionality of the sway control system must be switched off
and the crane operated manually without sway control until the fault has been corrected. If the fault
cannot be corrected with the aid of the product manual, please contact the Siemens AG.
Trademarks
All designations with the trademark symbol ® are registered trademarks of Siemens AG. Other
designations in this documentation may be trademarks whose use by third parties for their own purposes
can violate the rights of the owner.
Disclaimer of liability
We have checked that the contents of this document correspond to the hardware and software described.
However, since variance cannot be precluded entirely, we cannot guarantee full consistency. The
information in this publication is reviewed regularly and any necessary corrections are included in
subsequent editions.
Siemens AG Copyright © Siemens AG 2010

Automation and Drives Subject to change
P.O. Box 48 48
80437 Nuernberg
Germany
Preface
Content
This document is part of the SIMOCRANE Add-on Technology package. It describes the new "Sway
Control", "2D Trajectory" Add-on application solutions (basis: Sway Control) and "TLS Control" for
cranes based on the SIMOCRANE Basic Technology.
Prerequisite (area of validity)

This manual is valid for the application with SIMOTION SCOUT in conjunction with technology
package SIMOTION DCC as of version 4.1.4.1 and SINAMICS as of version 2.5.1, and SIMOCRANE
Basic Technology as of version V2.0.
Additional information
Hotline and Internet addresses

If you have any technical questions, please contact our Hotline (worldwide):
A&D Technical Support:
• Tel.: +49 (180) 50 50 222
• Fax: +49 (180) 50 50 223
• E–mail: adsupport@siemens.com
• Internet: http://www.siemens.de/automation/support-request
Siemens Internet address

The latest information about SIMOTION products, product support, and FAQs can be found on the
Internet at:
• http://www.siemens.de/simotion (German)
• Product Support: http://support.automation.siemens.com/WW/view/de/10805436
The latest information about SINAMICS products, product support, and FAQs can be found on the
Internet at:
• http://www.siemens.de/sinamics (German)
Additional support
We also offer introductory courses to help you familiarize yourself with SIMOCRANE Add-on
Technology.
Please contact the Siemens in D-39104 Magdeburg, Listemannstrasse 10, Tel. +49 (391) 56871-10.
SIMOCRANE Add-on Technology Sway Control

Operating Instructions, 05/2010 Edition, V1.02-E 5
Contents
1 System Description .................................................................................................................................. 13

1.1 Introduction ..................................................................................................................................13
1.2 System Overview .........................................................................................................................13
1.2.1 General information .....................................................................................................................13
1.2.2 Versions .......................................................................................................................................15
1.2.2.1 Version with camera for container cranes ...................................................................................15
1.2.2.2 Version without camera for ship unloader ...................................................................................17
1.3 Scope of Delivery .........................................................................................................................17
1.4 Product Structure .........................................................................................................................18
1.5 Functional scope ..........................................................................................................................19
2 Software Engineering for Sway Control on the SIMOTION D .................................................................. 21
2.1 Software Structure .......................................................................................................................21
2.1.1 Software structure ........................................................................................................................21
2.1.2 Structure of a function module .....................................................................................................25
2.1.3 Closed-loop control structure .......................................................................................................27
2.1.4 Global variables – Connection between the components ............................................................29
2.1.4.1 Overview ......................................................................................................................................29
2.1.4.2 Normalizations .............................................................................................................................30
2.1.4.3 Naming scheme for the global variables......................................................................................31
2.1.4.4 Add-on technology – basic technology ........................................................................................32
2.1.4.5 Add-on technology - TO objects ..................................................................................................33
2.1.4.6 Polarity of speeds and position values ........................................................................................34
2.2 Sway Control Function Blocks .....................................................................................................34
2.2.1 Add-on DCC library ......................................................................................................................34
2.2.1.1 General information .....................................................................................................................34
2.2.1.2 DCC_SCCommon ........................................................................................................................35
2.2.1.3 DCC_SCHoist ..............................................................................................................................37
2.2.1.4 DCC_SCTrolley ............................................................................................................................40
2.2.1.5 DCC_SCTLS ................................................................................................................................42
2.2.1.6 DCC_SCTargets ..........................................................................................................................45
2.2.1.7 DCC_SCObstacles ......................................................................................................................47
2.2.1.8 DCC_SCCamera ..........................................................................................................................50
2.2.1.9 DCC_SCDiag ...............................................................................................................................52
2.2.2 Add-on FB library .........................................................................................................................53
2.2.2.1 General information .....................................................................................................................53
2.2.2.2 FB_CommonPLCToAddOn..........................................................................................................54
2.2.2.3 FB_CommonAddOnToPLC..........................................................................................................56
2.2.2.4 FB_HoistPLCToAddOn ................................................................................................................57
2.2.2.5 FB_HoistAddOnToPLC ................................................................................................................58
2.2.2.6 FB_TrolleyPLCToAddOn .............................................................................................................59
2.2.2.7 FB_TrolleyAddOnToPLC .............................................................................................................61

Contents
2.2.2.8 FB_TLSPLCToAddOn ................................................................................................................. 62

2.2.2.9 FB_TLSAddOnToPLC ................................................................................................................. 64
2.2.2.10 FB_TargetsPLCToAddOn ........................................................................................................... 66
2.2.2.11 FB_TargetsAddOnToPLC ........................................................................................................... 67
2.2.2.12 FB_ObstaclesPLCToAddOn ....................................................................................................... 68
2.2.2.13 FB_ObstaclesAddOnToPLC ....................................................................................................... 70
2.2.2.14 FB_Send_Preparation ................................................................................................................. 71
2.2.2.15 FB_Receive_Analysis.................................................................................................................. 72
2.3 Sway Control Applications .......................................................................................................... 74
2.3.1 Simple Sway Control for ship unloader ....................................................................................... 74
2.3.1.1 General information..................................................................................................................... 74
2.3.1.2 Required blocks, signals and connections .................................................................................. 74
2.3.2 Simple Sway Control for container cranes .................................................................................. 75
2.3.3 SwayControl with 2D-Trajectory and Bay Scanning ................................................................... 76
2.3.3.2 Definitions ................................................................................................................................... 77
2.3.3.3 Bay scanning ............................................................................................................................... 79
2.3.3.4 Double spreader.......................................................................................................................... 79
2.3.4 TLS Control ................................................................................................................................. 81
2.3.5 SwayControl with TLS Control .................................................................................................... 83
2.4 Configuring .................................................................................................................................. 84
2.4.1 Requirements .............................................................................................................................. 84
2.4.2 Overview of the configuring steps to be performed .................................................................... 85
2.4.3 Perform setup .............................................................................................................................. 86
2.4.4 Import the SCOUT project of the AddOn technology.................................................................. 86
2.4.5 PROFIBUS configuration ............................................................................................................ 87
2.4.5.2 Configuring the connection ......................................................................................................... 88
2.4.5.3 Definition of the message frame ................................................................................................. 94
2.4.6 Copy I/O-Variablen...................................................................................................................... 94
2.4.7 Copying Add-on FB library .......................................................................................................... 96
2.4.8 Copying MCC charts ................................................................................................................... 97
2.4.9 Inserting DCC blocks .................................................................................................................. 98
2.4.10 Saving, compiling and checking consistency ............................................................................ 101
2.4.11 Connection between the basic technology and Add-on............................................................ 102
2.4.12 Connection between the TO objects and Add-on ..................................................................... 106
2.4.13 Required Add-on DCC blocks ................................................................................................... 108
2.4.14 Customization of the Add-on ..................................................................................................... 108
2.4.15 Execution system ...................................................................................................................... 113
2.4.16 Transferring the Project to the SIMOTION D ............................................................................ 114
2.4.17 Communication test .................................................................................................................. 115
2.4.18 Brief summary for various Add-on configurations ..................................................................... 121
3 SIMATIC S7 Configuration..................................................................................................................... 123
3.1 Software Structure .................................................................................................................... 123
3.1.1 Structure of the S7 blocks ......................................................................................................... 123
3.1.2 Brief description of the S7 blocks .............................................................................................. 124

8 Operating Instructions, 05/2010 Edition, V1.02-E
Contents
3.2 Mode-independent Logic ...........................................................................................................125

3.2.1 Formation of the “bTravel” travel signal .....................................................................................125
3.2.2 Formation of the signal for opening and closing the brake ........................................................125
3.2.3 Conversion of the Bay Scanner values ......................................................................................126
3.3 Accelerating and braking response ...........................................................................................128
3.4 Basic Operating Modes..............................................................................................................129
3.4.1 Speed control .............................................................................................................................130
3.4.2 Positioning..................................................................................................................................131
3.4.3 Hoist control ...............................................................................................................................135
3.4.4 Sway-c to load position (trolley) .................................................................................................137
3.4.5 Sway-neutralization to trolley position (trolley) ..........................................................................137
3.5 Activation of the AddOn Technologies in the Basic Technology ...............................................137
3.6 Sway Control Configurations .....................................................................................................139
3.6.1 Sway Control ..............................................................................................................................139
3.6.1.1 Required blocks .........................................................................................................................139
3.6.1.2 Control in the "SC Speed Control" AddOn mode.......................................................................139
3.6.1.3 Control in the "SC Automatic" AddOn mode ..............................................................................143
3.6.1.4 Control in the "SC Semi Automatic" AddOn mode ....................................................................153
3.6.1.5 Taking account of blocked regions ............................................................................................157
3.6.2 SwayControl with 2D-Trajectory and Bay Scanning ..................................................................157
3.6.2.1 Required blocks .........................................................................................................................157
3.6.2.3 Control in the "SC Automatic" AddOn mode ..............................................................................158
3.6.2.4 Control in the "SC Semi Automatic" AddOn mode ....................................................................161
3.6.2.5 Taking account of blocked regions ............................................................................................161
3.6.2.6 Double spreader in coupled mode .............................................................................................167
3.6.3 TLS Control ................................................................................................................................167
3.6.3.1 Required blocks .........................................................................................................................167
3.6.3.2 Control of the "TLS Control" AddOn ..........................................................................................168
3.6.4 Sway Control with TLS Control ..................................................................................................171
3.6.4.1 Required blocks .........................................................................................................................171
3.6.4.3 Control of the "TLS Control" AddOn ..........................................................................................171
3.7 PROFIBUS Interface ..................................................................................................................172
3.7.1 SIMATIC S7 → SIMOTION D for Add-on ..................................................................................172
3.7.1.1 Common.....................................................................................................................................172
3.7.1.2 Hoist ...........................................................................................................................................176
3.7.1.3 Trolley ........................................................................................................................................178
3.7.1.4 TLS.............................................................................................................................................180
3.7.1.5 Targets .......................................................................................................................................182
3.7.1.6 Obstacles ...................................................................................................................................184
3.7.2 SIMOTION D for → SIMATIC S7 Add-on ..................................................................................186
3.7.2.1 Common.....................................................................................................................................186
3.7.2.2 Hoist ...........................................................................................................................................190
3.7.2.3 Trolley ........................................................................................................................................191
3.7.2.4 TLS.............................................................................................................................................192
3.7.2.5 Targets .......................................................................................................................................194
3.7.2.6 Obstacles ...................................................................................................................................194
4 Commissioning AddOn Software ........................................................................................................... 197
4.1 Requirements .............................................................................................................................197
4.2 Ethernet communication ............................................................................................................197

Contents
4.2.1 General information................................................................................................................... 197

4.2.2 SIMOTION D for Add-on CenSOR M ....................................................................................... 198
4.2.2.1 SIMOTION D → CenSOR M ..................................................................................................... 199
4.2.2.2 CenSOR M → SIMOTION D ..................................................................................................... 199
4.2.3 Parameter assignment / addressing ......................................................................................... 201
4.3 Configuration of the Add-on Functions ..................................................................................... 201
4.4 CeCOMM commissioning software ........................................................................................... 203
4.4.1 Introduction ............................................................................................................................... 203
4.4.2 Installing software ..................................................................................................................... 203
4.4.4 Operation .................................................................................................................................. 204
4.4.5 Windows menu functions .......................................................................................................... 207
4.4.5.1 Windows menu function File ..................................................................................................... 207
4.4.5.2 Windows menu function View ................................................................................................... 207
4.4.5.3 Windows menu function Options .............................................................................................. 207
4.4.5.4 Windows menu function Calculations ....................................................................................... 209
4.4.5.5 Windows menu function Help ................................................................................................... 210
4.4.6 Monitors..................................................................................................................................... 210
4.4.6.1 Monitor display screens ............................................................................................................ 212
4.4.6.2 Monitor menus and special functions........................................................................................ 216
4.4.7 Image - checking the camera image ......................................................................................... 219
4.4.8 File manager ............................................................................................................................. 220
4.4.9 Diagram – user interface for recording curves .......................................................................... 221
4.4.9.1 General information................................................................................................................... 221
4.4.9.2 Procedure for recording diagrams ............................................................................................ 222
4.4.9.3 Elements and functionality of the diagram user interface ......................................................... 225
4.4.9.4 X/Y diagram .............................................................................................................................. 230
4.4.10 Web server ................................................................................................................................ 232
4.4.11 Telnet ........................................................................................................................................ 232
4.4.12 Calibrating the hoisting height ................................................................................................... 232
4.5 Camera Measuring System....................................................................................................... 233
4.5.1 Camera measuring system operating principle......................................................................... 233
4.5.2 Functions ................................................................................................................................... 233
4.5.2.1 Measurement of the offset ........................................................................................................ 233
4.5.2.2 Measuring the rotation angle .................................................................................................... 234
4.5.2.3 Measurement of the distance .................................................................................................... 234
4.5.3 CenSOR M camera interfaces .................................................................................................. 234
4.5.4 Installing/mounting, connection, operation................................................................................ 235
4.5.4.1 Installing/mounting .................................................................................................................... 235
4.5.4.2 Connecting ................................................................................................................................ 236
4.5.4.3 Operator Control (hardware) ..................................................................................................... 237
4.5.6 Camera measuring system configuration ................................................................................. 238
4.5.7 Commissioning requirements ................................................................................................... 239
4.5.7.1 General requirements, overview ............................................................................................... 239
4.5.7.2 Setting the access code ............................................................................................................ 239
4.5.7.3 Setting the language ................................................................................................................. 240
4.5.7.4 Checking the SIMOTION D – CenSOR M interface ................................................................. 240
4.5.7.5 Checking the camera image ..................................................................................................... 241
4.5.8 Camera measuring system commissioning .............................................................................. 241
4.5.8.1 Overview of the commissioning steps to be performed ............................................................ 241
4.5.8.2 Commissioning steps in the Commissioning menu .................................................................. 242
4.5.8.3 Checking and fine adjustment of the camera............................................................................ 246

Contents
4.6 Commissioning Requirements for AddOn Systems...................................................................250

4.6.1 General requirements, overview ................................................................................................250
4.6.2 Preparation of the PLC program ................................................................................................250
4.6.3 Preparation of the converters.....................................................................................................252
4.6.4 Setting the access code .............................................................................................................253
4.6.5 Setting the language ..................................................................................................................253
4.6.6 Checking of the communication between PLC and SIMOTION D ............................................253
4.7 Sway Control Commissioning ....................................................................................................255
4.7.1 Operation of Sway Control .........................................................................................................255
4.7.2 Commissioning of the Sway control system ..............................................................................260
4.7.2.1 Commissioning steps in the Commissioning menu ...................................................................260
4.7.2.2 Checking and fine adjustment of the sway control ....................................................................266
4.7.3 Commissioning of the positioning ..............................................................................................269
4.7.3.1 Changing the coordinate system ...............................................................................................269
4.7.3.2 Position controller setting ...........................................................................................................269
4.7.3.3 On-the-fly unloading ...................................................................................................................270
4.7.3.4 Other settings .............................................................................................................................271
4.7.4 Commissioning of the hoist control ............................................................................................271
4.8 2D-Trajectory Commissioning....................................................................................................273
4.9 TLS Control Commissioning ......................................................................................................274
4.10 Alarm, Error and System Messages ..........................................................................................277
4.10.1 Following error monitoring .........................................................................................................278
4.10.2 Velocity monitoring .....................................................................................................................278
4.10.3 Start sway control monitoring.....................................................................................................279
4.10.4 Collision protection .....................................................................................................................279
4.10.5 Application error messages .......................................................................................................280
4.10.5.1 General information ...................................................................................................................280
4.10.5.2 CenSOR M error messages.......................................................................................................280
4.10.5.3 AddOn technology error list .......................................................................................................283
4.10.5.4 CeCOMM diagnostic software ...................................................................................................294
4.10.6 Troubleshooting / FAQs .............................................................................................................294
5 General information ............................................................................................................................... 297
5.1 Maintenance and Service ..........................................................................................................297
5.1.1 Reflector .....................................................................................................................................297
5.1.2 Camera ......................................................................................................................................297
5.1.3 Update the camera software ......................................................................................................297
5.2 Technical Data ...........................................................................................................................298
5.2.1 Camera technical data ...............................................................................................................298
5.2.2 Dimension drawings ...................................................................................................................299
5.2.2.1 Camera ......................................................................................................................................299
5.2.2.2 Camera protective housing ........................................................................................................300
5.2.2.3 Reflector .....................................................................................................................................301
5.2.3 Circuit diagrams .........................................................................................................................304
5.2.4 Spare parts / accessories ..........................................................................................................306
5.3 Parameters.................................................................................................................................307
5.3.1 CenSOR M parameter list ..........................................................................................................307
5.3.1.1 Overview ....................................................................................................................................307
5.3.1.2 Camera/reflector parameters .....................................................................................................307
5.3.1.3 Distance parameters ..................................................................................................................311
5.3.1.4 General parameters 1 ................................................................................................................313
5.3.1.5 General parameters 2 ................................................................................................................314

Contents
5.3.2 AddOn technology parameter list.............................................................................................. 315

5.3.2.1 Overview of the parameter list .................................................................................................. 315
5.3.2.2 Trolley parameters .................................................................................................................... 316
5.3.2.3 Hoisting gear parameters .......................................................................................................... 322
5.3.2.4 Sway control parameters .......................................................................................................... 326
5.3.2.5 General parameters .................................................................................................................. 329
5.3.2.6 Camera/reflector parameters .................................................................................................... 332
5.3.2.7 Travel behavior parameters ...................................................................................................... 333
5.3.2.8 Controlled variable parameters ................................................................................................. 336
5.3.2.9 TLS parameters ........................................................................................................................ 338
5.3.2.10 Slewing gear parameters .......................................................................................................... 341
5.4 Appendix ................................................................................................................................... 344
5.4.1 CeCOMM commissioning software ........................................................................................... 344
5.4.1.1 Monitor menu tree ..................................................................................................................... 344
5.4.1.2 Analog signals of the path/speed time diagram ........................................................................ 347
5.4.2 Bibliography .............................................................................................................................. 348
5.4.3 Abbreviations ............................................................................................................................ 348
5.4.4 Terminology (German/English) ................................................................................................. 349

System Description 1
1.1 Introduction
The technology module T300 with MASTERDRIVES drive for crane-specific technology was used in
the previous crane application solution. Since mid-2007, the new sector solution SIMOCRANE Basic
Technology in the IDT MC Cranes business area is available. The new platform based on a
S7 + SIMOTION + SINAMICS hardware configuration contains the motion control of all main drives of
a crane. The modular construction makes it possible to customize the system to the associated crane.
The Add-on technologies described in these operating instructions can be used with or without the
SIMOCRANE Basic Technology:
Sway Control eliminates load oscillations on container cranes and ship unloaders for
the trolley through the specific influencing of the acceleration and
braking actions.
2D-Trajectory Automatic or semi-automatic motion of the load on a path curve taking
account of all blocked regions (e.g. container, crane design, etc.). The
blocked regions can be transferred in various ways or learnt internally
by "observing" the crane operator. Prerequisite is the "Sway Control"
Add-on.
TLS Control controls the so-called trim, list and skew positions of a spreader. The
current positions of all four TLS cylinders can be saved as zero
positions and approached again. An electronic skew control can also be
activated.
Bay Profile Scanning scans the container stacks during travel using a laser scanner and
sends the collected data to the PLC.
1.2 System Overview
1.2.1 General information

The Add-on functions are provided to augment new or extend existing crane controllers with or without
Siemens drive technology.
Requirements
• Use of a crane controller (PLC)
• SIMOTION D435 for calculations and the control of the drives (/Ref. 3/ and /Ref. 4/)

System Description
1.2 System Overview
• Sensors for the axes to be positioned when positioning is used, otherwise only for the hoisting
gear
The Add-ons are included as libraries in an existing SCOUT crane solution project. Depending on the
Add-on and the variant, additional hardware may be required (e.g. camera, reflector, hoisting gear,
laser, HMI, etc.) or various prerequisites must be satisfied.
Supplementary conditions
Each SIMOTION allows just one sway control system to be implemented (two independent trolleys not
possible). The Siemens Add-on technology uses parameter sets for the activation and control of the
drives. Speeds, accelerations and limitations are stored permanently during the commissioning and
can only be changed by switching the parameter set.
Note
In the basic technology /Ref. 2/, in case of failure of a drive, e.g. Hoist_1 or Trolley_1, a continuation
of the crane operation is possible only without 'Sway Control' Add-on technology.
System configuration
The following figure shows the communication paths between the individual components.
Fig. 1-1: Sway Control logical structure

Dashed lines represent a temporary connection for the commissioning and diagnostics. Solid
connection lines represent a permanent communication.

System Description
1.2 System Overview
The system receives the required process information via the PLC, the SIMOTION D (signals from the
base technology and TO objects) and the camera (optional) as well as the HMI (optional) or operator
controls. After processing, the calculated speed manipulated variables are forwarded to the drives via
the TO objects.
1.2.2 Versions
Each movement of a crane with cable guides results in the load swaying and therefore a longer
transport process. The task of the "Sway Control" and "TLS Control" Add-ons is the prevention of
these swaying motions. Together with "2D trajectory", they help relieve the crane operator and so
optimize the transfer times.
Basically two different versions are possible for these Add-ons:
• Version with camera
• Version without camera
1.2.2.1 Version with camera for container cranes

Swaying motions can be calculated and corrected using a mathematical oscillation mode. However, it
is not possible to compensate for swaying motions caused by external effects (e.g. wind or inclined
hoisting).
A camera measuring system used here uses an optical contact-free measurement to also determine
the hoisting height, swing angle and rotation angle parameters. The results are incorporated in the
calculation model. The calculations are performed on the SIMOTION D.
The resulting calculations are more accurate than for a system without camera and can also eliminate
sway caused by external forces.
If the measuring signal of the camera fails, only the states of the model are used.
This is the preferred version for container cranes (STS).
The camera measuring system consists of:
• Camera with lens and infra-red filter in protective housing with connection cable
• Reflector with infra-red LEDs
that must be installed at various locations on the crane.

System Description
1.2 System Overview
Fig. 1-2: Schematic representation of a container crane with sway control components when a camera
is used
Camera with lens system and infra-red filter

As standard, a camera with a 16 mm lens and an active reflector will be supplied for "seeing" systems.
If there are larger distances between the camera and the reflector, the 25 mm lens should be chosen.
The camera is installed in a protective housing.
When an active infra-red reflector is used, the camera is also equipped with an IR filter. This allows
measuring errors caused by shadows and artificial lighting to be largely prevented.
Reflector
The reflector is a construction specially designed to handle vibrations that typically occur on cranes.
The white areas of the active reflectors have an infra-red LED matrix backing. If necessary, the
reflector can be fitted with heating to thaw snow or ice.
Operation planning
The used lenses and reflector depend on the hoisting height of the crane. Up to the maximum
recommended distance (Table 1-1), a reflector will be detected very reliably. When very good light
conditions pertain, a reflector can be detected at 1.5 times the specified distance.
The relationship between the hoisting height, lens and reflector size, and the measuring accuracy of
the measuring system is contained in the following Table 1-1:

System Description
1.3 Scope of Delivery
Table 1-1 Measuring accuracy
Focal length of the lens 16 mm (standard) 25 mm

Resolution (relative to the distance) 0.12 mm/m 0.08 mm/m
Image length in the X direction 17° 11°
Image length in the Y direction 13° 8°
Measuring range in the X direction 292 mm/m 187 mm/m
(relative to the distance)
Measuring range in the Y direction 216 mm/m 138 mm/m
(relative to the distance)
Recommended maximum distance
Reflector 500 x 500 up to 23 m up to 37 m
Reflector 800 x 800 up to 35 m up to 55 m
The measuring system can also be configured using parameters.
Note
It is able that shadows are at the reflector because of strong insulation which leads to restrictions of
the TLS functions.
If the system is not able to eliminate the slew oscillation within 5 periods, the crane driver should
switch of the TLS function. Safety functionality could not be guaranteed.
Note
With strong wind influence at the unloading the TLS function can disturb at the dropping of container.
If the system is not able to eliminate the slew oscillation within 5 periods, the crane driver should
switch of the TLS function. Safety functionality could not be guaranteed.
1.2.2.2 Version without camera for ship unloader

In the version without camera, the sway control function is performed exclusively with the aid of an
arithmetic model. Swaying caused by external forces cannot be corrected.
This is the preferred version for ship unloaders (GSU).
1.3 Scope of Delivery

The package for
"Sway Control" Add-on,
"2D-Trajectory" Add-on,
"TLS Control" Add-on, contains:
Hardware (optional)
• Camera - CenSOR M (Siemens, connection box) with Ethernet connection
− Lens: 16 mm or 25 mm
− Camera casing: Aluminum or stainless steel

System Description
1.4 Product Structure
− Current firmware version and operating system

• Reflector
− 500x500 active or
− 800x800 active
Software
• CD with:
− Commissioning software - CeCOMM (Siemens)
− Java Runtime
− Add-on DCC library and online help
− Add-on FB library and standard application
− Setup for installation of the DCC library
− CenSOR M
− Language files, parameter files
− Documentation
• On the camera
− CenSOR M
− Siemens license
Software licenses
Depending on the scope of delivery, two RT licenses are used for the Add-on technologies.
• SIMOTION Crane Sway Control Basic Technology for Simotion C and D
This license releases the Sway Control and TLS Control basic functionality.
• SIMOTION Crane Sway Control Advanced Technology for Simotion C and D
This license releases the basic functionality plus 2D-Trajectory.
Because the memory card (CF card) is not part of the scope of delivery of the Add-on technologies, a
license key must be created and transferred to the CF card. This is done using the supplied
"Certificate of License".
This certificate contains the license number and the delivery note number with which the Internet link
www.siemens.com/automation/license can be used to create a license key and copied to the CF card
of the SIMOTION D. This enables the corresponding functionality of the Add-on technologies.
1.4 Product Structure

The software package contains an Add-on DCC library (e.g. DCC_SCHoist), an Add-on FB library
(e.g. FB_HoistPLCToAddOn) and a complete standard application.
The Add-on DCC library comprises a collection of blocks that are implemented as "Drive Control
Charts" (DCC) blocks. DCC is a representation which supports graphic configuring and
interconnecting. The detailed function scope of the Add-on DCC library is contained in Section 2.1.3.
The blocks are already wired to each other and preconfigured in the standard application.
The Add-on FB library comprises a collection of blocks for the implementation of data exchange
implemented as function blocks in "Structured Text" (ST). These blocks are called-up in the drive-
oriented sequential control.
The standard application contains a complete sequential control in which the maximum configuration
is implemented with the "Sway Control", "TLS Control" and "2D-Trajectory" Add-ons.

System Description
1.5 Functional scope

An overview of the AddOn modes and the dependencies on other systems and the associated
functions is shown in the following tables.
Table 1-2 Overview of the AddOn modes
Requires
Add-on Contained functionality AddOn mode
license
• Sway-controlled travel in manual • SC Speed Control Basic license

mode
Sway Control
• Sway-controlled travel in automatic • SC Automatic Advanced
and semi-automatic mode license
• SC Semi Automatic
• TLS Control
TLS Control Basic license
• Skew Control
• Sway-controlled travel in all AddOn

modes • SC Speed Control
2D- Advanced
Trajectory • Hoist control with internal and • SC Automatic license
external obstacle management
• SC Semi Automatic
• Internal target generator
The following dependencies of the Add-ons from other systems exist:

Table 1-3 Dependency matrix
Commis-
SIMATIC S7 Basic technology sioning Add-on techn.
tool
Sway Control X o X
2D-Trajectory X o X Sway Control
TLS Control X X
X – required, o - optional

System Description
Table 1-4 Overview of the blocks in the Add-on DCC library
No. Function Brief description
1 General In the "DCC_SCCommon" block, all axis data and camera measured
values are acquired concurrently. All data is grouped and the
manipulated values are calculated. It also controls the communication to
the CeCOMM commissioning tool. This block must be present.
2 Camera The "DCC_SCCamera" block makes data available for the
communication with the camera and accepts the camera measured
values.
3 Trolley control The "DCC_SCTrolley" block controls the trolley in all basic modes.
Creating the control signals influences the trolley behavior. The block
then issues an actuator speed, etc.
4 Hoisting gear The "DCC_SCHoist" block controls the hoisting gear in all basic modes.
control Creating the control signals influences the hoisting gear behavior. The
block then issues an actuator speed, etc.
5 Target The "DCC_SCTargets" block is responsible for learning the target
generator positions and their internal administration. Targets on the waterside are
always learnt independently by observation. A parking, a lashing and
several lane positions can also be learnt.
The correct function requires the use of the "DCC_SCTrolley" and
"DCC_SCHoist" DCC blocks.
6 Obstacles The "DCC_SCObstacles" block can be used to inform the system
externally about those blocked regions considered in the "SC Automatic"
AddOn mode.
Up to five blocked regions can be transferred simultaneously. When
deleted, all previously transferred blocked regions will be removed.
7 TLS Control The "DCC_SCTLS" block can be used to control the hydraulic cylinders
of a container bridge. This allows travel to the so-called trim, list and
skew positions of a spreader. sway control functionality is integrated for
the skew control.
8 Diagnostics The inputs and outputs for the CeCOMM diagnostic tool are controlled
with the "DCC_SCDiag" block.

Software Engineering for Sway Control on the
SIMOTION D 2
2.1 Software Structure
2.1.1 Software structure

The software for the SwayControl consists of units that implement the sending and receiving of data
between SIMATIC S7 and SIMOTION D (/Ref. 3/ and /Ref. 4/), and between SIMOTION D and the
camera. The software also has a manipulated value channel for influencing the acceleration and
speed change that was implemented with the DCC (Drive Control Chart) graphical programming
language.

Software Engineering for Sway Control on the SIMOTION D
PROFIBUS – Communication between SIMATIC S7 and SIMOTION D
SIMOTION D
Basic Technology
Global variables (ST)
MCC Chart „AddOn“

Receive Common
Receive Hoist
Receive Trolley
Receive TLS
Receive Targets
Receive Obstacles
Send Common
Send Hoist
Send Trolley
Send TLS MCC Chart „Camera“
Send Targets Receive Camera
Send Obstacles Send Camera
DCC Plan „SwayControl“

Common Camera
Hoist
Trolley
TLS
Targets
Obstacles
Diag
TO TO
Trolley_1 Hoist_1
PROFIBUS – Communication via DP-Integrated to SINAMICS
SINAMICS
DO DO
Trolley_1 Hoist_1
Fig. 2-1: Software structure

The "AddOn" MCC chart consists of the following receive blocks (see previous figure):
• FB_CommonPLCToAddOn
• FB_HoistPLCToAddOn
• FB_TrolleyPLCToAddOn
• FB_TLSPLCToAddOn
• FB_TargetsPLCToAddOn
• FB_ObstaclePLCToAddOn and the send blocks:
• FB_CommonAddOnToPLC
• FB_HoistAddOnToPLC
• FB_TrolleyAddOnToPLC
• FB_TLSAddOnToPLC
• FB_TargetsAddOnToPLC
• FB_ObstacleAddOnToPLC
The "Camera" MCC chart contains the following FB blocks (see previous figure):
• FB_Receive_Analysis
• FB_Send_Preperation
The "SwayControl" DCC chart consists of the following DCC blocks (see previous figure):
• DCC_SCCommon
• DCC_SCHoist
• DCC_SCTrolley
• DCC_SCTLS
• DCC_SCTargets
• DCC_SCObstacle
• DCC_SCCamera
• DCC_SCDiag
The following graphic shows how the "Sway Control" AddOn is generally activated and the "Sway
Control" manipulated values are used.

Fig. 2-2: SwayControl for Hoist_1 structure

2.1.2 Structure of a function module

The structure of a function module consists of a unit with an MCC program. In cyclical operation, the
receive blocks are performed first and then the send blocks. A separate unit with an MCC program is
stored for the optional camera.
In the "AddOn" unit, the "AddOnMCC" program is executed according to the following sequence:
Processing in AddOnMCC
Fig. 2-3: Unit "AddOn", program sequence "AddOnMCC"

Fig. 2-4: Receive and Send module

The function blocks in the "Receive PLC" module read the PROFIBUS DP input area for the
associated block and write it to the global variables.
The function blocks in the "Send PLC" module read the associated blocks from the global variables
and write them to the PROFIBUS DP output area.
In the "Camera" unit, the "CameraMCC" program is executed:
Processing in Camera MCC
Fig. 2-5: Unit "Camera", program sequence "CameraMCC"

Fig. 2-6: Camera module

The "Receive" block prepares the data and analyses this once it has been received. The data is
processed in the "DCC_SCCommon" DCC block. The "Send" block prepares the data before it is sent.
2.1.3 Closed-loop control structure

The control structure is constructed so that the function blocks implement the communication between
SIMATIC S7 ↔ SIMOTION and camera ↔ SIMOTION. The data received from the "Receive" blocks,
is prepared and forwarded to the appropriate DCC blocks. The data subsequently forwarded to the
"Send" blocks is evaluated and calculated there.

Fig. 2-7: AddOn control structure in the new SIMOTION D / SINAMICS platform

2.1.4 Global variables – Connection between the components
2.1.4.1 Overview
The function blocks are connected to the S7 using global variables in the I/O area.
The connection of the function blocks to the DCC blocks and from the basic technology to the DCC
blocks is made using unit-global variables.
To achieve a high control quality and eliminate runtime loss, the manipulated values for the trolley and
the hoisting gear are applied directly to the TO objects for the individual axes. The current position
values are also fetched directly from the drive (see Sections 2.2.1.3 and 2.2.1.4).
The signals from the basic technology, and from and to the technology objects are described in
Sections 2.1.4.4 and 2.1.4.5.
Note
Although some signals that come from the basic technology or form the interface to the technology
objects have data type LREAL, they are processed as DINT data format in the "SwayControl"
AddOn. Consequently, these signals have only the value range of the DINT data format, i.e. -
2**31 … +2**31-1.
Note
If the "AddOn" and "Camera" (optional) MCC unit has been imported, the unit-global variables are
already created and the connections pulled automatically once an AddOn DCC block is added to the
"SwayControl" DCC chart.
Using an example, the following figure shows the signal flow from the hoist block of the S7 to the
"DCC_SCHoist" (Release) DCC block and back (Ready = answer from Release).

Fig. 2-8: Example of the signal flow between the S7 and the DCC block
The detailed descriptions of the connections for function and DCC blocks are contained in Sections
2.2.1 and 2.2.2. This description makes it possible to track the connections from MCC programs to
DCC blocks.
2.1.4.2 Normalizations
To ensure a smooth communication between the basic technology, Add-on technology and the TO
objects, the reference data must be configured identically. They must be normalized to the maximum
values.
The following parameters are affected in the SIMOTION D:
Add-on technology
• Set velocity (trolley, hoisting gear, TLS cylinder) Æ normalization to the largest-possible setpoint
(e.g. 16384)
• Override of the basic technology for field weakening and heavy load (hoisting gear) Æ
normalization to 100%

TO objects
• Actuator speed (trolley, hoisting gear, TLS cylinder)
Notice
All reference data must be normalized to their associated maximum value.
These associated maximum values must also be notified to the sway control system and with
the help of the CeCOMM commissioning tool stored in the Siemens parameter files.
Important are:
P0 Maximum trolley actuator speed in mm/s
P40 Maximum hoisting gear actuator speed in mm/s
P183 Maximum TLS cylinder speed
The definition for the relationship between the percentage value and hexadecimal value is shown in
the following table and in the following diagram.
If only positive values are used in the process data, then the value range is doubled; this means that
the range starts at 0 and can be increased up to 65,535 (UINT, 0 to FFFF).
Table 2-1: Relationship between hexadecimal value and percentage value
1 word: Connector
Percentage value Hexadecimal value
0 16#0000
100 16#4000
199,994 16#7FFF
-200 16#8000
-100 16#C000
0,006 16#1
2.1.4.3 Naming scheme for the global variables

The global variables serve as connection elements between the components and have the following
structure:

Section Description Example

1 Specifies which DCC library block is involved. Trolley, Hoist, Common,
TLS, Targets, Obstacle,
Camera
2 Source of the variables. BT, SC, PLC, CAM
3 Meaning of the variables. This is identical with the e.g. Brake_Closed, Active
name on the DCC blocks and on the function blocks.
Example:
2.1.4.4 Add-on technology – basic technology
Basic technology Æ Add-on technology

The following signals are forwarded via unit-global variables of the "AddOn" MCC unit from the basic
technology /Ref. 2/ to the AddOn technology:
Table 2-2: Basic technology variables Æ Add-on technology
Variables Format Meaning Unit Range of values

External target
position from the
trolley_BT_S_Set_TR_Extern LREAL ± mm -2**31..2**31-1
basic technology
for the trolley
Normalized to the
maximum actuator
Set velocity for the speed (P0) of the
trolley_BT_V_Set_TR LREAL trolley from the mm/s trolley from the
basic technology Siemens parameter
set
-2**31..2**31-1
External target
position from the
hoist_BT_S_Set_HO_Extern LREAL basic technology ± mm -2**31..2**31-1
for the hoisting
gear
Normalized to the
maximum actuator
Set velocity for the speed (P40) of the
hoisting gear from hoisting gear from
hoist_BT_V_Set_HO LREAL mm/s
the basic the Siemens
technology parameter set
-2**31..2**31-1


0..100% of the
maximum actuator
Limitation from the speed (P40) of the
hoist_BT_Field_Weak REAL basic technology % hoisting gear from
for field weakening the Siemens
parameter set
-2**31..2**31-1
2.1.4.5 Add-on technology - TO objects
TO object Æ Add-on technology

Table 2-3: TO object variables Æ Add-on technology

TO_Trolley_1. Current position of
LREAL mm -2**31..2**31-1
positioningstate.actualposition the trolley
TO_Hoist_1. Current position of
LREAL mm -2**31..2**31-1
positioningstate.actualposition the hoisting gear
TO_Trolley_1. Current velocity of
LREAL mm/s -2**31..2**31-1
motionstatedata.actualvelocity the trolley
TO_Hoist_1. Current velocity of
LREAL mm/s -2**31..2**31-1
motionstatedata.actualvelocity the hoisting gear
Add-on technology Æ TO object

Table 2-4: Add-on technology variables Æ TO object

Normalized to the
maximum speed (P0) of
TO_Trolley_1 Actuator speed of the the trolley from the
LREAL mm/s
Defaultmotionin.velocity trolley Siemens parameter set
-2**31..2**31-1
Normalized to the
maximum speed (P40) of
TO_Hoist_1 Actuator speed of the the hoisting gear from
LREAL mm/s the Siemens parameter
Defaultmotionin.velocity hoisting value
set
-2**31..2**31-1

2.2 Sway Control Function Blocks
2.1.4.6 Polarity of speeds and position values

The following assignments are used for the polarities of speeds and position values for the individual
axes:
Axis Direction of motion Polarities

Positive speed
Raise
Increasing position values
Hoist
Negative speed
Lower
Decreasing position values
Positive speed
Right
Gantry
Negative speed
Left
Forwards Positive speed
(to the water side) Increasing position values
Trolley
Backwards Negative speed
(to the landside) Decreasing position values
Positive speed
Raise
Boom
Negative speed
Lower
2.2.1 Add-on DCC library
2.2.1.1 General information

Note
The source code of every DCC block is closed. A license for the SIMOCRANE Add-on Technology is
required to use the Add-on DCC library. If an under-licensing is determined during the startup, only a
manual operation without sway control is possible.
The naming scheme of the Add-on DCC blocks conforms to the naming scheme of the SIMOCRANE
Basic Technology /R1/.
If not otherwise noted, then the following statements apply to all DCC blocks.
Firmware version
• SIMOTION Drive Based (D4x5): Firmware V4.1.4.1 or higher
• SINAMICS: Firmware V2.5.1 or higher

Configuring
The DCC blocks in "SwayControl" operate in the sampling time of the SIMOTION interpolator cycle
(T2).
2.2.1.2 DCC_SCCommon
Icon
Brief description
The function block contains basic functions for the DCC blocks and the "Sway Control", "TLS" and
"2D-Trajectory" functions. It must always be used.
Operating principle
All data is grouped and the manipulated values are calculated in this block. It also writes and reads the
buffers for the communication to the "CeCOMM" commissioning tool.
The three last outputs of the block are hidden in the default setting. They specify memory locations
and buffer sizes for the Java communication. Their comments must not be changed.
Connections
The DCC block inputs are connected using unit-global variables of the "AddOn" MCC unit with the
outputs of the "FB_CommonPLCToAddOn" block. The DCC block outputs are interconnected with the
inputs of the "FB_CommonAddOnToPLC" block using unit-global variables.
Table 2-5: DCC_SCCommon connections
De- Data "AddOn" unit-

Name Type Meaning
fault type global variables
common_PLC_ Request
iParSet IN 1 SINT
ParSet Parameter set
Request
bNo_Wait_Pos IN 1 BOOL common_PLC_ Do not use wait
No_Wait_Pos position
common_PLC_ Hoisting gear
bHoist_Man IN 0 BOOL
Hoist_Man acceptance


Name Type Meaning
common_PLC_ Locking state of the
bLocked_Bit0 IN 0 BOOL
Locked_Bit0 spreader
common_PLC_ Locking state of the
bLocked_Bit1 IN 0 BOOL
Locked_Bit1 spreader
common_PLC_
bSlackrope IN 0 BOOL Slack rope
slackrope
common_PLC_
bBayscanner_Valid IN 0 BOOL Use Bay scanner
Bayscanner_Valid
Request
common_PLC_
bLearn_Profile_On IN 0 BOOL Learn height profile on
Learn_Profile_On
the waterside
Request
common_PLC_
bLearn_Profile_Reset IN 0 BOOL Initialize height profile
Learn_Profile_Reset
on the waterside
common_PLC_ Digital hoisting
bDig_Hoist_Dist_Corr IN 0 BOOL
Dig_Hoist_Dist_Corr distance correction
common_PLC_ Start of the 2D
bStart_2D_Calc IN 0 BOOL
Start_2D_Calc calculation
common_PLC_
bSpreaders_Coupled IN 0 BOOL Spreaders coupled
Spreaders_Coupled
common_PLC_
iLoad IN 0 INT Load [10 kg]
Load
common_PLC_
iValue_Bayscanner IN 0 DINT Bay scanner
Value_Bayscanner
common_PLC_ Numerator for Bay
iCount_Bayscanner IN 0 DINT
Count_Bayscanner scanner
Overall width of the
common_PLC_
iDS_Width IN 5000 INT double-spreader
DS_Width
operation
common_SC_ Answer
iParSet_OUT OUT 1 SINT
ParSet_OUT Parameter set
Answer
common_SC_
bNo_Wait_Pos_OK OUT 0 BOOL Do not use wait
No_Wait_Pos_OK
position
common_SC_
Answer
bLearn_Profile_On_OK OUT 0 BOOL Learn_Profile_On_O
Learning curve active
K
common_SC_
Answer
bLearn_Profile_Reset_OK OUT 0 BOOL Learn_Profile_Reset
Learning curve reset
_OK
common_SC_ Automatic must not be
bStart_Auto_OK OUT 0 BOOL
Start_Auto_OK started


Name Type Meaning
common_SC_ Manual hoisting gear
bHoist_TakeOver_OK OUT 0 BOOL
Hoist_TakeOver_OK acceptance is possible
common_SC_
bOpen_Grab OUT 0 BOOL Open grab
open_Grab
bFault1 OUT 0 DWORD common_SC_Fault1 Fault word 1
bFault2 OUT 0 DWORD common_SC_Fault2 Fault word 2
common_SC_
bInfo_No_Auto_Start OUT 0 DWORD Data for user output
Info_No_Auto_Start
bError OUT 0 BOOL Error bit from the block
Error number from the
iErrorID OUT 0 DINT
block
iSend_DataP OUT 0 DINT Send address
iReceive_DataP OUT 0 DINT Receive address
iBuffer_Size OUT 0 DINT Buffer size
Error messages
If an error occurs, output "boError" is set and the error number is output at output "iErrorID" (for
description and help, refer to Section 4.10.5.3). If several errors are present, the oldest error will be
displayed.
2.2.1.3 DCC_SCHoist
Icon

Brief description
The block controls the hoisting gear in all basic modes.
Operating principle
Creating the control signals allows the hoisting gear to be influenced. The block then issues an
actuator speed, etc.
Connections
outputs of the "FB_HoistPLCToAddOn" block. The DCC block outputs are interconnected with the
inputs of the "FB_HoistAddOnToPLC" block using unit-global variables.
Table 2-6: DCC_SCHoist connections

Name Type Meaning
hoist_PLC_
bRelease IN 0 BOOL Enable signal
Release
hoist_PLC_
bTravel IN 0 BOOL Travel signal
Travel
hoist_PLC_ Positioning
bOM_Pos IN 0 BOOL
OM_Pos basic mode
hoist_PLC_ Speed control
bOM_Speed IN 0 BOOL
OM_Speed basic mode
hoist_PLC_ Hoist control
bOM_Hoist_Control IN 0 BOOL
OM_Hoist_Control basic mode
hoist_PLC_
bLS_UP IN 1 BOOL Limit switch up
LS_UP
hoist_PLC_
bLS_DN IN 1 BOOL Limit switch down
LS_DN
hoist_PLC_
bPreLS_UP IN 1 BOOL Prelimit switch up
PreLS_UP
hoist_PLC_
bPreLS_DN IN 1 BOOL Prelimit switch down
PreLS_DN
hoist_PLC_
bBrake_Closed IN 1 BOOL Brake closed
Brake_Closed
bFast_Stop IN 0 BOOL - Quick stop
iOverride IN 100 INT Hoist_PLC_Override Override
Hoist_BT_
rField_Weak IN 100 REAL Field weakening
Field_Weak
TO_Hoist_1
Current
rS_Act_HO IN 0 LREAL positioningstate.
hoisting position
actualposition


Name Type Meaning
hoist_BT_
rS_Set_HO_Extern IN 0 LREAL Target position
S_Set_HO_Extern
TO_Hoist_1
Current hoisting gear
rV_Act_HO IN 0 LREAL motionstatedata.
velocity
actualvelocity
hoist_BT_
rV_Set_HO IN 0 LREAL Set velocity
V_Set_HO
hoist_SC_
bReady OUT 0 BOOL Enable signal
Ready
hoist_SC_
bActive OUT 0 BOOL Active
Active
hoist_SC_
bPos_Completed OUT 0 BOOL Positioning
Pos_Completed
hoist_SC_
bTravel_UP OUT 0 BOOL Raise
Travel_UP
hoist_SC_
bTravel_DN OUT 0 BOOL Lower
Travel_DN
TO_Hoist1
rV_Pos_HO OUT 0 LREAL Defaultmotionin. Actuator speed
velocity
rA_Pos_HO OUT 0 LREAL - Actuator acceleration
iErrorID OUT 0 DINT
block
Error messages
displayed.

2.2.1.4 DCC_SCTrolley
Icon
Brief description
The block controls the trolley in all basic modes.
Operating principle
Creating the control signals allows the trolley to be influenced. The block then issues an actuator
speed, etc.
Connections
outputs of the "FB_TrolleyPLCToAddOn" block. The DCC block outputs are interconnected with the
inputs of the "FB_TrolleyAddOnToPLC" block using unit-global variables.
Table 2-7: DCC_SCTrolley connections

Name Type Meaning
trolley_PLC_
bRelease IN 0 BOOL Request release
Release
trolley_PLC_
bTravel IN 0 BOOL Travel signal
Travel
trolley_PLC_ Positioning
bOM_Pos IN 0 BOOL
OM_Pos basic mode
trolley_PLC_
bOM_Speed IN 0 BOOL Speed control basic mode
OM_Speed
Sway-neutralization to load
trolley_PLC_
bOM_Load_Pos IN 0 BOOL position
OM_Load_Pos
basic mode
Sway-neutralization to
trolley_PLC_
bOM_Trolley_Pos IN 0 BOOL trolley position
OM_Trolley_Pos
basic mode


Name Type Meaning
trolley_PLC_
bOM_Hoist_Control IN 0 BOOL Hoist control basic mode
OM_Hoist_Control
trolley_PLC_
bSC_ON IN 0 BOOL sway control On
SC_ON
trolley_PLC_
bLS_FW IN 1 BOOL Limit switch forward
LS_FW
trolley_PLC_
bLS_BW IN 1 BOOL Limit switch backward
LS_BW
trolley_PLC_
bPreLS_FW IN 1 BOOL Prelimit switch forward
PreLS_FW
trolley_PLC_
bPreLS_BW IN 1 BOOL Prelimit switch backward
PreLS_BW
trolley_PLC_
bBrake_Closed IN 1 BOOL Brake closed
Brake_Closed
trolley_PLC_ sway control only when
bSC_When_Stop IN 0 BOOL
SC_When_Stop stopping
trolley_PLC_
bControlled_Stop IN 0 BOOL Controlled stop
Controlled_Stop
trolley_PLC_
bFlying IN 0 BOOL On-the-fly unloading
Flying
bFast_Stop IN 0 BOOL - Quick stop
trolley_PLC_
iOverride IN 100 INT Override
Override
TO_Trolley_1
rS_Act_TR IN 0 LREAL positioningstate. Current trolley position
actualposition
trolley_BT_
rS_Set_TR_Extern IN 0 LREAL Target position
S_Set_TR_Extern
TO_Trolley_1
rV_Act_TR IN 0 LREAL motionstatedata. Current trolley velocity
actualvelocity
trolley_BT_
rV_Set_TR IN 0 LREAL Set velocity
V_Set_TR
trolley_SC_
bReady OUT 0 BOOL Answer release
Ready
trolley_SC_
bActive OUT 0 BOOL Active
Active
trolley_SC_
bPos_Completed OUT 0 BOOL Positioning
Pos_Completed
trolley_SC_
bSC_Completed OUT 0 BOOL Sway-neutralized
SC_Completed


Name Type Meaning
trolley_SC_
bTravel_FW OUT 0 BOOL Forwards
Travel_FW
trolley_SC_
bTravel_BW OUT 0 BOOL Backwards
Travel_BW
trolley_SC_
bSC_State OUT 0 BOOL sway control status
SC_State
trolley_SC_
iLoad_Defl_TR OUT 0 INT Load deflection
Load_Defl_TR
TO_Trolley_1
rV_Pos_TR OUT 0 LREAL Defaultmotionin. Actuator speed
velocity
rA_Pos_TR OUT 0 LREAL - Actuator acceleration
iErrorID OUT 0 DINT
block
Error messages
displayed.
2.2.1.5 DCC_SCTLS
Icon
DCC_SCTLS
BOOL bTrim_RH bMove_Out_Cyl_A BOOL
BOOL bTrim_LH bMove_Out_Cyl_B BOOL
BOOL bList_WS bMove_Out_Cyl_C BOOL
BOOL bList_LS bMove_Out_Cyl_D BOOL
BOOL bSkew_CW bMove_In_Cyl_A BOOL
BOOL bSkew_CCW bMove_In_Cyl_B BOOL
BOOL bMove_To_Zero bMove_In_Cyl_C BOOL
BOOL bSave_Pos_As_Zero bMove_In_Cyl_D BOOL
BOOL bNo_Skew bOil_Pressure1 BOOL
BOOL bSkew_Control bOil_Pressure2 BOOL
BOOL bUse_Ext_Skew bZero_Reached BOOL
SINT iSpreader_Width bSkew_Removed BOOL
DINT iS_Skew_Extern iSpeed_Cyl_A INT
LREAL rS_Act_TR iSpeed_Cyl_B INT
LREAL rS_Act_HO iSpeed_Cyl_C INT
DINT iPos_Cyl_A iSpeed_Cyl_D INT
DINT iPos_Cyl_B bError BOOL
DINT iPos_Cyl_C iErrorID DINT
DINT iPos_Cyl_D

Brief description
This block can be used to control the TLS hydraulic cylinders of a container bridge.
Operating principle
It is possible to control the trim, list and skew, and to activate an automatic skew control . A required
rotational position (skew) can be specified here as angle. A current TLS position can also be saved
and traveled to again.
Connections
outputs of the "FB_TLSPLCToAddOn" block. The DCC block outputs are interconnected with the
inputs of the "FB_TLSAddOnToPLC" block using unit-global variables.
Table 2-8: DCC_SCTLS connections

Name Type Meaning
tls_PLC_
bTrim_RH IN 0 BOOL Trim right
Trim_RH
tls_PLC_
bTrim_LH IN 0 BOOL Trim left
Trim_LH
tls_PLC_
bList_WS IN 0 BOOL List waterside
List_WS
tls_PLC_
bList_LS IN 0 BOOL List landside
List_LS
tls_PLC_
bSkew_CW IN 0 BOOL Skew right
Skew_CW
tls_PLC_
bSkew_CCW IN 0 BOOL Skew left
Skew_CCW
tls_PLC_
bMove_To_Zero IN 0 BOOL Travel to zero position
Move_To_Zero
tls_PLC_ Define current position as
bSave_Pos_As_Zero IN 0 BOOL
Save_Pos_As_Zero zero position
tls_PLC_
bNo_Skew IN 0 BOOL Correct skew
No_Skew
tls_PLC_
bSkew_Control IN 0 BOOL Automatic skew control
Skew_Control
tls_PLC_
bUse_Ext_Skew IN 0 BOOL Use external rotation
Use_Ext_Skew
tls_PLC_
iSpreader_Width IN 0 SINT Spreader width
Spreader_Width
tls_PLC_
iS_Skew_Extern IN 0 DINT Required skew
S_Skew_Extern


Name Type Meaning
TO Trolley_1
rS_Act_TR IN 0 LREAL positioningstate. Trolley position
actualposition
TO Hoist_1
rS_Act_HO IN 0 LREAL positioningstate. Hoisting position
actualposition
iPos_Cyl_A IN 0 DINT tls_PLC_Pos_Cyl_A Cylinder A position
iPos_Cyl_B IN 0 DINT tls_PLC_Pos_Cyl_B Cylinder B position
iPos_Cyl_C IN 0 DINT tls_PLC_Pos_Cyl_C Cylinder C position
iPos_Cyl_D IN 0 DINT tls_PLC_Pos_Cyl_D Cylinder D position
tls_SC_
bMove_Out_Cyl_A OUT 0 BOOL Move cylinder A out
Move_Out_Cyl_A
tls_SC_
bMove_Out_Cyl_B OUT 0 BOOL Move cylinder B out
Move_Out_Cyl_B
tls_SC_
bMove_Out_Cyl_C OUT 0 BOOL Move cylinder C out
Move_Out_Cyl_C
tls_SC_
bMove_Out_Cyl_D OUT 0 BOOL Move cylinder D out
Move_Out_Cyl_D
tls_SC_
bMove_In_Cyl_A OUT 0 BOOL Move cylinder A in
Move_In_Cyl_A
tls_SC_
bMove_In_Cyl_B OUT 0 BOOL Move cylinder B in
Move_In_Cyl_B
tls_SC_
bMove_In_Cyl_C OUT 0 BOOL Move cylinder C in
Move_In_Cyl_C
tls_SC_
bMove_In_Cyl_D OUT 0 BOOL Move cylinder D in
Move_In_Cyl_D
tls_SC_
bOil_Pressure1 OUT 0 BOOL Oil pressure 1
Oil_Pressure1
tls_SC_
bOil_Pressure2 OUT 0 BOOL Oil pressure 2
Oil_Pressure2
tls_SC_
bZero_Reached OUT 0 BOOL Zero position reached
Zero_Reached
tls_SC_
bSkew_Removed OUT 0 BOOL Skew eliminated
Skew_Removed
tls_SC_
iSpeed_Cyl_A OUT 0 INT Cylinder A speed
Speed_Cyl_A
tls_SC_
iSpeed_Cyl_B OUT 0 INT Cylinder B speed
Speed_Cyl_B
tls_SC_
iSpeed_Cyl_C OUT 0 INT Cylinder C speed
Speed_Cyl_C


Name Type Meaning
tls_SC_
iSpeed_Cyl_D OUT 0 INT Cylinder D speed
Speed_Cyl_D
iErrorID OUT 0 DINT
block
Error messages
displayed.
2.2.1.6 DCC_SCTargets
Icon
Brief description
The block is responsible for the internal administration of the target positions. If it is omitted, although
automatic travel is also possible, the targets must then be specified by the PLC.
Operating principle
The correct function also requires the use of the "DCC_SCTrolley" and "DCC_SCHoist" Add-on DCC
blocks. The block can also be used to learn a parking, a lashing and several lane positions.
It also controls the administration of the learnt target positions integrated in the sway control system.
Targets on the waterside are always learnt independently by observation.
Connections
outputs of the "FB_TargetsPLCToAddOn" block. The DCC block outputs are interconnected with the
inputs of the "FB_TargetsAddOnToPLC" block using unit-global variables.

Table 2-9: DCC_SCTargets connections

Name Type Meaning
targets_PLC_
bUse_Lash_Platf IN 0 BOOL Use lash platform
Use_Lash_Plat
targets_PLC_
bStack_Form_Bit0 IN 1 BOOL Control bit 0
Stack_Form_Bit0
targets_PLC_
bStack_Form_Bit1 IN 1 BOOL Control bit 1
Stack_Form_Bit1
targets_PLC_
iLane_Ship_Load IN 0 SINT Load lane to the ship
Lane_Ship_Load
targets_PLC_
iLane_Ship_Unload IN 0 SINT Unload lane to the ship
Lane_Ship_Unload
No further loading of the
bNo_Ship_Load IN 0 BOOL -
ship
No further unloading of the
bNo_Ship_Unload IN 0 BOOL -
ship
targets_PLC_
bCycling IN 0 BOOL Cyclic operation
Cycling
targets_PLC_ Direction offset in the land
bOffset_To_Land IN 0 BOOL
Offset_To_Land direction
targets_PLC_ Direction offset in the water
bOffset_To_Water IN 0 BOOL
Offset_To_Water direction
targets_PLC_ Learn current position as
bLearn_Lash_Platf IN 0 BOOL
Learn_Lash_Platf lashing platform
targets_PLC_ Learn current position as
bLearn_Park_Pos IN 0 BOOL
Learn_Park_Pos parking position
targets_PLC_ Assign current position to a
iLearn_Pos_Lane IN 0 SINT
Learn_Pos_Lane truck lane
targets_PLC_ Use target position from
bUse_Extern_Targets IN 0 BOOL
Use_Extern_Targets PLC
targets_SC_ Target lies in the land
bDirection_Land OUT 0 BOOL
Direction_Land direction
targets_SC_ Target lies in the water
bDirection_Water OUT 0 BOOL
Direction_Water direction
Target coordinates for the
iTarget_Trolley OUT 0 DINT -
trolley
Target coordinates for the
iTarget_Hoist OUT 0 DINT -
hoisting gear
targets_SC_
iLane_Load_OK OUT 0 SINT Load lane to the ship
Lane_Load_OK
iLane_Unload_OK OUT 0 SINT targets_SC_ Unload lane to the ship


Name Type Meaning
Lane_Unload_OK
targets_SC_ Saving the positions was
bPos_Saved OUT 0 BOOL
Pos_Saved successful
iErrorID OUT 0 DINT
block
Error messages
displayed.
2.2.1.7 DCC_SCObstacles
Icon
Brief description
This block can be used to transfer as many as 200 external variable blocked regions to the sway
control block. The functionality of the blocked regions is described in Section 2.3.3.
Operating principle
Five blocked regions can be transferred simultaneously. When deleted, all previously transferred
blocked regions will be removed.

Connections
outputs of the "FB_ObstaclesPLCToAddOn" block. The DCC block outputs are interconnected with the
inputs of the "FB_ObstaclesAddOnToPLC" block using unit-global variables.
Table 2-10: DCC_SCObstacles connections

Name Type Meaning
obstacle_PLC_ Trolley position 1 - blocked
IN 0 DINT
iSet1_Tr1 Set1_Tr1 region 1
IN 0 DINT
obstacle_PLC_ Hoisting position - blocked
IN 0 DINT
iSet1_Hoist Set1_Hoist region 1
IN 0 DINT
IN 0 DINT
IN 0 DINT
IN 0 DINT
IN 0 DINT
IN 0 DINT
IN 0 DINT
IN 0 DINT
IN 0 DINT
IN 0 DINT
IN 0 DINT
IN 0 DINT
obstacle_PLC_ Request
bPrg_Obst IN 0 BOOL
Pgr_Obst Accept blocked regions
bDel_Obst IN 0 BOOL obstacle_PLC_ Request


Name Type Meaning
Del_Obst Delete blocked regions
Trolley position 1 - blocked
iRet1_Tr1 OUT 0 DINT -
region 1
region 1
Hoisting position - blocked
iRet1_Hoist OUT 0 DINT -
region 1
region 2
region 2
region 2
region 3
region 3
region 3
region 4
region 4
region 4
region 5
region 5
region 5
obstacle_SC_ Answer
bPrg_Obst_OK OUT 0 BOOL
Prg_Obst_OK Blocked regions transferred
obstacle_SC_ Answer
bObst_Deleted OUT 0 BOOL
Obst_Deleted Blocked regions deleted
obstacle_SC_
iNumber_Obst OUT 0 INT Number of blocked regions
Number_Obst
iErrorID OUT 0 DINT
block

Error messages
displayed.
2.2.1.8 DCC_SCCamera
Icon
Brief description
The block makes data available for the communication with the camera and accepts the camera
measured values.
Operating principle
The block does not communicate directly with the camera. The "FB_Receive_Analysis" and
"FB_Send_Preparation" FB blocks are required for this in the ST program. The implementation of the
communication to the camera and the integration in the execution system are described in Sections
4.2.2 and 2.1.2.
Connections
outputs of the "FB_Receive_Analysis" block. The "iHoist_Height_PLC" DCC block output is
interconnected with the "FB_Send_Preparation" block input using a unit-global variable. This signal is
transferred to the camera with a UDP message frame via Ethernet. The other DCC block outputs are
connected with the inputs of the DCC block using retentive unit-global variables.

Table 2-11: DCC_SCCamera connections
De- Data "Camera" unit-global

Name Type Meaning
fault type variables
camera_CAM_
bCamera_OK IN 0 BOOL Camera OK
Camera_OK
Deflection in X
iX_Pos IN 0 DINT camera_CAM_X_Pos
direction
Swaying speed in X
iV_X IN 0 DINT camera_CAM_V_X
direction
Deflection in Y
iY_Pos IN 0 DINT camera_CAM_Y_Pos
direction
Swaying speed in Y
iV_Y IN 0 DINT camera_CAM_V_Y
direction
iSkew IN 0 DINT camera_CAM_Skew Reflector skew
iV_Skew IN 0 DINT camera_CAM_V_Skew Skew speed
Hoisting position
camera_CAM_Hoist_
iHoist_Height IN 0 DINT (measured by the
Height
camera)
IP address of the
uIn_Addr_1 IN 192 USINT camera_SC_Addr [0]
camera (part 1)
IP address of the
camera (part 2)
IP address of the
camera (part 3)
IP address of the
camera (part 4)
uIn_Port IN 8500 UINT camera_SC_Port Camera port
Transfer hoisting
camera_SC_
iHoist_Height_PLC OUT 0 DINT position from the
Hoist_Height_PLC
PLC
De- Data "Camera" retentive

Name Type Meaning
fault type unit-global variables
IP address of the
uOut_Addr_1 OUT 192 USINT camera_SC_Addr [0]
camera (part 1)
IP address of the
camera (part 2)
IP address of the
camera (part 3)
IP address of the
camera (part 4)

De- Data "Camera" retentive

Name Type Meaning
fault type unit-global variables
uOut_Port OUT 8500 UINT camera_SC_Port Camera port
Error bit from the
bError OUT 0 BOOL
block
Error number from
iErrorID OUT 0 DINT
the block
Error messages
displayed.
2.2.1.9 DCC_SCDiag
Icon
DCC_SCDiag
BOOL bDiag_ON iStatus INT
Brief description
The block controls the inputs and outputs for the CeCOMM diagnostic tool.
Operating principle
WARNING
This block must be called after the "DCC_SCCommon" block!
This block may not operate in the T1 execution level. The task runtime must be at least 5 ms. The
block can require up to 4 ms computation time.
Connections
The inputs and outputs of the DCC block do not have to be connected. They are connected internally
with the "DCC_SCCommon" block.
Table 2-12: DCC_SCDiag connections
De- Data "AddOn" unit-global

Name Type Meaning
bDiag_ON IN 1 BOOL Diagnostics ON
Diagnostic status
iStatus OUT 0 INT
see below

Diagnostic status
1 – Diagnostics are being performed
2 – Waiting for the controller
3 – Block switched off
4 – Move diagnostics to slower task
5 – Move diagnostics to execution system behind the controller
6 – The controller has required too much computation time
2.2.2 Add-on FB library

The source code of each FB block is open for customer-specific adaptations.
The naming scheme of the Add-on function blocks conforms to the naming scheme of the
SIMOCRANE Basic Technology /Ref 2/.
If not otherwise explained, the following statements apply to all ST function blocks.
Firmware version
• SIMOTION Drive Based (D4x5): Firmware V4.1.4.1 or higher
• SINAMICS: Firmware V2.5.1 or higher
Call
The function blocks must be called in a cyclical task.

2.2.2.2 FB_CommonPLCToAddOn
Symbol (FBD representation)
Task
The "FB_CommonPLCToAddOn" block reads the input area from the PROFIBUS DP for the Common
block and separates the provided array into words and bits.
Connections
The outputs must be connected using unit-global variables of the "AddOn" MCC unit with the inputs of
the "DCC_SCCommon" DCC block.
Table 2-13: FB_CommonPLCToAddOn connections

Name Type Meaning
Input array for
ARRAY addon_common_
the Common
Common_IO_PIW IN - [0..11] receive
block (see Fig.
OF word (I/O-Global)
2-24)
Control word 1
not separated
b16_STW1 OUT 0 WORD -
into individual
bits
common_PLC_ Bit 2 of control
bo_STW1_No_Wait_Pos OUT 1 BOOL
No_Wait_Pos word 1
bo_STW1_Hoist_Man OUT 0 BOOL
Hoist_Man word 1
bo_STW1_Locked_Bit0 OUT 0 BOOL
Locked_Bit0 word 1
bo_STW1_Locked_Bit1 OUT 0 BOOL
Locked_Bit1 word 1
bo_STW1_Slackrope OUT 0 BOOL common_PLC_ Bit 6 of control


Name Type Meaning
slackrope word 1
bo_STW1_Bayscanner_Valid OUT 0 BOOL
Bayscanner_Valid word 1
bo_STW1_Learn_Profile_On OUT 0 BOOL
Learn_Profile_On word 1
common_PLC_
Bit 9 of control
bo_STW1_Learn_Profile_Reset OUT 0 BOOL Learn_Profile_
word 1
Reset
common_PLC_
Bit 10 of control
bo_STW1_Dig_Hoist_Dist_Corr OUT 0 BOOL Dig_Hoist_Dist_
word 1
Corr
bo_STW1_Start_2D_Calc OUT 0 BOOL
Start_2D_Calc word 1
bo_STW1_Spreaders_Coupled OUT 0 BOOL
Spreaders_Coupled word 1
common_PLC_ Weight of the
i16Load OUT 0 INT
Load load
common_PLC_ Bay scanner
i32Value_Bayscanner OUT 0 DINT
Value_Bayscanner value
common_PLC_ Bay scanner
i32Count_Bayscanner OUT 0 DINT
Count_Bayscanner counter
common_PLC_
i8ParSet OUT 1 SINT Parameter set
ParSet
Overall width of
common_PLC_ the double-
i16DS_Width OUT 5000 INT
DS_Width spreader
operation
Error messages
None

2.2.2.3 FB_CommonAddOnToPLC

FB_CommonAddOnToPLC
BOOL bo_ZSW1_No_Wait_Pos_OK Common_IO_PQW ARRAY
BOOL bo_ZSW1_Learn_Profile_On_OK
BOOL bo_ZSW1_Learn_Profile_Reset_OK
BOOL bo_ZSW1_Start_Auto_OK
BOOL bo_ZSW1_Hoist_TakeOver_OK
BOOL bo_ZSW1_Open_Grab
DWORD b32Fault1
DWORD b32Fault2
DWORD b32Info_No_Auto_Start
SINT i8ParSet_OUT
Task
The "FB_CommonAddOnToPLC" writes the Common block to the PROFIBUS DP output area.
Connections
The inputs must be connected using unit-global variables of the "AddOn" MCC unit with the outputs of
the "DCC_SCCommon" DCC block.
Table 2-14: FB_CommonAddOnToPLC connections
"AddOn" unit-
De-
Name Type Data type global Meaning
fault
variables
common_SC_
Bit 2 of status
bo_ZSW1_No_Wait_Pos_OK IN 0 BOOL No_Wait_Pos_
word 1
OK
common_SC_
Bit 3 of status
bo_ZSW1_Learn_Profile_On_OK IN 0 BOOL Learn_Profile_
word 1
On_OK
common_SC_
Bit 4 of status
bo_ZSW1_Learn_Profile_Reset_OK IN 0 BOOL Learn_Profile_
word 1
Reset_OK
common_SC_ Bit 5 of status
bo_ZSW1_Start_Auto_OK IN 0 BOOL
Start_Auto_OK word 1
common_SC_
Bit 6 of status
bo_ZSW1_Hoist_TakeOver_OK IN 0 BOOL Hoist_TakeOver
word 1
_OK
common_SC_ Bit 7 of status
bo_ZSW1_Open_Grab IN 0 BOOL
Open_Grab word 1
common_SC_
b32Fault1 IN 0 DWORD Fault area 1
Fault1
common_SC_
b32Fault2 IN 0 DWORD Fault area 2
Fault2
b32Info_No_Auto_Start IN 0 DWORD common_SC_ Information area

"AddOn" unit-
De-
Name Type Data type global Meaning
fault
variables
Info_No_Auto_ for automatic start
Start
common_SC_ Return value for
i8ParSet_OUT IN 0 SINT
ParSet_OUT parameter set
addon_common Output array for
ARRAY
_ the Common
Common_IO_PQW OUT - [0..11] OF
send block (see Fig.
word
(I/O-Global) 2-24)
Error messages
None
2.2.2.4 FB_HoistPLCToAddOn
Task
The "FB_HoistPLCToAddOn" block reads the input area from the PROFIBUS DP for the Hoist block
and separates the provided array into words and bits.
Connections
the "DCC_SCHoist" DCC block.
Table 2-15: FB_HoistPLCToAddOn connections

Name Type Meaning
ARRAY addon_hoist_ Input array for the
Hoist_IO_PIW IN - [0..5] receive Hoist block (see
OF word (I/O-Global) Fig. 2-24)
b16_STW1 OUT 0 WORD - Control word 1


Name Type Meaning
not separated into
individual bits
hoist_PLC_ Bit 0 of control
bo_STW1_Release OUT 0 BOOL
Release word 1
bo_STW1_Travel OUT 0 BOOL
Travel word 1
bo_STW1_OM_Pos OUT 0 BOOL
OM_Pos word 1
bo_STW1_OM_Speed OUT 0 BOOL
OM_Speed word 1
bo_STW1_OM_Hoist_Control OUT 0 BOOL
OM_Hoist_Control word 1
bo_STW1_LS_UP OUT 1 BOOL
LS_UP word 1
bo_STW1_LS_DN OUT 1 BOOL
LS_DN word 1
bo_STW1_PreLS_UP OUT 1 BOOL
PreLS_UP word 1
bo_STW1_PreLS_DN OUT 1 BOOL
PreLS_DN word 1
bo_STW1_Brake_Closed OUT 1 BOOL
Brake_Closed word 1
i16Override OUT 100 INT hoist_PLC_override PLC override
Error messages
None
2.2.2.5 FB_HoistAddOnToPLC
Task
The "FB_HoistAddOnToPLC" writes the Hoist block to the PROFIBUS DP output area.

Connections
the "DCC_SCHoist" DCC block.
Table 2-16: FB_HoistAddOnToPLC connections

Name Type Meaning
hoist_SC_
bo_ZSW1_Ready IN 0 BOOL Bit 0 of status word 1
Ready
hoist_SC_
bo_ZSW1_Active IN 0 BOOL Bit 1 of status word 1
Active
hoist_SC_
bo_ZSW1_Pos_Completed IN 0 BOOL Bit 2 of status word 1
Pos_Completed
hoist_SC_
bo_ZSW1_Travel_UP IN 0 BOOL Bit 4 of status word 1
Travel_UP
hoist_SC_
bo_ZSW1_Travel_DN IN 0 BOOL Bit 5 of status word 1
Travel_DN
ARRAY
addon_hoist_ Output array for the
[0..5]
Hoist_IO_PQW OUT - send Hoist block (see Fig.
OF
(I/O-Global) 2-24)
word
Error messages
None
2.2.2.6 FB_TrolleyPLCToAddOn

Task
The "FB_TrolleyPLCToAddOn" block reads the input area from the PROFIBUS DP for the Trolley
Connections
the "DCC_SCTrolley" DCC block.
Table 2-17: FB_TrolleyPLCToAddOn connections

Name Type Meaning
ARRAY
addon_trolley_ Input array for the
[0..5]
Trolley_IO_PIW IN - receive Trolley block (see
OF
(I/O-Global) Fig. 2-24)
word
Control word 1 not
b16_STW1 OUT 0 WORD separated into
individual bits
trolley_PLC_ Bit 0 of control
bo_STW1_Release OUT 0 BOOL
Release word 1
bo_STW1_Travel OUT 0 BOOL
Travel word 1
bo_STW1_OM_Pos OUT 0 BOOL
OM_Pos word 1
bo_STW1_OM_Speed OUT 0 BOOL
OM_Speed word 1
bo_STW1_OM_Load_Pos OUT 0 BOOL
OM_Load_Pos word 1
bo_STW1_OM_Trolley_Pos OUT 0 BOOL
OM_Trolley_Pos word 1
bo_STW1_OM_Hoist_Control OUT 0 BOOL
OM_Hoist_Control word 1
bo_STW1_SC_ON OUT 0 BOOL
SC_ON word 1
bo_STW1_LS_FW OUT 1 BOOL
LS_FW word 1
bo_STW1_LS_BW OUT 1 BOOL
LS_BW word 1
bo_STW1_PreLS_FW OUT 1 BOOL
PreLS_FW word 1
bo_STW1_PreLS_BW OUT 1 BOOL
PreLS_BW word 1


Name Type Meaning
bo_STW1_Brake_Closed OUT 1 BOOL
Brake_Closed word 1
bo_STW1_SC_When_Stop OUT 0 BOOL
SC_When_Stop word 1
bo_STW1_Controlled_Stop OUT 0 BOOL
Controlled_Stop word 1
bo_STW1_Flying OUT 0 BOOL
Flying word 1
Trolley_PLC_
i16Override OUT 100 INT PLC override
Override
Error messages
None
2.2.2.7 FB_TrolleyAddOnToPLC
Task
The "FB_TrolleyAddOnToPLC" writes the Trolley block to the PROFIBUS DP output area.
Connections
the "DCC_SCTrolley" DCC block.
Table 2-18: FB_TrolleyAddOnToPLC connections
"AddOn" unit-
Data
Name Type Default global Meaning
type
variables
trolley_SC_
bo_ZSW1_Ready IN 0 BOOL Bit 0 of status word 1
Ready
trolley_SC_
bo_ZSW1_Active IN 0 BOOL Bit 1 of status word 1
Active

"AddOn" unit-
Data
Name Type Default global Meaning
type
variables
trolley_SC_
bo_ZSW1_Pos_Completed IN 0 BOOL Bit 2 of status word 1
Pos_Completed
trolley_SC_
bo_ZSW1_SC_Completed IN 0 BOOL Bit 3 of status word 1
SC_Completed
trolley_SC_
bo_ZSW1_Travel_FW IN 0 BOOL Bit 4 of status word 1
Travel_FW
trolley_SC_
bo_ZSW1_Travel_BW IN 0 BOOL Bit 5 of status word 1
Travel_BW
trolley_SC_
bo_ZSW1_SC_State IN 0 BOOL Bit 7 of status word 1
SC_State
trolley_SC_
i16Load_Defl_TR IN 0 INT Current load deflection
Load_Defl_TR
ARRAY
addon_trolley_ Output array for the
[0..5]
Trolley_IO_PQW OUT - send Trolley block (see Fig.
OF
(I/O-Global) 2-24)
word
Error messages
None
2.2.2.8 FB_TLSPLCToAddOn
Task
The "FB_TLSPLCToAddOn" block reads the input area from the PROFIBUS DP for the TLS block and
separates the provided array into words and bits.

Connections
the "DCC_SCTLS" DCC block.
Table 2-19: FB_TLSPLCToAddOn connections

Name Type Meaning
ARRAY Input array for
addon_tls_receive
TLS_IO_PIW IN - [0..15] the TLS block
(I/O-Global)
OF word (see Fig. 2-24)
Control word 1
not separated
b16_STW1 OUT 0 WORD -
into individual
bits
tls_PLC_ Bit 0 of control
bo_STW1_Trim_RH OUT 0 BOOL
Trim_RH word 1
bo_STW1_Trim_LH OUT 0 BOOL
Trim_LH word 1
bo_STW1_List_WS OUT 0 BOOL
List_WS word 1
bo_STW1_List_LS OUT 0 BOOL
List_LS word 1
bo_STW1_Skew_CW OUT 0 BOOL
Skew_CW word 1
bo_STW1_Skew_CCW OUT 0 BOOL
Skew_CCW word 1
bo_STW1_Move_To_Zero OUT 0 BOOL
Move_To_Zero word 1
tls_PLC_
Bit 7 of control
bo_STW1_Save_Pos_As_Zero OUT 0 BOOL Save_Pos_
word 1
As_Zero
bo_STW1_No_Skew OUT 0 BOOL
No_Skew word 1
bo_STW1_Skew_Control OUT 0 BOOL
Skew_Control word 1
bo_STW1_Use_Ext_Skew OUT 0 BOOL
Use_Ext_Skew word 1
tls_PLC_ Cylinder A
i32Pos_Cyl_A OUT 0 DINT
Pos_Cyl_A position
tls_PLC_ Cylinder B
i32Pos_Cyl_B OUT 0 DINT
Pos_Cyl_B position
tls_PLC_ Cylinder C
i32Pos_Cyl_C OUT 0 DINT
Pos_Cyl_C position


Name Type Meaning
tls_PLC_ Cylinder D
i32Pos_Cyl_D OUT 0 DINT
Pos_Cyl_D position
tls_PLC_
i32S_Skew_Extern OUT 0 DINT PLC skew
S_Skew_Extern
tls_PLC_
i8Spreader_Width OUT 0 SINT Spreader width
Spreader_Width
Error messages
None
2.2.2.9 FB_TLSAddOnToPLC
Task
The "FB_TLSAddOnToPLC" writes the TLS block to the PROFIBUS DP output area.
Connections
the "DCC_SCTLS" DCC block.

Table 2-20: FB_TLSAddOnToPLC connections
Data "AddOn" unit-

Name Type Default Meaning
type global variables
tls_SC_ Bit 0 of status
bo_ZSW1_Move_Out_Cyl_A IN 0 BOOL
Move_Out_Cyl_A word 1
bo_ZSW1_Move_Out_Cyl_B IN 0 BOOL
Move_Out_Cyl_B word 1
bo_ZSW1_Move_Out_Cyl_C IN 0 BOOL
Move_Out_Cyl_C word 1
bo_ZSW1_Move_Out_Cyl_D IN 0 BOOL
Move_Out_Cyl_D word 1
bo_ZSW1_Move_In_Cyl_A IN 0 BOOL
Move_In_Cyl_A word 1
bo_ZSW1_Move_In_Cyl_B IN 0 BOOL
Move_In_Cyl_B word 1
bo_ZSW1_Move_In_Cyl_C IN 0 BOOL
Move_In_Cyl_C word 1
bo_ZSW1_Move_In_Cyl_D IN 0 BOOL
Move_In_Cyl_D word 1
bo_ZSW1_Oil_Pressure1 IN 0 BOOL
Oil_Pressure1 word 1
bo_ZSW1_Oil_Pressure2 IN 0 BOOL
Oil_Pressure2 word 1
bo_ZSW1_Zero_Reached IN 0 BOOL
Zero_Reached word 1
bo_ZSW1_Skew_Removed IN 0 BOOL
Skew_Removed word 1
tls_SC_
i16Speed_Cyl_A IN 0 INT Cylinder A speed
Speed_Cyl_A
tls_SC_
i16Speed_Cyl_B IN 0 INT Cylinder B speed
Speed_Cyl_B
tls_SC_
i16Speed_Cyl_C IN 0 INT Cylinder C speed
Speed_Cyl_C
tls_SC_
i16Speed_Cyl_D IN 0 INT Cylinder D speed
Speed_Cyl_D
ARRAY
addon_TLS_ Output array for
[0..15]
TLS_IO_PQW OUT - send the TLS block
OF
(I/O-Global) (see Fig. 2-24)
word

Error messages
None
2.2.2.10 FB_TargetsPLCToAddOn
Task
The "FB_TargetsPLCToAddOn" block reads the input area from the PROFIBUS DP for the Targets
Connections
the "DCC_SCTargets" DCC block.
Table 2-21: FB_TargetsPLCToAddOn connections

Name Type Meaning
ARRAY Input array for
addon_targets_
[0..5] the Targets
Targets_IO_PIW IN - receive
OF block (see Fig.
(I/O-Global)
word 2-24)
Control word 1
not separated
b16_STW1 OUT 0 WORD
into individual
bits
targets_PLC_ Bit 0 of control
bo_STW1_Learn_Park_Pos OUT 0 BOOL
Learn_Park_Pos word 1
bo_STW1_Learn_Lash_Platf OUT 0 BOOL
Learn_Lash_Platf word 1
bo_STW1_Use_Lash_Platf OUT 0 BOOL
Use_Lash_Plat word 1
bo_STW1_Stack_Form_Bit0 OUT 1 BOOL
Stack_Form_Bit0 word 1
bo_STW1_Stack_Form_Bit1 OUT 1 BOOL targets_PLC_ Bit 4 of control


Name Type Meaning
Stack_Form_Bit1 word 1
bo_STW1_Cycling OUT 0 BOOL
Cycling word 1
bo_STW1_Offset_To_Land OUT 0 BOOL
Offset_To_Land word 1
bo_STW1_Offset_To_Water OUT 0 BOOL
Offset_To_Water word 1
targets_PLC_
Bit 8 of control
bo_STW1_Use_Extern_Targets OUT 0 BOOL Use_Extern_
word 1
Targets
Number of the
targets_PLC_ lane from
i8Lane_Ship_Load OUT 0 SINT
Lane_Ship_Load which the ship
will be loaded
Number of the
lane from
targets_PLC_
i8Lane_Ship_Unload OUT 0 SINT which the ship
Lane_Ship_Unload
will be
unloaded
Store current
targets_PLC_ position with
i8Learn_Pos_Lane OUT 0 SINT
Learn_Pos_Lane this lane
number
Error messages
None
2.2.2.11 FB_TargetsAddOnToPLC
Task
The "FB_TargetsAddOnToPLC" writes the Targets block to the PROFIBUS DP output area.

Connections
the "DCC_SCTargets" DCC block.
Table 2-22: FB_TargetsAddOnToPLC connections

Name Type Meaning
targets_SC_
bo_ZSW1_Pos_Saved IN 0 BOOL Bit 0 of status word 1
Pos_Saved
targets_SC_
bo_ZSW1_Direction_Land IN 0 BOOL Bit 1 of status word 1
Direction_Land
targets_SC_
bo_ZSW1_Direction_Water IN 0 BOOL Bit 2 of status word 1
Direction_Water
Return the lane number
targets_SC_
i8Lane_Load_OK IN 0 SINT from which the ship will
Lane_Load_OK
be loaded
targets_SC_ Return the lane number
i8Lane_Unload_OK IN 0 SINT Lane_Unload_O from which the ship will
K be unloaded
ARRAY addon_targets_ Output array for the
Targets_IO_PQW OUT - [0..5] OF send Targets block (see Fig.
word (I/O-Global) 2-24)
Error messages
None
2.2.2.12 FB_ObstaclesPLCToAddOn

Task
The "FB_ObstaclesPLCToAddOn" block reads the input area from the PROFIBUS DP for the
Obstacles block and separates the provided array into words and bits.
Connections
the "DCC_SCObstacles" DCC block.
Table 2-23: FB_ObstaclesPLCToAddOn connections

Name Type Meaning
ARRAY addon_obstacle1_ Input array for the
Obstacle1_IO_PIW IN - [0..15] receive Obstacle block 1 (see
ARRAY addon_obstacle2_ Input array for the
Obstacle2_IO_PIW IN - [0..15] receive Obstacle block 2 (see
Control word 1 not
b16_STW1 OUT 0 WORD - separated into individual
bits
obstacle_PLC_
bo_STW1_Pgr_Obst OUT 0 BOOL Bit 0 of control word 1
Pgr_Obst
obstacle_PLC_
bo_STW1_Del_Obst OUT 0 BOOL Bit 1 of control word 1
Del_Obst
obstacle_PLC_Set1 Blocked region 1 trolley
i32Set1_Tr1 OUT 0 DINT
_Tr1 position 1
obstacle_PLC_ Blocked region 1 trolley
Set1_Tr2 position 2
obstacle_PLC_ Blocked region 1
i32Set1_Hoist OUT 0 DINT
Set1_Hoist hoisting position
Set2_Tr1 position 1
Set2_Tr2 position 2
Set3_Tr1 position 1
Set3_Tr2 position 2
i32Set4_Tr1 OUT 0 DINT obstacle_PLC_ Blocked region 4 trolley


Name Type Meaning
Set4_Tr1 position 1
Set4_Tr2 position 2
Set5_Tr1 position 1
Set5_Tr2 position 2
Error messages
None
2.2.2.13 FB_ObstaclesAddOnToPLC
Task
The "FB_ObstaclesAddOnToPLC" writes the Obstacles block to the PROFIBUS DP output area.
Connections
the "DCC_SCObstacles" DCC block.
Table 2-24: FB_ObstaclesAddOnToPLC connections

Name Type Meaning
obstacle_SC_
bo_ZSW1_Prg_Obst_OK IN 0 BOOL Bit 0 of status word 1
Prg_Obst_OK
obstacle_SC_
bo_ZSW1_Obst_Deleted IN 0 BOOL Bit 1 of status word 1
Obst_Deleted
obstacle_SC_ Number of blocked
i16Number_Obst IN 0 INT
Number_Obst regions
Obstacle1_IO_PQW OUT - ARRAY addon_obstacle1_ Output array for the


Name Type Meaning
[0..15] send Obstacle block (see
ARRAY addon_obstacle2_ Output array for the
Obstacle2_IO_PQW OUT - [0..15] send Obstacle block (see
Error messages
None
2.2.2.14 FB_Send_Preparation
Task
The block prepares the data for the camera before it is sent as UDP message frame.
Connections
The block input is connected with the output of the "DCC_SCCamera" DCC block using a unit-global
variable. The output signal is transferred to the camera with a UDP message frame via Ethernet.
Table 2-25: FB_Send_Preparation connections
Data "Camera" unit-

type global variables
Transfer external
camera_SC_
i32Hoist_Height_PLC IN 0 DINT hoisting position from
Hoist_Height_PLC
the PLC
Data "Camera" unit

type variables
ARRAY
[0..7] The data sent to the
aSenddata OUT 0 SendData
OF camera
BYTE
Error messages
None

2.2.2.15 FB_Receive_Analysis
Task
This block analyzes and processes the data received as UDP message frame.
Connections
At the input of the "FB_Receive_Analysis" function block, the data received as UDP message frame is
separated and interconnected to the associated output variables of the block. The outputs must be
connected using unit-global variables of the "Camera" MCC unit with the inputs of the
"DCC_SCCamera" DCC block.
Table 2-26: FB_Receive_Analysis connections
Data
Name Type Default "Camera" unit variables Meaning
type
ARRAY Data received from
aReceivedata IN 0 [0..169] ReceiveData the camera via
OF BYTE Ethernet
u32Datalength IN 0 UDINT udp_back_receive.dataLength Data length

Data "Camera" unit-global

type variables
bo_Camera_OK OUT 0 BOOL camera_CAM_Camera_OK Camera OK
Deflection in X
i32X_Pos OUT 0 DINT camera_CAM_X_Pos
direction
Deflection in Y
i32Y_Pos OUT 0 DINT camera_CAM_Y_Pos
direction
i32Skew OUT 0 DINT camera_CAM_Skew Reflector skew
Hoisting position
i32Hoist_Height OUT 0 DINT camera_CAM_Hoist_Height (measured by the
camera)
Swaying speed in X
i32V_X OUT 0 DINT camera_CAM_V_X
direction
Swaying speed in Y
i32V_Y OUT 0 DINT camera_CAM_V_Y
direction
i32V_Skew OUT 0 DINT camera_CAM_V_Skew Skew speed
Error messages
None

2.3 Sway Control Applications

This section describes the various SIMOCRANE Sway Control applications. Each application consists
of a "SwayControl" DCC chart. This chart contains a wide range of Sway Control options. An "AddOn"
MCC unit is also present. This unit manages the communication between the controller (S7) and the
SIMOTION Sway Control. A camera application also has an additional "Camera" MCC unit. This unit
fetches and processes the camera data.
2.3.1 Simple Sway Control for ship unloader

The application is a simple configuration example for a ship unloader. Trolleys and hoisting gear can
be controlled manually and automatically. When automatic control is used, the targets must be
specified and managed by the PLC. Fixed blocked regions can be considered during the automatic
travel (see Section 2.3.3.2).
The sway control system operates only with an internal oscillation model. A camera is not used.
The controller possesses appropriate functions for ship unloaders, such as pre-limit and limit
shutdown, the consideration of reduced speeds for large loads or a grab emptying during the motion
(on-the-fly unloading).
2.3.1.2 Required blocks, signals and connections
Required FB blocks
Required DCC blocks

• DCC_SCCommon
• DCC_SCHoist
• DCC_SCTrolley
• DCC_SCDiag

Inclusion of the blocks in execution levels

The blocks are calculated in the following execution groups:
The DCC blocks in "SwayControl" operate in the sampling time of the SIMOTION interpolator cycle.
The function blocks in the "AddOn" MCC unit operate in a cyclical execution level.
Required signals from the drive line for SIMOCRANE SwayControl

• Load-dependent field weakening
• Speed setpoints (trolley and hoisting gear)
• Actual position values (trolley and hoisting gear)
• Actual speed values (trolley and hoisting gear)
Required connections
The required connections are contained in the tables for the connections of the required DCC and FB
blocks ("Variables" column) in Sections 2.2.1 and 2.2.2.
2.3.2 Simple Sway Control for container cranes

The application is a simple configuration example for a container crane. Trolleys and hoisting gear can
be controlled manually and automatically. The sway control system operates with an internal
oscillation model. A camera that records the load oscillation is also used. This allows oscillations
caused by external forces also to be corrected.
The controller possesses appropriate functions for container bridges, such as pre-limit and limit
shutdown or the consideration of reduced speeds for large loads.
When automatic control is used, the targets must be specified and managed by the PLC. Fixed
blocked regions can be considered during the automatic travel (see Section 2.3.3.2).
Required FB blocks
• FB_Send_Preparation

Required DCC blocks

• DCC_SCCommon
• DCC_SCHoist
• DCC_SCTrolley
• DCC_SCCamera
• DCC_SCDiag

The function blocks in the "AddOn" and "Camera" MCC units operate in a cyclical execution level.

2.3.3 SwayControl with 2D-Trajectory and Bay Scanning

The application is an extended configuration example for a container crane. Trolleys and hoisting gear
can be controlled manually and automatically. The sway control system operates with an internal
oscillation model. A camera that records the load oscillation is also used. This allows oscillations
caused by external forces also to be corrected.
The "2D-Trajectory" Add-on permits the automatic motion of the load on the path curve. The path
curve is determined here so that the spreader or the grab does not collide with the crane construction,
the containers or any other obstacles.
The basis is a layout of the working area in which blocked regions are defined. Blocked regions can be
defined during the commissioning, transferred from the PLC or learnt internally during the travel.
Travel is permitted only outside these blocked regions. Depending on the starting point and the target
position, the fastest possible travel path is generated from the data about the blocked regions. The
target position is determined automatically. A parking position, a lashing position and several lane
positions can also be learnt and used to calculate the path curve.
If a Bay Scanner is used, the signal of the measured hoisting height is also evaluated and also used to
calculate the path curve (see Section 2.3.3.3).

2.3.3.2 Definitions
Obstacles
An obstacle is a physical object that must be avoided in order to prevent collisions. Such examples
are, on the waterside, containers, structures in the form of cell guides, frames for container
attachments, etc., and on the landside, crane constructions (e.g. Silbeam), the lashing platform or
trucks.
Blocked regions
Blocked regions are individual or several combined
obstacles or also areas, which the crane should not
enter for safety reasons.
A blocked region is described by two trolley positions
and one hoisting position. Up to 20 fixed and 200
variable blocked regions can be defined.
Fixed blocked regions

Fixed blocked regions are primarily defined on the landside. They are entered from the "CeCOMM"
commissioning tool in the "B" region menu (set blocked regions) during the commissioning and stored
in the "Par0.txt" to "Par3.txt" parameter files.
Beim Laden werden die Werte aus der „Par0.txt“ übernommen.
Variable blocked regions

Note
Variable blocked regions are used only in conjunction with the "2D-Trajectory" AddOn.
Variable blocked regions are created dynamically and principally on the waterside for transfer of the
container stack. Depending on the type of the transfer, variable blocked regions are divided into
external variable blocked regions and internally-learnt variable blocked regions.
External variable blocked regions are designated as those blocked regions transferred from the
PLC to the SwayControl system. This is necessary when the container management should be
realized in a higher-level control system. The blocked regions are transferred to the SwayControl
system prior to the automatic start.
External variable blocked regions can also be used for other purposes, such as the blocking of all
heights below the trucks.
Internally-learnt variable blocked regions are created from the height profile by
• Monitoring the spreader movements in all basic modes, and also optionally by
• Acquiring the laser values of the Bay Scanner
External variable blocked regions and internally-learnt variable blocked regions are stored internally in
different data storage areas, but linked before the automatic start.

Container stack
The container stack is the two-dimensional location description of all containers in a row on the ship.
Height profile
If the container stacks are learnt internally, all spreader positions are recorded as a height profile
irrespective of the basic operating mode. The laser values of the Bay Scanner can also be used. The
learnt height profile extends from the start to the end of the waterside. The internal learnt variable
blocked regions are created continually from the height profile.
If the measured values of the Bay Scanner are not used, the height profile during the unloading at the
begin of the learning process does not correspond to the real container stack, although it approaches
this after each unloading action.
Limit curve
With the initialization and calculation of the automatic travel, all fixed and variable blocked regions are
combined in a limit curve.
List of switchover points

The fastest possible travel path is generated from the limit curve data, taking account of not only the
start point and the target position, but also the maximum speed of the hoisting gear and trolley. The
result is a switchover point.
Fig. 2-9: Relationship between blocked regions, limit curves and switchover point list
Path curve
The path curve is the calculated optimum travel curve of the spreader. The switchover point list forms
the basis.
Fig. 2-10: Sequence for determining the optimum path curve

2.3.3.3 Bay scanning

If a Bay Scanner is also used, this signal of the obstacle height is evaluated in addition to the traveled
curve. If the Bay Scanner signal is valid, it takes priority over the learnt travel curve. This allows more
exact values of the container stack to be determined.
Note
Depending on the installation position of the laser, the system is able to travel to the next position in
automatic loading operation.
The distance (hm) from the scanner to the surface of the container stack is measured (dashed lines).
The PLC must convert this value into a laser value (hVB) that represents the distance between the
hoisting height ZERO (h0) to the upper edge of the container stack at this position (Bay Scanner value,
see following figure). The height between two valid measuring points is direction-dependent and is set
to the height of the second measuring point.
Fig. 2-11: Measurement of the height of the container stack with the laser scanner
Formula for calculating the obstacle height:

hVB=hs-hm (see also Section 3.2.3)
2.3.3.4 Double spreader

The "Sway Control" AddOn technology can also be used on cranes with double spreaders in "single
mode" and in coupled mode. The following must be observed:
CAUTION
The camera must be attached via the landside spreader.

Single mode
CAUTION
In single mode, the waterside spreader must be pulled up to the upper limit switch. Otherwise the
"Sway Control" AddOn technology must be deactivated. This is a safety function and must be
implemented in the S7.
No additional signals are required and there are no changes in the behavior compared to operation
with a single spreader.
Coupled mode
In "coupled mode", the landside spreader is the master. This is monitored by a camera. The "master"
is always positioned. Its position (middle of the landside spreader) must be transferred on the sway
control via the interface.
During learning and when avoiding obstacles, the current total width of the double spreader is taken
into account. The double spreader is treated as a large spreader, with regard to the learning behavior.
The width of the blocked regions is increased in the landside direction (see Fig. 4-49).
The current total width and the signal for coupled mode must be specified via the interface (Section
3.6.2.6).
Required FB blocks
• FB_TargetsPLCToAddOn (optional)
• FB_TargetsAddOnToPLC (optional)
• FB_ObstaclesPLCToAddOn (optional)
• FB_ObstaclesAddOnToPLC (optional)
Required DCC blocks

• DCC_SCCommon
• DCC_SCHoist
• DCC_SCTrolley
• DCC_SCDiag
• DCC_SCObstacles (optional)
• DCC_SCTargets (optional)

The use of the "DCC_SCTargets" and "DCC_SCObstacles" blocks, and the associated FB blocks for
receiving and sending data depends on the transfer mode of the blocked regions.
Table 2-27: Transfer modes of blocked regions
Internal learning
Fetching from the
External via PLC Acquisition by Bay
parameter file
Scanner
Fixed blocked
Variable blocked regions
regions
Required FB_ObstaclesPLCToAddOn FB_TargetsPLCToAddOn

FB blocks No further blocks FB_ObstaclesAddOnToPLC FB_TargetsAddOnToPLC
required
Required DCC_SCObstacles DCC_SCTargets
DCC blocks
A combination of all transfer modes is possible. In this case, all blocks marked as optional must be
present and configured.

The function blocks in the "AddOn" MCC unit operate in a cyclical execution level.

2.3.4 TLS Control

"TLS Control" controls the so-called trim, list and skew positions of a spreader.
The TLS Control assumes that
• the lengths or
• the pivot points

of the four carrying cables of a spreader can be adjusted by hydraulic cylinders with the aid of the
camera.
Through actuation of these hydraulic cylinders in pairs, the spreader can be tilted to the left or right
(trim), inclined towards the waterside or landside (list) or rotated in a clockwise or counterclockwise
direction (skew). All of these movements can be carried out simultaneously.
The current positions of all four cylinders can be saved as zero positions and approached again. The
command to approach the zero positions has priority over the trim, list and skew commands.
The Skew Control function, the electronic sway control function, can also be activated. With this
function, the skewing motion of the spreader is measured with the camera and eliminated through
control of the hydraulic cylinders. Optionally, travel is made to the last TLS setting on the landside and
waterside or an externally specified rotational position (e.g. from Truck Positioning). This command will
not be performed when the "Move zero" or a TLS command is present.
Required FB blocks
Required DCC blocks

• DCC_SCCommon
• DCC_SCTLS
• DCC_SCCamera
• DCC_SCDiag


2.3.5 SwayControl with TLS Control

The application is a simple configuration example for a container crane with trim, list and skew control.
Trolleys and hoisting gear can be controlled manually and automatically. When automatic control is
used, the targets must be specified and managed by the PLC. Fixed blocked regions can be
considered during the automatic travel (see Section 2.3.3.2).
The sway control system operates with an internal oscillation model. A camera that records the load
oscillation is also used. This allows oscillations caused by external forces also to be corrected.
In addition, the trim, list and skew control and an skew control is used. Further information is contained
in Section 2.3.4.1.
Required FB blocks
Required DCC blocks

• DCC_SCCommon
• DCC_SCHoist
• DCC_SCTrolley
• DCC_SCTLS
• DCC_SCCamera
• DCC_SCDiag


2.4 Configuring

2.4 Configuring
2.4.1 Requirements
Functional project
Prerequisite for the installation of the Add-on technology is a functional project of the basic
technology /Ref 2/( SIMOTION SCOUT combined with Technology packet SIMOTION DCC start with
version 4.1.4.1 and SINAMICS start with version 2.5.1. also SIMOCRANE Basic Technology Version
V2.0.).
This can be checked as follows:
• Save and compile project with the "Save Project and compile all" icon
• Consistency check from the "D435" context menu, "Check consistency" entry
Setting the system cycle clocks

The task run time settings must also be checked. This requires that the SIMOTION container in
SCOUT is selected. The "Target System/Expert/Set System Cycle Clock" menu is used to set the
system cycle clocks as shown in the following screenshot.

2.4 Configuring
Fig. 2-12: Setting the task run times
2.4.2 Overview of the configuring steps to be performed

The following steps should be performed in succession:
1. Perform setup (installation of the DCC library) (Section 2.4.3)
2. Import the SCOUT project of the AddOn technology (Section 2.4.4)
3. PROFIBUS configuration (Section 2.4.5)
4. I/O variables copied (Section 2.4.7)
5. Copy Add-on FB library (Section 2.4.8)
6. Copy MCC charts (Section 2.4.9))
7. Add DCC blocks (Section 2.4.10)
8. Save, compile and check consistency (Section 2.4.11)
9. Establish connection between the basic technology and Add-on (Section 2.4.11)11
10. Customize the Add-on to the company's conditions (Section 2.4.15
11. Include the "AddOn" and "Camera" programs in the execution system (Section 2.4.16)
12. Transfer the project to the SIMOTION D (Section 2.4.17)
13. Communications test (Section 2.4.17)

2.4 Configuring
2.4.3 Perform setup

CAUTION
To install the Add-on DCC library, SCOUT must be closed.
To install the required DCC library, the supplied "Setup.exe" must be executed. Follow the instructions
displayed during the installation. This installation adds the current DCC blocks to the DCC library.
Fig. 2-13: Installation of the Add-on DCC library
2.4.4 Import the SCOUT project of the AddOn technology

The SCOUT project of the AddOn technology must be imported next.
CAUTION
To import a project in the "XML-Format", the SCOUT must be open, although all projects must be
closed.
Click the icon to start the import of a SCOUT project. To import the project, the
"SwayControl_SimoD.xml" file on the CD must be selected. After clicking "OK" to confirm, enter an
arbitrary project name in the following window and select a target folder for the project.
Note
The example project is a ZIP File at the CD. This File must be unzipped with the WinZip program.
Then the dates can be used for import into SCOUT. The incurred project which includes the example
modules could be opened with help of the SIMATIC Manager.

2.4 Configuring
Fig. 214: Import of the SCOUT project of the AddOn Technology

After clicking "OK" to confirm, the project will be imported and compiled.
Note
After the import, it is essential to check whether the compilation was successful.
2.4.5 PROFIBUS configuration

Open the SCOUT projects of the basic technology /Ref. 2/ and the Add-on technology. Later, once
PROFIBUS has been configured, you can copy the programs from one project into another project.

Communication between the higher-level SIMATIC S7 control and the drive-related control SIMOTION
D435 is established via PROFIBUS DP (up to max. 12 process data items per axis). The SINAMICS
control unit is integrated in the drive-based SIMOTION D (/Ref. 3/ and /Ref. 4/). The communication
between these has the same character as PROFIBUS DP, but with motion control extension with up to
a maximum of 25 process data items (in accordance with PROFIdrive - Profile Drive technology /Ref.
1/) for Vector Control and is called DP-Integrated.
SIMOTION D435 has three PROFIBUS DP interfaces (two DP interfaces and one DP integrated
interface).
The communication between SIMATIC S7 and SIMOTION basic technology /Ref. 2/ is configured on
DP1, whereas DP2 is used for the complete Add-on technology. The connection between SIMOTION
and SINAMICS is permanently configured on the internal DP interface.
The following PROFIBUS addresses have been defined for the PROFIBUS DP interface on the
SIMOTION D:
Table 2-28: PROFIBUS DP interfaces on the SIMOTION D for Add-on technologies
PROFIBUS DP Communication to the PROFIBUS

interface ... address
DP1 Basic technology 44
DP2 Add-on technology 45
DP Integrated SINAMICS Internal

2.4 Configuring
2.4.5.2 Configuring the connection

Communication between SIMATIC S7 and SIMOTION D is established via PROFIBUS DP. The S7
module is the master and the SIMOTION is an intelligent slave.
SIMOTION hardware configuration

The DP2/MPI line must be opened in the hardware configuration of the SIMOTION.
Fig. 2-15: Hardware configuration SIMOTION

The PROFIBUS address of the DP2/MPI line of the SIMOTION is defined as "45".

2.4 Configuring
Fig. 2-16: Object properties of DP1

The DP2/MPI line must now be configured as intelligent DP-SLAVE. This is done under Properties -
DP2/MPI in the "Operating Mode" tab. The checkbox for Programming, status/modify or other PG
functions and unconfigured communication connections possible MUST be set.
Fig. 2-17: Setting up an intelligent DP slave

2.4 Configuring
Note
The DP2/MPI line can no longer be seen in the hardware configuration after this was configured as
intelligent slave.
SIMATIC S7 hardware configuration

The DP line is set up in the hardware configuration of the SIMATIC S7 as PROFIBUS with a
transmission rate of 6 Mbit/s. Then, the SIMOTION is inserted from the catalog under "already
configured stations":
Fig. 2-18: Overview of the SIMATIC S7 hardware configuration

When inserting the already configured SIMOTION station, a coupling is listed, refer to the diagram
below. Click the "Connect" button to establish the coupling between SIMATIC S7 and SIMOTION.
Note
Communication between SIMATIC S7 and SIMOTION can only be configured after the coupling has
been established.

2.4 Configuring
Fig. 2-19: Object properties of the DP line

After the coupling has been established, data transfer between SIMATIC S7 and SIMOTION must be
configured. The appropriate process data must be configured for each block.
Note
For the Add-on technology, identical I/O address ranges are used in the SIMATIC S7 and the
SIMOTION D. The address ranges of 2000-2043 are reserved.
The addresses 2000-2167 of this range are used for "Sway Control", "TLS Control" and "2D-
Trajectory".
Table 2-29: I/O address ranges for the Add-on technologies
PROFIBUS Length
Block Functions I/O address ranges
address (byte)
DCC_SCCommon General 45 24 2000-2023
DCC_SCHoist Hoisting gear 45 12 2024-2035
DCC_SCTrolley Trolley 45 12 2036-2047
Slewing gear (not yet
- 45 12 2048-2059
specified)
DCC_SCTLS TLS 45 32 2060-2091
DCC_SCTargets Targets 45 12 2092-2103
DCC_SCObstacles Blocked regions 45 32 2104-2135

2.4 Configuring
PROFIBUS Length
address (byte)
Block1
Blocked regions
45 32 2136-2167
Block2
Other Add-on
- 45 76 2168-2243
functions
For each function, these addresses must be created under "DP slave properties" in the
"Configuration" tab.
Fig. 2-20: I/O peripherals definition in the S7 hardware configuration (1st part)

2.4 Configuring
Fig. 2-21: I/O peripherals definition in the S7 hardware configuration (2nd part)
The send and receive direction must be configured for each function. For example, the trolley with
start address 2036 is configured once as output for the master and once as input for the slave.
The following settings in the DP slave properties window are very important:
Properties of the output words Properties of the input words

Fig. 2-22: Properties of the input and output words to be created (trolley example)

2.4 Configuring
Once all functions of the Add-on technology have been configured, the hardware configurations must
be compiled in the SIMATIC S7 and SIMOTION.
The complete SIMATIC S7 and SIMOTION hardware is displayed in the "NETPRO" screen. The
PG/PC should be connected at the DP1 line. An active connection must be configured at the PC/PC,
otherwise routing to SINAMICS_Integrated and the CX32 modules is not possible.
Fig. 2-23: Netpro overview
2.4.5.3 Definition of the message frame

The PROFIBUS module used for the standard application can exchange 244 bytes of data between
SIMATIC S7 and SIMOTION. The standard message frame in accordance with PROFIdrive profile
V4.1 /Ref. 1/ is used as message frame.
Twelve function blocks (e.g. FB_CommonPLCToAddOn, FB_CommonAddOnToPLC) are
programmed in the Add-on technology to process communication message frames (or interconnect
and convert signals) between SIMATIC S7 and SIMOTION.
In addition, the corresponding function blocks and data blocks on the SIMATIC S7 side for defined
communication are made available to users on the Software CD.
2.4.6 Copy I/O-Variablen

In SIMOTION, the complete communication with the I/O or with the master is performed using the I/O
variables. An I/O array with process data must be created for receiving and sending for each function
module participating in communication.
The required I/O arrays are preferably copied from the AddOn project to the project with the basic
technology. The I/O variables of the AddOn project are shown below.

2.4 Configuring
Fig. 2-24: Overview of the I/O variables in SCOUT (communication between SIMATIC S7 and
SIMOTION)
To copy, the "I/O" container is activated in the AddOn project, the arrays selected in the symbol
browser and copied with the context menu. The I/O arrays are inserted in the project with the basic
technology by activating the "I/O" container, selecting the first free cell in the symbol browser and then
with the Enter key.
Fig. 2-25: Copying the I/O variables

2.4 Configuring
2.4.7 Copying Add-on FB library

The library is preferably copied from the AddOn project to the project with the basic technology. To do
this, select in the Add-on and copy it from the context menu. In the project with the basic technology, it
is added by selecting the "LIBRARIES" container and clicking Paste. The prompt for the objects to be
copied should be answered with "Yes".
Basic technology Add-on

Fig. 2-26: Importing the Add-on FB library
Fig. 2-27: Inserting an AddOn library
Fig. 2-28: Also copying objects

The newly added library must now be compiled.

2.4 Configuring
Fig. 2-29: Accept and compile library
2.4.8 Copying MCC charts

After the successful compilation, the "AddOn" and "Camera" MCC programs can be copied into the
project with the basic technology.
Fig. 2-30: Copy MCC programs in the Add-on
Fig. 2-31: Insert MCC programs in Basic Technology

2.4 Configuring
2.4.9 Inserting DCC blocks

Before the "SwayControl" DCC chart is copied, the newly-installed DCC block library is checked. To
do this, an arbitrary DCC chart, such as "Gantd_1", is opened in the project with the basic technology.
"Options / Block Types…" is selected from the menu item.
Fig. 2-32: Update block types

The following pop-up should be answered with "OK".
Fig. 2-33: Pop-up for updating the DCC library

The available libraries are now shown on the left-hand side with the previously-imported libraries
shown on the right-hand side. Only import the most-recent available library. You must now click the
arrow pointing to the right.

2.4 Configuring
Fig. 2-34: Available and installed libraries

You see that the library appears on the right-hand side.

2.4 Configuring
Fig. 2-35: Available and installed libraries are identical

You can now copy the "SwayControl" DCC chart from the AddOn project to the basic technology
project. To do this, select with the right mouse button the chart in the AddOn project and copy it.
Fig. 2-36: Copy DCC chart from the AddOn

In the basic technology, the chart can be inserted by selecting the "PROGRAMS" container and
pressing the right mouse button.

2.4 Configuring
Fig. 2-37: Insert the DCC chart in the basic technology
Note
The DCC chart can be inserted in a SCOUT project only by copying.
2.4.10 Saving, compiling and checking consistency
The project is compiled and saved ( ). Then press the "Ctrl + Alt + K" key combination to perform a
consistency check. The project should now be free from any errors.

2.4 Configuring
2.4.11 Connection between the basic technology and Add-on

For the communication between the basic technology and Add-on, the connections for the speed,
position and load-dependent field weakening must be established if this has not been done
automatically.
To do this, the connection to the AddOn must first be established in the "Hoistp_1" and "Trollp_1"
interface from the "Connections" tab.
Hoistp_1
Trollp_1
Fig. 2-38: Connection from "Hoistp_1" and "Trollp_1" to the AddOn

2.4 Configuring
The following variables for the Add-on must now be interconnected:
Velocity setpoint
The velocity setpoint is interconnected for the individual axes in the associated MCC charts of the
basic technology in the "Receive S7" module (see following figure).
Table 2-30: Interconnection of the velocity setpoints
Axis MCC MCC chart Basic technology AddOn unit-global

program variables variables
Hoisting hoistp_1 hoistmcc_1_s my_Hoist_1_receive. hoist_BT_V_Set_HO
gear r64comvelocity
Trolley trollp_1 trollmcc_1_s my_Trolley_1_receive. trolley_BT_V_Set_TR
r64comvelocity
Fig. 2-39: Example for the interconnection of the velocity setpoint for the hoisting gear

2.4 Configuring
Position setpoint
The position setpoint is interconnected for the individual axes in the associated MCC charts of the
basic technology in the "Receive S7" module (see following figure).
Table 2-31: Interconnection of the position setpoints
Axis MCC MCC chart Basic technology AddOn unit-global variables

program variables
Hoisting hoistp_1 hoistmcc_1_s r64targetposition hoist_BT_S_Set_HO_Extern
gear
Trolley trollp_1 trollmcc_1_s r64targetposition trolley_BT_S_Set_TR_Extern
Fig. 2-40: Example of the interconnection of the position setpoint for the hoisting gear

2.4 Configuring
Field weakening
For the "Load-dependent field weakening override“ signal, the corresponding output for the
"LoadDependingFieldWeak" in the "Hoistd_1" is interconnected with the corresponding input in the
Add-on.
Table 2-32: Interconnection of the signal for the field weakening
Basic Basic technology DCC Connection AddOn unit-global

techno- block variables
logy DCC
program
Hoistd_1 LoadDependingFieldWeak rSetPointVelAfterRampGen Hoist_BT_Field_Weak
Fig. 2-41: Interconnection between Hoistd_1 and Add-on

2.4 Configuring
"Positioning complete" signal

The "Positioning complete" signal is interconnected for the individual axes (on the master drive when
several axes are used) in the associated MCC charts of the basic technology in the "Operation Mode"
module (see following figure).
Table 2-33: Interconnection on the Mode block
Axis MCC MCC chart Basic technology AddOn unit-global variables

program variables
Hoisting hoistp_1 hoistmcc_1_s boswaycontrolpositi Hoist_SC_Pos_Completed
gear oncompleted
Trolley trollp_1 trollmcc_1_s boswaycontrolpositi Trolley_SC_Pos_Completed
oncompleted
Fig. 2-42: Example of the interconnection on the Mode block for the trolley
2.4.12 Connection between the TO objects and Add-on

The connections for velocity and position must be established for the communication between the TO
objects and Add-on. The "SwayControl" DCC chart must be opened first.

2.4 Configuring
Actual position value

Table 2-34: Interconnection of the actual position values
Axis TO objects DCC block Connection

Hoisting Hoist_1.positioningstate.actualposition DCC_SCHoist rS_Act_HO
gear
Trolley Trolley_1.positioningstate.actualposition DCC_SCTrolley rS_Act_TR
TLS Hoist_1.positioningstate.actualposition DCC_SCTLS rS_Act_HO
TLS Trolley_1.positioningstate.actualposition DCC_SCTLS rS_Act_TR
Fig. 2-43: Example of the interconnection of the actual position value for the hoisting gear
Actual speed
Table 2-35: Interconnection of the actual speed
Axis TO objects DCC block Connection

Hoisting Hoist_1.motionstatedata.actualvelocity DCC_SCHoist rV_Act_HO
gear
Trolley Trolley_1.motionstatedata.actualvelocity DCC_SCTrolley rV_Act_TR
Actuator speed
The following block entries are interconnected with the TO variables.

2.4 Configuring
Table 2-36: Interconnection of the actuator speed
Axis SwayControl Connection TO objects

DCC block
Hoisting DCC_SCHoist rV_Pos_HO Hoist_1.defaultmotionin.velocity
gear
Trolley DCC_SCTrolley rV_Pos_TR Trolley_1.defaultmotionin.velocity
2.4.13 Required Add-on DCC blocks

The following table shows which Add-on DCC blocks are required for the associated Add-on.
Table 2-37 Required and optional DCC blocks for the various Add-ons
Add-on DCC block Sway Control 2D-Trajectory TLS Control
DCC_SCCommon X X X
DCC_SCCamera o o o
DCC_SCTrolley X X -
DCC_SCHoist X X -
DCC_SCTargets - X -
DCC_SCObstacles - X -
DCC_SCTLS - - X
DCC_SCDiag X X X
X – required o - optional
2.4.14 Customization of the Add-on

Example of a customization of the Add-on for the case without TLS
For a project that contains all features (maximum expansion), the TLS should be removed. The
following explains which blocks and variables must be removed.
Step 1: Remove the superfluous functions blocks

The "AddOnMCC" MCC program is opened.

2.4 Configuring
Fig. 2-44: "AddOnMCC" MCC program

The "Receive PLC" and "Send PLC" modules are then opened successively and the subroutine call for
the TLS block removed (see following figures).
Fig. 2-45: The subroutine call for TLS in the Receive module is deleted

2.4 Configuring
Fig. 2-46: The subroutine call for TLS in the Send module is deleted
Step 2: The global variables for TLS are removed

A double-click on the "AddOn" MCC source causes it to open on the right-hand side of the window
with the global variables. All variables that belong to the TLS are removed here.

2.4 Configuring
Fig. 2-47: Superfluous global variables
Step 3: The DCC block for TLS is removed
Fig. 2-48: Superfluous TLS DCC_Block

2.4 Configuring
Then click to recompile the project.
Fig. 2-49: Recompiling a DCC chart

2.4 Configuring
Step 4: The I/O variables for TLS are removed
Fig. 2-50: Superfluous I/O variables
Step 5: Compile project
As last step, the project is compiled ( ). Then press the "Ctrl + Alt + K" key combination to
perform a consistency check. The project should now be free from any errors.
2.4.15 Execution system

The newly-inserted "AddOn" and "Camera" programs must still be integrated in the execution system.
They supply PLC ("AddOn") and camera ("Camera") values to the sway control system.
Both programs must be integrated in the background task.

2.4 Configuring
Note
Under no circumstances may the "Camera" program be called in the TimerInterruptTask, because
the program uses system functions not permissible in this task.
2.4.16 Transferring the Project to the SIMOTION D

After completion of the configuring with "SCOUT", the following files must be transferred to the CF
card of the SIMOTION D.
Copying language files and online helps for the AddOn system from the CD
The "SWAYCONTROL" directory must be created on the CF card. Into this directory, the following
• "Sprache0.txt" and "Sprache1.txt" language files, and the
• "Help_D.chm" and "Help_E.chm" online helps
must be copied from the CD.
Copying JAVA Runtime from the CD

From the "CD_1/Software/JAVA" directory on the CD, copy the files
• "buffer.jar"
• "jinvoke.xml"
• "Simotion.jar"
• "VMconfig.ini"
to the main directory of the CF card.
Transferring a SCOUT project

The successfully compiled SCOUT project must be transferred to the CF card. This requires that an
online connection with the SIMOTION exists. Alternatively, a card reader can also be used.

2.4 Configuring
Fig. 2-51: Transferring the SCOUT project
Creating and transferring a license key

At least one license key for the "SIMOTION Crane Sway Control Technology" on the SIMOTION D CF
card is required. This must be created first.
• Enter the license number and delivery note number (on your Certificate of License) on the Internet
link www.siemens.com/automation/license
• Create a license key and copy it to the CF card of the SIMOTION D
This enables the corresponding functionality of the Add-on technologies.
2.4.17 Communication test

The communication between the PLC and the sway control system can be checked by issuing a signal
and tracking the signal characteristic.
This path starts at the higher-level SIMATIC S7 controller. The signal must reach the SIMOTION using
the I/O variables. From here, the signal from the MCC sources is queried and processed in the
appropriate function blocks. The signal is then forwarded to the DCC chart and from there to the MCC
sources and technology objects. From the MCC sources, the signal returns to the S7; from the
technology object it goes to the drive object (see following overview figure).

2.4 Configuring
Fig. 2-52: Signal characteristic overview figure

To improve understanding, a signal characteristic in accordance with the above principle is observed
step-by-step in the following section.
Signal characteristics
Step 1: Check execution system and SIMOTION in Run

Prior to the actual observing, a check must be made whether the programs in the execution system
are assigned to the appropriate tasks, because otherwise the programs cannot be processed.
The "AddOn" and "Camera" MCC execution programs must be integrated in a cyclical task that should
not be called more often than the DCC chart assigned in the default settings of the IPO task.
To activate the tasks, the SIMOTION must be switched to Run.
Step 2: Create value on the S7 and check on the I/O variables

The S7 writes a value (500 decimal = 0000.0001.1111.0100 binary) for the "DCC_SCTargets" block to
the first word of the array. The I/O address range of 2092-2103 is reserved for the "DCC_SCTargets"
DCC block.
When this value reaches the SIMOTION, it must be available in the I/O area. To do this, the "I/O" is
selected and the symbol browser observed (see following figure).

2.4 Configuring
Fig. 2-53: I/O area

The value specified by the S7 is present in the I/O area.
Note
To prevent misunderstandings, the display format should be identical with that of the S7.
Step 3: Check the value at the inputs of the FB block

The "AddOn" MCC source or the "AddOnMCC" MCC program calls the "FB_TargetsPLCToAddOn"
function block and accesses the array in the I/O area for which it was parameterized.

2.4 Configuring
Fig. 2-54: Array assignment
Fig. 2-55: Signal in the function block

2.4 Configuring
The "FB_TargetsPLCToAddOn" function block copies word 1 (targets_io_piw[0]) to the "b16_STW1"

output and also separates it into bits. These are applied to the block outputs. The bit separation has
the following form.
bo_STW1_Learn_Park_Pos =0 (control word 1, bit 0)
bo_STW1_Learn_Lash_Platf = 0 (control word 1, bit 1)
bo_STW1_Use_Lash_Platf =1 (control word 1, bit 2)
bo_STW1_Stack_Form_Bit0 =0 (control word 1, bit 3)
bo_STW1_Stack_Form_Bit1 =1 (control word 1, bit 4)
bo_STW1_Cycling =1 (control word 1, bit 5)
bo_STW1_Offset_To_Land =1 (control word 1, bit 6)
bo_STW1_Offset_To_Water =1 (control word 1, bit 7)
bo_STW1_Use_Extern_Targets= 1 (control word 1, bit 8)
Because the "b16_STW1" word at the block output is no longer further interconnected, the following bit
variables are set
• bo_STW1_Use_lash_Platf
• bo_STW1_Stack_Form_Bit0
• bo_STW1_Stack_Form_Bit1
for tracking the signal.
Step 4: Check the value at the inputs of the DCC block

The outputs of the function block are interconnected with unit-global variables. The inputs and outputs
of the DCC blocks from the DCC charts are interconnected with the unit-global variables. The three bit
variables to be tracked are connected with the Targets block.

2.4 Configuring
Fig. 2-56: DCC blocks

The three variables arrive at the block exactly as specified by the S7. Because the signals in the DCC
block are further processed, they cannot be further tracked.
To track the path back to the S7, you can select a variable at the block output and track it back in the
same manner.
The technology object has only the following variables supplied by the Add-on technology or sent back
from the technology object.
Add-on technology Æ TO object

• TO_Trolley_1.Defaultmotionin.velocity
• TO_Hoist_1.Defaultmotionin.velocity
TO object Æ Add-on technology

• TO_Trolley_1.positioningstate.actualposition
• TO_Hoist_1.positioningstate.actualposition
• TO_Trolley_1.motionstatedata.actualvelocity
• TO_Hoist_1.motionstatedata.actualvelocity

2.4 Configuring
2.4.18 Brief summary for various Add-on configurations

Simple Sway Control for ship unloader (minimum configuration)
Components to be removed:
DCC block in
MCC‚ Add-on I/O Variables
'SwayControl'
- Blocks for receiving PLC data
- addon_targets_receive
(Targets, TLS, Obstacles)
- addon_targets_send
- Blocks for sending PLC data
- addon_obstacle1_receive
- DCC_SCTargets - addon_obstacle1_send
- Global variables for Targets, TLS,
- DCC_SCTLS - addon_obstacle2_receive
Obstacles
- DCC_SCObstacles - addon_obstacle2_send
MCC Camera - DCC_SCCamera - addon_slew_receive
- addon_slew_send
- Block for camera - addon_tls_receive
- Camera - addon_tls_send
Simple Sway Control for container cranes

DCC block in
MCC 'Add-on' I/O Variables
'SwayControl'
- addon_targets_receive
- addon_targets_send
- addon_obstacle1_send
- Blocks for sending PLC data - DCC_SCTargets
(Targets, TLS, Obstacles) - DCC_SCTLS
- Global variables for Targets, TLS, - DCC_SCObstacles
- addon_slew_receive
Obstacles
- addon_slew_send
- addon_tls_receive
- addon_tls_send
Sway Control‚ 2D-Trajectory and Bay Scanning with camera

DCC block in
'SwayControl'
- Blocks for receiving PLC data - addon_obstacle1_receive
(Obstacles) - addon_obstacle1_send
- Blocks for sending PLC data - DCC_SCTLS - addon_obstacle2_receive
(Obstacles) - DCC_SCObstacles - addon_obstacle2_send
- Global variables for Targets, - addon_slew_receive
Obstacles - addon_slew_send

2.4 Configuring
DCC block in
'SwayControl'
- addon_tls_receive
- addon_tls_send
TLS Control with camera

DCC block in
'SwayControl'
- addon_hoist_receive
- addon_hoist_send
- addon_trolley_receive
- addon_trolley_send
(Trolley, Hoist, Targets, Obstacles)
- DCC_SCTrolley - addon_targets_receive
- DCC_SCHoist - addon_targets_send
- DCC_SCTargets - addon_obstacle1_receive
- Global variables for Trolley, Hoist,
Targets, Obstacle
- addon_slew_send
Sway Control, TLS Control with camera

DCC block in
'SwayControl'
- addon_hoist_receive
- addon_hoist_send
- addon_trolley_receive
- addon_trolley_send
- DCC_SCTrolley - addon_targets_receive
- DCC_SCHoist - addon_targets_send
- DCC_SCTargets - addon_obstacle1_receive
- Global variables for Trolley, Hoist,
Targets, Obstacle
- addon_slew_send

SIMATIC S7 Configuration 3
3.1.1 Structure of the S7 blocks

The sample interface consists of several functions (FC), function blocks (FB) and data blocks (DB).
The most important relationships are shown in the following figure. All data is stored in the DB990 and
DB995 data blocks. The SFC14 and SCF15 functions are responsible for receiving and sending data.
The blocks have the following specific tasks:

1. SFC15 Sends current data to the SIMOTION D via PROFIBUS

SIMATIC S7 Configuration
Sends the processed data from the provided data area (DB995) to the I/O output area.
Warning
All data may not be transferred as consistent data.
2. SFC14 Receives current data from the SIMOTION D via PROFIBUS
Loads the received data from the I/O input area into the provided data area (DB990).
3. FB990 Processing the received data
Processes and links the received data.
4. FB995 Preparing all data
Prepares the transferred data for sending.
5. DB995 Send data for the SIMOTION D
6. DB990 Receive data from the SIMOTION D
3.1.2 Brief description of the S7 blocks

Table 3-1: Brief description of the data and function blocks
Function Name Description

FB990 AddOn_Recv_data Call the instance blocks for the state signals
Relocate the state signals from the Common block from
FB1831 AddOn_Recv_Common
the I/O to an internal flag area
Relocate the state signals from the Hoist block from the
FB1832 AddOn_Recv_Hoist
I/O to an internal flag area
Relocate the state signals from the Trolley block from the
FB1833 AddOn_Recv_Trolley
Relocate the state signals from the Slew block from the
FB1834 AddOn_Recv_Slew
Relocate the state signals from the TLS block from the I/O
FB1835 AddOn_Recv_TLS
to an internal flag area
Relocate the state signals from the Targets block from the
FB1836 AddOn_Recv_Targets
Relocate the state signals from the Obstacle block from
FB1837 AddOn_Recv_Obstacle
the I/O to an internal flag area
Call the instance blocks for the control signals Evaluation
FB995 AddOn_Send_data of the state signals and form the control signals for the
sway control taking account of the crane signals
Relocate the control signals from the Common block from
FB1841 AddOn_Send_Common
the internal flag area to the I/O
Relocate the control signals from the Hoist block from the
FB1842 AddOn_Send_Hoist
internal flag area to the I/O
FB1843 AddOn_Send_Trolley Relocate the control signals from the Trolley block from

3.2 Mode-independent Logic
Function Name Description

Relocate the control signals from the Hoist block from the
FB1844 AddOn_Send_Slew
Relocate the control signals from the Slew block from the
FB1845 AddOn_Send_TLS
Relocate the control signals from the Targets block from
FB1846 AddOn_Send_Targets
Relocate the control signals from the Obstacle block from
FB1847 AddOn_Send_Obstacle
Data block with state signals from the sway control system
DB990 AddOn_Receive_interface
fetched from the I/O via SFC14 (FC1810)
Data block with state signals from the sway control system
DB995 AddOn_Send_interface
written to the I/O via SFC15 (FC1810)
FC1810 AddOn_Communication Call SFC14 and 15 for reading and writing the I/O data
3.2.1 Formation of the “bTravel” travel signal

Note
The travel signal must be set while the travel request exists or the "bPos_Completed" signal has not
yet been set. Otherwise, the compensation of the swaying motion will be aborted and the target
position not reached.
Fig. 3-1: Formation of the travel signal
3.2.2 Formation of the signal for opening and closing the brake
The signal for opening and closing the brake must be formed in the PLC with the following logic from
the direction signals output from the sway control system.

Trolley Hoist
Fig. 3-2: Formation of the signal for closing the brake
Note
The brake must be closed when no further direction signals are output; the brake must be opened in
the opposite situation. The real mechanical brake opening times (0.5 -1.0 seconds) mean a time
delay occurs between the "brake open" and "brake closed" signal. For this reason, the "brake closed"
signal should always be applied to the "Brake_Closed" bit for trolley and hoisting gear. This means a
dead time behavior for the control can be avoided.
3.2.3 Conversion of the Bay Scanner values

The Bay Scanner measures the distance of the scanner to the surface of the container stack
(Measured laser value hm). The PLC must convert this value into a laser value (Value Bay Scanner vB)
that represents the distance between the hoisting height ZERO to the upper edge of the container
stack at this position (see also Section 2.3.3.3). The conversion can be performed as follows in the
PLC software for the evaluation of the Bay Scanner data (FC84 SIMO_Bayscanner):
1. Lower the spreader to the quay, and record the actual position of the hoisting gear
(Actualposition hoistQuay) and the bay scanner value (Measured laser valueQuay).
2. The measured laser value (Measured laser valueQuay) and the actual position of the hoisting gear
(Hoist actualpositionQuay) at a defined position produce the installation height of the scanner
(Scanner height hs) that can be calculated manually:
hs = Measured laser valueQuay + Actualposition hoistQuay
hs = 45000 mm + 1000 mm
hs = 46000 mm
3. The converted laser value (Value Bay Scanner hVB) is then calculated using the Scanner height hs
equation transferred with the "ValueBayscan" signal to the sway control computer:
hVB = hs - hm

hVB = 46000 mm – 31000 mm

hVB = 15000 mm
Fig. 3-3: Example of the conversion in S7 FC84 "SIMO_Bayscanner"

This converted laser value (Value Bay Scanner hVB) is also displayed in the "Hoist control [6]" display
screen (Section 4.4.6.1).
4. Checking of the adjustment of the bay scanner values and the hoisting height in the "Hoist control
[6]" display screen. These must be approximately the same (±100 mm) for the spreader lowered to
the quay.

3.3 Accelerating and braking response
Fig. 3-4: Checking of the adjustment of the bay scanner values and the hoisting height
3.3 Accelerating and braking response

The oscillation of the load at container and STS cranes will be eliminated by the use of selective
influence at accelerating- and braking response of the trolley.
The accelerating- and braking response of the sway control will be adjusted through three ramps resp.
Accelerating values.
The ramp at the Acceleration without sway control /minimum acceleration (P7) is usually the
same the drive is using, when the sway control is completely deactivated. The minimum acceleration
acts as a limitation, when one of the following conditions is applied:
• Prelimitswitch is on
• Velocity decrease based on a changing of the extern override
• It is driven in use of the sway control software, but the bit „SC_ON“( = sway control on) is „0“.
The minimum acceleration doesn`t work at the normal radius of action and when the override is not
changing. The sway control is able to brake slower for catching the oscillation.
The maximum acceleration (P5) represents a limit towards the other direction. The sway control will
not stronger accelerate or brake as those ramp. Ideally she should be adjusted at the physical
maximal possible value.
The set acceleration (P6) is the calculation base for the control speed of the sway control. It will not
be strictly driven at this ramp to ensure the capture of the oscillation.

3.4 Basic Operating Modes
The following adjustments are commended:

• P5: the maximum reachable acceleration of the drive
• P6: approx. 75% of P5
• P7: It is the condition: P7 < P6 < P5. The concrete value results in the position of the prelimit
switch to the limit switch. The optimal values have to be adjusted at the crane experimentally.
The observance of the limit values has priority towards the catching of the oscillation.
Fig. 3-5: Beschleunigungs- und Bremsverhalten der Pendeldämpfung

The following basic operating modes are available for the trolley and hoist axes:
• Speed control
• Positioning
• Hoist control
• Sway-neutralization to load position (trolley only)
• Sway-neutralization to trolley position (trolley only)
Only one basic operating mode can be selected for each axis at any time. The basic operating mode
is selected by the PLC by setting the appropriate operating mode bit.
The AddOn operating modes listed in Table 3-2 result from the linking of various basic operating
modes for trolley and hoisting gear in the PLC. AddOn operating modes are virtual operating modes
as used by the crane operator.

Table 3-2: AddOn operating modes - basic operating modes relationship
AddOn mode Axis Basic operating mode Operating mode bit

Trolley Speed control OM_Speed (Table 3-15)
SC Speed Control
Hoist Speed control OM_Speed (Table 3-13)
Trolley Hoist control OM_Hoist_Control (Table 3-15)
SC Automatic
Hoist Hoist control OM_Hoist_Control (Table 3-13)
Trolley Positioning OM_Pos (Table 3-15)
SC Semi Automatic
Hoist Speed control OM_Speed (Table 3-13)
3.4.1 Speed control

In the "speed control" basic operating mode the speed is specified manually from a higher-level
controller. This operating mode is also called manual mode in the rest of the documentation. The
trolley is accelerated or decelerated to the set speed in such a way that the load sway has been
eliminated when the set speed is reached. If the crane is to be operated in manual mode without sway
control, this must be specified explicitly.
The possibilities of the different activation in this basic operating mode are described in Section
3.6.1.2, "Possible settings".
Activation of the basic operating mode

The "speed control" basic operating mode is activated by setting the appropriate operating mode bit
"OM_Speed" on the axes (see Table 3-15, Table 3-13, control bits for trolley and hoisting gear).
This basic operating mode can be started from all other basic operating modes without having to stop
the drives.
Movements of the hoisting gear are possible during the speed control and have very little effect on the
quality of the sway control.
Internal deactivation of the sway control system

The sway control system is internally disabled under the following conditions (although the axes can
still be moved by the system):
• The control bit "SC_ON" (= " sway control ON", see Table 3-15, trolley control bits) is reset.
• The activation speed (P146) has not been reached.
• The activation time (P147) has not yet expired.
• The sway control switch-on conditions are no longer satisfied and the sway control switch-off
delay (P148) has expired.
• The "SC_When_Stop" control bit (=sway control only for stopping, see Table 3-15, trolley control
bits) is set. The sway control function is only active when stopping. This bit is only effective in the
speed control mode.
• The hoisting gear is located above the set upper or below the lower sway control limit (P83, P84).
• The license is damaged or missing.

3.4.2 Positioning
In the "positioning" basic operating mode, the higher-level controller or the internal setpoint encoder
can specify a target position for each individual axis. This position is approached automatically after
enabling. The trolley is controlled in such a way that the load sway is eliminated not only when the
maximum speed is reached, but also at the target position.
Both axes do not need to be in this basic operating mode.
CAUTION
Blocked regions are not considered for the calculation of the travel curve.

The "positioning" basic operating mode is activated by setting the appropriate operating mode bit
"OM_Pos" (see Table 3-15, Table 3-13, control bits for trolley and hoisting gear).
Abort the positioning

The positioning can be aborted at any time, by
• Setting the "Controlled_Stop" control bit (see Table 3-15, trolley control bits), or
• Resetting the "bTravel" travel signal (see Table 3-15, Table 3-13, trolley and hoisting gear control
bits)
Causes
The positioning should be aborted in the PLC in the following cases:
• Overload
• Twist-lock motion - however only when an axis is traversed manually
• Specification of a new target from an external source (PLC)
• When bit "bStart_2D_Calc" is no longer present
If a limit switch has been overtraveled, the software internally aborts the positioning.
Response to overtraveling a limit switch

• The crane stops with maximum deceleration and does not travel any further.
• The sway control function is deactivated
• The automatic control has no effect
• The crane can only be traversed in manual operation without sway control

On-the-fly unloading
The positioning with on-the-fly unloading utilizes the swinging of a grab when unloading bulk goods
and saves turnover time in this way. The trolley is braked before the target position while the grab
sways to the target (e.g. funnel).
CAUTION
The on-the-fly unloading can only be used with time-optimized control (see Section 4.7.1 and
4.7.3.3). Because of the unpleasant travel behavior, the crane operator cabin should not be linked to
the trolley.
The following figure below shows an example of such a travel operation.
The trolley initially decelerates from the 60 m position with time-optimized control to -1.7 m/s (travel
from the waterside to land). The target position at 20 m is reached with a load deflection of approx.
0.8 m. The return travel is restarted shortly after the "Open_Grab" state bit (see

Table 3-23, Common state bits) has been reset. The grab remains for approximately two seconds in
the target area of 20 m … 21 m. The duration which the grab is present within a target area results
mainly from the braking acceleration. The smaller the braking acceleration, the longer is the duration.
Fig. 3-6: Travel operation over time (in seconds) for on-the-fly unloading
The following figure illustrates the unloading:

Fig. 3-7: Unloading operation for the on-the-fly unloading

Section 1:
Travel is started with time-optimized control. The "FLYING" bit is set.
Section 2:
In the acceleration phase, the load sways backward and the controller compensates this swaying as
fast as possible.
Section 3:
Because the trolley is in the braking phase, the grab sways forward. The signal to "open grab" is set
because the "distance before opening the grab" (P31) has been undershot. The unloading begins (the
loading good is dispatched in the funnel).
Section 4:
Once the trolley speed is less than the "on-the-fly unloading abort speed" (P30), the "OPEN_GRAB"
state bit will be reset. A new target (ship) has been specified. To save cycle time, the grab can remain
open. The "FLYING" bit must be set.
Activation of the on-the-fly unloading

To be able to use the on-the-fly unloading, the following conditions must be satisfied:
• The specified target must be on the landside.
• The "positioning" basic operating mode (command bit "OM_POS") must be set for the trolley and
either the "positioning" or the "speed control" basic operating mode (command bit "OM_SPEED")

for the hoisting gear or the "hoist control" basic operating mode (command bit
"OM_HOIST_CONTROL") for both axes.
• The time-optimized control is activated in P152 (= #.23..).
• The "FLYING" control bit (= "on-the-fly unloading", see Table 3-15, trolley control bits) must also
be set.
• The actuator speed > "on-the-fly unloading abort speed" (P30)
• The signal to "open grab" is set when the "distance before opening the grab" (P31) is undershot.
3.4.3 Hoist control

Obstacles are taken into consideration during the automatic target approach in the "hoist control" basic
operating mode. The load is moved along an optimum path curve. The swaying of the load has been
eliminated when the stationary speed or standstill is reached. The hoist control enables collisions with
obstacles located in blocked regions to be avoided.
The travel behavior with hoist control exhibits the following characteristics:
• Advanced calculation of the travel course from the starting position to the target position taking
account of the blocked regions.
• It is possible to disable the automatic target approach on the waterside (automatic mode - P109).
Automatic journeys are only possible in the land direction. This only applies when no external
targets are specified (bUse_Extern_Targets = 0 bit).
• To give the crane operator trust in the automatic target approach, the spreader is lowered after a
specific trolley position for each travel from the waterside to the landside. At the earliest, this
position is two spreader widths before the water/land boundary.
Both axes (hoist, trolley) must be in this basic operating mode and are controlled concurrently. The
transition to the "speed control" basic operating mode always effects the trolley travel and the hoisting
gear.
The hoist control is configured via parameters (notes, see Section 4.3).

The "speed control" basic operating mode is activated by setting the appropriate operating mode bit
"OM_Speed" on the axes (see Table 3-15, Table 3-13, control bits for trolley and hoisting gear).
Taking account of blocked regions

The principles for blocked regions are described in Section 2.3.3. Notes for considering blocked
regions are contained in Section 3.6.2.5.

Target generator
The Target generator function monitors the activities of the crane operator and "remembers" where
containers are picked up or put down. Once the "DCC_SCTargets" block is contained in the
"SwayControl" DCC plan, the "memory" for all travel movements in all basic operating modes will be
activated.
The "memory" on the waterside is cleared when the "Learn_Profile_Reset" (see Table 3-11, Common
control word) is set and consequently the internally learnt variable blocked regions deleted. This must
be done, at least, when the crane travels. The land position is retained, as it is assumed that the truck
track does not change.
If the target generator knows useful positions, the automatic approaches these independently at the
start of a travel operation. If, for example, a container has just been fetched from a truck, the next
logical position is the place where the previous container was put down (on the ship). The crane
recognizes whether the crane operator wants to load or unload.
The S7 interface (bits 2-4, Targets control word, Table 3-19) can be used to specify
• Stacking type
• Approach of the parking position
• Use of the lashing platform
The stacking type is the method of operation with which the automatic stacks the containers on the
ship. The options are column-by-column, row-by-row towards the land or row-by-row away from the
land.
Note
For the "row-by-row towards land" stacking type, the automatic does not go beyond the water-land
boundary; a subsequent manual travel must follow.
Note
If the stacking type is changed (also affects the selection of the parking position), all internally learnt
variable targets will be deleted and a manual travel is necessary. The current travel is terminated.
If a lashing platform is used, it will be integrated in the sequences.
WARNING
The lashing position should normally always be approached from above. This means that a fixed
blocked region must be defined below this position and two others that are higher, in front and
behind. The automatic mode then always lowers from above down to the lashing platform.
The on-the-fly unloading can also be used in the "hoist control" basic operating mode. The trolley and
the hoisting gear must be in this basic operating mode for this. Further information on the activation
can be found in Section 3.4.2, at

3.5 Activation of the AddOn Technologies in the Basic Technology
On-the-fly unloading.
3.4.4 Sway-c to load position (trolley)

The "sway neutralization to load position" basic operating mode (only for the version with camera) is
used to eliminate swaying movements of the load from standstill. The sway neutralization is linked to a
positioning, whereby the target position is the load position at the time when the basic operating mode
is activated.
The sway neutralization results in slight travel movements to both sides of the target position.
The signal sequence corresponds to that of the positioning.
3.4.5 Sway-neutralization to trolley position (trolley)

The "sway neutralization to trolley position" basic operating mode (only for the version with camera) is
used to eliminate swaying movements of the load from standstill. The sway neutralization is linked to a
positioning, whereby the target position is the trolley position at the time when the basic operating
mode is activated.
The sway neutralization results in slight travel movements to both sides of the target position.
The signal sequence corresponds to that of the positioning.

In the basic technology /Ref. 2, Sections 4.3.4 and 4.3.5/, there is an axis-related "SwayControl" basic
technology operating mode, with which the AddOn technologies (Section 1.1) are activated.
When the "SwayControl" basic technology operating mode is active, the entire motion control is
specified by the AddOn technologies (Fig. 2-2). Neither the motion control nor the monitoring is then
performed by the basic technology.
When the "SwayControl" basic technology operating mode is not active and consequently one of the
basic technology modes is active, the entire motion control and the monitoring are performed by the
basic technology. To prevent jerky movements when switching from an arbitrary basic technology
operating mode to the "SwayControl" basic technology operating mode, it is useful to run the used
AddOn technology/technologies in parallel despite inactivity.
The "SwayControl" basic technology operating mode is selected by the S7 controller in application
control word 1, bit 15. The basic technology returns the state of the "SwayControl" basic technology
operating mode axis related in application status word 1, bit 15. The other basic technology modes
may not be selected (application control word1, bit 9 to bit 14). Switchover to the "SwayControl" basic
technology operating mode is made only when all the conditions mentioned below are satisfied:
Prerequisites for the associated axis:
1. Selection of the "SwayControl" basic technology operating mode
2. No error is present
3. The drive is not in closed-loop control
4. Axis homed
In SIMOTION D, the Motion-In interface will be activated when the "SwayControl" basic technology
operating mode is selected. This means the speed setpoints are not transferred by the travel

commands to the technology object, but rather the speed setpoint is transferred directly from the
AddOn technology to the technology object.
Note
Irrespective of whether the "SwayControl" basic technology operating mode is active or not, an
additional speed setpoint is available from the basic technology (DCC block "DCC_StartPulse") in
mm/s for the hoisting gear. This prevents or reduces the "load sag" when starting the hoisting gear
with a suspended load.
Note
In master-slave operation or synchronous operation, the "SwayControl" basic technology operating
mode must be selected for both the master and the slave.
Note
The PLC must contain a logic for the selection of the basic technology operating mode that does not
select any basic technology operating mode in a fault situation.
The "SwayControl active" feedback (via HOIST1_APPL_ZSW1_BIT15 and
TROLLEY1_APPL_ZSW1_BIT15) sets the release for the "Trolley" and "Hoist" blocks in the "Sway
Control" AddOn technology.
Fig. 3-8: "Sway Control" release sequence

Section 1:
Activate the "SwayControl" basic technology operating mode via the basic technology. If a successful
activation is confirmed, the individual axes of the Add-on technology (trolley, hoist) can be released.
Section 2:
Normal operation with AddOn technology.
Section 3:
Deselect the "SwayControl" basic technology operating mode via the basic technology.

3.6 Sway Control Configurations

The sway control system is configured using parameters (Section 4.3) and can be controlled by the
PLC by setting various control bits.
3.6.1 Sway Control
3.6.1.1 Required blocks

PROFIBUS Length
address (byte)
3.6.1.2 Control in the "SC Speed Control" AddOn mode

In the "SC Speed Control" AddOn mode, the travel signal is set by actuating the master switch. If all
input signals are fault-free, the sway control system issues an actuator speed to the drives.
If one of the two direction signals is active, the brake must be opened. As long as the brake is closed,
an actuator speed is not output.
The travel signal can be reset when "bPos_Completed" (positioning complete) is signaled.
CAUTION
As soon as a drive axis of the sway control system receives valid travel signals, the actuating signals
should also be used for the drives. In the reverse case, if control is not requested by the
sway control system, the travel signals have to be reset. Otherwise there may be sudden travel
movements.
CAUTION
With an "EMERGENCY OFF" or "EMERGENCY STOP", the crane is stopped abruptly without
braking ramps or sway neutralization. The crane operator must take this into account.
Stopping through the specification of a speed setpoint of zero is recommended.

Fig. 3-9: Control in the "SC Speed Control" AddOn mode, hoisting gear
Fig. 3-10: Control in the "SC Speed Control" AddOn mode, trolley

Start of a travel motion
Requirements
The following is true for the "DCC_SCHoist" and "DCC_SCTrolley" blocks: All Boolean input signals
must be set or reset as described. The set velocity (rV_Set_HO, rV_Set_TR) is ZERO before travel
begin. All other signals should have a value within the value range (i.VR).
In this AddOn mode, only the following signals are taken into account on the "DCC_SCCommon"
block:
• The "iParSet" signal that transfers the number of the associated parameter set, and
• "bDig_Hoist_Dist_Corr" signal (see Sections 3.7.1.1 and 4.7.2.2).
Table 3-4: Assignment of the input signals for sway control
DCC_SCHoist DCC_SCTrolley DCC_SCCommon

De- De- De-
Name Name Name
fault fault fault
bRelease 1 bRelease 1 iParSet i.VR
bTravel 0 bTravel 0 bNo_Wait_Pos 1
bOM_Pos 0 bOM_Pos 0 bHoist_Man 0
bOM_Speed 1 bOM_Speed 1 bLocked_Bit0 0
bOM_Hoist_Control 0 bOM_Load_Pos 0 bLocked_Bit1 0
bLS_UP 1 bOM_Trolley_Pos 0 bSlackrope 0
bLS_DN 1 bOM_Hoist_Control 0 bBayscanner_Valid 0
bPreLS_UP 1 bSC_ON 1 bLearn_Profile_On 0
bPreLS_DN 1 bLS_FW 1 bLearn_Profile_Reset 0
bBrake_Closed 1 bLS_BW 1 bDS_ON 0
bFast_Stop 0 bPreLS_FW 1 bDig_Hoist_Dist_Corr i.VR
iOverride i.VR bPreLS_BW 1 bStart_2D_Calc 0
rField_Weak i.VR bBrake_Closed 1 bSpreader_LS 0
rS_Act_HO i.VR bSC_When_Stop 0 iLoad 0
rS_Set_HO_Extern i.VR bControlled_Stop 0 iDS_Width 5000
rV_Act_HO i.VR bFlying 0 iValue_Bayscanner 0
rV_Set_HO 0 bFast_Stop 0 iCount_Bayscanner 0
iOverride i.VR
rS_Act_TR i.VR
rS_Set_TR_Extern i.VR
rV_Act_TR i.VR
rV_Set_TR 0

A travel motion is triggered by setting the "bTravel" travel signal with the master switch and by
resetting the "bBrake_Closed" signal.
The following signal sequence is performed:
Fig. 3-11: Signal sequence at the start of a travel motion

Section 1:
The sway control system is activated and the "speed control" basic operating mode selected with help
of the "bOM_Speed" bit for all used axes.
Section 2:
The master switch is deflected. The travel signal must be set (see Section 3.2.1). If this is the case
and no fault is present, the direction signals, and thus the signals for opening the brake, are output
(see Section 3.2.2).
Section 3:
The brake is opened. The actuator signals are transferred to the drives.
End of a travel motion

The travel motion is complete when the actuator speed is small and the "bPos_Completed" positioning
status bit is set by the sway control system.
This requires that the set velocity (rV_Set_HO, rV_Set_TR) is set to zero.

Fig. 3-12: Signal sequence at the end of a travel motion for the "SC Speed Control" AddOn mode
Section 1:
Sway-controlled travel.
Section 2:
The travel has been terminated by the master switch; the actuator speed becomes smaller.
Section 3:
Actuator speed is ZERO which causes the "bPos_Completed" signal to be set.
Section 4:
The travel signal must be reset (see Section 3.2.1). This causes no direction signals to be output and
so the signal to close the brake initiated (see Section 3.2.2).
Section 5:
The brake has been applied.
Possible settings
Mode
Two different operating modes are possible for the trolley in the speed control:
• Mode 1: Sway control is active permanently.
The sway control function is already active when accelerating to a specified constant speed. In
this way, the load sway is suppressed during travel and has been eliminated when the constant
speed is reached.
• Mode 2: Sway control is only active when stopping.
In this mode the load sway is only eliminated when stopping. As with mode 1, the load sway has
been eliminated after stopping. The load sway is not corrected when starting.
The changeover is made with the command bit "SC_When_Stop" (= "sway control only when
stopping", Table 3-15, trolley control bits) from the crane PLC.
Activating/deactivating the sway control function

• The sway control function can be activated or deactivated by the "SC_ON" command bit (= " sway
control ON", see Table 3-15, trolley control bits). When the function is switched off, the controller
generates standard ramps corresponding to the set accelerations.
The internal activation of the sway control function is indicated by the "SC_State" status bit (= "sway
control ON", see Table 3-30, trolley status bits).
3.6.1.3 Control in the "SC Automatic" AddOn mode

For the "SC Automatic" AddOn mode, the "hoist control" mode is activated. In this AddOn mode, the
travel signal is triggered by the "Start Automatic" signal (e.g. by foot-operated pushbutton). If the
"bStart_Auto_OK" status bit is evaluated, the "minimum hoisting height on the landside" set in
parameter P66 must also be reached in addition to many internal conditions (e.g. no blocked regions
in the path). If all input signals are fault-free, the sway control system issues an actuator speed
determined by parameter P41 to the hoisting gear drive. Once the "Start_2D_Calc" signal is set in the
PLC, the travel curve can be calculated and actuating signals issued to the trolley drive. Parameter P1
determines the actuator speed of the trolley.

If one of the two direction signals is active, the brake must be opened. As long as the brake is closed,
an actuator speed is not output.
The travel signal can be reset when "bPos_Completed" (positioning complete) is signaled.
At the AddOn operating mode „SC Automatic“ the base operating mode „Hoist control” will be
activated. In this AddOn operating mode the travel signal will be started by the use of the “start
automatic” signal (e.g.: through foot button). The system checks if the automatic could start. The
reasons why an automatic start was not able could be read at the statal-word
“INFO_NO_AUTO_START“ (tableTable 3-26). If one of the conditions is not complied the statal-bit
„bStart_Auto_OK“ will not be set. An automatic start should only be happen when this bit is set.
CAUTION
If the signal „bStart_Auto_OK“ is not used for the start of the automatic, the PLC programmer has to
care for a suitable monitoring of the conditions which are listed at table 3-26.
If all input signals are faultless and the signal „Start_2D_Calc“ is set at the PLC the travel curve can be
calculated and a position velocities at the trolley and at the hoist can be put out.
The positioning velocity of the trolley will be determined by the parameter P1, the one of the hoist by
the parameter P41.
If one of the direction signals is activated the brake has to be opened. As long as the brake is closed
no position velocity will be put out.
The travel signal could put back when „bPos_Completed“ (positioning ready) will be send.
CAUTION
If the automatic travel is interrupted by signals (e.g. bRelease = 0), but the travel signal is not
present, the crane continues with automatic travel when the signal returns. Uncontrolled travel motion
can result. It is recommended that the travel signals are reset when automatic travel is interrupted.
CAUTION
If the "Start_2D_Calc" signal is removed during automatic travel, the crane stops with sway control,
as acceptance of obstacles during travel is prohibited.
Various setpoints and actual values can be checked during travel with the "Hoist control [6]" display
(see Section 4.4.6.1).

Fig. 3-13: Control in the "SC Automatic" AddOn mode, hoisting gear
Fig. 3-14: Control in the "SC Automatic" AddOn mode, trolley

Start of a travel motion
Requirements
The following is true for the "DCC_SCHoist" and "DCC_SCTrolley" blocks: All Boolean input signals
should be set or reset for a simple positioning as described. For at least one axis, the target position
must differ from the actual position (rS_Set_HO_Extern ≠ rS_Act_HO or
rS_Set_TR_Extern ≠ rS_Act_TR). All other signals should have a value within the value range (i.VR).
In this AddOn mode, all signals are used on the "DCC_SCCommon" block and many combinations are
possible. When the specified values are created, only those fixed blocked regions saved during the
commissioning in the parameter file are considered during the travel. The "bUse_Extern_Targets"
signal is automatically set to "1" internally in this configuration.
Für die Bausteine „DCC_SCHoist“ und „DCC_SCTrolley“ gilt: Alle booleschen Eingangssignale sollen
für einen einfachen Positioniervorgang wie beschrieben gesetzt bzw. zurückgesetzt sein. Bei
mindestens einer Achse muss die Zielposition ungleich der Istposition sein
(rS_Set_HO_Extern ≠ rS_Act_HO oder rS_Set_TR_Extern ≠ rS_Act_TR). Alle anderen Signale sollen
einen Wert innerhalb des Wertebereiches haben (i.WB).
Am Baustein „DCC_SCCommon“ werden in dieser AddOn-Betriebsart alle Signale verwendet und es
sind viele Kombinationen möglich. Bei Anlegen der vorgegebenen Werte werden während der Fahrt
nur die festen Sperrbereiche, die während der Inbetriebnahme in der Parameterdatei gespeichert
wurden, berücksichtigt.
Ist der Baustein „DCC_SCTargets“ nicht vorhanden, so werden als Zielpositionen immer die externen
Ziele verwendet. Bei Verwendung des Bausteins „DCC_SCTargets“ werden die Zielpositionen in
Abhängigkeit vom Bit „bUse_Extern_Targets“ benutzt:
• „bUse_Extern_Targets“ = 1: targets from PLC
• „bUse_Extern_Targets“ = 0:targets from target generator
Table 35: Assignment of the input signals for sway control with 2D Trajectory

De- De- De-
Name Name Name
fault fault fault
bRelease 1 bRelease 1 iParSet i.VR
bTravel 0 bTravel 0 bNo_Wait_Pos 1
bOM_Pos 0 bOM_Pos 0 bHoist_Man 0
bOM_Speed 0 bOM_Speed 0 bLocked_Bit0 0
bOM_Hoist_Control 1 bOM_Load_Pos 0 bLocked_Bit1 0
bLS_UP 1 bOM_Trolley_Pos 0 bSlackrope 0
bLS_DN 1 bOM_Hoist_Control 1 bBayscanner_Valid 0
bPreLS_UP 1 bSC_ON 1 bLearn_Profile_On 0
bPreLS_DN 1 bLS_FW 1 bLearn_Profile_Reset 0
bBrake_Closed 1 bLS_BW 1 bDS_ON 0
bFast_Stop 0 bPreLS_FW 1 bDig_Hoist_Dist_Corr i.VR


De- De- De-
Name Name Name
fault fault fault
iOverride i.VR bPreLS_BW 1 bStart_2D_Calc 0
rField_Weak i.VR bBrake_Closed 1 bSpreader_LS 0
rS_Act_HO i.VR bSC_When_Stop 0 iLoad i.VR
rS_Set_HO_Extern i.VR bControlled_Stop 0 iDS_Width 5000
rV_Act_HO i.VR bFlying 0 iValue_Bayscanner 0
rV_Set_HO i.VR bFast_Stop 0 iCount_Bayscanner 0
iOverride i.VR
rS_Act_TR i.VR
rS_Set_TR_Extern i.VR
rV_Act_TR i.VR
rV_Set_TR i.VR
A travel motion of the hoisting gear is triggered by setting the "bTravel" travel signal with "Start
Automatic" (e.g. foot-operated button) and by resetting the "bBrake_Closed" signal. The trolley can be
moved only when the "bStart_2D_Calc" bit is set on the "DCC_SCCommon" block and the travel curve
(i.e. the acceleration and speed change for the complete positioning) has been calculated. The travel
motion is interrupted with sway control and this bit is no longer set.
As in the other AddOn modes, the travel signals must remain set throughout the entire travel motion. If
a travel signal is cancelled, the actuating signals of both axes are immediately set to zero.
Fig. 3-15: Signal sequence at the start of "SC Automatic" AddOn mode
Section 1:
The sway control system is activated and the "hoist control" ("bOM_Hoist_Control" bit) basic operating
mode selected for the hoisting gear and the trolley. A target position has been specified.

Das Sway Control System ist aktiviert und für Hubwerk und Katze ist die Grundbetriebsart
„Hubwerksteuerung“ (Bit „bOM_Hoist_Control“) angewählt. Eine Zielposition wurde vorgegeben.
Section 2:
The automatic start (e.g. with foot-operated pushbutton) has been triggered. If no fault has occurred
that blocks this AddOn mode ("bStart_Auto_OK" bit set), the travel signal must be set. If this is the
case and no fault is present, the direction signals, and thus the signals for opening the brake, are
output.
Der „Start Automatic“ (z.B. mit Fußtaster) wurde ausgelöst. Ist kein Fehler aufgetreten, der diese
AddOn-Betriebsart blockiert (Bit „bStart_Auto_OK“ gesetzt), muss das Fahrsignal gesetzt werden. Erst
wenn alle externen variablen Sperrbereiche übertragen wurden, ist das Steuerbit „bStart_2D_Calc“
(Common-Block) zu setzen. Damit wird die Berechnung der Fahrkurve gestartet. Ist die Berechnung
abgeschlossen, werden Richtungssignale und damit die Signale zum Öffnen der Bremse ausgegeben.
Section 3:
The brake is opened. The actuating signal is issued to the drive for the hoisting gear and the
automatic positioning of the hoisting gear commenced. The field weakening is determined during this
hoist operation and the transfer of the external variable blocked regions terminated.
Die Bremse ist geöffnet. Die Stellsignale werden an die Katze und Hubwerk ausgegeben und mit der
Positionierung der beiden Achsen begonnen.
Der Hubvorgang beginnt mit 48% der Maximalgeschwindigkeit (P40). Während des Hebens wird die
Feldschwächung ermittelt und die Geschwindigkeit während der Fahrt angepasst
End of a travel motion

The travel motion in the "SC Automatic" AddOn mode is complete when the "bPos_Completed"
positioning status bit is set by the sway control system.
Requirements
• The actual position in the tolerance of the target position has been reached
(rS_Act_TR=rS_Set_TR_Extern ± tolerance, rS_Act_HO=rS_Set_HO_Extern ± tolerance).
• The "bSC_Completed" (sway-neutralized) bit at the "DCC_SCTrolley" trolley block is set. This is
achieved with a small load deflection.
For use of the on-the-fly unloading, the sum of the trolley position and the load deflection corresponds
to the target position and the trolley has come to a standstill. This bit is then held until the start of a
new motion although the load sways away from the target position.

Fig. 3-16: Signal sequence at the end of positioning in the "SC Automatic" AddOn mode
Section 1:
Sway-controlled travel of both axes to the target position.
Section 2:
Actual position (rS_Act_HO, rS_Act_TR) comes near the target position; actuator speed becomes
smaller.
Section 3:
Target position is attained, actuator speed is ZERO, which causes the "bPos_Completed" signal to be
set.
Section 4:
The travel signal must be reset (see Section 3.2.1). This causes no direction signals to be output and
so the signal to close the brake initiated (see Section 3.2.2).
Section 5:
The brake has been applied.
Possible settings
Manual hoisting motion during the "SC Automatic" AddOn mode

During an automatic positioning operation in the "SC Automatic" AddOn mode, the hoisting motion can
be diverted from the intended path by an external control.
The relevant monitoring functions and error messages are deactivated by setting the "Hoist_man"
control bit (= "Manual actuation of hoisting gear", see Table 3-11, Common control bits). The specified
target position is still approached by the trolley. The set "hoist control" basic operating mode does not
need to be switched here.
The sway control must be informed of the actuating signal via the "rV_Set_HO" hoisting gear speed
setpoint (see Table 3-13, hoist control bits) by the basic technology.

After resetting the "Hoist_man" control bit, the spreader is guided back to the calculated path with the
aid of the position controller.
Interruption of the "SC Automatic" AddOn mode

In the this AddOn mode, the travel motions can be interrupted at one of the positions (P25, P65)
specified with parameters, if the command bit "NO_WAIT_POS" (= "Wait position not approached",
see Table 3-11, Common control bits) is not set.
If a waiting position is to be controlled, approach is first made to the trolley position (P25) located on
the travel curve. Shortly before reaching this position, the hoisting gear will be lowered to the
parameterized value (P65). If the "NO_WAIT_POS" command bit is set before the waiting position is
reached, travel will be continued to the target position without interruption.
Start of the "SC Automatic" AddOn mode during a manual hoist operation with sway control
General
It is possible to start the "SC Automatic" AddOn mode during a manual hoist operation. In this way, the
crane operator can first lift the spreader out of the hazardous area and then switch to automatic
control without stopping. A field weakening coefficient "rField_Weak" (see Table 2-6, DCC_SCHoist
connections) for the hoisting gear can be calculated by the basic technology or taken externally from
the drives ("Override" signal, see Table 3-12, hoist control bits) and used.
Note
Protection must be provided in the PLC against an unintentional operator error, so that the "SC
Automatic" AddOn mode is stopped when the master switch is not released within two seconds after
the automatic start.
Start on the landside.

The following steps are performed when starting on the landside:
• Raising until the "Slack rope" signal (see Table 3-11, Common control word) is no longer set
• Slow hoisting to determine the field weakening coefficient (if supported by the crane control)
• Rapid hoisting
Alternatively, the start can be programmed exclusively from a hoisting movement through operating
mode control.
Start on the waterside
An automatic start is only possible on the waterside when no "Slack rope" (see Table 3-11, Common
control word) is detected and the hoisting gear is located above the immersion point (see following
section). If these conditions are satisfied, the following steps are performed:
• Slow hoisting to determine the field weakening coefficient
• Rapid hoisting
Start of AddOn „SC Automatic“ with slack rope

Should the operating mode „SC Automatic“ be started although the bit “slack rope” is set, the bit
„bSTART_AUTO_OK“ must not be evaluated.

Is P47 > 0 tuned, the automatic will start with a lower velocityt, till the bit “slack rope” isn`t set. If the bit
"slack rope“ is set continuously because of a defect, it will be lifted up to the maximum travalling area
or to the limit switch. The trolley will not drive
CAUTION
The monitoring of the load cell must be realised at the PLC. The PLC decides when the automatic
have to break.
Override
The travel speed can be reduced in all basic operating modes using an externally definable override
"Override" (see Table 3-12, hoist control bits) between 0% and 100%. This speed reduction is useful
for commissioning purposes (test with reduced speed).
The external override may change in steps. The effect is delayed as internal acceleration limits are
maintained.
A superimposed internal override takes effect when prelimit switches are triggered.

Fig. 3-17: Field weakening flow chart

The speed setpoint is specified in the "SC Speed Control" AddOn mode by the master switch and in
the "SC Automatic" AddOn mode by the internally calculated speed setpoint.
Use of the "bOpen_Grab" (open grab) status bit

The time after when the opening of the grab is possible is specified with parameter P31 (distance for
opening the grab) and triggers the setting of the "Open_Grab" status bit (see

Table 3-23, Common status bits). This bit can be used to open the grab.
The reset of this bit indicates that the grab can be closed again. The positioning control expects at this
time a new target (position over the ship) for the start of a new travel. The reset is triggered by
parameter P30 (on-the-fly unloading abort speed).
3.6.1.4 Control in the "SC Semi Automatic" AddOn mode

This AddOn mode is a combination of automatic and manual operation. One axis is in the "Positioning"
("bOM_Pos" bit) basic operating mode and the other axis in the "speed control" ("bOM_Speed" bit)
mode. The axis in the "positioning" basic operating mode continues to travel automatically to the
assigned target. Note that blocked regions are not considered. The crane operator controls the other
axis with the master switch in the "Speed control" basic operating mode. An application example for
this AddOn mode is the so-called hoisting gear acceptance.
Hoisting gear acceptance

For this operation, the sway control system is in the "SC Automatic" AddOn mode and travel has
started. The crane operator accepts the hoisting gear with the master switch, for example, to lower
faster.
When the trolley and the hoisting gear is in the "hoist control" ("bOM_Hoist_Control" bit) basic
operating mode, an operating mode switchover can be performed through actuating the master switch
with the following logic (Fig. 3-18).
• The basic operating mode of the hoisting gear is immediately switched to "speed control"
("bOM_Speed" bit).
• The basic operating mode of the trolley is switched to "positioning" ("bOM_Pos" bit) when the
"bHoist_TakeOver_OK" confirmation bit (bit 6 in the "ZSW1_Common_PLC" status word,

Table 3-23) is set. The trolley continues to travel automatically to the target.
• If the "bHoist_TakeOver_OK" bit is not set, the trolley will also be switched to the "speed control"
basic operating mode.
The "bHoist_TakeOver_OK" bit is set when a safe height is reached and consequently no blocked
region exists between the current position and the target position of the trolley.
Fig. 3-18: Hoisting gear acceptance

Fig. 3-19: Hoisting gear acceptance status diagram
Case A
Section 1:
Hoisting gear and trolley are in the "Hoist control" basic operating mode ("bOM_Hoist_Control" bit).
The hoisting gear is not yet at a safe height, i.e. the "bHoist_TakeOver_OK" confirmation bit is not yet
set.
Section 2:
The crane operator deflects the master switch and so requests a hoisting gear acceptance. Because
the danger of a collision still exists, this action must cause termination of the trolley motion. The trolley
and the hoisting gear are switched to the "speed control" basic operating mode ("bOM_Speed" bit).
Section 3:
Trolley and hoisting gear are in the "speed control" basic operating mode ("bOM_Speed" bit), the
crane operator has complete control over both axes with the master switches.
Case B
Section 1:
Trolley and hoisting gear are in the "hoist control" basic operating mode ("bOM_Hoist_Control" bit).
The hoisting gear is at a safe height, i.e. the "Hoist_TakeOver_OK" confirmation bit is set.
Section 2:
The crane operator deflects the master switch and so requests a hoisting gear acceptance. Because
no danger of a collision exists, the trolley and the hoisting gear can be switched to the "positioning"
basic operating mode ("bOM_Pos" bit) and the "speed control" basic operating mode ("bOM_Speed"
bit) respectively.
Section 3:
The trolley is in the "positioning" basic operating mode ("bOM_Pos" bit), i.e. it moves further in the
direction of the specified target without, however, taking account of any obstacles. The crane operator

is responsible for the safe height of the load. The crane operator has complete control over the
hoisting gear with the master switch.
Note
An acceptance of the hoisting gear from the automatic into the manual mode should be prevented by
the PLC when the master switch is actuated only very briefly (unintentional operator error). This
delays the acceptance of the hoisting gear into manual mode by the wait time.
Note
The conditions when the "SC Semi Automatic" AddOn mode should be cancelled are described in
Section 3.4.2.

3.6.1.5 Taking account of blocked regions

The principles for the blocked regions are contained in Section 2.3.3 and the notes for the behavior of
the system in Section 3.6.2.5.
DANGER
The blocked regions are only taken into account in the "Hoist control" basic operating mode. In all
other basic operating modes, also the "Positioning" basic operating mode, collisions can occur if the
crane operator is inattentive.
Note
For the calculation of the path curve, the PLC requires the position of the lower edge of the spreader
as the position to the hoisting gear (concerns hoist (TO) actual position).
Only fixed blocked regions can be considered in this AddOn.
3.6.2 SwayControl with 2D-Trajectory and Bay Scanning

PROFIBUS Length I/O address

Block Functions
address (byte) ranges
DCC_SCTargets
(optional; for use of the learning Targets 45 12 2092-2103
mode and the Bay Scanner)
Blocked
45 32 2104-2135
DCC_SCObstacles regions Block1
(optional; for transfer by PLC) Blocked
45 32 2136-2167
regions Block2

The control in the "SC Speed Control" AddOn mode is made in this configuration in the same method
of operation as for Sway Control (see Section 3.6.1.2). The statements concerning the parameter sets
also apply here (see Section 4.3).

3.6.2.3 Control in the "SC Automatic" AddOn mode

The control in the "SC Automatic" AddOn mode is made in this configuration in the same method of
operation as for Sway Control (see Section 3.6.1.3). The statements concerning the parameter sets
also apply here (see Section 4.3). In addition to the settings specified in Section 3.6.1.3, the following
functions can be controlled:
Possible settings
Target generator
In this configuration, the blocked regions on the waterside can be learnt by observing the spreader
motions. The learning process is started by setting the "Learn_Profile_ON" bit (bit 8 in the
"STW1_PLC_Common" control word, Table 3-11). In addition to learning the height profile, the
function "notes" where containers can be picked up or placed down. If the automatic control knows
useful positions, it approaches these independently at the automatic start. Further information for the
execution and for the target generator are contained in Section 3.4.3.
Position offset
To simplify the loading and unloading tasks above deck, the trolley position can be automatically given
an offset for the automatic target approach. A stop is made shortly before or after a calculated target.
The most recently approached target position is saved internally at the load change when loading or
unloading (logic combination of the interlock state change, the slack rope signal, load change cycle)
and an offset is added for the next target approach of the trolley.
Two different offset values can be saved in the P35 (position offset for unloading) and P36 (position
offset for loading) parameters. Depending on the locking state of the spreader, the corresponding
value in the target generator is used.
Selection possibility for the direction of the position offset
The "Offset_To_Land" and "Offset_To_Water" control bits (see Table 3-19, Targets control word) can
be used to select the offset increment in the water- or landside direction. The control can be made, for
example, from a Crane Operator Panel or a control element. A negative or a positive offset is added
for the next target position approach (trolley only). If none of the control bits is set, the trolley positions
again at the last target position.
Fig. 3-20: Normal path for container pick-up in automatic mode

Fig. 3-21: Changed stopping point in automatic mode with Offset_To_Land
Fig. 3-22: Changed stopping point in automatic mode with Offset_To_Water
Immersion point
The immersion point is activ at the STS crane. At the GSU crane the immersion point ist deactivated.
The immersion point is a conservative estimate of the hoisting height learnt by observing the manual
travel above which the trolley can be freely positioned above the ship. This means, no superstructure
(cell guides, frames for container fastening, etc.) is present above this height.
No automatic travel is possible here, because it is assumed that the spreader is located in the cell
guides or between two container stacks.
The following figure shows the principle of the immersion point. At point A, the immersion point is set
to a value that lies above the "real" deck height because the spreader immerses between two
container stacks. Under some circumstances, an automatic travel in this area would cause damage to
the ship and the crane. Point B lies approximately in the height of the ship deck and corresponds to
the begin of the cell guides.

Fig. 3-23: Principle of the immersion point

The "Learn_Profile_Reset" bit (bit 9 in the "STW1_PLC_Common" control word, Table 3-11) resets
both the immersion point and the height profile to their initialization values. The initialization value for
the immersion point results from P69 (maximum position for hoisting gear positioning) – 3*P108
(maximum container height).
The immersion point is set dynamically to the current hoisting height using two conditions:
• The trolley moves on the waterside above the speed limit P46 + 10%, the hoisting gear, however,
is located below the current immersion point.
• For the transition of the trolley speed from 10% above to 10% below the speed in parameter P46,
the current immersion point is set on the waterside. The value refers to the maximum speed of the
trolley.
Example (following figure):
P46: 20% (upper limit value: 30%; lower limit value: 10% of the maximum speed of the trolley)
P0: 3500 mm/s (upper limit value: 1050 mm/s (lower limit value: 350 mm/s)
Immersion point at the begin (before overtraveling the waterside): 31000 mm

Transition LS -WS
Trolley speed in mm/s
Hoistposition in mm
Old immersion point
Upper limit of trolley speed
New immersion point
Lower limit of trolley speed B
Time in s
Fig. 3-24: Setting the immersion point

The first condition is satisfied in the A area. The immersion point is rematched to the current hoisting
height in each cycle.
A traversal of the band between the upper and lower limit value for the velocity is then made in which
the immersion point is not updated.
The second condition takes effect at point B. The lower speed setpoint is undershot and the current
hoisting height is assigned as new immersion point. The new value for the immersion point is located
at approx. 18600 m.
3.6.2.4 Control in the "SC Semi Automatic" AddOn mode

The control in the "SC Semi Automatic" AddOn mode is made in this configuration in the same method
3.6.2.5 Taking account of blocked regions

The principles for blocked regions are described in Section 2.3.3.
DANGER
The blocked regions are only taken into account in the "Hoist control" basic operating mode. In all
other basic operating modes, also the "Positioning" basic operating mode, collisions can occur if the
crane operator is inattentive.

Note
as the position to the hoisting gear (concerns hoist (TO) actual position).
General features
Table 3-7: General features of the blocked regions
Fixed blocked regions Variable blocked regions

External Internally learnt
• By observation of the
Deletion and spreader movements in
Region menu in the
Input, edit and transfer via PLC manual operation
CeCOMM diagnostic
save before automatic
program, "B" key • By acquisition of the laser
start
values from the Bay Scanner
Maximum height of the
Default values hoisting gear if obstacles are
Saved regions in the
for the None to be learnt
parameter files
activation (bLearn_Profile_On = 1),
otherwise none
Spreader in the Although automatic starts, only the hoisting gear is

Automatic does not start
blocked region controlled until the blocked region is exited
Target in the The blocked region causes the trolley to be stopped

Automatic does not start
blocked region at the target position
List display of "Region menu" for

"Limit curve" screen page in CeCOMM (with the "G"
the blocked CeCOMM (with the "B"
key) (Section 4.4.6.2)
regions key) (Section 4.4.6.2)
Graphical
display of the CeCOMM diagnostic program, Diagram function in the X/Y representation
blocked (Section 4.4.9.4).
regions
External variable blocked regions

Transfer sequence for external variable blocked regions:
1. First delete all external variable blocked regions of the previous travel job.
2. Unsorted transfer of the current container stack via the PLC. The blocked regions are written with
the data field in the obstacles block (see Section 3.7.1.6), an array comprising five elements each
with three int32 values.
The external variable blocked regions can be taken over during travel. It is recommended that the
transfer of the external variable blocked regions be checked thoroughly before the commissioning.

Transfer
The transfer of a data set containing up to five blocked regions is performed with the following signal
assignment:
Fig. 3-25: Transfer of external variable blocked regions
Sequential transfer
If more than five blocked regions have to be transferred, the
transfer must be sequential, i.e. over several cycles.
A special control bit and confirmation bit are provided for this.
• The rising edge of the "Prg_Obst" control bit (bit 0 in the
"STW1_PLC_Obstacles" control word, Table 3-21)
transfers the blocked regions present on the Obstacles
block.
• The "PrgBlock" confirmation bit (bit 0 in the
"ZSW1_Obstacles_PLC" status word, Table 3-36) is set as
acknowledgment and the next block transfer can now
begin.
• The current total number of blocked regions in the sway
control system is returned in the "Number_Obst" data field
(SIMOTION → SIMATIC S7, Obstacles, see Table 3-35).
If zero values have been assigned to blocked regions, these
are not transferred and therefore less than five blocked
regions can be transferred.
The current list of transferred blocked regions can be

displayed in the diagnostic program on the screen page
"Limit curve" (with <G> key) (Section 4.4.6.2).
Fig. 3-26: Sequential transfer of external variable blocked regions

Delete
The deletion of external variable blocked regions is made with the following signal assignment:
Fig. 3-27: Deletion of all external variable blocked regions
The deletion of external variable blocked regions is performed

according to the same principle as the transfer, with two bits in the
interface section "Obstacles".
• The list of external variable blocked regions is deleted in the
sway control system by setting the control bit "Del_Obst" (bit 1
in the "STW1_PLC_Obstacles" control word, Table 3-21).
• The "Obst_Deleted" confirmation bit (bit 1 in the
"ZSW1_Obstacles_PLC" status word, Table 3-36) signals the
successful execution to the PLC.
• At the same time, the current total number of external variable
blocked regions in the sway control system in the
"Number_Obst" data field (SIMOTION → SIMATIC S7,
Obstacles, see Table 3-35) is set to zero and returned.
• Only the external variable blocked regions will be blanked in use
of the delete function. The internal variable blocked regions will
be survived. It is necessary to know how many learned variable
blocked regions are needed in order to prevent that the total
number of 200 will not be exceeded. For the number of the
transferable external variable blocked regions the following
applies:
Maximum value = 200 – Maximum internal learned blocked
regions
Fig. 3-28: Deletion of external variable blocked regions (sequence)
Internally learnt variable blocked regions

The height profile can also be learnt internally. It extends from the waterside start to end (parameters
P26 and P29). The following sequence must be followed:
1. First delete all internally learnt variable blocked regions.
2. Start the learning process by setting the "Learn_Profile_ON" bit in the Common block control word
This sets the blocked region for the waterside to the maximum position of the hoisting gear. .
Reset (delete) the internally learnt variable blocked regions (height profile)
The internally-learnt variable blocked regions (height profile) can be reset be setting the
"Learn_Profile_Reset" bit (bit 9 in the "STW1_PLC_Common" control word, Table 3-11). If the
"Learn_Profile_ON" bit is active at the same time, the waterside blocked region is set to the maximum
position of the hoisting gear, otherwise to the minimum position.

The "Learn_Profile_Reset_OK" confirmation bit (bit 4 in the "ZSW1_Common_PLC" status word,

Table 3-23) signals the successful execution to the PLC.
Fig. 3-29: Resetting all internally learnt variable blocked regions

The "Learn_Profile_Reset" bit must be reset after the deletion.
Note
The internally learnt height profile must always be reset at least when the crane traverses to a new
row of containers and starts with the loading or unloading.
A reset must also be performed when

• The "Crane OFF" signal has been pending for more than two minutes
• The crane jib is not down
• Errors occur in the trolley, hoisting gear and travelling gear (PLC) position sensors
• The variations of the redundancies are too large in the position mapping of the trolley and hoisting
gear
• A container has not been locked or unlocked for 15 minutes
Starting the learning process

Deletion of the blocked regions has priority over learning. Therefore, the "Learn_Profile_Reset" bit
must be reset for a learning process.
The learning process is started by setting the "Learn_Profile_ON" command bit (bit 8 in the
"STW1_PLC_Common" control word, Table 3-11). All motions of the spreader position independent of
the associated basic operating mode are logged as height profile and dynamically combined in
internally-learnt variable blocked regions. All blocked regions above the spreader at the current trolley
position are cut off because no obstacle can occur there.
The "Learn_Profile_On_OK" confirmation bit (bit 3 in the "ZSW1_Common_PLC" status word,

Table 3-23) signals the successful start to the PLC.
Note
An automatic start is not possible after the learning process has been started: Travel must first be
performed in manual operation.
During the learning process, the "Learn_Profile_ON" command bit must remain set in all basic
operating modes.
Fig. 3-30: Learning internal variable blocked regions
3.6.2.6 Double spreader in coupled mode

The operation of double spreaders is described in Section 2.3.3.4.
Note
as the position to the hoisting gear (relevant for hoist actual position (TO)). The middle of the
landside spreader is required for the position of the trolley (relevant for trolley actual position (TO)).
The operation of coupled double spreaders is activated by setting the "Spreaders_Coupled" control bit
(bit 12 in the "STW1_PLC_Common" control word, Table 3-11).
The current total of the double spreader "DS_Width" is required as further value (see Table 3-10). The
total width is taken into account in the calculation of the path curve and is displayed on the
"PROFIBUS-Interface [2]" display screen in the CeCOMM.
3.6.3 TLS Control

"TLS Control" controls the so-called trim, list and skew positions of a spreader. Basic information is
contained in Section 2.3.4.1.
Activation of the "TLS Control" AddOn

This AddOn is activated in parameter P197 ("Trim/List/Skew control") by enabling "Trim/List/Skew
control on".
The AddOn can be used independently of all other basic operating modes, AddOn modes and
AddOns.

PROFIBUS Length
address (byte)
DCC_SCTLS TLS 45 32 2060-2091

3.6.3.2 Control of the "TLS Control" AddOn
Activation and deactivation of the TLS commands

The "Trim", "List", "Skew" and "Approach zero position" TLS functions are activated by setting the
associated command bit on the "DCC_SCTLS" DCC block. The command bit serves as basis for
determining the set positions for each cylinder. The cylinder remains controlled until each cylinder has
reached its set position – even when the command bits have already been reset.
With the help of the status bits, the cylinder states are returned to the PLC and the hydraulic cylinders
controlled (binary move in/out bits).
Note
If, for technical reasons with one of the TLS commands the target is not attained within 30 seconds
after resetting the command bits, the control of the affected cylinder will be terminated.
Activation and deactivation of the Skew Control function

The Skew Control function is activated by setting the "Skew_Control" command (see Table 3-17, TLS
control word, bit 9). All other TLS command bits (Trim, List, Skew, "Approach zero position") are not
set.
A deactivation of the Skew Control function is disabled by resetting the "Skew_Control" command bit
or setting another TLS command bit.
The control of the skew control cylinder is terminated when
• The swaying of the internal skew model is less than the set residual sway, or
• The determined cylinder speed is less than the "TLS speed for zero signal" parameter (P186).
The following signal sequence is performed with activated Skew Control function during skew in
clockwise direction and the correction of the skew:
Fig. 3-31: Signal sequence with activated Skew Control function

Section 1:
Skew Control function is switched on. There is no skew.
Section 2:
Skew in clockwise direction starts. This resets the "Skew_Removed" status bit.
Section 3:
Skew is finished.

Section 4:
"Correct skew" is requested with the "No_Skew" control bit.
Section 5:
The "Skew_Removed" status bit is set when the skew is corrected. This signal can be used to reset
the "No_Skew" control bit.
Designation of the cylinders

The hydraulic cylinders are designated as follows:
Cylinder designation Carrying cable
A Landside, left
B Waterside, left
C Waterside, right
D Landside, right
Priorities
If several commands are present concurrently, the following priorities apply:
1. "Move_To_Zero" (highest priority),
2. Trim, list and skew commands and
3. "Automatic Skew Control".
Internal setpoints are calculated for each cylinder with all commands. Position controllers ensure that
each cylinder reaches the calculated target position. If, for example, one cylinder moves in or out
slower than the others, then it runs on for a certain time until it has also reached the target position.
The limit values that can be set for the trim, list and skew with the P194, P195, P196 parameters are
relative to the position saved with "Save_Pos_As_Zero" (= "Save zero position", see Table 3-17, TLS
control word). The limits are monitored in all directions. When the end positions are reached, further
movement in or out is prevented.
TLS commands
Trim
The inclination of the container is set left/right with the aid of the binary control commands "Trim_LH"
and "Trim_RH" (= "Trim left/right", see Table 3-17, TLS control word).
List
The inclination of the container to the landside/waterside with the aid of the binary control commands
"List_WS" and "List_LS" (= "List waterside/landside", see Table 3-17, TLS control word).
Skew
The skew is set with the aid of the binary control commands "Skew_CW" and "Skew_CCW" (= "Turn
clockwise/counterclockwise", see Table 3-17, TLS control word).

Approach/save zero position

The current cylinder positions can be saved with "Save_Pos_As_Zero" (= "Save zero position", see
Table 3-17, TLS control word) and automatically approached with "Move_To_Zero" (= "Approach zero
position", see Table 3-17, TLS control word).
Skew control
The "Skew_Control" command (= "Automatic skew control", see Table 3-17, TLS control word)
activates the automatic travel to the zero point with skew control. This command is preferred for the
automatic positioning operation of the trolley.
In this case, the target point is the last position set with the TLS or "Move_To_Zero" commands (and
not the position saved with "Save_Pos_As_Zero"). One last position is used for the waterside and one
for the landside. These two target points can only be learnt, not parameterized.
By setting the command "Use_Ext_Skew" (= "External rotational position", see Table 3-17, TLS
control word), the rotational position specified as "S_Skew_Extern" (= "Set angle", see Table 3-16)
converted into cylinder positions is used as target point rather than the internally saved last position on
the landside or waterside. The set angle must be specified in 1/100 degrees.
When the skew control is switched on, the "NO_SKEW" command (= "Correct skew", see Table 3-17,
TLS control word) can be used to correct the skew, without the list and trim being affected.
Hydraulic control
The hydraulic control uses the position data of the individual cylinders for
• The automatic travel to the target point and
• The switch-off at limit.
It calculates the cylinder speeds and the associated binary move in/out bits (see Table 3-32, TLS
status bits) that are used for the control of the hydraulics.
If at least one of the speeds is not equal to zero, one of the oil pressure signals is set according to the
following principle: If the set speed of at least one hydraulic cylinder exceeds the set speed limit, the
output signal "bOil_Pressure2" (oil pressure 2) is activated, otherwise "bOil_Pressure1" (oil pressure
1) (see Table 3-32, TLS status bits). The oil pressure signals can be switched off with a settable delay.
Confirmation that the zero position has been reached is signaled with the "bZero_Reached" bit (see
Table 3-32, TLS status bits).
The control bits for the skew are generated automatically internally based on the TLS commands. As
for the trolley and hoisting gear, status bits of the slewing gear ("bReady", "bActive",
"bPos_Completed", etc.) can be used for the monitoring of the TLS motions.

3.6.4 Sway Control with TLS Control

PROFIBUS Length
address (byte)
DCC_SCTLS TLS 45 32 2060-2091

The control in the "SC Speed Control" AddOn mode is made in this configuration in the same method
3.6.4.3 Control of the "TLS Control" AddOn

The control in the "TLS Control" AddOn is made in this configuration in the same method of operation
as for TLS Control (see Section 3.6.3.2). The statements concerning the parameter sets also apply
here (see Section 4.3).

3.7 PROFIBUS Interface
3.7.1 SIMATIC S7 → SIMOTION D for Add-on
3.7.1.1 Common
Table 3-10: SIMATIC S7 → SIMOTION, Common
PZD Signal name Unit Format Comment

Control word
1 STW1_PLC_Common - WORD
see below, Table 3-11
Load
2 LOAD 10 kg INT
see below
Parameter set
Number for the selection of the four
different parameter sets for "Sway
Control". For example, various speeds or
accelerations can be set in the associated
sets
1: parameter set 1
PARSET 1-255 SINT 2: parameter set 2
3
3: parameter set 3
4: parameter set 4
NOTE
If the upper or lower limit is violated,
the value is limited to the upper or
lower limit.
Reserved
4 Bay scanner value
VALUE_BAYSCANNER mm DINT
5 see below
6 Bay scanner counter

COUNT_BAYSCANNER - DINT
7 see below
Overall width of the double-spreader

8 DS_WIDTH mm INT operation
see below
9-12 Not used

VALUE_BAYSCANNER
Absolute height of the obstacle determined at the current trolley position. If the value is valid (see
STW1_PLC_Common, bit 7), this has priority over the curve calculated from the learnt blocked regions
(target generator).
COUNT_BAYSCANNER
Counter for the new value for the Bay scanner. This counter checks whether the transferred Bay
scanner value is a currently determined value or an old value. Because each scanner has its own
counter value, they are prepared by the PLC so that only one value is transferred to the sway control
system.
LOAD
The current load is determined by the load measuring system and transferred by the PLC to the sway
control system.
DS_WIDTH
In double-spreader operation, this value informs the sway control system how wide the two containers
are, incl. the spacing of the cylinders. The current total width (dynamic value) is expected, from the
outside edge of the container on the first spreader to the outside edge of the container on the second
spreader. The current total width is taken into account in the calculation of the path curve.
Table 3-11: STW1_PLC_Common
Bit Signal name Comment

0 Reserved
1 Reserved
Do not approach wait position
This bit specifies whether a waiting position, defined from the
trolley and the hoisting position, is to be approached. The
2 NO_WAIT_POS positions are defined in the P25 (trolley) and P65 (hoisting gear)
parameters.
0: Inactive
1: Active
Manual hoisting gear
If this bit is set, the hoisting gear can be raised manually without
having to change the basic operating mode. The specified target
3 HOIST_MAN position is still approached by the trolley.
0: Inactive
1: Active
Locking state of the spreader

00: No spreader locked
4 LOCKED_BIT0 01/10: Spreaders are partly locked. Spreaders are partly locked
• when only one spreader of a double spreader in coupled
mode has been locked or


• a 20-foot container has been locked on a spreader at
maximum width.
The travel curves are calculated as required with loaded
spreader. The automatic learning does not take account of the
height of the locked container.
5 LOCKED_BIT1 11: Spreaders are completely locked. The travel curves are
calculated as required with loaded spreader. The lower edge of
the container(s) is used to learn the blocked regions.
Note:
Left bit = LOCKED_BIT1
Right bit = LOCKED_BIT0
Slack rope
0: No slack rope
6 SLACKROPE 1: Slack rope available
NOTE
This bit has no effect in the "SC Speed Control" AddOn mode.
Bay scanner value valid
7 BAYSCANNER_VALID 0: Bay scanner values not valid
= 1: Bay scanner values valid
Learn height profile
If this bit is active, the permissible height profile is measured or
recorded during the spreader motion in manual operation based
on the position values of the trolley / hoisting gear in the
waterside area (parameterizable) and combined in internally
learnt variable blocked regions. No obstacle can exist at those
positions where the spreader is located.
These internally learnt variable blocked regions are then taken
into account in the "hoist control" basic operating mode when
8 LEARN_PROFILE_ON calculating the travel curve as superimposed motion of the
trolley and hoisting gear. At the same time, the external variable
and the fixed blocked regions are also included.
If the height profile has first been deleted and then the learning
bit set, a large blocked region is initialized first, which stretches
from the start of the waterside to the end of the waterside and
which is set to maximum hoisting height.
0: Do not learn
1: Learn


Delete height profile
This bit deletes a height profile that has been recorded up to that
point in time.
0: Do not delete height profile
9 LEARN_PROFILE_RESET
1: Delete height profile
NOTE
The height profile will be deleted only when the
"LEARN_PROFILE_ON" signal for learning is set to "0".
Digital center of gravity displacement
This bit displaces the weight center of gravity by a specified
amount (parameter P80). This is used to define two different
types of load carrying devices with different weight center of
10 DIG_HOIST_DIST_CORR gravities. The digital offset acts parallel to the analog weight
center of gravity taking account of the load weight.
0: Inactive
1: Active
Start 2D calculation
The bit informs the "Sway Control" that the calculation of the 2D
travel curve can be started. It should be set when all blocked
regions have been fully transferred and the field weakening is
valid (is evaluated in S7). The automatic mode performs the path
calculation and starts travel. If this bit is not set, only the hoisting
11 START_2D_CALC gear travels in automatic mode.
0: Inactive
1: Active
CAUTION
As soon as this bit changes from active to inactive, the crane
stops with sway control.
Spreaders coupled
Bit indicates whether the two spreaders are coupled when using
a double spreader. This has an effect on the calculation of the
12 SPREADERS_COUPLED path curve.
0: Spreaders not coupled
1: Spreaders coupled
13 Not used
14 Not used
15 Not used

3.7.1.2 Hoist
Table 3-12: SIMATIC S7 → SIMOTION, Hoist
Control word
1 STW1_PLC_Hoist - WORD
Speed limitation
2 OVERRIDE 0..100% INT
see below
3-6 Not used
OVERRIDE
This value can be used to limit the speed. With a value of 100, the path speed is not reduced, with 0,
the control stops the axis. This value can be used for the field weakening (see special functions).
Table 3-13: STW1_PLC_Hoist

Release
Hoisting release. The values are processed and actuator values
0 RELEASE issued. Can be used for disabling "Sway Control".
0: Emergency stop
1: Basic operating modes and travel signal are evaluated
Travel signal
A direction signal, with which the brake can be opened, is not
output until this signal is present. The current basic operating
1 TRAVEL mode is taken over.
0: Stop with maximum deceleration (P50), without sway control
1: Activation of the specified basic operating mode
"Positioning" basic operating mode
A set position is specified by the higher-level controller or the
internal setpoint encoder. In this basic operating mode, the
2 OM_POS hoisting gear travels to this position.
0: Inactive
1: Active
"Speed control" basic operating mode
The higher-level controller specifies a set speed.
3 OM_SPEED
0: Inactive
1: Active
4 Reserved
5 Reserved


"Hoist control" basic operating mode
If the trolley and the hoisting gear are in this basic operating mode
and target positions are specified for both axes, a calculated path
6 OM_HOIST_CONTROL curve will be travelled.
0: Inactive
1: Active
7 Reserved
Limit switch up
8 LS_UP 0: Actuated
1: Not actuated
Limit switch down
9 LS_DN 0: Actuated
1: Not actuated
Prelimit switch up
This bit is active only when P115 < 1. Otherwise the dynamic
10 PRELS_UP prelimit switch will be used.
0: Actuated
1: Not actuated
Prelimit switch down
This bit is active only when P115 < 1. Otherwise the dynamic
11 PRELS_DN prelimit switch will be used.
0: Actuated
1: Not actuated
Brake closed
Braking signal for hoisting gear.
12 BRAKE_CLOSED
0: Brake is open
1: Brake is closed, no motion possible
13 Not used
14 Not used
15 Not used

3.7.1.3 Trolley
Table 3-14: SIMATIC S7 → SIMOTION, Trolley

Control word
1 STW1_PLC_Trolley - WORD
Speed limitation
2 OVERRIDE 0-100% INT
see below
3-6 Not used
OVERRIDE
This value can be used to limit the trolley speed. With a value of 100, the path speed is not reduced,
with 0, the control stops the axis. This value can be used for the field weakening (see special
functions).
Table 3-15: STW1_PLC_Trolley

Release request
Release request for the trolley. The values are processed and
0 RELEASE actuator values issued. Can be used for disabling "Sway Control".
0: Emergency stop
1: Basic operating modes and travel signal are evaluated
Travel signal
A direction signal, with which the brake can be opened, is not output
until this signal is present. The current basic operating mode is taken
1 TRAVEL over.
0: Stop with maximum deceleration (P5), without sway control
1: Activation of the specified basic operating mode
"Positioning" basic operating mode
A set position is specified by the higher-level controller or the internal
setpoint encoder. In this basic operating mode, the trolley travels to
2 OM_POS this position.
0: Not active
1: Active
"Speed control" basic operating mode
The higher-level controller specifies a set speed.
3 OM_SPEED
0: Not active
1: Active
"Sway-neutralization to load position" basic operating mode
4 OM_LOAD_POS 0: Not active
1: Active
"Sway-neutralization to trolley position" basic operating mode
5 OM_TROLLEY_POS 0: Not active
1: Active


"Hoist control" basic operating mode
If the trolley and the hoisting gear are in this basic operating mode
and target positions are specified for both axes, a calculated path
6 OM_HOIST_CONTROL curve will be travelled.
0: Not active
1: Active
Sway control On
7 SC_ON 0: sway control not active
1: sway control active
Limit switch forward
8 LS_FW 0: Actuated
1: Not actuated
Limit switch backward
9 LS_BW 0: Actuated
1: Not actuated
Prelimit switch forward
This bit is active only when P115 < 1. Otherwise the dynamic prelimit
10 PRELS_FW switch will be used.
0: Actuated
1: Not actuated
Prelimit switch backward
This bit is active only when P115 < 1. Otherwise the dynamic prelimit
11 PRELS_BW switch will be used.
0: Actuated
1: Not actuated
Brake closed
Braking signal for the trolley.
12 BRAKE_CLOSED
0: Brake is open
1: Brake is closed, no motion possible
Sway control only when stopping
0: sway control is active for approaching and stopping
1: sway control is only active when stopping
13 SC_WHEN_STOP
NOTE
This bit acts only when bit 7 (SC_ON) has been set and the speed
control mode selected.
Controlled stop
Stop the trolley with normal deceleration and sway control
14 CONTROLLED_STOP
0: Not active
1: Active
With set bit and activated time-optimized control (parameter P152),
15 FLYING the target position is approached in "Positioning" basic operating
mode so that the trolley stops before the target and the load sways to
the target position. The bit has no significance in all other basic


operating modes or when the time-optimized control is deactivated.
0: No on-the-fly unloading
1: Positioning with on-the-fly unloading
3.7.1.4 TLS
Table 3-16: SIMATIC S7 → SIMOTION, TLS
WORD Control word

1 STW1_PLC_TLS -
2 Position cylinder A
POS_CYL_A mm DINT
3 see below
4 Position cylinder B
POS_CYL_B mm DINT
5 see below
6 Position cylinder C
POS_CYL_C mm DINT
7 see below
8 Position cylinder D
POS_CYL_D mm DINT
9 see below
10 Set angle
S_SKEW_EXTERN 1/100° DINT
11 see below
Spreader width
Depending on the spreader state, the following
values must be specified.
1: 20’
2: 30’
SPREADER_WIDTH 1-255 SINT 3: 40’
12 4: 45’
NOTE
In twin-operation, the value "4" must be
specified for a width of 45.
Reserved USINT
13-
Not used
16

POS_CYL_A/B/C/D
Position data from four hydraulic cylinders, which is used for the trim, list, skew and skew control. The
application is specified with the aid of parameters.
S_SKEW_EXTERN
External value for the set skew of the spreader by a specified angle.
Table 3-17: STW1_PLC_TLS

Trim right
0 TRIM_RH 0: No command
1: Incline to the right command
Trim left
1 TRIM_LH 0: No command
1: Incline to the left command
List waterside
2 LIST_WS 0: No command
1: Incline to the waterside command
List landside
3 LIST_LS 0: No command
1: Incline to the landside command
Skew in clockwise direction
4 SKEW_CW 0: No command
1: Rotate in clockwise direction command
Skew in counterclockwise direction
5 SKEW_CCW 0: No command
1: Rotate in counterclockwise direction command
Approach zero position
6 MOVE_TO_ZERO 0: No command
1: Move all cylinders to zero position command
Save zero position
7 SAVE_POS_AS_ZERO 0: No command
1: Save current cylinder positions as zero positions command
Correct skew
NO_SKEW 0: No command
8
1: Skew is corrected to zero in the "automatic skew control"
mode. Trim and list remain unchanged.
Automatic skew control
9 SKEW_CONTROL 0: No command
1: Suppress skewing motion automatically command

External rotational position

The internally learnt values are always used as target for trim
and list.
USE_EXT_SKEW 0: The internal rotational position is used separately according

10
to water- or landside as target in the "automatic skew control"
mode
1: The "S_SKEW_EXTERN" input value (set angle) is used as
target in the "automatic skew control" mode
11-15 Not used
3.7.1.5 Targets
Table 3-18: SIMATIC S7 → SIMOTION, Targets

Control word
1 STW1_PLC_Targets - WORD
LANE_SHIP_LOAD Loading the lane number

- SINT
see below
2
LANE_SHIP_UNLOAD Unloading the lane number
- SINT
see below
LEARN_POS_LANE Save position

- SINT
3 see below
Reserved
4 Not used
5 Not used
6 Not used
LANE_SHIP_LOAD/ UNLOAD
These values specify the numbers of the lanes on which the trucks are loaded or unloaded.
If there is only one number given for load or unload processes (e.g. LANE_SHIP_LOAD = 0 (no lane)
and LANE_SHIP_UNLOAD = 2 (lane 2)) the given lane takes effect for all load and unload processes
(in this case: lane 2).
The information, for example, is generated by the crane operator panel or a control element and is
transferred to the sway control system.
LEARN_POS_LANE
This value specifies which lane number is to be assigned to the current position (0Æ None; 1Æ Lane1;
2Æ Lane2, etc.). It is mainly used during the commissioning, but can also be used for later corrections.
This value, for example, is generated by the crane operator panel or a control element and is

The value must remain present until the "POS_SAVED" status bit (Section 3.7.2.5) provides the
confirmation that the position has been learnt. The brake must be applied during the learning process.
After being learnt, the value must be set back to "0".
Table 3-19: STW1_PLC_Targets

Save parking position
This bit is used for saving the current position as parking
position.
0 LEARN_PARK_POS
0: Do not save parking position
1: Save parking position
For more information, see below.
Save lashing position
This bit is used for saving the current position as lashing
platform.
1 LEARN_LASH_PLATF
0: Do not save lashing platform
1: Save lashing platform
For more information, see below.
Approach lashing position
This bit must be set if the lashing platform is to be approached
during loading or unloading. This signal, for example, is
2 USE_LASH_PLATF generated by the crane operator panel or a control element
and is transferred to the sway control system.
0: Do not approach lashing platform
1: Lashing platform should be approached
Stacking form
This signal, for example, is generated by the crane operator
3 STACK_FORM_BIT0 panel or a control element and is transferred to the sway
control system.
00: Parking position should be approached
01: Ship should be unloaded or loaded row-by-row from the
landside to the waterside
10: Ship should be unloaded or loaded row-by-row from the
waterside to the landside
4 STACK_FORM_BIT1 11: Ship should be unloaded or loaded stack-by-stack
Note:
Left bit = STACK_FORM_BIT1
Right bit = STACK_FORM_BIT0
Cycling
5 CYCLING This is a function that permits the concurrent loading and
unloading of a ship in a single cycle.
Offset landside
When positioning the trolley, an offset is added to the target
6 OFFSET_TO_LAND position on the landside. This signal, for example, is generated
by the crane operator panel or a control element and is


0: Offset landside is not active
1: Offset landside is active
Offset waterside
When positioning the trolley, an offset is added to the target
position on the waterside. This signal, for example, is
7 OFFSET_TO_WATER generated by the crane operator panel or a control element
and is transferred to the sway control system.
0: Offset waterside is not active
1: Offset waterside is active
Targets from PLC
This bit specifies whether the targets are specified by the PLC
8 USE_EXTERN_TARGETS or the internal target generator.
0: Targets from the target generator
1: Targets from the PLC
9-15 Not used
LEARN_PARK_POS / LEARN_LASH_PLATF
Although the control bits are used mainly for the commissioning, they can also be used for subsequent
corrections. The associated signal, for example, is generated by the crane operator panel or a control
element and is transferred to the sway control system.
The associated control bit must remain present until the "POS_SAVED" status bit (Section 3.7.2.5)
provides the confirmation that the position has been learnt. The brake must be applied during the
learning process. After the learning, the control bit must be reset.
3.7.1.6 Obstacles
Obstacles can be taken into consideration by the transfer of external variable blocked regions. The
functionality of the blocked regions is described in Section 2.3.3.
Table 3-20: SIMATIC S7 → SIMOTION, Obstacles
WORD Control word

1 STW1_PLC_Obstacles -
2 Sperrbereich1_Katzposition1
SET1_TR1 mm DINT
3 First trolley position for blocked region 1
SET1_TR2 mm DINT
5 Second trolley pos. for blocked region 1
6 Sperrbereich1_Hubposition
SET1_HOIST mm DINT
7 Hoisting position for blocked region 1
SET2_TR1 mm DINT


SET2_TR2 mm DINT
SET2_HOIST mm DINT
SET3_TR1 mm DINT
SET3_TR2 mm DINT Second trolley position for blocked region
17 3
SET3_HOIST mm DINT
SET4_TR1 mm DINT
SET4_TR2 mm DINT
SET4_HOIST mm DINT
SET5_TR1 mm DINT
SET5_TR2 mm DINT
SET5_HOIST mm DINT
32 Reserved
Blocked region data sets

The interface allows for each transfer a data set with up to five blocked regions. Not only a start and
an end position of the trolley, but also the associated hoisting position, can be specified for each
blocked region. An unused blocked region contains the value zero for all three entries. The transfer of
the blocked regions to the sway control system is described in Section 3.6.2.5.
Table 3-21: STW1_PLC_Obstacles

Programming blocked regions
0 PRG_OBST Bit for acceptance of the external variable blocked regions
used to calculate the path curve. Zero data sets are


ignored. This bit can also be set from the motion.
0: Do not accept
1: Accept (see Section 3.6.2.5)
Delete blocked regions
Bit to delete the variable blocked regions.
1 DEL_OBST
0: Do not delete
1: Delete
2-15 Not used
3.7.2 SIMOTION D for → SIMATIC S7 Add-on
3.7.2.1 Common
Table 3-22: SIMOTION → SIMATIC S7, Common

Status word
1 ZSW1_Common_PLC - WORD see below, Table 3-23
2 Fault message 1 from Add-on
FAULT1 - DWORD
3 technology, see below Table 3-24
4 Fault message 2 from Add-on

FAULT2 - DWORD
5 technology, see below Table 3-25
Automatic start information

6 Contains information for the visualization
INFO_NO_AUTO_START - DWORD for which reason an automatic start is not
7 possible. (Bit 5‚ "START_AUTO_OK" is
not set) see below, Table 3-26
Parameter set confirmation
Confirmation of the number of the
parameter set used for "Sway Control".
PARSET_OUT 1-255 SINT 1: Parameter set 1
8
2: Parameter set 2
3: Parameter set 3
4: Parameter set 4
Reserved
9-12 Not used

Table 3-23: ZSW1_Common_PLC

0 Reserved
1 Reserved
Waiting position is not approached
2 NO_WAIT_POS_OK Confirmation of the general "NO_WAIT_POS" command bit.
The hoist control does not stop.
Height profile learnt
3 LEARN_PROFILE_ON_OK Response bit for "Learn height profile" mode is activated.
The height profile is being learnt.
Height profile deleted
4 LEARN_PROFILE_RESET_OK Response bit for the deletion of the internally learnt variable
blocked regions. The height profile has been deleted.
Automatic start permitted
Bit for releases of the automatic without a fault message
5 START_AUTO_OK
being issued. An exact explanation why a start is not
possible can be seen in Table 3-26.
Hoisting gear acceptance allowed
This bit is set at the height above which the trolley
positioning motion starts. A manual acceptance of the
hoisting gear is possible as of this time. If this bit is not set,
6 HOIST_TAKEOVER_OK
no manual control for the hoisting gear may be permitted
during the automatic trolley travel. A collision with obstacles
could occur. In this case, the automatic must be aborted for
the trolley and the hoisting gear.
Open grab
0: Grab can be closed
1: Grab can be opened
7 OPEN_GRAB
This bit serves as control signal for opening and closing the
grab. The time of opening is specified by parameter P31;
the time of closing is specified by parameter P30.
8-
Not used
15

Table 3-24: FAULT1

An error has occurred while loading the parameter
0 Invalid parameter file files. Parameter files are missing or are faulty. The
relevant parameter set will be set to default values.
An unavailable basic operating mode or several basic
operating modes cannot be selected at the same time.
1 Invalid basic operating mode The error message also appears when the "Hoist
control" basic operating mode has been selected for
only one axis.
2 Reserved
A basic operating mode has been selected, but there is
3 Under-licensing
no license for this.
The target position of the trolley is outside the set
4 Invalid target position
limits.
5 Reserved
Start of positioning with too much The positioning motion was started when there was too
6
swaying much swaying.
The sway control function has been switched off as the
7 sway control Off (pendulum length)
hoisting height is not within the specified limits.
8 Reserved
Invalid basic operating mode at the Only the "Speed control" basic operating mode is
9
limit switch permitted at the limit switch.
Because of large swaying movements, the damping
10 sway control temporarily reduced factor for the trolley or the slewing gear has been
temporarily significantly reduced for stability reasons.
The trolley, the hoisting gear or the slewing gear are
11 Speed error not moving, are moving too fast or in the wrong
direction.
12 Camera measuring system faulted The camera does not identify a reflector any more.
The DCC chart is faulty At least one DCC block is
13 Fault in the DCC chart
missing for the selected application.
The software copy protection is damaged. The sway
14 Copy protection damaged
control function is deactivated.
15 Load stuck The load has stuck when starting to move.
An attempt has been made to transfer more than 200
16 Too many variable blocked regions
variable blocked regions.
The load is in a fixed blocked region at the time a
Starting point in fixed blocked
17 travel operation is started with hoist control. The travel
region
job is not executed.
The load is in a variable blocked region at the time a
Starting point in variable blocked travel operation is started with hoist control. This
18
region warning does not result in a cancellation and remains
pending until the region is exited.
Because of large swaying movements, the damping
19 sway control temporarily reduced factor for skewing has been temporarily significantly
reduced for stability reasons.
20-
Reserved
23


A travel job in the "Hoist control" basic operating mode
24 Group error abort, hoist control has been aborted. Refer to other error messages for
the exact cause of the error.
The target position is in a fixed blocked region. A travel
25 Target in fixed blocked region
job is not generated.
The target position is in a variable blocked region. The
26 Target mislaid travel job is started. Positioning stops before/above the
variable blocked region.
Position setpoint in fixed blocked The position setpoint calculated during a travel
27
region operation has violated a blocked region.
The actual position has violated a fixed or variable
28 Actual position in blocked region blocked region. The course has deviated too far from
the setpoint.
The difference between the actual and the set position
29 Following error, trolley
is greater than the set permissible following error.
The difference between the actual and the set position
30 Following error, hoisting gear
is greater than the set permissible following error.
The hoist control could not find a path between the
31 No path found
starting position and the target position.
Table 3-25: FAULT2

0-31 Reserved
Each fault is represented by a bit. The "FAULT2" fault word has been added as reserve. Several faults
can be present concurrently in both error messages. Both doublewords are always evaluated.
The messages described below are used primarily to detect why an automatic start is not possible.
The messages can be forwarded to a crane operator panel or a display element in the crane operator
cabin.
An assignment of the individual bits to the CePLuS error numbers and recommended categories is
made in a subsequent section (see Table 4-9).

Table 3-26: INFO_NO_AUTO_START

Target position not in permitted limits
Target position not in permitted
0 Target position is not within the set limits for the
limits
positioning.
Starting position not in permitted limits
Starting position not in
1 Starting position is not within the set limits for the
permitted limits
positioning.
Starting position in a fixed Starting position in a fixed blocked region
2
blocked region Current starting position is in a fixed blocked region.
Target position in a fixed Target position in a fixed blocked region
3
blocked region Target position is in a fixed blocked region.
No path found
4 No path found A travel curve cannot be calculated for the starting and
target point by the target generator.
Starting position is same as target position
The starting position is the same as target position. This
Starting position is same as prevents an automatic start. If the trolleyposition is less
5
target position then the double positioning accuracy to the target
position, the bit will be issued.The auto start bit will not
be set.
Initial sway
6 Initial sway
The initial sway is too large for automatic operation.
Slack rope on the waterside
7 Slack rope on the waterside An automatic start is not possible on the waterside with
slack rope.
Hoisting gear below immersion point
Hoisting gear below immersion
8 No automatic start when the hoisting gear is below
point
immersion point.
Target mislaid
9 Target mislaid The automatic mode starts, but is stopped before/over
the variable blocked region.
10-31 Not used
3.7.2.2 Hoist
Table 3-27: SIMOTION → SIMATIC S7, Hoist
WORD Status word

1 ZSW1_Hoist_PLC -
2 Not used
3 Not used
4 Not used
5 Not used
6 Not used

Table 3-28: ZSW1_Hoist_PLC

Ready
0: The actuator speed is zero, an emergency stop has been
0 READY performed
1: The drive axis is ready for operation and is activated by setting a
basic operating mode and the travel signal activated
Active
ACTIVE 0: The actuator speed is zero
1
1: The drive axis is active and outputs the currently required actuator
speed
Positioning complete
0: The target position has not been reached yet, the actuator speed is
2 POS_COMPLETED not equal to zero
1: The target position has been reached (positioning, hoist control) or
setpoint and actuator speed are zero (speed control)
3 Reserved
Raise travel direction (path values become larger)

4 TRAVEL_UP 0: Actuating signal is negative or zero
1: Actuating signal is positive
Lower travel direction (path values become smaller)
5 TRAVEL_DN 0: Actuating signal is positive or zero
1: Actuating signal is negative
6-15 Not used
3.7.2.3 Trolley
Table 3-29: SIMOTION → SIMATIC S7, Trolley

Status word
1 ZSW1_Trolley_PLC - WORD
2 LOAD_DEFL_TR ± mm INT Load deflection, see below
3 Not used
4 Not used
5 Not used
6 Not used
LOAD_DEFL_TR
Current load deflection. Relative position difference between the trolley and load.

Table 3-30: ZSW1_Trolley_PLC

Ready
Response to the release request.
READY 0: The actuator speed is zero, an emergency stop has been
0
performed
1: The drive axis is ready for operation and is activated by setting a
basic operating mode and the travel signal activated
Active
ACTIVE 0: The actuator speed is zero
1
1: The drive axis is active and outputs the currently required actuator
speed
Positioning complete
0: The target position has not been reached yet, the actuator speed is
POS_COMPLETED not equal to zero
2
1: The target position has been reached (positioning, sway
neutralization, hoist control) or setpoint and actuator speed are zero
(speed control)
Sway neutralization complete
0: The swaying motion of the load is greater than the specified
3 SC_COMPLETED tolerance
1: The swaying motion has been eliminated within the specified
tolerance
Travel direction forwards (path values become larger)
4 TRAVEL_FW 0: Actuating signal is negative or zero
1: Actuating signal is positive
Travel direction backwards (path values become smaller)
5 TRAVEL_BW 0: Actuating signal is positive or zero
1: Actuating signal is negative
6 Reserved
Sway control On
7 SC_STATE 0: The sway control function is not active
1: The sway control function is active
8-15 Not used
3.7.2.4 TLS
Table 3-31: SIMOTION → SIMATIC S7, TLS
WORD Status word

1 ZSW1_TLS_PLC -
Speed cylinder A
2 SPEED_CYL_A mm/s INT
see below
Speed cylinder B
3 SPEED_CYL_B mm/s INT
see below


Speed cylinder C
4 SPEED_CYL_C mm/s INT
see below
Speed cylinder D
5 SPEED_CYL_D mm/s INT
see below
6-16 Not used
SPEED_CYL_A/B/C/D
Actuator speed for all four TLS hydraulic cylinders relative to the TLS cylinder maximum speed (P183
in the CePLuS parameter file).
The output actuator speed of the cylinders is always positive. The direction is determined by the
signals for extending or retracting the cylinders (see Table 3-32).
Table 3-32: ZSW1_TLS_PLC

Move cylinder A out
0 MOVE_OUT_CYL_A
Control signal for extending cylinder A
Move cylinder B out
1 MOVE_OUT_CYL_B
Control signal for extending cylinder B
Move cylinder C out
2 MOVE_OUT_CYL_C
Control signal for extending cylinder C
Move cylinder D out
3 MOVE_OUT_CYL_D
Control signal for extending cylinder D
Move cylinder A in
4 MOVE_IN_CYL_A
Control signal for retracting cylinder A
Move cylinder B in
5 MOVE_IN_CYL_B
Control signal for retracting cylinder B
Move cylinder C in
6 MOVE_IN_CYL_C
Control signal for retracting cylinder C
Move cylinder D in
7 MOVE_IN_CYL_D
Control signal for retracting cylinder D
Oil pressure 1
8 OIL_PRESSURE1
Select pressure 1 (cylinder speed 1)
Oil pressure 2
9 OIL_PRESSURE2
Select pressure 2 (cylinder speed 2)
Zero position reached
10 ZERO_REACHED All cylinders are in the tolerance range around the zero
position.
11 Reserved
Skew eliminated
12 SKEW_REMOVED The skew has been eliminated. Trim and list have not
been changed.
13 Not used
14 Not used
15 Not used

3.7.2.5 Targets
Table 3-33: SIMOTION → SIMATIC S7, Targets

Status word
1 ZSW1_Targets_PLC - WORD
Loading the lane number confirmation
LANE_LOAD_OK - SINT
see below
2 Unloading the lane number
LANE_UNLOAD_OK - SINT confirmation
see below
3-6 Not used
LANE_LOAD_OK/UNLOAD_OK
Confirmation of the lane number for loading/unloading (1..155) for the values present at
"LANE_SHIP_LOAD"/"LANE_SHIP_UNLOAD" (Table 3-18). This signal can, for example, be
forwarded to the crane operator panel or used by the PLC to release the automatic. Automatic may be
permitted only when the signaled value and the confirmed value are identical.
Table 3-34: ZSW1_Targets_PLC

Position learning successful
0 Position learning unsuccessful
0 POS_SAVED 1 Position learning successful
This bit is used for the confirmation of the successful learning of
the positions for parking, lashing platform and lane.
Next target in the landside direction
If a target position has been entered for the trolley or determined
1 DIRECTION_LAND
by the target generator, which, compared to the current position,
lies in the land direction, this bit is set.
Next target in the waterside direction
If a target position has been entered for the trolley or determined
2 DIRECTION_WATER
by the target generator, which, compared to the current position,
lies in the water direction, this bit is set.
3-15 Not used
3.7.2.6 Obstacles
Table 3-35: SIMOTION → SIMATIC S7, Obstacles
WORD Status word

1 ZSW1_Obstacles_PLC -
Number of blocked regions
2 NUMBER_OBST - INT
see below
3-32 Not used

NUMBER_OBST
Number of variable blocked regions transferred after the last deletion.
Table 3-36: ZSW1_Obstacles_PLC

Blocked regions programmed
0 PRG_OBST_OK Confirmation of the general command bit "Program
blocked regions". The blocked regions are saved.
Blocked regions deleted
1 OBST_DELETED Confirmation of the general command bit "Delete blocked
regions". The blocked regions have been deleted.
2-15 Not used

Commissioning AddOn Software 4
4.1 Requirements
The following requirements for the commissioning of the AddOn software must be satisfied:
1. All components of the system must be installed, connected, functional and interconnected
2. Installation and start of the CeCOMM diagnostic program (Section 4.4.2) on the commissioning
PC.
3. Setting of the IP address of the commissioning PC in accordance with the SIMOTION (same
subnet).
4. When a camera is used, the camera measuring system must be operational (Section 4.5.8).
4.2 Ethernet communication
4.2.1 General information

The connection between the following components is implemented with Ethernet using the TCP/IP
network protocol (Fig. 4-1):
• Camera and the Add-on function in the SIMOTION D (1)
• Camera and the CeCOMM diagnostic tool (2)
• Add-on function in the SIMOTION D and the CeCOMM diagnostic tool (3)

Commissioning AddOn Software
Fig. 4-1: Ethernet communication

Whereas dashed connections ((2) and (3)) are only present during the diagnosis or commissioning,
solid connections are always present.
The Ethernet connection between the SIMOTION D and the CeCOMM diagnostic tool (3) requires a
JAVA application. This JAVA application (Buffer.jar) and the "DCC_SCCommon" block on the
SIMOTION D control both the communication and the data flow.
Note
The JAVA application is not part of the SCOUT project, but is contained on the supplied CD. The
customer must copy this application to the CF card of the SIMOTION D (Section 2.4.16).
The continuous communication between the Add-on functions on the SIMOTION D and the camera
(1) is not performed directly but using FB blocks. The interface is described in more detail in the next
section.
4.2.2 SIMOTION D for Add-on CenSOR M

Fig. 4-1 shows schematically the signal flow between the camera, the commissioning tool and the
SIMOTION D components.
It shows that the "FB_Receive_Analysis" and "FB_Send_Preparation" ST programs perform the
communication between the "DCC_SCCamera" DCC block and the camera. The sequence chain is
described in Section 2.1.2.
The IP address and the port of the camera are stored in retentive variables. This information is
available when the SIMOTION D is restarted and forwarded to the "DCC_SCCamera" block.
If the IP address of the camera is changed, this new address must be notified to both the
SIMOTION D and the camera via CeCOMM.

4.2.2.1 SIMOTION D → CenSOR M

The SIMOTION D data on the CenSOR M camera measurement system has the following structure:
Table 4-1: SIMOTION D → CenSOR M
BYTE Signal name Unit Format Comment

1-4 Reserved
Ext_Dist
5-8 DISTANCE_PLC ± mm DINT
External distance
DISTANCE_PLC:
The distance between the camera and the reflector measured using an encoder. This value is
forwarded by the PLC via PROFIBUS DP to the SIMOTION D and then to the camera.
4.2.2.2 CenSOR M → SIMOTION D

Table 42: CenSOR M → SIMOTION D

1 Status word
ZSW1_SC_CAM - WORD
2
3 Error message 1
EW1_SC_CAM - WORD
4 see below, Table 4-4
Deflection in the X direction
5-8 X_POS ± mm DINT Deviation of the reflector position from the
zero position in the X direction
Deflection in the Y direction
9-12 Y_POS ± mm DINT Deviation of the reflector position from the
zero position in the Y direction
Skew
± cgr
13-16 ROTATION DINT Deviation of the reflector position from the
(1/100°)
zero position with regard to skew
Distance between camera and reflector
17-20 DISTANCE_CAM + mm DINT Relative position difference between camera
and reflector
21-24 V_X ± mm/s DINT Velocity in the X direction
25-28 V_Y ± mm/s DINT Velocity in the Y direction
29-32 V_ROTATION ± cgr/s DINT Speed of rotation
33-36 V_DISTANCE ± mm/s DINT Distance change


Message frame counter
Message frame The SIMOTION D uses the unsigned counter
37-40 - DINT
counter to detect whether a new message frame has
been received
The following figure illustrates the CenSOR M measured values for the distance values.
Fig. 4-2: Graphical representation of the CenSOR M measured values
Table 4-3: ZSW1_SC_CAM

0 Reserved
1 Reserved
The signals report the calibration status of the camera
2 Calibration status 1 measurement system (commissioning step 4). Two calibration steps
exist. The calibration is complete when both signals are set. The
signals are normally linked with lamps.
3 Calibration status 2 0: Calibration step not completed

1: Calibration step completed
Flashing: Calibration currently being performed
The signal is negated cyclically after 200 ms. It confirms that the
4 Watchdog
endless loop of the controller is being processed
5-15 Not used
Table 4-4: EW1_SC_CAM

An error has occurred while loading the parameter files. One or
0 Invalid parameter file more parameter files is missing or faulty. The relevant
parameter set will be set to default values.

4.3 Configuration of the Add-on Functions

1 Reserved
A calibration was started by pressing the rotary switch on the
Camera measuring connection box or in the commissioning menu of the diagnostic
2 system not calibrated program and has not yet completed. The camera measuring is
deactivated until the calibration has completed.
Soiling or poor lighting and visibility conditions has caused a
Camera measuring
3 reduction in the quality of the camera measuring. The reflector,
system impaired
however, is still recognized sufficiently well.
Camera measuring
4 The camera does not identify a reflector any more.
system faulted
5 Invalid distance The externally specified distance lies outside the set limits.
6-15 Not used
4.2.3 Parameter assignment / addressing

For the communication between the components, the SIMOTION D must make the IP address
available to the camera. The camera is delivered with a predefined IP address.
If the IP address of the camera is changed, this new address must be made available to the
SIMOTION D. The CeCOMM diagnostic software (see Section 4.3) is used for this purpose. After
calling the Parameters menu with the "P" key and calling the "I" function, follow the instructions.
Default settings
IP address of the camera 192.168.1.155
Camera port 8500

The Add-on functions are configured during the commissioning using the CeCOMM diagnostic
program (Section 4.4) by setting parameters. These parameters are values and settings that do not
change continually during crane travel (such as maximum speed, accelerations, maximum positions,
etc.). The parameters are stored in parameter sets. They are loaded at each restart and can be used
for the calculations.
Parameter sets
Four parameter sets are provided. They are stored as text file in the /SWAYCONTROL/ directory on
the SIMOTION D CF card. The files are named Par0.txt, Par1.txt, Par2.txt and Par3.txt files. If no
parameter sets are available at the start of the program or if they are faulty, all parameters are set to
their default values.
CAUTION
The parameter sets are numbered 1 to 4 in the CeCOMM diagnostic program. Therefore, file Par0.txt
contains parameter set 1 and Par3.txt parameter set 4.
If, when loading, a parameter exceeds the specified limits, an error message is generated and the
value of the relevant parameter is set to the default value. The error is only reset after all parameter
sets have been loaded successfully.

The current parameter set is defined by control bits in the Common block (see Table 3-10). All
parameter sets can be edited irrespective of which parameter set is switched active by the control bits.
Switching the parameter sets

Note
The control response or the configurations can be changed by switching the parameter sets. In
conjunction with control elements, the crane operator can select a desired configuration.
Different parameter sets can be used, for example, when different speeds and/or accelerations should
be used.
The parameter P101 "Parameter set locked during travel“ can be used to prevent the switching of
parameter sets during travel.
Input and editing of parameters

To input and edit parameters, the Parameters menu is called from the main menu or another display
screen with the "P" key (Section 4.4.6.2). The Parameters menu contains an overview of the
parameter groups that can be displayed in short form, page-by-page via the keys "1", "2", etc.
Parameters that differ from the default values are identified by a "+". When "?" and the parameter
number is entered, a detailed explanation of the parameter is displayed together with the current,
default, minimum and maximum values.
The parameter can be changed with "C" and the parameter number. Only values in the range between
the fixed minimum and maximum values can be entered for the parameter.
If acceleration parameters less than 20 are entered, these values are interpreted as times and
converted to the corresponding parameter values.
CAUTION
Always use the parameter menu of the "CeCOMM" diagnostic program to edit the parameter sets.
The files can be destroyed when an editor is used.
Note
Detailed information about the parameters is contained in Section 5.3.1, Section 5.3.2 and the online
help.
Saving parameters, effect

Note
Each changed parameter takes effect immediately, but is not stored permanently. Changed
parameters should be confirmed with "OK" and then saved permanently with "S" (saving of all
parameter sets and fixed ranges). All parameter sets are saved.
Note
Changes to parameters P100 – P104, P106 and P110 take effect in all parameter sets, otherwise
only in the respective, active parameter set.

4.4 CeCOMM commissioning software
CAUTION
The semiautomatic commissioning sets parameters only in the current parameter set.
Note
A documentation of all set values can best be created with the functions Parameter listing ("L"),
History call ("F2"), Select (e.g. CTRL+A) and Save ("F4").
Note
All parameters, whose setting during the commissioning is not absolutely necessary and therefore
not described explicitly in the appropriate sections, should be left with their default settings and only
changed when problems occur.
4.4.1 Introduction
The diagnostic program is used for the commissioning, parameterization and diagnosis of the Add-on
technology on the SIMOTTION D and the CenSOR camera
This program can be used for the following tasks:
• Check and change the current parameter settings
• Check the current camera image
• Record curves
• Transfer updates
• Save and load parameter sets
Prerequisite for the diagnosis and commissioning is the Ethernet connection of the laptop/PC with the
SIMOTION D and the CenSOR M camera.
Note
The following sections describe the principle of the structure and the operation of the diagnostic
program. The displayed menus and functions can differ for the diagnosis or commissioning because
of the connected sway control system.
4.4.2 Installing software

The CD contains a commissioning and diagnostic program. The installation that can be made on any
PC or laptop is started from the CD drive by executing the "Setup CeComm.exe" file.

Note
The program can run under the WINDOWS 2000 or WINDOWS XP operating systems. This requires
that the user is logged on to the PC as administrator.
The installation program leads you step by step through the whole installation process. After the
installation, the diagnostic program is available under "Windows Start Æ Programs".

For the commissioning and diagnosis, the IP address of the commissioning laptop/PC must lie in the
same subnet as the SIMOTION.
Note
Any 'personal firewalls' (e.g. Windows Firewall for Microsoft XP) should be deactivated or exceptions
permitted. The correct operation of the "CeCOMM" diagnostic program requires unrestricted access
to specific ports (FTP, Telnet).
4.4.4 Operation
General
The diagnostic program consists essentially of four parts (Fig. 4-3):
• Windows menu (Section 4.4.5)
• Icons for establishing the communication
• Functions (Sections 4.4.6 to 4.4.12)
• Status bars

Fig. 4-3: General structure

The Windows menu functions are located in the upper area. The icons for establishing the
communication are located below.

After the successful connection to the devices, the following Functions are available on the tabs:
– Monitor: Display all diagnostic information, change parameters, display error
messages, etc.
– Image: Load the current camera image
– Explorer: User interface for copying, renaming, editing, etc. files
– Diagram: User interface for recording, saving and loading curves
– Web server: Use of the Web server available on the target system
– Telnet: Establish connection to the sway control system with Telnet
– Calibrate hoisting height:Tool for calibrating the hoisting height
Note
Most of the available functions can be operated using a button (e.g. "F2 - History") and also the key
(e.g. "F2") shown on the button. The following description only describes the button.
Note
The displayed menus, functions and dialogs in the function part depend on the connected sway
control system and so can vary greatly.

The "Monitor" function and its subfunctions have a monitor status line in the last line used to display
information and enter values. The Windows status line contains the IP address of the connected
device, the interface version and the version of the sway control system and the loaded *.ini file. The
icon can also be used to keep the window in foreground, even when it is not active. Pressing the
icon again deactivates this function.
Establishing the communication
After the program start, one of the icons must be used to establish the
connection to the devices using the COM or Ethernet interface.
The connection is established in four successive phases:
Phase 1 The application attempts to reach the

SIMOTION D or the CenSOR M using
the set IP address.
Phase 2 The node can be reached in the

network and a connection established..
Phase 3 The current version of the application

will be loaded.
Phase 4 The language files will be loaded

appropriately for the current
configuration.
Note
After a SIMOTION/camera restart (switch-on process, general reset) phases 1, 2 and 3 can take as
long as one minute. In this case, to allow the connection to be established correctly, the
communication should not be disconnected.
If a connection cannot be established check the adjustment of the interface at the diagnosis PC and
at the commissioning tool „CeCOMM“.Maybe the "CeCOMM" commissioning tool and the sway
control system must be restarted.

4.4.5 Windows menu functions
4.4.5.1 Windows menu function File
Open
When the connection is established, the software detects automatically the connected hardware
(SIMOTION D, CenSOR M, etc.) and loads the associated *.ini file from the program directory.
The "INI" file contains all settings and properties for the diagram (such as data selection, colors, line
thicknesses).
If these settings are to be saved and reused with a different name, this can be realized using the "File /
Save as" and "File / Load" Windows menu items.
If these *.ini files are deleted unintentionally, new files will be created using the default settings.
Save as
The settings for the diagram can be saved in an *.ini file.
Note
For all changed properties (F8), the properties of the diagram will be saved automatically in the
DiagXXX.ini or DiagXXX_engl.ini file in the program directory or the currently set directory and file
name.
Reload last chart

This function loads the last recorded chart.
Connect/disconnect network drive

These are the usual Windows Explorer functions for the connection and disconnection of drives.
Properties
This function is only active in the "Explorer" tab and opens the Windows properties window when a file
or a folder is selected.
4.4.5.2 Windows menu function View

The "View" Windows menu function can be used to call all functions provided on tabs.
4.4.5.3 Windows menu function Options

Note
The Windows "Send text file", "Save image content" and "Start cemgr" menu functions are available
only when the "Monitor" function (tab) is active.

Send text file

Note
This Windows menu function is available only for the commissioning and diagnosis of the camera.
This function sends a prepared text file similar to the batch file to the Shell, a part of the operating
system on the camera. This text file is used for the simple execution of saved MS-DOS commands
and command sequences.
Save image content

This function is used to save the content of the current screen (e.g. display screen 1 = kinematics) in a
text file (*.txt) that can be opened with a simple editor.
Start cemgr
This function is provided for service purposes and serves to start the program in debug mode.
Ping
This function can be used to quickly test whether a connection from the diagnostic tool to the camera
or to the SIMOTION D exists. The following screenshot shows a successful connection request.
Fig. 4-4: Ping to the camera
Interface
The IP address of the attached device can be changed using this function. It is also possible to
configure the connection type and the associated required interfaces.
Fig. 4-5: Configuration of the IP address

Language
German and English are currently available. It is possible to switch from one language to the other at
any time. The current language of the diagnostic program will also be set on the target system when
the connection is made to the target system.
Auto configuration
When this function is activated, the program detects automatically the connected hardware
(SIMOTION D, CenSOR M, etc.) and loads the associated *.ini file.
Configuration file
The DiagHPC.ini configuration file will be loaded and can be edited.
Choose Root directory

This function is only active in the "Explorer" tab and opens the root directory of the camera.
Set System time

At the camera the time won`t be permanent saved.If the camera reboot the time will be set to 0. At the
connection building between camera and diagnosis tool the system time of the programming PC will
be automatic transferred. With help of the function “Set System time” the system time could
transferred manually.
4.4.5.4 Windows menu function Calculations
Position parameters
This tool can be used to calibrate the sensor data. The associated measurement data and the
required position data are entered. The required conversion factors of the measurement data for
position data will be displayed.
Fig. 4-6: Calculations position parameters

Speed parameters
The crane manufacturers frequently specify the crane-specific P1 – P5 parameters in units that cannot
be used directly in the parameters. This function is used for the simple conversion of the specified
crane data into mm/s and mm/s².
Fig. 4-7: Calculations speed parameters
4.4.5.5 Windows menu function Help
INFO
The version number of the program is displayed under Info.
Help for CeCOMM

Note
This function is available only for the commissioning and diagnosis of the camera.
This menu entry provides help for using the CeCOMM diagnostic program.
Load online help

The commissioning help will be uploaded from the associated connected device or system and
displayed in HTML format.
4.4.6 Monitors
General information
When the space bar is pressed, all available keyboard commands will be displayed.
Note
The displayed menus, functions and dialogs in the function part depend on the connected sway
control system and so can vary greatly.

Fig. 4-8: Monitor - Main menu

To trace the performed diagnostic steps, for copying or for the improved view of scrolling windows
(e.g. Parameter Listing), the "F2 - History" button can be used to display all previous steps. When this
history function is called, the display screen will have a gray-colored background. After marking the
required text using <CTRL>-<A> or <CTRL>-<C>, the "F4 - Save as…" button will be enabled and this
selection can be saved with an entered name (see next figure).

Fig. 4-9: Marked text section from the parameter list

The "F3 - Return to monitor" button returns to the monitor function.
The functionality of the monitor function can be divided into three groups:
• Display screens
• Parameterization menus
• Special functions
4.4.6.1 Monitor display screens

Depending on the target system, different display screens are available.
The display screens are called from the main menu using the appropriate keys (e.g. "1" for
"Kinematics", Fig. 4-10).

Fig. 4-10:Monitor - Kinematics display screen, sway control system

The "1" to "7" keys can be used to change arbitrarily between the display screens. Pressing the space
bar causes the main menu to be displayed.
In general, the values displayed in the individual screens are self-explanatory because of their labeling
and layout.
Some of the values are explained in greater detail below.
Load deflection/angle - "Kinematics [1]" display screen

The load deflection is the deviation of the load from the rest position. It is displayed in the "Kinematics
[1]" display screen below the acceleration value (previous figure). The load deflection in the trolley
direction is on the left-hand side and is specified in mm. The deviation of the load from the rest
position during skew (Skew Control) is an angle and is specified in cgr on the right-hand side.
Effective pendulum length - "Kinematics [1]" display screen

The effective pendulum length is the basis for the calculation model for the prevention of swaying. It is
displayed in the "Kinematics [1]" display screen for swaying in the trolley direction and the swaying
during the skew (Skew Control) below the laser value (previous figure).
The effective pendulum length for the swaying in the trolley direction is the distance between the
suspension point and the load center of gravity. For the slewing gear or the skew for the TLS (second
value), the effective pendulum length is a virtual pendulum length. It is the length with which the
skewing motion is eliminated when the same swaying duration as for the swaying movement is
assumed. The swaying duration of the skewing motion is also independent of the load length. The
factor between the pendulum length of the skewing motion and the offset are determined with the

"calibrate hoisting height" commissioning step and, depending on the spreader type, saved in the P89,
P90 (20 ft), P91, P92 (30 ft) or P93, P94 (40 ft) parameters.
Laser and Lanes - "Hoist control [6]" display screen
Fig. 4-11:"Hoist control" display screen, sway control system

The following displays are available for the laser scanner
Laser
Measured height above zero.
Count
Used for control: Will be increased continually when a new valid value comes from the PLC. Because
only the last two places are displayed, it starts at zero again at overflow.
Distance
The distance is the position difference of the trolley between two valid heights from the laser scanner.
At this distance, the height of the obstacles is set to the higher value.
Laser Freq.
Displays the frequency of how many cycles of the SIMOTION D a valid value comes from the laser
scanner. Notes for the validity of the laser values are described in Section 4.7.4.
The selected Lanes for loading and unloading are displayed for the laser values. If only one lane is
specified, the other lane receives the same number.

Monitor Logger Listing

For a fault analysis, it is important to know under what conditions the phenomenon or unwanted
behavior occur. To receive an indication when which input signal changes, the signal sequence of
selected input signals is recorded. Such examples are the setting of the basic operating mode, target
positions and override.
The "L" key in the "Monitor" function can be used to display the logged signals. The maximum number
of entries is 9999. If this number is reached, the first entries will be overwritten.
Fig. 4-12: Monitor - logger listing
Content
1. Column: Sequential number of the entry
2. Column: Time of the event in the format "hh-mm-ss.ms"
3. Column: Name and content of the changed signal
Particularly important signals, such as the basic operating modes, are color-highlighted.
The following functions are available for operating this screen:

H – Home
Display the first page
E – Endpos
Display the last page

B – Backw
Scroll back one page
F – Forw
Scroll forward one page
S – Save
Save the logged signal sequences in the "Logger.txt" file in the /SWAYCONTROL/ directory
RETURN – Refresh
Update this page
ESC – Escape
Exit this display screen
4.4.6.2 Monitor menus and special functions
General information
The target systems offer various Parameterization menus.
The functions described below are examples implemented in this or similar form on all target systems.
The menus and special functions can be called from the main menu and from the display screens. The
menus contain various subitems documented in the menu tree(section 5.4.1.1) and whose use is
largely self-explanatory. The current menu will be displayed after the subitem has been completed.
The menus are closed with the ESC key and with the last-called screen displayed.
Parameters menu
The Parameters menu can be called from the main menu and all display screens with the "P" key (Fig.
4-13). All parameters can be displayed, changed, saved and copied in this menu.
Note
Only those parameters are displayed that correspond to the setting of parameter P100 (= access
code).
The following access codes are available:

Access code 0 – crane operators, maintenance staff
Access code 1 – commissioning engineers
Access code 2 – service technicians and specially trained commissioning personnel
Access code 3 – development engineers

Fig. 4-13: Monitor - Parameters menu

The digits "1" to "12" can be used to display the parameters as groups. The "1" to "12" keys can be
used to change arbitrarily between the display screens of the parameters. From these display pages it
is also possible to execute the functions of the parameter menus.
Note
Whereas the "C – Change parameters" and "F – Search parameters" functions refer to individual
parameters, all others apply to the complete parameter set.
C – Change parameters
After pressing the "C" key, the parameter number must be entered (e.g. "1" for parameter P1) and
closed with <ENTER>. The new value is then entered and confirmed twice with <ENTER>.
Changed parameters are marked with a "+" and a different font color in the displays ("1" … "12").
Note
Each changed parameter takes effect immediately, but is not stored permanently. Changed
parameters should be confirmed with "OK" and then saved permanently with "S" (saving of all
parameter sets and fixed ranges). All parameter sets are saved.

D – Set default values

The "D" key can be used to delete all previous settings and to load the initial settings.
I – Communication addresses
The address of the camera can be set here.
S – Save all parameter sets and fixed areas
This function saves and accepts all changed settings.
N – New parameter/area set
This loads a different parameter set. The required number must be entered and confirmed with
<ENTER>.
Y – Copy parameter/area set
This function can be used to copy all ("A") or only a part (<ENTER>) of the parameters from the
loaded parameter set into one of the three other parameter sets. The number of the target parameter
set must be entered.
L – Parameters/area listing
List all parameters. "F2 - History" can be used to view the list.
R – Reload parameters
Load all parameters of the current parameter set. This is useful when a parameter has been changed
and the previous version should be restored. If a parameter set is copied into the directory, the
parameters must also be reloaded for updating.
P – Search parameters
A search term can be entered. All parameters that contain this search term will be listed.
Commissioning menu
The commissioning menu can be called from the main menu and all display screens with the "I" key.
All commissioning steps are performed in this menu.
The commissioning steps depend on the associated attached device. A detailed description for the
commissioning steps for Sway Control on the SIMOTION D is contained in Section 4.7.2.1. The
commissioning steps for the camera are described in Section 4.5.8.2.
Monitor special functions

The special functions
– E– Faults
– G– Display limit curve
– H– Faults history
– S– Shell
– V– Version information
– X– Simulation of the loading
– !– Stop diagnosis,
are called from the main menu and from the display screens.
The "Faults" special function lists all currently pending faults. The "?" key and input of the fault
number (e.g. "12") can be used to display a more detailed description of the fault.

Faults marked red are forwarded to the PLC and the crane operator panel. The faults marked green
have the status of a warning and are not forwarded to the PLC.
The "Faults history" special function lists all faults that have occurred previously. All faults marked
with an asterisk * are still active.
Note
All faults are listed just once in the "Faults history" screen with the system time of the last occurrence,
even if they have occurred several times.
The appropriate letter (E, H) can be used to switch between the "Faults" and "Faults History"
functions.
For the fault analysis, the "Monitor" function also contains the "L – Listing of logger" display screen
that displays all changing and recorded input signals.
The "Display limit curve (G)" function displays the external variables and internally learnt blocked
regions ).
The "Version information (V)" function displays information about the current version.
The "Shell" function is available only for the diagnosis of the camera and is used to monitor the boot
process and to change special settings. The function can be called only when a connection to the
camera using the serial interface has been established.
The "Simulation of the loading (X)" special function is used during the commissioning of the hoisting
gear to test the correct functioning of the automatic mode. Pressing the "x" key in all display screens
simulates the locking of a container, and when pressed again the unlocking. The current state is
shown in the status line.
CAUTION
Only an empty spreader can be simulated as being loaded. Consequently, in simulation mode, the
internally learnt obstacles are corrected as if a container were locked to the spreader. In such a state,
travel must be performed at an adequate height (> max. container height P108) above the actually
existing obstacles. Otherwise collisions can occur during automatic operation.
The "Stop diagnosis (!)" special function is provided for service purposes.
All special functions should preferably be closed using the "ESC" key. The last-called display screen is
then displayed.
4.4.7 Image - checking the camera image

Note
This function is available only for the commissioning and diagnosis of the camera.
This function provides support during the commissioning, checks the calibration and determines the
height in which the reflector will no longer be recognized.

CAUTION
If this function is used during crane travel, errors can occur with the calculation of the control
algorithm and a correct travel can no longer be guaranteed.
After activation of the "Image" function and pressing the "F5 - Update" button, the current camera
image will be loaded (only CenSOR M).
Fig. 4-14:Image function

The "Image" function provides the following additional functionality:
• Display a fast image sequence
The display of a fast image sequence is started with the "F2 - Multi-Burst" button. The number of
images to be recorded is set in the side listbox and decremented after the start. "F3 - Stop" can be
used to cancel this display prematurely.
• Display a live image
The "F4 - Live" button is used to continually display live images.
• Save image
The "F6 - Save image" button is used to save the current image in "*.JPG" format.
• Display a crosshair
To improve orientation, the "F7 - Crosshair" button displays a crosshair.
4.4.8 File manager

The file manager can be used to edit, copy, rename and delete files. Directories can be created.

Note
The displayed files in the function part depend on the connected sway control system and so can
vary greatly.
Fig. 4-15:Explorer function

Prerequisite for the correct function is the correct assignment of the IP address and the connected
device in the "Options/interface" Windows menu function.
4.4.9 Diagram – user interface for recording curves

The "Diagram" function is a user interface for recording, loading and saving characteristic and signal
curves.
Basically there are two diagram types:
• Path/speed time diagram
This diagram displays the signal characteristics (speed, path, degree) over time. All curve
characteristics of the calculated and actual speeds and paths (upper area) as well as all states of
the input/output bits from and to the PLC on the sway control system (lower area) can be tracked
(Fig. 4-16, left-hand side).
• X/Y diagram
The path characteristics for two axes in the X/Y plane with displayed fixed and variable blocked

regions can be monitored. Although a cyclical refreshing of the blocked regions in the self-learning
mode on the waterside is possible and useful, it requires a higher process time (Fig. 4-16, right-
hand side).
The recorded measured values are used for both diagram types. F11 or F12 can be used to switch
between the diagram types.
Path/speed time diagram X/Y diagram

Fig. 4-16:Diagram function
4.4.9.2 Procedure for recording diagrams

The "F2 - Start" button is used to select which axes are affected, and which axes and parameters are
to be recorded. The "Diagram view" window with the "Axes", "Main values", "Input bits" and "Output
bits" tabs appears.
Fig. 4-17:Diagram function, F2 - Start, Axes tab
The following settings can be made in the "Axes" tab:

• Axes – Trolley, Hoist, Skew
The required axes will be activated.

• Recording cycle
If the recording takes a long time, the number of values to be recorded per time unit can be
reduced. For a "1" setting, a value will be recorded for each sampling time (camera = 70 ms); for
a "10" setting, a value will be recorded only every tenth sampling time (camera = 700 ms).
• Delete diagram
The diagram will be removed.
• X/Y display
This function is not supported. To display the X/Y diagram, the "position setpoints" and "actual
position values" must be recorded. They will be selected automatically when the checkbox is
activated.
The recording task is starting with the "F2 - Start" or "F4 - Start Trigger" button. When started with
the "F4 - Start trigger" button, the recording is performed only when the crane moves, otherwise
immediately and permanently. The "Diagram view" window will be closed automatically.
The crane can now be operated so that the interesting states are visible. The recording phase can be
monitored online on the screen and starts displaying the signal characteristics over time. It is,
however, possible to switch to the X/Y diagram at any time. The recording is completed with the "F3 -
Stop" button (next figure).
Fig. 4-18:Diagram function, completing the recording

To improve clarity, the number of parameters to be recorded can be restricted. This is done using the
"Main values", "Input bits" and "Output bits" tabs of the "Diagram view" window.
The following settings can be made in the "Main values" tab (next figure):
• Values to be transferred
Activate all interesting parameters to be displayed as curves in the upper half.
• All ON
Select all parameters.
• All OFF
Select no parameters.

Fig. 4-19:Diagram function, F2 - Start, Main values tab

The following settings can be made in the "Input bits" and "Output bits" tabs:
Fig. 4-20:Diagram function, F2 - Start, Input and output bits tab

• Bit signals from/to PLC
Selection of the bits from and to the PLC displayed in the diagram (lower area).
• All ON
Select all parameters.
• All OFF
Select no parameters.
• Recording ON
If this checkbox is deactivated, the recording of the bits can be completed without losing the
settings of the parameters to be selected.
However, it is also possible to record all parameters first and then restrict the recording using the "F7 -
View" button.

4.4.9.3 Elements and functionality of the diagram user interface
General information
The user interface displays the signal characteristics with a legend on the right-hand side in which
individual or just a few parameters can be selected. If the user moves the mouse cursor over the
curves, the current X- and Y-values will be displayed dynamically in the corners, as shown in the
following figure.
Fig. 4-21:Diagram function, display elements

Because of the size relationships, the speed values and the load deflection and the curves for the path
are located on the left-hand axis and right-hand axis, respectively, in the path/speed time diagram.
The signals are displayed only as numeric values without unit so that the user can arbitrarily assign
the curves to the axes. The default assignment of the signals to the axes and the associated unit are
described in the following table:

Table 4-5 Description of the analog signals
Short designation Meaning Axis Unit

Trolley
VSet ext. trolley Trolley set speed specified from the master switch Right mm/s
VSet int. trolley Trolley set speed using the set ramps Left mm/s
VActuator trolley Trolley speed calculated by the oscillation model Left mm/s
VActual trolley Trolley actual speed Left mm/s
Trolley model Load deflection calculated by the model (deviation of Left mm
the load from the rest position)
Trolley camera Load deflection recorded by the camera (deviation of Left mm
SSet trolley Position setpoint, trolley Right mm
SActual trolley Actual position, trolley Right mm
SDelay trolley Position after the set delays Right mm
VDelay trolley Actuator speed after the set delays Left mm/s
P104 Trolley Variable value that depends on the setting in the Right Variable
Parameters menu
Hoisting gear
VSet ext. hoisting Hoisting gear set speed specified from the master Right mm/s
gear switch
VSet int. hoisting Hoisting gear set speed using the set ramps Left mm/s
gear
VActuator hoisting Hoisting gear speed calculated by the oscillation model Left mm/s
gear
VActual hoisting Hoisting gear actual speed Left mm/s
gear
SSet hoisting gear Hoisting gear set position Right mm
SActual hoisting Hoisting gear actual position Right mm
gear
SDelay hoisting Position after the set delays Right mm
gear
VDelay hoisting Actuator speed after the set delays Left mm/s
gear
P104 Hoist Variable value that depends on the setting in the Right Variable
Parameters menu
Slewing gear
VSet ext. slewing Slewing gear set speed specified from the master Right cgr/s
gear switch
VSet int. slewing Slewing gear set speed using the set ramps Left cgr/s
gear
VActuator slewing Slewing gear speed calculated by the oscillation model Left cgr/s
gear
VActual slewing Slewing gear actual speed Left cgr/s
gear
Slewing gear model Rotation angle calculated by the model (deviation of Left cgr
the load from the zero point)
Slewing gear angle Skewing angle recorded by the camera (deviation of Left cgr


SSet slewing gear Position setpoint, slewing gear Right cgr
SActual slewing Actual position, slewing gear Right cgr
gear
SDelay slewing Position after the set delays Right cgr
gear
VDelay slewing Actuator speed after the set delays Left cgr/s
gear
P104 Slewing gear Variable value that depends on the setting in the Right Variable
Parameters menu
The lower area of the diagram user interface, the states of the input and output bits in the PLC are
displayed with a legend on the right-hand side in the path/speed time diagram; this diagram also
allows the selection of a single parameter or just a few parameters.
Zoom
To provide a detailed display, areas of the diagram can be increased in size. This is done by clicking
and dragging with the mouse pointer (from the top left to the bottom right - rectangular form) over the
area of interest. If the original state should be restored, drag the rectangle in the opposite direction.
The axes can be scrolled and zoomed.
The zoom function for the detailed view can also be used during the recording. Press the space bar to
leave the zoom again. The monitoring of the recording continues.
The Zoom In and Zoom Out function is also active in the lower diagram area for displaying the states
of the bits.
Icons
Icon Short designation Description

Grid lines A new window appears in which the axes for which the grid
lines are to be drawn can be selected (default: time axis).
Measuring points In the analog curves, all actual measuring points are
indicated with a small icon. This makes it possible to check
which measuring points produced the curve.
Delete curves Delete the diagram. If individual elements of the display are
to be removed again, this can be realized by deactivating
the appropriate checkbox in the legend on the right-hand
side.
Start Select which axes and parameters should be recorded and
start the recording task.
Stop Stop the recording.
Load Load existing "*.dgr" diagram file.
Save Save the diagram content (data) in a "*.dgr file".


Print Print the diagram after selecting the printer and the print
preview.
View Select the displayed parameters and change the
characteristics.
Properties Change the characteristics of the diagram, such as the
designation of all parameters and axes, limits and colors.
Help Function description of the keys for scrolling and zooming in
the diagram display.
The icons for operating the X/Y diagram are explained in Section 4.4.9.4.
The functions of selected icons are described in detail in the following sections.
Print, print preview – F6

The diagram can be printed using the "F6 - print" button. After selecting the printer and the printer
settings, a print preview appears when the "OK" button is pressed to confirm (following figure). Various
details (e.g. print with/without legend) can be set in this print preview. Zooming with the mouse is also
possible.
Fig. 4-22:Print, print preview function
View – F7
Pressing the "F7 - View" button opens the "Display measurement series" window (next figure) with the
"General" and "Bit signals" tabs that are used to select the displayed parameters and to change the
characteristics (color, name, line type and line thickness). A selected parameter can be placed on the

left-hand axis or on the right-hand axis. The direction arrow keys (up or down) can be used to change
the order of the display.
Fig. 4-23:Diagram function, F7 - View, General tab
Properties – F8
The "F8 - Properties" button can be used to set and change the designation of all parameters and the
axes. The limits and the colors can be specified for the background and for individual elements of the
diagram.
Fig. 4-24:Diagram function, F8 - Properties, Analog values tab

Note
For all changed properties (F8), the properties of the diagram will be saved automatically in the
DiagXXX.ini or DiagXXX_engl.ini file in the program directory or the currently set directory and file
name.
Help – F1
Pressing the "F1 - Help" button opens another window that contains all keyboard commands for
scrolling and zooming in the diagram display.
Fig. 4-25:Diagram function, Help
4.4.9.4 X/Y diagram
One of the two buttons can be used to change to the X/Y diagram (next figure).
This diagram shows the travel curve for two axes in the X/Y plane, where one axis represents the
movement of the trolley and the other axis the path of the hoisting gear. When one of the other buttons
(F11 or F12) is pressed, the axes will be interchanged. Activating the same button again changes to
the path/speed time diagram.

Fig. 4-26:Diagram function, X/Y representation with blocked regions

The calculated and the actually travelled curve are displayed. The following icons can be used to
display additional information.
Icons

Interpolation points Add the curve with the interpolation points used as basis for
calculating the travel curve.
Blocked regions Display all blocked regions (fixed and variable). If the
"Cyclical refresh" option is selected, the internally learnt
variable blocked regions on the waterside will be updated
continually during the crane travel.
Note
The curves drawn in the diagram are always relative to the lower edge of the spreader.
Note
When the spreader is locked to a container, all fixed and variable blocked regions are increased by a
fixed amount (parameter P108, maximum container height in mm).
If a container will be taken away the blocked regions will be decreased about the minimum container
high (fixed value 2000mm).
Note
The zero line is drawn at the minimum position for the hoisting gear positioning (P63).

4.4.10 Web server

An integrated Web server can be used to display camera images (only CenSOR M). In addition, the
system time can be set and the diagnostic buffer read.
4.4.11 Telnet
The connection to the camera (only CenSOR M) can also be established using Telnet. In this case, a
connection to the Shell will be established using the Ethernet connection. The Shell is part of the
operating system on the camera and permits the interpretation of the entered commands, such as
display directories. The Shell is always started automatically.
4.4.12 Calibrating the hoisting height

The "Calibrate hoisting height" function corresponds to commissioning steps 2 and 3 (Section 4.7.2.1)
of the sway control system. The values for the hoisting height, the number of swayings and the
duration of these swayings, however, must be determined and entered by the user.
The individual steps are self-explanatory and closed with "F5 - Send values" (Fig. 4-27). The P60 and
P61 parameters are set during the calibration of the hoisting height – trolley. During the calibration of
the hoisting height – skew, depending on the spreader type, the P89, P90 (20 ft), P91, P92 (30 ft) or
P93, P94 (40 ft) parameters are changed.
The integrated stopwatch can also be used individually with "F2 - Start" and "F2 - Stop".
Fig. 4-27:Calibrate hoisting height function

4.5 Camera Measuring System
4.5.1 Camera measuring system operating principle

The camera measuring system determines the offset and skew of the reflector, initially in pixels and
then converts them into millimeters. Various algorithms are used to check and correct the reliability of
the measuring signals.
The mounting parameters can be set with an automatic calibration. In this case, the reflector is
dimensioned in the zero position for various distances.
The measuring system can also be configured using parameters.
4.5.2 Functions
4.5.2.1 Measurement of the offset

The camera measuring system records the offset in two axes.

The absolute measuring accuracy of the camera measuring system depends on the distance of the
camera to the reflector. When a lens with a 16 mm focal length is used, the absolute measuring
accuracy is 5 mm at 10 m distance.
If a larger accuracy is required, a lens with longer focal length can be used. This, however, reduces
the measuring range because of the smaller aperture angle.
The distance between the camera and the reflector can lie within the range 1 to 50 m. The larger the
maximum distance, the larger must also the reflector be.
4.5.2.2 Measuring the rotation angle

The camera uses the reflector skew to determine the rotation angle. The resolution depends on the
reflector size and the distance.
To achieve a high resolution even for large distances, a second reflector turned through 90° can also
be used. The camera then determines for a large distance the angle of rotation by measuring both
reflectors. In the near area, as previously, the angle is determined from the skew of a reflector.
The maximum measurable angle of rotation is ± 15°. A larger skew would cause the pattern of the
reflector no longer to be recognized by the camera.
4.5.2.3 Measurement of the distance

The camera measuring system uses the size of the reflector to determine the distance between the
camera and the reflector. The measuring accuracy relative to the distance is approx. 2%.
4.5.3 CenSOR M camera interfaces

The CenSOR M camera possesses an Ethernet interface, a serial interface and a video interface.
Table 4-6 Camera interfaces
Connectors Connector type Signals

Serial I/O 15-pin 3-row D 2x RS232 serial
Video out, Hsync out, Vsync
Video out, digital I/O 15-pin 3-row D (VGA)
out, 2 in, 2 out
Ethernet RJ45 10BaseT
Ethernet is used for both the communication with the controller and the communication to the
diagnostic software.

4.5.4 Installing/mounting, connection, operation
4.5.4.1 Installing/mounting
Camera
Note
Ensure that the camera protection housing is installed to the load carrying device (L) largely vertical
over the reflector (R). The glass window of the housing must point down. The camera must have a
free view of the reflector (R).
The camera should be easily accessible by the maintenance personnel later. Details concerning the
dimensions are contained in Section 5.2.2.2.
Mounting of the stainless steel enclosure Mounting of the weather protection enclosure
Fig. 4-28: Camera installation drawing
Mounting of the stainless steel enclosure

If a stainless steel enclosure is used (Fig. 4-28, left), the camera unit (C) is mounted on the side of the
trolley (T). The stainless steel enclosure has four holes with a female thread. The trolley is connected
to the camera unit with four M6 screws.
Note
The mounting side of the housing must be located at the left or right when viewed in the trolley
direction (A–B).
Mounting of the weather protection enclosure

As shown in Fig. 4-28 right, fasten the camera unit (C) with the mounting plate (P) to the trolley (T).
Note
The mounting plate (P) of the housing must be located at the left or right when viewed in the trolley
direction (A–B).
The mounting plate (P) provides four holes with internal thread. The trolley is connected to the camera
unit with four M8 screws.

Reflector
Attach the reflector (R) to the load carrying device (L) as shown in Fig. 4-29.
Δ ≤ 10°
Fig. 4-29: Reflector installation drawing
CAUTION
Improper installation can damage the reflector.
Note
The reflector must be well visible vertically from above and may not be covered by other
constructions. The rotation of the reflector (R) relative to the camera unit (C) must not exceed 10°
(Fig. 4-29).
First attach the four supplied rubber cushions (M) to reflector (R) with four M10 screws as shown in
Fig. 4-29. The reflector with the rubber cushion (M) is then attached at the provided installation points
of the load carrying device (L) using four additional M10 screws. Details concerning the dimensions
are contained in Section 5.2.2.3.
Ethernet hub (optional)

The Ethernet hub (optional) must be clipped on to a DIN rail in a switchgear cabinet.
4.5.4.2 Connecting
Overview
The individual components must be connected as shown in the following schematic diagram.

Fig. 4-30: Connection schematic diagram for the camera variant
Camera
The camera is supplied with a pre-fabricated cable attached on one side. The camera must be
connected to the 24 VDC supply. The camera must be connected to the hub with the Ethernet cable.
CAUTION
A regulated switched-mode power supply must be used (see camera technical data).
Details of the connection are contained in Section 5.2.3.
Reflector
The reflector is connected at the terminal socket to the 110 … 230 V AC power supply.
Details of the connection of the reflector are contained in Section 5.2.3.
Hub (optional)
The Ethernet hub is connected to the 24 V DC power supply. An Ethernet cable is used to connect to
the SIMOTION D4xx.
4.5.4.3 Operator Control (hardware)
Camera lens settings
Fine focus
If the camera image is not in focus, the distance setting on the lens must be changed.
The hoisting gear must be lowered to the lowest point so that the distance between the camera and
the reflector is largest. The distance setting on the lens must be changed so that this position
produces a focused image.

Brightness
The camera aperture has the following factory settings:
1.4 - with IR filter
2 - for indoor applications
7 - for outdoor applications
These values are appropriate for most application scenarios. For particularly dark conditions, the
aperture can be reduced; for very bright ambient light, the aperture can be increased. In addition to
this setting, an automatic gain and offset control ensures the optimum picture brightness.

Each device must have its own IP address for communication in the Ethernet network.
CAUTION
The IP address for a device may only be used once within a network.
The IP address of the camera can be changed using the Parameters menu in the diagnostic software.
After calling the Parameters menu with the "P" key and calling the "I" function, follow the instructions.
The IP address of the camera can be changed first and then the address of the peer (SIMOTION D).
Camera default settings

Setting the own IP address
IP address of the camera: 192.168.1.155
Subnet mask: 255.255.255.0
Setting the IP address of the peer
IP address of the peer (SIMOTION D): 192.168.1.158
Port of the peer (SIMOTION D): 8500
4.5.6 Camera measuring system configuration

The camera measuring system is configured during the commissioning using the CeCOMM diagnostic
program (Section 4.4) by setting parameters. The parameters are stored in parameter sets. They are
loaded at each restart and can be used for the calculations.
The specifications described in Parameter sets, Input and editing of parameters and Saving
parameters, effect in Section 4.3 apply. Deviations from these specifications are listed below.

CAUTION
Four parameter sets are provided, but for this configuration only parameter set 1 has been
permanently set. No other parameter sets can be used.
Storage is in the /FlashFx/ directory on the camera.
CAUTION
The semiautomatic commissioning sets the parameters in all parameter sets.
Note
Detailed information on the parameters is contained in Section 5.3.1.
4.5.7 Commissioning requirements
4.5.7.1 General requirements, overview

The following requirements for the commissioning of the camera measuring system must be
satisfied:
1. All components of the system (camera, reflector, hub, SIMOTION D) must be installed, connected,
functional and interconnected (see Section 4.5.4.1)
2. Setting of the IP addresses of the camera and the SIMOTION D peer (Section 4.5.5 and 4.4.3)
3. Start of the diagnostic program and establishment of the connection between the commissioning
PC and the camera (Section 4.4.4)
4. Setting of the access code (Subsection 4.5.7.2) and the language of the diagnostic program
(Section 4.5.7.3)
5. Checking of the communication between SIMOTION D and the camera measuring system
(Section 4.5.7.4)
6. Checking the camera image (Section 4.5.7.5)
4.5.7.2 Setting the access code

The access code sets the user level. This determines the visibility of the individual parameters. The
access code is saved under parameter P100.
Note
code).
Parameter P100 (= access code) should be set to 2 for the commissioning.
The following settings are available:

Access code 3 – development engineers

The message "No authorization!" appears when an attempt is made to change a parameter that does
not correspond to the access code. In order to be able to edit all parameters, parameter P100 should
be set to 3.
4.5.7.3 Setting the language

The language of the diagnostic program is set via the menu "Options/Language" and saved under
parameter P110. German and English are available.
Alternatively the language parameter P110 can be changed via the Parameters menu. The
appropriate language file is then automatically opened and read. Only the screen displays are
updated. The icons for the connection and the functions will be stay at the old language.
4.5.7.4 Checking the SIMOTION D – CenSOR M interface

Initially the communication between the SIMOTION D and the camera measuring system must be
checked with the CeCOMM diagnostic program.
This includes the principle data exchange and the use of the correct data formats and contents.
The "CenSOR Interface" display screen (called with the "1" key ) shows the current input and output
data of the camera measuring system. They should first be checked for correctness.
Prerequisite for other steps is that the send and receive counters increase in display screen 1. This
means that the camera receives and sends data message frames.
Fig. 4-31 Monitor function, "CenSOR interface" display screen

4.5.7.5 Checking the camera image

The camera image is checked using the diagnostic tool. After activation of the "Image" function and
pressing the "F5 - Update" button, the current camera image will be loaded.
Fig. 4-32:Checking the camera image

The current camera image should have the following characteristics:
• The reflector must be correctly focused and well illuminated. (Prior to the commissioning, it is
possible that the image is still too light or dark – correction possibilities are described in Section
4.5.4.3.)
• For all hoisting heights, the reflector is located almost in the center of the image.
• If the camera measuring system is provided only for one axis, the travel direction and thus the
swaying direction should lie in the horizontal image direction.
4.5.8 Camera measuring system commissioning
4.5.8.1 Overview of the commissioning steps to be performed

The following steps should be performed in succession:
1. Commissioning steps in the Commissioning menu
2. Checking and fine adjustment of the camera

4.5.8.2 Commissioning steps in the Commissioning menu

The commissioning steps in the Commissioning menu of the CeCOMM diagnostic tool must be
performed next. This menu is called via the "I" key from the main menu or the display screens.
The commissioning must be started with the first step and continued step-by-step.
The parameters of the active parameter set are set (notes, see Section 4.3).
DANGER
For this reason, the active parameter set may not be changed during the commissioning.
Some parameters are set automatically in these steps. The successful completion of a commissioning
step is identified by a "+". After the commissioning steps have been performed successfully, it is no
longer necessary to set these parameters manually.
Note
Depending on the configuration, individual steps can be hidden.
Setting the configuration and important parameters (commissioning step 1)

In this commissioning step, all required parameters are successively called automatically and must be
set correctly.
Semiautomatic commissioning of the camera measurement (commissioning steps 2 to 4)

The commissioning steps 2 to 4 run semiautomatically. The result of these steps is set automatically in
some parameters.
Determine the reflector type (commissioning step 2)

From the viewpoint of the camera, the reflector can be aligned in two ways.
Different alignment of
reflector
The algorithm searches for the two alignments and shows the result. The result is saved in camera
parameter P2.
Normally, the reflector is correct in one alignment and not recognized in the other alignment.

Note
While checking the alignment, the distance between the reflector and the camera should lie in the
range 5 m to 10 m.
If both alignments are detected, this can have the following causes:
a) Two reflectors are present in the field of vision of the camera.
b) A light-dark combination in the field of vision was incorrectly identified as a reflector. In this case,
the parameter P2 must be varied manually and the measurement result in display 4 compared
with the position of the reflector.
If no reflector is detected, this can have the following causes:

c) The camera is not aligned correctly. The reflector is not in the field of vision.
d) The ambient light is too bright or too weak. The parameters for gain and offset (P0 and P1) can be
temporarily set to zero. The camera then automatically sets the gain and the offset to the
brightness of the complete image. After the successful commissioning step, the parameters must
be reset to the original or required values.
e) The window size (parameter P3) is set to values that are too large or too small. By default, P3=11
should be set.
After completion of the commissioning step, the current distortion of the reflector is also saved. This
size is important for the correct distance measurement.
Determine the reflector position (commissioning step 2.1)

If in commissioning step 1 it was specified that the reflector position is to be supplied from an external
source (P102 = 0), a relation must be established between the transferred position and the measured
distance via a linear equation y=mx+n (where m = P20 and n = P21).
The correct position determination is checked in the Monitor function, "CenSOR Interface" display
screen.

Fig. 4-33:Monitor function, "CenSOR interface" display screen

The values signify:
(1) – External distance, read in via the PLC
(2) – Internal value, dependent on P102
P102 = 0 (reflector position from external source): The value converted with P20 and P21 from
the PLC
P102 = 1 (reflector position from internal source): Value from the camera
(3) – Distance measured by the camera
Prerequisite for this step is that the measured distance (3) displayed in Fig. 4-33 corresponds to the
real distance between the camera and reflector.
Procedure
1. The external distance (1) and the measured distance (3) must be read and recorded in two
different hoisting heights (distance > 10 m).
2. In the "Calculations" window of the "CeCOMM" diagnostic program, the two measured distances
(3) must be entered at "Measured value" and the two associated position values (1) in the
"Position value" column.

Fig. 4-34: Calibration of the position values for the hoisting gear
3. "Calculate" determines the resolution (factor) and the offset for the distance sensor; these values
must be entered in the P20 and P21 parameters.
4. The correct determination of the reflector position must be checked by traveling various distances.
Whereby the internal distance (2) and the measured distance (3) must be identical.
The external transfer of the reflector position via the PLC is recommended for all STS cranes. This
enables the reflector pattern to be identified more quickly which increases the measuring reliability.
Determine minimum window size (commissioning step 3)

To achieve a high measuring reliability, the smallest size of the reflector in the image must be set in
parameter P3.
The image will then be searched for a reflector with this minimum size and all similar smaller-sized
patterns ignored.
Note
For the semiautomatic determination of the size, lower the reflector as far as possible.
The result of the commissioning step is an integer value between 1 and 10. 1 means that the reflector
is very small in the image, 10 very large. The following appears at the end of the commissioning step
(example):
"The factor for the window size is: 9 Æ 19". This means that the diagnostics have identified the factor
9 as suitable and stored the value 19 (factor + 10) in parameter P3.
Factors > 10 mean that the window size is automatically varied after the commissioning depending on
the distance. If, however, a reflector cannot be found during the automatic size control, the factor (P3
– 10) (in this case: 9) is used.
Calibrate the camera measurement (commissioning step 4)

CAUTION
The calibration is possible only when no camera measuring fault is present. All TLS cylinders must
be in the zero position, i.e. trim, list and skew are 0°.
The zero position of the reflector is determined during this commissioning step.

The reflector is measured in two different hoisting heights.

The result of the calibration is saved in the camera parameters P7, P8 and P12 - P13.
After the automatic calibration, P27 must be adjusted so that any existing rotation (skew through
mechanical mounting) is compensated.
Example:
If the rotation in in the display is 2 1.20°, then the value -120 must be entered in parameter P27.
CAUTION
After completion of the calibration, the determined load deflection in both directions and the rotation
must be almost zero. (display 2).
Simulate errors (commissioning step 5)

All error bits of the controller can be simulated in this step to check the error analysis on the
SIMOTION D side.
The relevant bits can be found in Section 4.10.5.2.
Save parameters (commissioning step S)

All parameter sets are saved.
The commissioning parameters can be copied to the other parameter sets in the Parameters menu.
4.5.8.3 Checking and fine adjustment of the camera

The following parameters can be set manually from the Parameters menu of the diagnostic program:
Reflector type
The reflector type is determined in commissioning step 1.
If no reflector is found, even though it lies in the field of vision, the set window size (P3) must also be
checked.
Distance measurement
If no internal path sensor for measuring the distance between the camera and the reflector is present,
this must be entered in the P102 parameter. The distance is then determined using the size of the
reflector, the set focal length of the lens and the size of the white reflector area.
The accuracy of the external distance measurement decreases with the distance between the camera
and the reflector. It is approximately 2% of the distance.
Lens
If the accuracy is not adequate, a lens with a longer focal length can be used. This, however, reduces
the maximum measurable swing angle.
The focal length of the set lens must be set in the P17 parameter.

Brightness
The camera is adjusted as described in Section 4.5.4.3.
The software controls the reflector brightness depending on the ambient light when the P0 – Video
input gain and P1 – Offset of the video input parameters are set appropriately.
The default values mean:
Gain = 64 The gain is adjusted proportional to the offset.
Offset = 256 The offset is changed increasing and decreasing from 1-255 until a reflector is found.
The regulating is then made to constant reflector brightness.
Note
The current offset and gain values are displayed for the camera diagnosis in Display 2.
Window size
The camera searches for a reflector that has a specific size. For a window size of 1, a search is made
in a 12 x 12 pixel field. For a window size of 10, the reflector in the image must have a size of
66 x 66 pixels. As comparison: the complete image has a size of 640 x 480 pixels.
Note
To prevent incorrect measurements, the set window size should be as large as possible.
If, however, the set window size is larger than the reflector image, a reflector is not found (see figure).
For this reason, the parameter (P3) for setting the window size should be checked at the largest
distance between the camera and the reflector.
Values between 1 and 10 mean that the reflector is always sought with a fixed window size in the
image, irrespective of how far the reflector is from the camera. This is only recommended when the
distance remains constant.
Values larger than 10 activate the automatic control of the window size. This means that the window
size is varied automatically depending on the distance. If no reflector is found during the automatic
size control, "window size = P3 – 10" is used.
Note
The current window size is shown in Display 2.

Limitation of search area

If the camera incorrectly identifies a reflector in an incorrect image area, the search area for the global
search should be limited.
The limiting of the search area acts only while no reflector is found (global search). Once the reflector
has been found, the search is made only in the immediate vicinity of the last position (local search).
The P15 and P16 parameters can be used to reduce the search area beginning from the edges by up
to 90%.
Measuring reliability
Several parameters can be used to influence the measuring reliability.
The algorithms first use fast search functions to find a reflector in the image and determine a
recognition reliability. The P4 ("Reflector recognition limit") parameter is used to specify the starting
reliability for recognizing a reflector as such. If the reflector has dark shadows, this value should not
exceed 650 (65%).
If the reflector has been detected, only a search near the reflector is required. The recognition limit in
the direct environment can be reduced with the parameter P19 "Reflector recognition limit (reflector
environment)".
The subsequent size measurement then returns a high reliability for the presence of a reflector in the
image. Up to 16 characteristics are checked here. The P6 ("Measuring reliability of the camera")
parameter can be used to specify the number of characteristics to be used. If more than ten
characteristics are specified to be checked, a reflector will be used only when the reflector size was
determined using the characteristics. This means P67 > 10 achieves a very high measuring reliability.
Reflector detection
The reflector detection could be checked by using the monitor „CenSOR– Camera [2] “.

Fig. 4-35:checking the reflector detection

Note the following items:
• The reflector is located in the middle of the picture (shown with a cross).
• The contrast between the black and the white areas should be acceptable large.(quantity of pixel
per grey tone, bold printed) At the example the histogram (His) find 76 pixel for the black area and
77 pixel for the white area.
• The ascertained „Distance“ should be the same like the real distance.
• An acceptable reflector detection could be read at the „Safety“ value (nearly 100%) and the
„Fault“ value (nearly 0).
The following values are given for information:

Fault rate: Fault rate in %
Gain: Gain of the video input (P0)
Offset: Exposure time of the camera (P1)
Size: Size of the reflector at the picture in pixel
Average: Ascertained average grey tone of the reflector
Rotation: Rotation of the reflector
Black-White-Grey value: Black-White-Grey value (P18)

4.6 Commissioning Requirements for AddOn Systems
4.6.1 General requirements, overview

The drive system and all safety functions of the crane, especially switch-off at limit, safety interlocks,
EMERGENCY STOP functions and the load monitoring must be commissioned and functional.
DANGER
The commissioning and testing of the Sway Control functions may only be performed by trained
personnel who are familiar with the operation of the crane. The regulations of the crane operator
must be observed. A further requirement is the successful completion of a commissioning training
course of the CePLuS Steuerungstechnik GmbH.
DANGER
All safety functions of the crane must be implemented independently of the sway control system.
Measures must be taken to ensure that the crane stops without any adverse affects on persons or
goods when a fault occurs.
WARNING
The PLC programmer is required to evaluate the error messages of the sway control system. In a
fault situation, the manipulated values of the sway control system may no longer be used. Only the
higher-level controller may implement the control of the drives.
The following requirements for the commissioning of the sway control system must be satisfied:
1. All the drives to be controlled and the hoisting gear must be functional
2. All components of the system must be installed, connected, functional and interconnected
3. Preparation of the PLC program (Section 4.6.2)
4. Preparation of the converters (Section 4.6.3)
5. Start of the diagnostic program and establishment of the connection between the commissioning
PC and the sway control system (Section 4.4.4)
6. Setting of the language of the diagnostic program (Section 4.6.5) and the access code (Section
4.6.4)
7. Checking of the communication between the PLC and the sway control system (Section 0)
4.6.2 Preparation of the PLC program

The PLC program must be prepared so that all signals are provided for the sway control system and
all output data is processed further (Section 3.7.1 and 3.7.2).

Note
The error bits must be evaluated in all circumstances in order to detect malfunctions and to be able to
respond appropriately.
Examples of the implementation of the signal sequences in the PLC are contained in Sections 3.2 to
3.6.

4.6.3 Preparation of the converters

Parameter sets of the converters
The converters should have their own parameter set for the sway control function.
The setpoint comes continuously from the sway control computer. The parameters are set as
described in the following sections.
Acceleration and deceleration ramps

The internal converter acceleration and deceleration ramps should be set to approx. 1 s (50 Hz/s).
WARNING
Acceleration and deceleration ramps that are too slow can cause swaying movements!
WARNING
The sway control system can calculate higher accelerations and decelerations than those that occur
in normal travel operation – especially when neutralizing large swaying movements.
Initial and final rounding

As the speed characteristic is defined by the sway control, an initial and final rounding should be
deactivated.
WARNING
Roundings in the converter that are too large can cause swaying movements!
Minimum frequency of the converters

In order to be able to eliminate small swaying movements after stopping, the minimum frequency of
the converter must be set to 1 Hz or smaller.
WARNING
If the minimum frequency is too large, the residual swaying movements may be relatively large and
the crane does not or only rarely come to rest!
Speed controller of the converter

The internal speed control of the converter can be activated in order to achieve a control response that
is as good as possible. In addition to the proportional component, an adequate integral component
should also be set. Good results have been achieved for the SIMOVERT MASTERDRIVES with
kP = 3..5 and Tn ≤ 200.

Limitation of the speed actuating signal
Note
Limitations of the actuating signal (e.g. in the converter) can result in the tripping of the following error
and therefore should only be intended for safety reasons.
The following error is the path difference between the calculated curve and the curve actually
travelled (= set-actual deviation).
4.6.4 Setting the access code

The access code sets the user level and determines the visibility of the individual parameters. The
access code is saved under parameter P100.
Note
code).
Parameter P100 (= access code) should be set to 2 for the commissioning.

The following settings are available:
Access code 3 – development engineers (password protected)
The message "No authorization!" appears when an attempt is made to change a parameter that does
not correspond to the access code.
4.6.5 Setting the language

The language of the diagnostic program is set via the menu "Options/Language" and saved under
parameter P110. German and English are available.
Alternatively the language parameter P110 can be changed via the Parameters menu. The
appropriate language file is then automatically opened and read. Only the screen displays are
updated. The icons for the connection and the functions will be stay at the old language.
4.6.6 Checking of the communication between PLC and SIMOTION D

The communication between the PLC and SIMOTION D must be checked first. This includes the
principle data exchange and the use of the correct data formats and contents.
The CeCOMM program can display various diagnostics screens that allow the communication to be
checked. The "PROFIBUS interface" display screen is called from the main menu or another display
screen with the "2" key (Fig. 4-36).

Fig. 4-36: Monitor function, "PROFIBUS – Interface" display screen

The current input and output data of the sway control system are shown on this display screen. They
should first be checked for correctness.
Note
The values of the Trolley and Hoist axes are output in mm and the skew in cgr.
The "State of drive axis" display screen is called with the "3" key (Fig. 4-37). The command and status
bits are displayed here. They should also be checked for correct assignment before the
commissioning. The color differences in the display of the actual values show which values or states
are OK or active (green).
Note
Red display indicates an error case or stop in the system, "Not enabled", "Stop", "Off", etc.

4.7 Sway Control Commissioning
Fig. 4-37: Monitor function, "Status of the travel axes" display screen

Once all the requirements (Section 4.6) have been satisfied, you can start with the commissioning.
The commissioning of the camera measuring system is performed by setting parameters with the
CeCOMM diagnostic program (notes, see Section 4.3).
4.7.1 Operation of Sway Control

Operation and characteristics
The sway control system determines the swing angle with the aid of a camera measuring system. The
pendulum angle and the distance are used to calculate the load deflection. The reliability of the
measuring signal is checked with various algorithms and, if required, corrected. If the measuring signal
fails, a mathematical oscillation model is used for the current states.
CAUTION
The acceleration and deceleration ramps can vary greatly. They depend on the initial swaying and
the pendulum length.

Generally, the sway control system has the following characteristics:

• The swaying of the load has been eliminated when the stationary speed or standstill is reached
• In positioning operation, the load only overshoots the target position by a very small amount
The sway control system is configured using parameters (Section 4.3) and can be controlled by the
PLC by setting various control bits.
The sway control system calculates speed manipulated variables that are forwarded to the drives
using TO objects.
Sway control algorithms

As sway control algorithm, the parameter P152 (trolley) can be used either for
• conventional state feedback or the
• time-optimized control.
Use of the conventional state feedback produces an aperiodic characteristic for the swing angle.
The acceleration ramp is smoothed. The acceleration times are approx 1.1 times the natural oscillation
duration of the load oscillation. The travel operations are performed with low stressing of the entire
crane structure.
The time-optimized control is based on the "Theory of the optimal control". Short deceleration ramps
are inserted in the acceleration operation and short acceleration ramps inserted in the deceleration
operation. This achieves the quickest possible suppression of a swaying movement. The acceleration
and deceleration times depend on the available drive power. The time restrictions of the conventional
state feedback do not apply.
Note
The time-optimized control is not appropriate for STS cranes.
Dynamic prelimit switch

Dynamic prelimit switches improve the travel behavior of the crane at the outer position areas.
In contrast to fixed prelimit switches, the axes are braked at various positions. This position depends
on the current axis speed. This means an axis traveling at low speed can be braked much later in
order to reach the prelimit switch speed at the positions (P24, P27, P64, P68) specified by
parameters.
The following figures use two different speeds to illustrate the operation of the dynamic prelimit
switches:
P115: 1 (dynamic limit switches active)
P24: 95000 mm (position for trolley VES speed backwards)
P27: 6000 mm (position for trolley VES speed forwards)
P0: 3500 mm/s (maximum actuator speed of the trolley

Fig. 4-38: Trolley behavior with dynamic prelimit switches at full speed
Fig. 4-39: Trolley behavior with dynamic prelimit switches at half-speed

The figures show clearly the different braking points depending on the speed. For fixed prelimit
switches, this point is always at the same trolley position (P115<1).
Although the behavior is similar for hoisting gear (P64, P68), the behavior on the landside and the
waterside differ. On the waterside, the lower dynamic prelimit switch does not act in order to allow the
immersion in the ship's hold. In this case, the higher-level controller must ensure that no damage can
occur to the crane or the ship.
CAUTION
If P115 < 1, ensure that the correct operation of the prelimit switches is guaranteed.
At the following figures the behavior with dynamic prelimit switches compared to the behavior with
fixed prelimit switches will be shown:
Behavior of P6 (set acceleration, trolley) < P7 (Acceleration without sway control /minimum
acceleration) and P115=0

Fig. 4-40: Behavior P6 < P7 at P115 = 0

The crane moves with 50% of the maximum velocity into the prelimit switch. The maximum velocity is
shown at the white graph and the set velocity at the blue graph. When the prelimit switch is reached
two things are happen:
The trolley will be brake down to prelimit switch velocity. As calculation base conduces P6 (green
graph). The sway control is active.
The maximum allowed velocity will be reduced by P7.
When the blue graph (set velocity) cuts the white graph, the blue one will be limited by the white’s
value. But she could have a value under the limitation. If it is useful to change the driving direction for
catching the oscillation (the blue graph is under the pink graph) temporary the maximum velocity will
be permitted.
Behavior at P6 > P7 and P115=0

Fig. 4-41: Behavior at P6 > P7 and P115=0

At the shown example the limitation has no influence, because of the very low ramp. As a result the
work of the sway control is visible. If the prelimit switch velocity comes under the set velocity the limit
value has to be pulled down, because acceleration over prelimit switch velocity is forbidden
The fixed prelimit switches are completely independent of the distance measuring system and they
also work when the encoder do not work or do not exist.
Behavior at P115=1

Fig. 4-42: Behavior at P115 = 1

The trolley can drive with set velocity. The maximum velocity will be limited in dependence of the
distance to a parameterized position.For those reason the root function results.
At a normal working situation a crane driver would not drive through a limit switch without a reason. In
an extreme case he would drive to a position near the limit switch and then he would let off or reduce
the master switch before the target is reached. The crane driver doesn`t feel the dynamic prelimit
switch, except the target is extremely near to the limit switch and he misses the right moment. He will
only be limited, when the last possible point is reached. It is shown that in this case the sway control is
active and the oscillation will be caught.
Note
If the delay should be occurred pendulum damped at prelimit switch velocity, the reducing of the set
value is to realize at the crane control.
4.7.2 Commissioning of the Sway control system
4.7.2.1 Commissioning steps in the Commissioning menu

Next, the commissioning steps in the Commissioning menu must be performed. This menu is called
via the "I" key from the main menu or the display screens (Fig. 4-43).

Fig. 4-43: Monitor function, Commissioning menu

The commissioning must be started with the first step and continued step-by-step.
Some parameters of the active parameter set are set automatically in these steps.
WARNING
For this reason, the active parameter set may not be changed during the commissioning.
The successful completion of a commissioning step is identified by a "+". After the commissioning
steps have been performed successfully, it is no longer necessary to set these parameters manually.
Note
Depending on the configuration, individual steps can be hidden.
Note
The anit-sway must be switched off during commissioning steps 1 to 3. This is implemented internally
and temporarily triggers error E61.

Setting the configuration and important parameters (commissioning step 0)

In this commissioning step, all required parameters are successively called automatically and must be
set correctly.
The request begins with the parameter for the configuration of the system (P102).
In the subsequent processing, the parameters
• Maximum actuator speed
• Positioning speed
• Set acceleration
• Maximum acceleration
• Prelimit switch speed
• Minimum and maximum position
should be set for each axis. These parameters are specified by the crane manufacturer or derived
from these specifications.
The maximum actuator speed (P0, P40) is the maximum speed that can be attained by the drive
axis. It has an effect on the amplitude of the oscillation model and therefore must be set precisely.
The positioning speed (P1, P41) is the maximum specified set speed for an automatic positioning.
Depending on the control process, the actual speed can be less or greater, but never greater than the
maximum actuator speed.
The set acceleration (P6, P51) is the acceleration with which the set speed rises or falls at the input
of the sway control. As the sway control causes an additional deceleration, it should be set larger than
the acceleration and deceleration actually wanted.
With a deceleration gain (P8, P52) greater than one, the set deceleration is greater than the set
acceleration.
The maximum acceleration (P5, P50) limits the acceleration of the output signal of the sway control.
It should be set to the same or a smaller value than the converter acceleration limit.
When the prelimit switch signal is active, the prelimit switch speed (P2, P43) in the relevant direction
of travel is not exceeded – also not through control processes of the sway control system. For this
reason, the elimination of swaying movements in the prelimit switch range often takes longer.
The minimum (P23, P63) and maximum position (P28, P69) is only checked at the start of an
automatic positioning. A target outside of this range is not approached.
Other queried parameters are:
• Upper and lower limit of the sway control system
• Acceleration without sway control
The parameters "Upper and lower sway control limits" (P83, P84) specify the hoisting height
range in which the "sway control " function is active.
When the sway control is deactivated, the drive accelerates and decelerates with the set acceleration
value P7 acceleration without sway control.
Fig. 4-44 provides an overview of the use of the speed and acceleration parameters.

Preparation setpoint
Speed setpoint
Standardization speed setpoint/

actuator speed, e.g. 32767
Maximum actuator speed
Maximum speed setpoint

Prelimit switch speed
Set acceleration Maximum acceleration
Sway control, conventional - 0

Sway control, time-optimized - 1
Sway control OFF - 2 0 1 2
Sway
Sway control ON/OFF
control
Maximum acceleration
Maximum actuator speed
Standardization speed setpoint /

actuator speed
Actuator speed
Fig. 4-44: Overview of the speed control
There is a detailed description of all parameters in Section 5.3.2.
Set alignment of the camera (commissioning step 1)

In this commissioning step, the assignment of the directions of motion to the camera orientation is
determined and the result saved in parameter P120.
Note
After starting the commissioning step, the trolley should then be moved when the load is steady.
The diagnostics record the main direction of sway and the sign of the beginning deflection. From this
information, the assignment of the trolley direction to the camera x or y direction and its sign are
determined.

The result can be saved when the sway control is only to be activated for the trolley direction.
Otherwise the crane has to be moved so that the sign of the deflection in the crane direction can be
determined.
Oscillation in
bridge direction
Camera
housing
Oscillation in
trolley direction
Mounting board
Calibrate hoisting height - TROLLEY (commissioning step 2)

Note
Only systems with a camera can perform this automatic commissioning step. For systems without a
camera, this step must be performed manually with the tool on the "Calibrate hoisting height" tab.
Fig. 4-45: Calibrate hoisting height – TROLLEY (commissioning step 2)

The following options can be selected for this commissioning step:
0 – Reset P80, P81
Parameters P80 and P81 are set to 0 and therefore have no effect.
1 – Basic Calibration
It is essential that this basic calibration step be performed. Swaying movements are initiated at two
different heights. From the swaying measurements, the gain and offset are determined for the

conversion of the transmitted hoisting height to an effective pendulum length with correct sign and
absolute value. The result is entered in parameters P60 and P61.
This automatic commissioning step was successful when the swaying duration displayed in the tool is
roughly identical in each cycle. If this is not the case, the step can be performed manually with the tool
on the "Calibrate hoisting height" tab.
Not the calibrated hoisting height, but the hoisting height taken from the interface is used for the
control and positioning of the hoisting gear. This must have increasing values with the increasing
height of the load carrying device above the ground.
2 – Dig. hoisting dist. corr.
This step is optional. Shifts in the center of gravity that result from the use of different load carrying
devices are compensated with the digital hoisting distance correction. Parameter P80 is written.
3 – Anal. hoisting dist. corr.
Note
Before performing step 3, the weight of the load carrying device must be determined and stored in
parameter P82.
This step is optional. With the analog hoisting distance correction, shifts in the center of gravity that
result from the load mass, can be taken into account. Parameter P81 is written.
Note
In most cases it is sufficient to perform the basic calibration. After being performed successfully, this
commissioning step is displayed in green, although the digital and the analog hoisting distance
corrections have not yet been performed. These steps are optional.
Calibrate hoisting height - SKEW (commissioning step 3)

Note
Only systems with a camera (P102) and activated TLS (P197) can perform this automatic
commissioning step.
In the calibration of the hoisting height, the gain and offset are determined for the conversion of the
transmitted hoisting height to an effective pendulum length with correct sign and absolute value.
The calibration is performed with two sway measurements at different heights.
A swaying movement must be induced at different heights. The respective effective cable lengths and
conversion parameters are determined from these movements. Depending on the spreader type, the
result is entered in the P89, P90 (20 ft), P91, P92 (30 ft) or P93, P94 (40 ft) parameters.
This automatic commissioning step was successful when the swaying duration displayed in the tool is
roughly identical in each cycle. If this is not the case, the step can be performed manually with the tool
on the "Calibrate hoisting height" tab.
Simulate errors (commissioning step 4)

All error bits of the sway control system can be simulated in this step to check the error analysis on the
PLC side.
The relevant bits can be found in the error list, Section 4.10.5.2.

Determine speed limit (commissioning step 5)

The speed limit can be set automatically in this step when the current actual position value is
transferred with the PLC data.
The axes should be moved singly and steadily with constant speed in the "speed control" basic
operating mode. If the axis moves with constant speed, this should be confirmed by pressing
<ENTER> twice. The maximum actual speed, i.e. the speed limit, produced at the maximum actuating
signal is determined from the maximum actuator speed output on the converter and the measured
actual speed value.
The determined speed limit can be taken over in the respective parameter (P0 for the trolley or P40 for
the hoisting gear) as well as the resulting positioning speed (P1 (trolley) and P41 (hoisting gear)).
Save parameters (commissioning step 6)

All parameter sets are saved.
The commissioning parameters can be copied to the other parameter sets in the Parameters menu.
4.7.2.2 Checking and fine adjustment of the sway control

The following parameters can be set manually from the Parameters menu of the diagnostic program:
Selection of the control method

The control method (conventional or time-optimized control) is selected via parameter P152.
With the conventional control, the travel behavior is smooth and comfortable for the crane operator.
Precise positioning is possible. There is a noticeable counter-response (greater deceleration when the
opposite direction is specified) with different values for set and limit acceleration.
If time-optimized control is selected, the drive accelerates and decelerates in the minimum time to
the set speed. The deceleration sections integrated in the acceleration operations can be
uncomfortable for the crane operator. The time-optimized control algorithms use search algorithms
that require a lot of computation time. For this reason, time-optimized control should only be used for
maximum two axes in manual operation or one axis in positioning mode. Computation time can be
saved by reducing the parameter P171 "Quality of the time-optimized control". The quality of the sway
control function then must be checked.
Note
The time-optimized control is not appropriate for STS cranes.
Load carrying device: Compensate

If different load carrying devices are used, this must be incorporated in the program as the center of
gravity and/or the pendulum length changes.
If not already performed semi-automatically in commissioning step 2, the adaptation to the load
conditions is performed with the following parameters:
P80 Digital hoisting distance correction
Shifts in the center of gravity that result from the use of different load carrying devices are
compensated
P81 Analog hoisting distance correction
Shifts in the center of gravity that result from the load mass are taken into account
P82 LAM weight

The effective pendulum length is corrected. It is calculated as follows:

Correction effective pendulum length = analog correction eff. pendulum length+ digital correction eff. pendulum length
Analog correction eff. pendulum length

The value in parameter P81 for the analog hoisting distance correction acts only when the load (iLoad
on DCC_SCCommon) is greater than the weight of the load carrying device (P82). In this case, the
value for the load in screen 2 (PROFIBUS interface) of the diagnostic tool is displayed in green,
otherwise in red.
Analog correction eff. pendulum length = (load – P82) x P81 |if (load - P82) > 0, otherwise
=0
Digital correction eff. pendulum length

If digital hoisting distance correction is to be used, the offset must be entered in parameter P80. The
used command is set by the "Dig_Hoist_Dist_Corr" command bit (see Table 3-11, Common control
word). In this case, the value for the load in screen 2 (PROFIBUS interface) of the diagnostic tool is
displayed bold.
Analog correction eff. pendulum length = P80 if bDig_Hoist_Dist_Corr = 1; otherwise = 0
Fig. 4-46 provides an overview of the internal processes used to determine the distances for the
oscillation model and the camera calibration.

Fig. 4-46: Compensation of the load carrying device
Setting the permissible residual sway

The parameters for the residual sway (P169, P170) should only be set as small as required. Values
that are too small can result in swaying after stopping because of dead times.
Setting the damping factor

A damping factor (P85, P86, P87, P88) can be set for each travel axis, separately for the acceleration
and deceleration phase. Values greater than 1.4 result in aperiodic transition characteristics, values
less than 1.4 to overshoot. Damping factors in the range from 1 to 1.2 represent a compromise
between shorter rise time and less overshoot. The difference between the damping factors for
acceleration and deceleration should not be too large, as actuating signal jumps can occur during the
transition to the deceleration phase.
Specifying minimum speed and minimum time

The sway control function is only activated when the minimum speed (P146) and minimum time
(P147) are reached. It is recommended that both parameters be left at zero.
At the activation velocity a hysteresis of +- 5% interacts to prevent a permanent switching (on / off) of
the sway control.
Setting the switch-on delay of the drives

For each axis (P149, P150), the switch-on delay of the frequency converter after releasing the brake
can be set.

4.7.3 Commissioning of the positioning
4.7.3.1 Changing the coordinate system

If an automatic positioning is to be commissioned and also the coordinate system of the trolley
changed, the position values must be calibrated.
In the "Calculations" window of the "CeCOMM" diagnostic program, two position values of the
previous coordinate system and the two associated position values of the new coordinate system must
be entered as "Measured value" and in the "Position value" column, respectively.
Fig. 4-47: Calibration of the position values for the trolley

"Calculate" determines the resolution (factor) and the offset for the trolley position sensor; these
values must be entered in the P20 and P21 parameters.
4.7.3.2 Position controller setting

The position controllers must be set as shown in the following sequence:
Set position controller (P160, P163) to zero and start the positioning over a longer distance
The set and the target position must be nearly identical at the end. Slight differences result through the
deactivated position controller.
Greater differences can be caused by a faulty maximum actuator speed or limits in the drive system.
(To correct the errors, the sway control function can be deactivated by setting the damping factors to
zero - only possible with conventional control.)
Setting the position controllers and the sway control factors to default values
All controllers must be set to have a small overshoot. This affects both the speed and the target
position. This achieves short rise times.
The value of the position controller should not be greater than 0.5.
The value must be reduced when the application of the controller causes an oscillating speed change
and an overshoot at the target position.

Note
An overshoot at the target position often results not from a large position controller value but rather
from an incorrectly set limit speed. Consequently, before reducing the position controller value, in
controlled operation (position controller is zero or manual operation), a recheck should be made
whether for travel at constant speed, the actual speed is nearly equal to the set speed.
The control method can use negative position controller values to switch to target control. In this case,
the positioning operation also uses the speed control without position control. The travel curves
correspond to those for manual operation. The target control determines only the begin and the exact
course of the braking phase. A recommended value for the position controller value is -0.7.
The set speed v = 2 ⋅ k R ⋅ aS ⋅ Δs for the target control is determined from the size of the position
control value k R , the deceleration aS and the distance from the target Δs .
A value of -0.7 specifies the time of the beginning the braking, deceleration is made with 70% of the
set accleration. During the braking phase, the target control has a control reserve of 30%, because the
deceleration can be increased to 100% aS .
4.7.3.3 On-the-fly unloading

The following setting of parameter P152 "Conventional/time-optimized control, trolley" is
recommended for on-the-fly unloading:
Table 4-7: P152 setting for for on-the-fly unloading
Selection Short designation On-the-fly On-the-fly

unloading with unloading
const. with max.
deflection deflection
1 Time-optimized control only for automatic OFF OFF
control
2 Time-optimized control only for automatic ON ON
control
3 On-the-fly unloading permitted ON ON
4 On-the-fly unloading with max. deflection OFF ON
5 Time-optimized control only for stopping OFF OFF
Generally, on-the-fly unloading is only used together with an automatic control (selection 2 = ON).
Only then does the activation of selections 3 and 4 take effect.
Selection 3 must always be on for on-the-fly unloading. In this case, the load deflection during travel
towards the land and back again remains constant. If the load deviation is not to be constant, but
maximum at the time of unloading, then selection 4 must also be switched on.
If the time-optimized control is switched on for all basic operating modes (selections 1 and 2), this
behavior can be restricted to the stopping procedure (selection 5 = ON).

4.7.3.4 Other settings

The following parameters can be set manually:
Positioning range
The permissible positioning range can be set with the parameters "Minimum position" (P23, P63) and
"Maximum position" (P28, P69). The values should be set halfway between the prelimit switch and the
limit switch (Fig. 4-48). Positioning outside of this range is not possible.
Permissible positioning range
Limit Minimum Prelimit Prelimit Maximum Limit

switch position switch switch position switch
Fig. 4-48: Permissible positioning range

If a drive axis of the crane enters the range between prelimit switch and limit switch, the axis is braked
with at least the ramp with which the crane would brake without sway control (P7).
Positioning accuracy (P162, P165, P190)

The set positioning accuracy should be as small as necessary and only affects the "Positioning
complete" message. Positioning continues while the basic operating mode and the travel signal
remain set.
Following error (P161, P164)

The following error is the difference between the calculated and the actual position and, when
exceeded, initiates a fault.
4.7.4 Commissioning of the hoist control
WARNING
Prerequisite for the commissioning of the hoist control is the successful commissioning of the Sway
Control and positioning functions.
In this basic operating mode, the spreader/grab moves on the path curve taking account of blocked
regions.
The PLC program must be prepared so that external variable blocked regions can be transferred
and/or the learning of the height profile is activated (Section 3.6.2.5).
All blocked regions (fixed and variable) are displayed in the diagnostic program, function diagram in
the x/y representation.
Defining the limit curve parameters

The clearances to the blocked region can be set as parameters. If a double spreader is used, the
width of the blocked region increases in the landside direction. The following figure provides an
overview of the effect of the various parameters.

The following also applies:
Note
When the spreader is locked to a container, all fixed and variable blocked regions are increased by a
fixed amount (parameter P108, maximum container height in mm).
If a container will be taken away the blocked regions will be decreased about the minimum container
high (fixed value 2000mm).
Fig. 4-49: Mode of operation of the limit curve parameters
Collision protection
A collision protection is activated in the software in the "hoist control" basic operating mode. Based on
the current container crane position, it is determined how far the spreader is from a possible obstacle.
If this is approached too closely, there is a reaction via the actuating signals (Section 4.10.4).

4.8 2D-Trajectory Commissioning
Override
In the "SC Automatic" AddOn mode, the travel speed on the path curve can be reduced using an
externally definable override "Override" (see Table 3-12, hoist control bits) between 0% and 100%.
This speed reduction is useful for commissioning purposes (test with reduced speed).
A value of 100 means maximum speed. With 0 the drive stops. Jumps in the override result in
maximum acceleration or deceleration (parameter setting).
The override can be specified separately for each axis and therefore used, for example, for the
software-controlled prelimit switches.
Laser
The laser values in the "Hoist Control [6]" screen of the CeCOMM commissioning tools (Section
4.4.6.1) should be checked.
Note
Ensure that the laser scanner is updated as fast as possible (Laser Freq. ≤ 3) so that the values can
be used for calculating the travel curve.
Conditions for validity of the laser values:

• Laser frequency ≤ 3
A valid value comes from the laser scanner at least every three cycles of the SIMOTION D
• Position difference of the trolley (distance) between two measured values < 50 cm
If the conditions are not satisfied, the values from the laser and the distance will be ignored. Should
the values become invalid, they will be displayed RED, otherwise GREEN.
4.8 2D-Trajectory Commissioning

Learning the parking position, lashing platform and lanes
The Parking position is learnt by the crane operator traveling to the position and setting the
"Learn_Park_Pos" bit (bit 0 in the "STW1_PLC_Targets" control word, Table 3-19) for learning the
position from a control element.
The Lashing position is learnt by the crane operator traveling to the position and setting the
"Learn_Lash_Platf" bit (bit 1 in the "STW1_PLC_Targets" control word, Table 3-19) for learning the
position from a control element.
The Lane positions are also learnt by traveling to the position to be learnt. The "Learn_Pos_Lane"
value on the Targets module (see Table 3-18) assigns (and saves) the lane number to the current
position (0Æ none; 1Æ Lane1; 2Æ Lane2, etc.).
The learnt positions "Parking position", "Position of the lashing platform" and "Position of the used
lanes" are stored in the "TargetPos.txt" file in the /SWAYCONTROL/ directory on the SIMOTION D.

4.9 TLS Control Commissioning
Deleting the parking position, lashing platform and lanes

The saved parking position, the position of the lashing platform and the position of the lanes can be
removed by deleting the "TargetPos.txt" file in the /SWAYCONTROL/ directory on the SIMOTION D. A
new file is created when one of these positions is learnt again.
If, for example, only the position of a lane is to be deleted, the appropriate line can be deleted with a
simple editor (z.B. Notepad).
CAUTION
If the "TargetPos.txt" file is edited incorrectly, errors can occur while positioning in "SC Automatic"
AddOn mode.
Twistlock simulation
Simulation of the loads is possible with the "CeCOMM" diagnostic program. It is used during the
commissioning of the hoisting gear to test the correct functioning of the automatic mode.
Pressing the "x" key in all display screens simulates the locking of a container, and when pressed
again the unlocking.
WARNING
Only an empty spreader can be simulated as being loaded. Consequently, in simulation mode, the
internally learnt obstacles are corrected as if a container were locked to the spreader. In such a state,
travel must be performed at an adequate height (> max. container height P108) above the actually
existing obstacles. Otherwise collisions can occur during automatic operation.

Activating TLS Control
All available functions can be activated with the parameter "Use trim/list/skew control“ (P197). This
calls up the input and output functions and the test commands are available.
Use of the "Trim / List / Skew [7]" display screen on the diagnostic tool for commissioning
This display screen is used for the commissioning and diagnosis of the TLS functions. Not only can
the ingoing and outgoing signals be monitored, but also individual TLS commands tested.
The "Angle" skew angle output in screen 7 represents the angle supplied by the camera.

Fig. 4-50: Monitor function, "Trim / List / Skew [7]" display screen
Assignment of the cylinders

The cylinders are designated A, B, C, D and assigned as follows:
A – landside, left
B – waterside, left
C – waterside, right
D – landside, right
The assignment of the positions and output speed is made in the PLC.
Cylinder positions
The positions of the individual cylinders must be set with the parameter "Gain for the TLS cylinder
positions"(P187) in such a way that when turning by approx. 1° an offset of 100 mm (50 mm on each
side) is measured.

The absolute position is not important at first. A position is saved as zero position for each cylinder
(P200 - P203) and all positions in "mm" are then always positions relative to the stored zero position.
The minimum and maximum cylinder positions (P188, P189) also always refer to this zero position.
The permissible angles can be set with the TLS limit values (P194 - P196). According to the above
setting of the position values, 250 corresponds to an angle of 2.5°.
TLS speeds
The speed setpoint (P180-P182) is used to approach the zero position as well as for the execution of
the TLS commands. If the hydraulic cylinders only have one speed, this must be set there.
The speed value is the change of the internal position values in each time unit. If a time of 2 s is
required for trimming 1°, i.e. an offset of 50 mm on each side, then the speed setpoint to be set is
25 mm/s.
The set speed can also be determined in the "Display screen TLS [7]" of the diagnostic tool. To do
this, the set speeds are set to the default values and a TLS command (e.g. trim left) initiated. The
values displayed as "IN-Speed" are entered as set speeds in the P180-P182 parameters.
Skew control set speed

The electronic skew control uses the internal slewing gear axis in the "Positioning" basic operating
mode. The positioning speed is set with parameter P221 and the maximum permissible speed with
P220 . With a rotation of 1°/2s, a value of 50 cgr/s should be set for the positioning speed.
TLS speed limit

With the skew control, a speed greater than the speed setpoint may be required for a short time. The
maximum permissible speed of the cylinder (P183) should be set here.
The ratio P183:P180 should correspond to the ratio P220:P221.
Pressure system
Two different pressures have been prepared. The actuator speed for each cylinder is adapted to the
pressure conditions. With a low pressure, the proportional valve is opened more than with a high
pressure.
The pressure threshold is selected with P184.
If the system requires a minimum pressure, this can be set with P193. As soon as the output signal
exceeds the "TLS speed for zero signal" (P186), the output signal is at least the value of parameter
P193.
Skew control
The actuator speed of the internal rotary axis can be adapted to the cylinder speed with the parameter
P185 "TLS switch-in for skew control".
Output speed
In order that the cylinders are not loaded unnecessarily, the switching threshold for the cylinder
activation can be adapted with parameter P186 "TLS speed for zero signal". If the cylinder control
signals are less than this value, the output and the direction signals are set to zero.
Under certain circumstances, the same output speed can result in a higher lowering speed than
hoisting speed because of the earth's gravitational attraction. In this case, the actuator speed during
lowering should be reduced with parameter P191.

4.10 Alarm, Error and System Messages
Test commands
The following functions are available for testing:
S – Test Skew Control
After pressing the "S" key, the setpoint for skew must be entered and applied with <ENTER>. The
cylinders then turn to attain the specified skew.
C – Test Cylinder
The "C" key can be used to test the correct operation of the individual cylinders. To do this, the
cylinder (1..4) and the direction (+ or -) is entered (e.g. the input of "4+" causes cylinder D to extend
fully).
N – Save Zero
The "N" key causes the current position of the cylinder to be stored as zero position in all parameter
files.
T – Test TLS
The "T" key can be used to test TLS commands. Possible inputs are:
TL Trim left
TR Trim right
LW List waterside
LL List landside
SL Skew left
SR Skew right
The cylinders move in the specified direction until they reach the limit value.
R – Reset
"R" (Reset) terminates any TLS command that has not yet completed.
Z – Move Zero
The "Z" key causes the cylinders to be moved to the zero position.
The cylinders continue to move until the target position is reached while taking account of the
positioning accuracy, even when the commands are no longer present.
Note
If a TLS command has not completed, this will be done automatically at the next key click with "TLS-
Reset".

Safety-relevant monitoring operations must operate correctly both with and without sway control and
be fail-safe. They must be implemented in the higher-level controller (PLC).
Because parts of the TO monitoring are deactivated during the "Sway Control" basic technology mode
(positioning, standstill and following error monitoring), sway control itself must be monitored. The
following TO monitoring operations, etc., remain active:

• Maximum speed
• Maximum acceleration
• Jerk
• Encoder error
The sway control system monitors only what the higher-level controller cannot monitor.
4.10.1 Following error monitoring

The following error is the difference between the calculated curve and the curve actually travelled (=
set-actual deviation).
The permitted deviation between the set and actual position during a travel operation in the
"positioning" and "hoist control" basic operating modes is stored for each axis in the P161 (trolley),
P164 (hoisting gear) and P167 (slewing gear) parameters during the commissioning.
If these tolerances are exceeded, the associated axis-related error (E41 – trolley following error, E42 –
hoisting gear following error) will be initiated and travel in the "SC Automatic" AddOn mode aborted.
The following error will not be monitored when the value = 0 is set in the parameters.
Work-around:
Increase the control reserve, reduce the damping factors, increase the position controller, reduce the
brake derivative action time, change the following error.
Note
Limitations of the speed actuating signal (e.g. in the converter) can result in the tripping of the
following error and therefore should only be intended for safety reasons.
4.10.2 Velocity monitoring

The velocities of the individual axes are monitored.
A velocity error occurs when the trolley (E50), the hoisting gear (E51) or the slewing gear (E52) are
not moving, are moving too fast or in the wrong direction.
This error is triggered when:
• The actuator speed is > 10% of the maximum speed (P0, P40, P220) and the crane is not moving
or moving in the wrong direction
• The difference between the actuator speed and the actual speed > 20% of the maximum speed
(P0, P40, P220) (e.g. defective drive)
The error appears with a delay of approx. 3 s. The error message is acknowledged when the axis
moves.
The causes of these errors can be:
• Defective encoder
• Faulty connection to the drive
• Brake is still closed
The speed is not monitored when the following error parameter of the axis (P161, P164, P167) is set
to zero.

Work-around:
Check position values and transfer of the actuator speed.
4.10.3 Start sway control monitoring

The warning E65 " sway control Off (Start)" occurs when the set start speed (P146) has not yet been
attained or the start time (P147) has not yet expired. This warning is only issued in the "Speed control"
basic operating mode. At the activation velocity a hysteresis of +- 5% interacts to prevent a permanent
switching (on / off) of the sway control.
4.10.4 Collision protection

Monitoring before the automatic start
Note
A travel job is not executed if the current load position or the target position is in a fixed blocked
region.
If the actual position is below the limit curve, a travel job is still generated. In this case, hoisting is
performed until the hoist position is above the limit curve. The internal sway control is switched off
during this phase in order to avoid collisions with adjacent containers.
If a target position below the limit curve is specified, a point is approached that is vertically above the
specified target.
Note
With an automatic start close to a stack of containers (obstacle), swaying of the load can result in an
abort of the automatic travel. Here it is essential to avoid an inclined hoisting when picking up a
container close to a further row of containers.
Monitoring during automatic operation

A software collision protection is activated in the "SC Automatic" and "SC Semi Automatic" AddOn
modes. Based on the current container crane position, it is determined how far the spreader is from a
possible obstacle. If this is approached too closely, there is a reaction via the actuating signals.
The following protection mechanisms are available:
1. Stopping with sway control outside the limit curve
2. Reduction of the actuating signal by further approach to the obstacle limit (without consideration of
the sway control, only deceleration ramp)
3. Actuating signal is set to zero when the position is in the blocked region. Simultaneously the error
message E37 "Actual position in the blocked region" is generated.
Normally the first protection barrier is effective. The other two protection mechanisms should be
considered as additional safety functions.
After setting the travel signal again, the errors are automatically cleared when the error conditions no
longer exist.

4.10.5 Application error messages

Errors can occur during the operation of an Add-on.
The "DCC_SCCommon" block returns errors with error bits. These errors can be processed in the
PLC using the bits set in the "bFault1" and "bFault2" error words. Because several bits can be set at
once, more than one error may be present.
CAUTION
The PLC programmer is required to evaluate the error messages of the system. In a fault situation,
the manipulated values of the sway control system may no longer be used. Only the PLC may
implement the control of the drives.
During the commissioning or a diagnosis, such errors can be detected and corrected with the
"CeCOMM.EXE" diagnostic program.
The currently pending errors are displayed by pressing the "E" key from the main menu or the display
screens. The error history can be called via the "H" key (Section 4.4.6.2).
Each error has a number, a title, an error description and a note on the remedy.
Errors that are transferred to the PLC, are identified by an error bit. Errors without error bit should be
interpreted as warnings. Both errors and warnings are visible in the "CeCOMM" diagnostic tool.
All errors are self-acknowledging and will be transferred only while they are present.
A detailed description of these errors is found in the following sections:
4.10.5.2 CenSOR M error messages

Errors that are identified by an error bit are passed on to the sway control system. Errors without error
bit should be interpreted as warnings. Both errors and warnings are visible in the "CeCOMM"
diagnostic tool.
Errors E1, E3, E4, E15 as well as a faulty connection of the camera to SIMOTION (monitored by
watchdog) result in a message on the "DCC_SCCamera" DCC block that the camera is not functioning
correctly. The "bCamera_OK" bit changes from "1" to "0".
If this signal is present on the DCC block for more than 14 s, error E4 is triggered in the sway control
system and passed on to the SIMATIC S7 by the "DCC_SCCommon" DCC block.
For detailed information in a fault situation, the "CeCOMM" diagnostic tool must be connected to the
camera.
E0 (Bit 0) Invalid parameter file

An error has occurred while loading the parameter files. The relevant parameter set will be set to
default values.

Error values: [1] - Parameter file missing

[2] - Incorrect parameter version
[3] - Incorrect number of parameters
[4] - Incorrect number of blocked regions
[5] - Incorrect number of target positions
[6] - Internal memory error
Error type: Error
Remedy: Check parameter in the Parameters menu and save
E1 (Bit 1) Field bus error

The camera could not establish the communication to the PLC or has not received any data for at
least two seconds. If the camera sends data, but does not receive any, the sway control system is
informed.
Type of error: Error
Remedy: Check the cable, check the PLC
E2 (Bit 2) Camera measuring system not calibrated

A calibration was started by pressing the rotary switch on the connection box or in the commissioning
menu of the diagnostic program and has not yet completed. The camera measuring is deactivated
until the calibration has completed.
Remedy: Complete calibration
E3 (Bit 3) Camera measuring system impaired

Soiling or poor lighting and visibility conditions has caused a reduction in the quality of the camera
measuring. The reflector, however, is still recognized sufficiently well. The sway control system is
informed about the faulty function.
If this error is present for more than 14 s, this error is replaced by E4 in the camera system.
Remedy: Clean the reflector, improve the lighting and visibility conditions
E4 (Bit 4) Camera measuring system faulty

The camera does not identify a reflector any more. This may be due to the following causes:
• The reflector no longer lies within the camera's field of vision
• The reflector is misaligned by 90° (see P2).
• The reflector is too small for the set window size (P3), i.e. too far away
• The ambient light is too bright or too dark
• The camera image is not focused.
This error replaces E3. The sway control system is informed about the faulty function.
Remedy: Correct the listed causes

E5 (Bit -/-) Parameter file not found

A parameter file could not be opened at the start of the program. The relevant parameter set has been
set to default values.
Type of error: Warning
E6 (Bit -/-) Parameter file with incorrect version

A parameter file contains parameters of an incorrect version. The relevant parameter set has been set
to default values.
E7 (Bit -/-) Parameter file with incorrect number of parameters

A parameter file contains an incorrect number of parameters. The relevant parameter set has been set
to default values.
E8 (Bit -/-) Invalid parameter value

An invalid value [X*10000+P] was found when loading parameter P in parameter set (1-4) from file
parX.txt (X:0-3). The value has been set to the default value. The error is only reset after the
parameter files have been loaded successfully.
Remedy: Check parameter and save
E9 (Bit -/-) Copy protection damaged

The software copy protection is damaged.
Remedy: Request the correct copy protection from the CePLuS GmbH
E10 (Bit -/-) Calibration switch actuated

The calibration switch in the connection box is not in the neutral position. If the calibration switch is in
the neutral position, there may be a wiring error on the calibration switch.
Remedy: Complete calibration, if required, check wiring
E11 (Bit -/-) Reflector distance has jumped

The reflector distance has jumped to an illegal height.


Remedy: Reference hoisting height encoder again
E12 (Bit -/-) Corrupted language file

Lines that are too long or cannot be displayed have been found when loading the language file
Sprache0.txt.
Error values: 0..199 – Parameter texts
200..300 – Error texts
Error type: Warning
Remedy: Correct language file, save and reload
E13 (Bit -/-) Internal floating-point data error

A floating-point error has occurred during the calculation.
100:SNAN 200:QNAN 300:NINF 400:ND 500:PD 600:PINF
0-9: controller, 10-19: oscillation model, 20-29: VSet, 30-39: oscillation model + offset, 40-49: RT
Remedy: -
E14 (Bit -/-) Incorrect IP address

The entered or read-in IP address of the peer entity is incorrect. It does not have the form
192.168.1.140.
Remedy: Enter a valid IP address in the parameter menu
E15 (Bit 5) Invalid distance

The externally specified distance lies outside the set limits (parameter list CenSOR M P32, P33).
The sway control system is informed about the faulty function.
Remedy: Check external distance and parameters
E18 (Bit -/-) Number of received message frames in % too low

The number of received message frames in % is too low.
Remedy: Check PLC cycle time, increase parameter sampling time
4.10.5.3 AddOn technology error list
Overview
The errors from the sway control system are categorized as follows:
General and severe errors E0 to E19

Error in the limit or prelimit switch area E20 to E29

Error in automatic operation E30 to E49
Other errors 1 E50 to E59
Other errors 2 E60 to E69
The categorization is a recommendation and can be adapted specifically for the project by the PLC
programmer.
Table 4-8 Error categories
Category Meaning
A Display on the CMS, manual and automatic mode permitted
B Display on the CMS, manual mode permitted and automatic mode not permitted
C Display on the CMS, manual and automatic mode not permitted
Brief description
The assignment of the error bits to the error messages in the output data and the concurrent output to
the DCC blocks are as follows:
Table 4-9 Error messages from the sway control system to the PLC (see Table 3-24, Fault1 in the
Common block)
Error Bit Block Brief description Cat.

General and severe errors
E0 - Common Cycle time too long -
E1 13 Common Fault in the DCC chart C
E2 14 Common Copy protection damaged A
E3 3 Common License error A
E4 12 Camera Camera measuring system faulted A
E5 1 Trolley Invalid basic operating mode, trolley B
E6 1 Hoist Invalid basic operating mode, hoisting gear B
E7 9 Trolley Invalid basic operating mode at the limit switch, trolley A
Hoist Invalid basic operating mode at the limit switch, hoisting A
E8 9
height
E9 - Hoist Hoisting height has jumped -
E10 0 Common Invalid parameter file C
E11 - Common Invalid parameter value -
E12 - Common Incorrect language file -
E13-E19 - Reserved -

Error Bit Block Brief description Cat.

Error in the limit or prelimit switch area
E20 - Trolley Forward prelimit switch switches incorrectly, trolley -
E21 - Hoist Upper prelimit switch switches incorrectly, hoisting gear -
E22 - Trolley Backward prelimit switch switches incorrectly, trolley -
E23 - Hoist Lower prelimit switch switches incorrectly, hoisting gear -
E24 - Trolley Forward limit switch switches incorrectly, trolley -
E25 - Hoist Upper limit switch switches incorrectly, hoisting gear -
E26 - Trolley Backward limit switch switches incorrectly, trolley -
E27 - Hoist Lower limit switch switches incorrectly, hoisting gear -
E28-E29 Reserved -
Error in automatic operation
E30 31 Common No path found B
E31 4 Trolley Invalid target position, trolley B
E32 4 Hoist Invalid target position, hoisting gear B
E33 16 Obstacles Too many variable blocked regions B
E34 24 Common Group error abort, hoist control B
E35 17 Common Starting point in an invalid region B
E36 18 Common Starting point in variable blocked region A
E37 28 Common Actual position in blocked region B
E38 25 Common Target in fixed blocked region B
E39 26 Common Target mislaid A
E40 - - - -
E41 29 Trolley Following error, trolley B
E42 30 Hoist Following error, hoisting gear B
E43 - - Crane geometry /dynamic response is incorrect -
E44-E49 Reserved -
Other errors 1
E50 11 Trolley Speed error, trolley B
E51 11 Hoist Speed error, hoisting gear B
E52 11 TLS Speed error, slewing gear B
E53-E59 Reserved -
Other errors 2
E60 15 Common Load stuck B
E61 7 Common Sway control Off (pendulum length) A
E62 6 Common Start of positioning with too much swaying B
E63 10 Trolley Sway control temporarily reduced, trolley B
E64 19 TLS Sway control temporarily reduced B
E65 - Trolley Sway control Off (start) -
E66 - Trolley Sway control only when stopping -
E67 - Common Controlled stop active -
E68 - Internal floating-point data error -
General and severe errors

E0 (Bit -/-) Cycle time too long
The cycle time is greater than 100 ms.


Remedy: Hang the DCC chart in a faster task
E1 (Bit 13) Fault in the DCC chart.

The DCC chart is faulty At least one DCC block is missing for the selected application.
Remedy: Add missing DCC block
E2 (Bit 14) Copy protection corrupted

The license is damaged or missing. The sway control function is deactivated.
Remedy: Create and transfer a license key
E3 (Bit 3) License error

A basic operating mode has been selected, but there is no license for this.
Remedy: Reset command bit or purchase license
E4 (Bit 12) Camera measuring system faulty

The camera does not identify a reflector any more. This may be due to the following causes: The
reflector is not in the field of vision of the camera, is rotated through 90° (camera parameter P2), is too
far away for the set window size (camera parameter P3) or the environment is too light or too dark or
the camera image is not in focus.
Remedy: Check camera and connection to camera, if the system is blind, set P102 selection
1 = ON
E5 (Bit 1) Invalid basic operating mode, trolley

An unavailable basic operating mode or several basic operating modes cannot be selected at the
same time. The error message also appears when the "Hoist control" basic operating mode has been
selected for only one axis.
Remedy: Check the PLC program, only set one operating mode bit for each travel axis
E6 (Bit 1) Invalid basic operating mode, hoisting gear

An unavailable basic operating mode or several basic operating modes cannot be selected at the
same time. The error message also appears when the "Hoist control" basic operating mode has been
selected for only one axis.
Remedy: Check the PLC program, only set one operating mode bit for each travel axis

E7 (Bit 9) Invalid basic operating mode in the limit switch, trolley

Only the "Speed control" basic operating mode is permitted at the limit switch.
Remedy: Activate "Speed control" basic operating mode
E8 (Bit 9) Invalid basic operating mode in the limit switch, hoisting gear
Only the "Speed control" basic operating mode is permitted at the limit switch.
Remedy: Activate "Speed control" basic operating mode
E9 (Bit -/-) Hoisting height has jumped

The hoisting gear position has jumped to an illegal height (> 10 m).
Remedy: Reference hoisting height encoder again
E10 (Bit 0) Invalid parameter file

An error has occurred while loading the parameter files. Parameter files are missing or are faulty. The
relevant parameter set will be set to default values.
Error values: 1..4; value specifies which parameter set could not be loaded correctly
Error type: Error
Remedy: Check parameters in the parameter menu, save and reload
E11 (Bit -/-) Invalid parameter value

An invalid value [X*10000+P] was found when loading parameter P in parameter set (1-4) from file
parX.txt (X:0-3). The value has been set to the default value. The error is only reset after the
parameter files have been loaded successfully.
Remedy: Check parameters in the parameter menu, save and reload
E12 (Bit -/-) Corrupted language file

Lines that are too long or cannot be displayed have been found when loading the language file
Sprache0.txt.
Error values: 0…199 – Parameter texts
200..300 – Error texts
300..400 – Commissioning texts
Error type: Warning
Remedy: Correct language file
E13 – E19 Reserve

Error in the limit or prelimit switch area

E20 (Bit -/-) Forward prelimit switch switches incorrectly, trolley
The prelimit switch in the forward direction became active for negative speed or inactive for positive
speed.
Remedy: Exchange forward and backward prelimit switch signals
E21 (Bit -/-) Upper prelimit switch switches incorrectly, hoisting gear
The prelimit switch in the forward direction became active for negative speed or inactive for positive
speed.
Remedy: Exchange upper and lower prelimit switch signals
E22 (Bit -/-) Backward prelimit switch switches incorrectly, trolley

The prelimit switch in the backward direction became active for positive speed or inactive for negative
speed.
Remedy: Exchange forward and backward prelimit switch signals
E23 (Bit -/-) Lower prelimit switch switches incorrectly, hoisting gear
The prelimit switch in the backward direction became active for positive speed or inactive for negative
speed.
Remedy: Exchange upper and lower prelimit switch signals
E24 (Bit -/-) Forward limit switch switches incorrectly, trolley

The limit switch switches for the wrong direction of motion or is set simultaneously with the prelimit
switch in the opposite direction.
Remedy: Exchange forward and backward limit switch signals
E25 (Bit -/-) Upper limit switch switches incorrectly, hoisting gear
Remedy: Exchange upper and lower limit switch signals
E26 (Bit -/-) Backward limit switch switches incorrectly, trolley



Remedy: Exchange forward and backward limit switch signals
E27 (Bit -/-) Lower limit switch switches incorrectly, hoisting gear
Remedy: Exchange upper and lower limit switch signals
E28 – E29 Reserve
Error in automatic operation

E30 (Bit 31) No path found
The hoist control could not find a path between the starting position and the target position.
Remedy: Check starting position and target position as well as blocked regions
E31 (Bit 4) Invalid target position, trolley

The target position of the trolley is outside the set limits (P23, P28).
Remedy: Check parameters for limits
E32 (Bit 4) Invalid target position, hoisting gear

The target position of the hoisting gear is outside the set limits (P63, P69).
Remedy: Check parameters for limits
E33 (Bit 16) Too many variable blocked regions

An attempt has been made to transfer more than 200 variable blocked regions.
Remedy: Check PLC program
E34 (Bit 24) Group error abort, hoist control

A travel job in the hoist control basic operating mode has been aborted. Refer to other error messages
for the exact cause of the error.
Remedy: Evaluate other error messages
E35 (Bit 17) Starting point in an invalid region

The load is outside the set limits at the time an automatic travel operation is started or in a fixed
blocked region with hoist control. The travel job is not executed.
Remedy: Traverse manually to valid regions. Check fixed blocked regions and limits.
E36 (Bit 18) Starting point in variable blocked region

The load is in a variable blocked region at the time a travel operation is started with hoist control. This
warning does not result in a cancellation and remains pending until the region is exited.
Remedy: Move manually from the blocked region.
E37 (Bit 28) Actual position in blocked region

The actual position has violated a fixed or variable blocked region. The course has deviated too far
from the setpoint.
Remedy: Increase the control reserve, reduce the damping factors, increase the position
controller, reduce the brake derivative action time
E38 (Bit 25) Target in fixed blocked region

The target position is in a fixed blocked region. A travel job is not generated.
Remedy: Check the target position and the fixed blocked region
E39 (Bit 26) Target mislaid

The target position is in a variable blocked region. The travel job is started. Positioning stops
before/above the variable blocked region.
Remedy: Check the target position and the variable blocked region
E41 (Bit 29) Trolley following error

The difference between the actual and the set position is greater than the set permissible following
error (P161), see Section 4.10.1
controller, reduce the brake derivative action time, change the following error
E42 (Bit 30) Hoisting gear following error

The difference between the actual and the set position is greater than the set permissible following
error (P164), see Section 4.10.1


controller, reduce the brake derivative action time, change the following error
E43 (Bit -/-) Crane geometry /dynamic response is incorrect

Inconclusive value combinations have been determined. Correct functioning cannot be guaranteed.
Remedy: Check parameters
E44 – E49 Reserve
Other errors 1
E50 (Bit 11) Trolley speed error
The trolley does not move, moves too fast or in an incorrect direction. The error is triggered when:
• The actuator speed is > 10% of the maximum speed (P0) and the crane is not moving or
moving in the wrong direction
• The difference between the actuator speed and the actual speed > 20% of the maximum
speed (P0) (e.g. defective drive)
The error appears with a delay of approx. 3 s. The error message is acknowledged when the trolley
moves.
The error is not signaled when the following error parameter of the axis (P161) is set to zero.
Remedy: Check position values and transfer of the actuator speed
E51 (Bit 11) Hoisting gear speed error

The hoisting gear does not move, moves too fast or in an incorrect direction. The error is triggered
when:
The error appears with a delay of approx. 3 s. The error message is acknowledged when the hoisting
gear moves.


E52 (Bit 11) Speed error during skew

The slewing gear does not move, moves too fast or in an incorrect direction. The error is triggered
when:
The error appears with a delay of approx. 3 s. The error message is acknowledged when the trolley
moves.
E53 – E59 Reserve
Other errors 2
E60 (Bit 15) Load stuck
The load has stuck when starting to move.
Remedy: Control crane manually or change P105.
E61 (Bit 7) Sway control Off (pendulum length).

The sway control function has been switched off as the hoisting height is not within the specified limits
(P83, P84).
Remedy: Check parameters
E62 (Bit 6) Start of positioning with too much swaying

The positioning motion was started when there was too much swaying.
Remedy: Eliminate swaying manually, check parameter P156
E63 (Bit 10) Trolley sway control temporarily reduced

Because of large swaying movements, the damping factor for trolley has been temporarily significantly
reduced for stability reasons.
Remedy: Eliminate swaying manually
E64 (Bit 19) skew control temporarily reduced

Because of large swaying movements, the damping factor for skewing has been temporarily
significantly reduced for stability reasons.
Remedy: Eliminate swaying manually
E65 (Bit -/-) sway control Off (start)

The set starting speed (P146) has not been reached or the start time (P147) has not yet elapsed, in
order to start the sway control function. This warning is only issued in the "Speed control" basic
operating mode.
Remedy: -
E66 (Bit -/-) sway control only when stopping

The command bit " sway control only when stopping" is set.
Remedy: Reset command bit
E67 (Bit -/-) Controlled stop active

The command bit "Controlled stop" is set.
Remedy: Reset "Controlled stop" bit
E68 (Bit -/-) Internal floating-point data error

A floating-point error has occurred during the calculation.
Error values: 100:SNAN 200:QNAN 300:NINF 400:ND 500:PD 600:PINF
0-9: controller, 10-19: oscillation model, 20-29: VSet, 30-39: oscillation model + offset, 40-49: RT
Remedy: -

4.10.5.4 CeCOMM diagnostic software

Operating errors in the "Monitor" function are normally displayed in the monitor status line. An example
is the "Display screen not assigned" message.
4.10.6 Troubleshooting / FAQs

Table 4-10 Troubleshooting/FAQ
Scenario Possible causes and remedy

Camera does not receive any message frames Check the hardware configuration.
although the PLC receives data. Error
message "Field bus error". The status LEDs of
the sway control system and the camera
connection are lit up on the hub. However, only
the transmit LED of the camera flashes.
Crane does not settle after completion of the Check minimum frequency and ramp-up time of the
travel motion. converter.
The actual pendulum length differs greatly from the
internally calculated effective pendulum length
(screen 01 in the CeCOMM). Calibrate hoisting
height (commissioning steps 2 and 3 on the
sway control system).
sway control system starts swaying Check acceleration and deceleration ramps of the
movements. converter, remove any roundings and check the
control parameters of the converter.
Set the alignment of the camera (commissioning
step 1 on sway control system).
Crane moves a short distance on its own for no Camera loses the reflector and for a short time finds
reason. objects in the vicinity similar to reflectors. Determine
minimum window size (commissioning step 3 on
camera). Change the low-pass frequency factor
(P28-30 on the camera), restrict the camera search
area (P15, P16 on the camera), increase the
contrast (P0, P1 on the camera).
Trim oscillations occur with a higher frequency Activation of the low-pass filter (camera P28-30) for
than the swaying movement. the appropriate drive axis (typical value: 2-3) and
reduction of the camera injection (SIMOTION P123,
P124) (typical value: 0.015)
Residual swaying movements are always or Check ramps and speed controller of the converter.
occasionally too large.
Trolley moves uncontrolled and the automatic Display the currently pending errors with the
start does not react at all. diagnostics tool. If error E2 is active, the license has
been deleted or damagedÆ Check licenses
Empty main menu (space bar) in the CeCOMM License is damaged or missing. Error E2 "Copy
diagnostic tool protection damaged" is displayed on the "Faults"
display screen ("E" key). Æ Check licenses

Scenario Possible causes and remedy

Camera measuring system faulty (E4 error). This message does not automatically result in
cancellation of the automatic travel. If this message
is present permanently, there is a hardware fault. If
it occurs sporadically, there is a problem detecting
the reflector.
The system integrator must decide whether the
automatic travel is to be interrupted.

General information 5
5.1 Maintenance and Service
5.1.1 Reflector
The reflector must be cleaned regularly depending on the degree of soiling. If only light dust
contamination is present, a yearly inspection/cleaning suffices. If, however, heavy dust contamination
prevails, the reflector must be cleaned in 4-6 weekly intervals. The secure reflector mounting must be
checked as part of the regular crane inspection.
5.1.2 Camera
The front window of the camera protective housing must be inspected and cleaned regularly at the
intervals specified in "Reflector". The secure mounting of the camera must be checked. After changing
the reflector or the cable, the camera must be recalibrated using the "CeCOMM" diagnostic software
(semiautomatic commissioning).
5.1.3 Update the camera software

While updating the camera software, the marked files (see fig. 5-1) at the explorer have to be
transferred into the directory „/FlashFx/“ of the camera
The check mark at the file attribute (F2-Attributes) „Read only“ have to be deleted.
After copying the version should be checked at the version display (button “V”).

General information
5.2 Technical Data
Fig. 5-1:Update the camera software
5.2 Technical Data
5.2.1 Camera technical data

The CenSOR M camera measuring system can be used under the following mechanical and climatic
conditions:

General information
5.2 Technical Data
Table 5-1 Mechanical and climatic operational conditions CenSOR M
Condition Permissible range

Storage temperature -25° C … + 85° C
Operating temperature -25° C … + 60° C
Maximum humidity 85% without condensation
Atmospheric pressure 1,060 -700 hPa
(corresponds to a height up to 3000 m)
Vibration in operation (sinusoidal vibration) 10 - 58 Hz: 0.35 mm
Vibration in operation (constant amplitude) 58 - 150 Hz: 50 m/s²
in accordance with DIN EN 60068-2-68, IEC 68-2-6
Shock resistance in accordance with DIN EN 60068- 10 g amplitude, 6 ms duration
2-27, IEC 68-2-27
Power requirement 8...24 V (± 10% ripple)
Typ. 300 mA at 12 V, max. 450 mA
Typ. 3.5 W, max. 5 W
Serial I/O 9-pin Sub-D socket (RS232)
Weight Approx.350 g
5.2.2 Dimension drawings
5.2.2.1 Camera
Fig. 5-2: Camera

General information
5.2 Technical Data
5.2.2.2 Camera protective housing
Weather protection enclosure
Fig. 5-3: Weather protection enclosure, front view
Fig. 5-4: Weather protection enclosure, side view

General information
5.2 Technical Data
Fig. 5-5: Weather protection enclosure, top view
5.2.2.3 Reflector
Reflector 500 mm active
Fig. 5-6: Reflector 500 mm active, front view

General information
5.2 Technical Data
Fig. 5-7: Reflector 500 mm active, rear and side view
Reflector 800 mm active
Fig. 5-8: Reflector 800 mm active, front view

General information
5.2 Technical Data
Fig. 5-9: Reflector 800 mm active, rear and side view

General information
5.2 Technical Data
5.2.3 Circuit diagrams

HUB circuit diagram
Fig. 5-10: HUB circuit diagram

General information
5.2 Technical Data
Camera measuring system circuit diagram
Fig. 5-11: Camera measuring system circuit diagram

General information
5.2 Technical Data
Reflector circuit diagram
Fig. 5-12: Reflector circuit diagram
5.2.4 Spare parts / accessories

Spare parts and accessories can currently only be obtained from CePLuS Steuerungstechnik GmbH
in Magdeburg.
Order number Item

1304 Replacement camera with lens (CenSOR M)
1618 Ethernet hub
1620 IR band elimination filter 830 nm
1450 Reflector unit 800 mm
1452 Reflector unit 500 mm
1455 Rubber cushion

General information
5.3 Parameters
5.3 Parameters
5.3.1 CenSOR M parameter list
5.3.1.1 Overview
The parameters for configuring the CenSOR M camera are assigned as follows:
Camera/reflector parameters P0 to P19
Distance parameters P20 to P39
General parameters 1 P40 to P59
General parameters 2 P100 to P119
5.3.1.2 Camera/reflector parameters

The following parameter list on the camera can be used to establish a connection between the camera
and the PC for diagnostic purposes or for manually changing parameters.
P0 Gain of the video input
Gain of the video signal. For zero, the automatic gain control will be activated. The maximum value is
64.
0 Automatic gain control (depending on the brightness of the complete image).
1 – 63 Fixed gain (bright environment => small values).
64 The gain results from ¼ of the current offset of the video input. This allows the gain also
to be maintained depending on the brightness of the reflector.
Default: 64 min: 0 max: 64
Access code: 2
P1 Offset of the video input

Exposure time of the camera. The exposure time can be set to a value between 1 and 255. If the
exposure time is set automatically, the brightness of the complete image or the brightness of the
reflector must be chosen as setting. The maximum value is 511.
The value 255 must be set when a rectangular retro-reflector is used.
0 Automatic exposure time (depending on the brightness of the complete image).
1 – 255 Fixed exposure time (bright environment => small values).
255 Fixed exposure time for a retroreflector.
256 Automatic exposure time depending on the brightness of the reflector when the reflector
was recognized, otherwise search for the optimum exposure time.
257 – 511 255+a: Automatic exposure time (depending on the brightness of the reflector), if the
reflector was recognized; if the reflector was not recognized, the fixed exposure time a
(1..255) will be set.
Access code: 2

General information
5.3 Parameters
P2 Reflector type and alignment

Selection:
1 Black-and-white reflector: White areas, bottom left and top right
2 Black-and-white reflector: White areas, top left and bottom right
The parameter specifies how the white areas of the standard reflector are aligned. An incorrect setting
will cause error E4 when a connection is established with the sway control system or with the camera.
Access code: 0
P3 Window size for the reflector recognition

This parameter increases the internal reflector model. The largest possible value must be set for the
largest distance between the camera and the reflector. An incorrect setting will cause error E4 when a
connection is established with the sway control system or with the camera.
0 Automatic size control (distance-dependent).
1-10 Fixed window size.
11-20 Fixed window size (1..10) when no reflector was recognized, otherwise automatic size
control.
Access code: 2
P4 Reflector recognition limit (complete image)

The probability for the recognition of the reflector determined by the correlation function is compared
with this factor. Only when the determined probability has at least this value is the reflector accepted
as being recognized. The value is used for the search in the complete image.
Default: 700 [‰] min: 300 [‰] max: 1000 [‰]
Access code: 2
P5 Size of the white reflector area

Width of the white reflector area in mm. This parameter is used to determine the distance between the
camera and the reflector.
Default: 100 [mm] min: 10 [mm] max: 10000 [mm]
Access code: 0

General information
5.3 Parameters
P6 Measuring reliability of the camera

The value specifies the degree of the required measuring reliability for determining the reflector size
(0...7). If the 3rd bit is also set, a swing angle measurement is valid only when a successful size
measurement has been performed (8..15).
Access code: 1
P7 Upper reflector position for camera calibration

For this reflector distance (internal, calibrated value), the upper measured value is acquired for the
camera calibration.
Access code: 0
P8 Lower reflector position for camera calibration

For this reflector distance (internal, calibrated value), the lower measured value is acquired for the
camera calibration.
Access code: 1
P9 Camera offset in the X direction

Value from the automatic camera calibration.
Default: 0 [mm] min: - 3000 [mm] max: 3000 [mm]
Access code: 3
P10 Camera offset in the Y direction

Access code: 3
P11 Camera offset in the Z direction

Value from the automatic camera calibration. If the value is zero, a newer calibration procedure with
higher accuracy will be used. If the traditional calibration procedure should be used, prior to the
calibration, the value must be set to a non-zero value.
Access code: 3
P12 Camera skew in the X direction

Default: 0 min: - 200000 max: 200000
Access code: 3

General information
5.3 Parameters
P13 Camera skew in the Y direction

Default: 0 min: - 200000 max: 200000
Access code: 3
P14 Minimum reflector contrast

For the image evaluation, the contrast between the bright and dark areas must have at least this
value. The measured contrast can lie between 0 and 255. Normally, the contrast of a reflector lies
within the range 40 to 100, where the contrast of an active reflector is higher than that of a passive
reflector.
Access code: 2
P15 Limiting of the global search (X)

If the reflector was not found, the horizontal image area in which the reflector is searched can be
limited. For 0% or 90%, all 640 image columns or only the middle 64 image columns will be searched
for the presence of a reflector, respectively.
Default: 0 [%] min: 0 [%] max: 90 [%]
Access code: 2
P16 Limiting of the global search (Y)

If the reflector was not found, the vertical image area in which the reflector is searched can be limited.
For 0% or 90%, all 480 image rows or only the middle 48 image rows will be searched for the
presence of a reflector, respectively.
Default: 0 [%] min: 0 [%] max: 90 [%]
Access code: 2
P17 Focal length of the lens

The parameter specifies the focal length of the used lens in mm. Typical focal lengths are: 8 mm, 12
mm, 16 mm, 25 mm, 50 mm.
Access code: 2

General information
5.3 Parameters
P18 Monochrome limit

Selection:
0 Arithmetic average of the reflector (default)
1 Suppress dark disturbances on white areas (shadows)
2 Suppress light disturbances on dark areas
This parameter can be used to specify the light-dark limit.
Access code: 2
P19 Reflector recognition limit (reflector environment)

The probability for the recognition of the reflector determined by the correlation function is compared
with this factor. Only when the determined probability has at least this value is the reflector accepted
as being recognized. The value is used only for searching near a recognized reflector.
Default: 600 [‰] min: 300 [‰] max: 1000 [‰]
Access code: 2
5.3.1.3 Distance parameters

P20 Distance sensor resolution
Calibration value for the external distance position.
Default: 1 min: - 100 max: 100
Access code: 1
P21 Distance sensor offset

Calibration value for the external distance position.
Access code: 1
P22 X measured value resolution

Calibration value for the measured value output.
Default: 1 min: - 100000 max: 100000
Access code: 1
P23 X measured value offset

Access code: 1

General information
5.3 Parameters
P24 Y measured value resolution

Default: 1 min: - 100000 max: 100000
Access code: 1
P25 Y measured value offset

Access code: 1
P26 Rotation angle measured value resolution

Default: 1 min: - 100000 max: 100000
Access code: 1
P27 Rotation angle measured value offset

Access code: 1
P28 X measured value smoothing time constant

Smoothing time constant for smoothing the measured value (first order delay element). If the
parameter value is zero, the smoothing is deactivated.
Default: 0 [s] min: 0 [s] max: 1000 [s]
Access code: 1
P29 Y measured value smoothing time constant

Access code: 1
P30 Rotation angle measured value smoothing time constant

Access code: 1

General information
5.3 Parameters
P31 Distance measured value smoothing time constant

Access code: 1
P32 Minimum reflector distance

The reflector distance must have a value at least the size of the set value. Otherwise it will be set to
this value.
Access code: 1
P33 Maximum reflector distance

The reflector distance may not be larger than the set value. Otherwise it will be set to this value.
Access code: 1
5.3.1.4 General parameters 1

P42 Second camera available
If a second camera is used in the Ethernet network (e.g. to acquire large measuring ranges), this
parameter must be set to 1. The device then deactivates its send function while it is not receiving any
data from the PLC. If the parameter is set to zero, the camera sends irrespective of whether or not it is
receiving data.
Access code: 1
P43 Commissioning status

Information encoded bit-by-bit about which commissioning steps have been completed successfully.
Access code: 1
P44 Diagnostics value

Depending on the set value, the diagnostics variable is assigned 10 and sent to CeCOMM.
0-2 limits, 3-5 setpoints, 6-8 actual values, 9-11 manipulated variables,
12-14 delayed manipulated variables, 15-17 oscillation model, 18-21 camera measured values.
Always in the sequence, position-speed-acceleration.
Access code: 0

General information
5.3 Parameters
P45 Save camera image once

Selection:
1 Do not save
2 Save once unconditionally
3 Save once in case of an incorrect size measurement
4 Save once in case of an incorrect center determination
If this parameter is non-zero, the camera image will be saved as the "BildBin.txt" file for further offline
processing.
The save operation causes the camera to be blocked for several seconds. After performing the
command, the parameter will be automatically reset to zero.
Access code: 3
5.3.1.5 General parameters 2

P100 Access code
Selection:
1 every user
2 commissioning engineers
3 service technicians
4 Developer
Access code for changing parameters.
Access code: 0
P101 Sampling time

This value corresponds to the current sampling time of the control process in milliseconds. A reduction
is sensible only to the extent that the calculations do not exceed the set sampling time.
Default: 70 [ms] min: 40 [ms] max: 200 [ms]
Access code: 2
P102 Reflector position from external (0) / internal (1)

0 Reflector position is read using the PROFIBUS DP interface
1 Reflector position is determined from the size of the reflector.
>1 Fixed reflector distance in mm
The parameter "Size of the white reflector area" must be set correctly for a correct measurement.
Access code: 1

General information
5.3 Parameters
P103 Ethernet/PROFIBUS interface

Selection:
1 CenSOR standard interface (CePLuS)
2 HIPAC-PROFIBUS interface (Siemens)
Access code: 0
P110 Language
Selection:
1 German
2 English
This parameter specifies the language used by the diagnostic software.
Independent of the settings from P110 (language) and P100 (Access code) the language can be set in
use of the commissioning software CeCOMM (Windows Menu functions, options/ language).
Access code: 0
P111 Passive (0) or active (1) reflector

When the appropriate reflector type is selected, the automatic brightness control takes account of the
associated light conditions.
Access code: 0
P112 Reflector distortion

Specifies the optical distortion of the reflector. This parameter is set automatically during the
commissioning.
Access code: 2
5.3.2 AddOn technology parameter list
5.3.2.1 Overview of the parameter list

The parameters for the configuration of the sway control system on the sway control system are
grouped as follows:
Trolley parameters P0 to P39
Hoisting gear parameters P40 to P79
sway control parameters P80 to P99
General parameters P100 to P119

General information
5.3 Parameters
Camera/reflector parameters P120 to P139

Travel behavior parameters P140 to P159
Parameter controlled variables P160 to P179
TLS parameters P180 to P219
Slewing gear parameters P220 to P239
Option parameters
Parameters, in which one or more options can be selected, are identified by a"#" in front of the
character string. Selected options are specified with the corresponding digit; options that are not
selected with a dot ".".
Examples of parameter P152 (conventional/time-optimized control, trolley):
#..... None of the five options has been selected
#.23.. Options 2 and 3 of five options have been selected
#123.5 Options 1, 2, 3 and 5 of five options have been selected
Note
Only the default values are specified for the parameters with selection options, but not the minimum
and maximum.
5.3.2.2 Trolley parameters

P0 Maximum actuator speed, trolley
Speed limit in mm/s. The set value corresponds to the maximum attainable speed. The maximum
speed is the speed attained when sending the normalizing value P103. Set manually according to
manufacturer or customer specifications.
Default: 3500 [mm/s] min: 10 [mm/s] max: 5000 [mm/s]
Access code: 0 Display: Always
Note
After confirmation of the parameter P0, a prompt will be made whether the P1, P7, P6 and P5
parameters should be updated. The updating is appropriate only when the speeds and accelerations
dependent on P0 have already been entered and only P0 is adapted again.
For this "update", the P1, P7, P6 and P5 parameters will be changed in the same ratio as P0.
P1 Positioning speed, trolley

This value (in mm/s) corresponds to the maximum speed in the "Positioning" basic operating mode. In
order to allow a slight overshoot, a value of 90% of the maximum actuator speed (P0) should be set.
Set manually according to manufacturer or customer specifications. Record in order to check the
speed setpoint in Positioning mode.

General information
5.3 Parameters
P2 Prelimit switch speed, trolley

Percentage speed value of P0 within the prelimit switches.
Default: 10 [%] min: 0 [%] max: 100 [%]
P3 Trolley speed for zero speed signal

If the target position of the trolley has been reached and the actuating signal is less than
P3/100*P103, no further manipulated variable and therefore no further direction signal is output. The
brake can be closed.
Default: 3 [%] min: 0 [%] max: 75 [%]
P4 Speed reduction factor for horizontal target point approach

Percentage value of the positioning speed of the trolley (P1). The maximum speed setpoint is reduced
by this factor when a horizontal target point approach is performed (VSet=P1*P4/100).
Default: 20 [%] min: 1 [%] max: 100 [%]
P5 Maximum acceleration, trolley

Acceleration limit in mm/s². The set value corresponds to the maximum drive
acceleration/deceleration. The value should be approx. 50..100% above the maximum acceleration
(P6). Input values less than 20 are interpreted as ramp time.
Set manually according to manufacturer or customer specifications.
Default: 550 [mm/s²] min: 1 [mm/s²] max: 2000 [mm/s²]
P6 Set acceleration, trolley

The set acceleration is an internal acceleration variable in mm/s². It is effective in all basic operating
modes not only in the acceleration, but also in the deceleration phase. The set acceleration is attained
with deactivated sway control or time-optimized control. The value should be approx. 75% of the
maximum acceleration (P5). Input values less than 20 are interpreted as ramp time.

General information
5.3 Parameters
P7 Acceleration without sway control / minimum acceleration

value. The value is used as minimum deceleration when the prelimit switch range is reached. Input
values less than 20 are interpreted as ramp time. Set manually according to manufacturer or customer
specifications. The value should be approx. 65% of the maximum acceleration (P5). The drive must be
braked with this deceleration from full speed at the prelimit switch down to prelimit switch speed (P2)
at the limit switch.
P8 Deceleration gain, trolley

Gain factor for the increase or decrease of the deceleration. The deceleration results from P6 * P8,
with countering from P6 * P8 * P142.
Default: 1 min: 0,5 max: 5
P9 Reduction factor for set acceleration, trolley, automatic travel

This parameter can be used to reduce the set acceleration in the "Hoist control" basic operating mode.
The parameter acts only with time-optimized control.
P10 Acceleration reduction factor for horizontal target point approach

Percentage value of the set acceleration of the trolley (P6). The maximum speed setpoint is reduced
by this factor when a horizontal target point approach is performed (ASet = P6*P10/100).
Default: 20 [%] min: 1 [%] max: 100 [%]
P11 Trolley rounding for operation without sway control

Initial and final rounding of the trolley setpoint. The percentage value is based on the ramp-up time to
the maximum speed. The rounding is active when the parameter is greater than zero and the sway
control is deactivated.
Default: 10 [%] min: 0 [%] max: 50 [%]
P12 Smoothing of torque setpoint, trolley

In addition to the actuator speed, the actuator acceleration for the torque precontrol of a speed control
loop is returned to the PLC. The smoothing of the torque setpoint can be set with this time constant. If
the value is less than 1, the delay element is deactivated.

General information
5.3 Parameters
P13 Boost factor, trolley

This value raises the output speed in the range below the zero speed signal. If the boost factor is 3%
for 5% zero speed signal, then output values below 5% are in the 3%...5% range.
Default: 0 [%] min: 0 [%] max: 100 [%]
P20 Resolution of position sensor, trolley

Calibration value for the trolley position.
P21 Offset of position sensor, trolley

Calibration value for the trolley position.
P22 Encoder increments per millimeter for trolley

Factor for the conversion of the counted encoder pulses over a distance in mm.
Default: 0 [1/mm] min: - 500000 [1/mm] max: 500000 [1/mm]
CAUTION
This parameter is visible in the CeCOMM diagnostic tool, but is not relevant for this product as it is
not possible to connect encoders directly.
P23 Minimum position for positioning, trolley

Smaller target positions are ignored. Note that the limitation refers to calibrated target positions (after
conversion with resolution and offset). Error E31 is triggered for smaller target positions of the trolley.
P24 Position for trolley VES speed backwards

Position where the trolley must have attained the prelimit switch speed (P2). The position where the
trolley is braked depends on the speed (dynamic prelimit switch). The parameter acts only when P115
= 1.

General information
5.3 Parameters
P25 Waiting position, trolley

This parameter specifies the waiting position of the trolley. The trolley waits at this position until the bit
"NO_WAIT_POS" has been set by the PLC. This function can be used, for example, for container
cranes with several trolleys for mutual locking.
P26 Trolley position, start of waterside

Trolley position that corresponds to the start of the waterside. The offset approach (P34) only applies
to the waterside.
P27 Position for trolley VES speed forwards

Position where the trolley must have attained the prelimit switch speed (P2). The position where the
trolley is braked depends on the speed (dynamic prelimit switch). The parameter acts only when P115
= 1.
P28 Maximum position for positioning, trolley

Larger target positions are ignored. Note that the limitation refers to calibrated target positions (after
conversion with resolution and offset). Error E31 is triggered for larger target positions of the trolley.
P29 Trolley position, end of waterside

Trolley position that corresponds to the end of the waterside. The offset approach (P34) only applies
to the waterside.
P30 On-the-fly unloading abort speed

For on-the-fly unloading, the "open grab" signal will be reset once the trolley undershoots the specified
speed.
Access code: 1 Display: Only for GSU (P102, selection 0 = ON)

General information
5.3 Parameters
P31 Distance for opening the grab

For on-the-fly unloading, the "open grab" state bit will be set when the distance between the grab and
the target position is smaller than this parameter value.
Access code: 1 Display: Only for GSU (P102, selection 0 = ON)
P32 Travel clearance of trolley to limit curve

Safety clearance that is maintained when travelling around the limit curve in the trolley direction.
Minimum travel clearance of the trolley in addition to the safety clearance of the limit curve.
P33 Safety clearance, trolley

Safety clearance to obstacle limit in the trolley direction. This parameter is used to define the safety
zone (smart slowdown with stop with sway control).
P34 Offset for target point approach

This parameter only applies for target point approaches on the waterside. If the parameter is not equal
to zero, a target position is approached that is offset by this value in the trolley direction. The trolley
then travels to the target position.
P35 Position offset during unloading

When learning target positions, the value for the trolley is changed by this parameter. The value is
limited internally to a spreader width.
P36 Position offset during loading

When learning target positions, the value for the trolley is changed by this parameter. The value is
limited internally to a spreader width.

General information
5.3 Parameters
P37 Bay Scanner position offset

Deviation of the laser position from the trolley position. Positive values mean that the Bay Scanner
measuring laser is offset by this value from the defined trolley position in the waterside direction.
Access code: 1 Display: Only for STS (P102, selection 1 = ON)
5.3.2.3 Hoisting gear parameters

P40 Maximum actuator speed, hoisting gear
Speed limit in mm/s. The set value corresponds to the maximum attainable speed. The maximum
Note
After confirmation of the parameter P40, a prompt will be made whether the P41, P51 and P50
parameters should be updated. The updating is appropriate only when the speeds and accelerations
dependent on P40 have already been entered only P40 has to be adapted again.
For this "update", the P41, P51 and P50 parameters will be changed in the same ratio as P40.
P41 Positioning speed, hoisting gear

This value (in mm/s) corresponds to the maximum speed in the "Positioning" basic operating mode. In
order to allow a slight overshoot, a value of 90% of the maximum actuator speed (P40) should be set.
Set manually according to manufacturer or customer specifications. Record in order to check the
speed setpoint in Positioning mode.
P43 Prelimit switch speed, hoisting gear

Percentage speed value within the prelimit switches.
Default: 10 [%] min: 0 [%] max: 100 [%]
P44 Hoisting speed for zero speed signal

If the actuating signal of the hoisting gear is less than P44/100*P103 and the target or intermediate
position is reached, no further manipulated variable and therefore no further direction signal is output.
The brake can be closed.
Default: 3 [%] min: 0 [%] max: 75 [%]
P45 Hoisting speed reduction

General information
5.3 Parameters
Percentage value of the positioning speed when hoisting (P41). The maximum speed setpoint is
reduced by this factor. Applies in the "Hoist control" and "Positioning" basic operating modes
(VSet = P41*P45/100)
Default: 100 [%] min: 1 [%] max: 100 [%]
P46 Immersion point speed limit

For the transition of the trolley speed from 10% above to 10% below the speed, the current immersion
point is set on the waterside. The value refers to the maximum speed of the trolley.
Default: 20 [%] min: 15 [%] max: 85 [%]
P47 Reduction of speed when raising

Factor for the reduction of the speed until the bit "Slack rope" is no longer set.
ACHTUNG
Wird der Wert = 0 gesetzt, ist diese Reduzierung nicht aktiv und es wird mit voller Geschwindigkeit
angehoben.
P49 Reduction of speed when lowering

Just before putting the load down (P74), the lowering speed is determined from the positioning speed
and this reduction factor (P41 * P49).
Default: 0,5 min: 0 max: 1
ACHTUNG
Wird der Wert = 0 gesetzt, ist diese Reduzierung nicht aktiv und es wird mit voller Geschwindigkeit
abgesetzt.
P50 Maximum acceleration, hoisting gear

Acceleration limit in mm/s². The set value corresponds to the maximum drive
acceleration/deceleration. The value should be approx. 50..100% above the maximum acceleration
(P51). Input values less than 20 are interpreted as ramp time.
P51 Set acceleration, hoisting gear

The set acceleration is an internal acceleration variable in mm/s². It is effective not only in the
acceleration, but also in the deceleration phase. Input values less than 20 are interpreted as ramp

General information
5.3 Parameters
time. Set manually according to manufacturer or customer specifications. The value should be approx.
75% of the maximum acceleration (P50).
P52 Deceleration gain, hoisting gear

Gain factor for the increase or decrease of the deceleration. The deceleration results from P51 * P52,
with countering from P51 * P52 * P142.
P53 Acceleration reduction when hoisting

Percentage value of the set acceleration when hoisting (P51). The set acceleration is reduced by this
factor when hoisting. Applies in the "Hoist control" and "Positioning" basic operating modes (ASet =
P51*P53/100)
Default: 100 [%] min: 1 [%] max: 100 [%]
P54 Hoisting gear rounding

Initial and final rounding of the hoisting gear setpoint. The percentage value is based on the ramp-up
time to the maximum speed. The rounding is active when the parameter is greater than zero.
Default: 10 [%] min: 0 [%] max: 50 [%]
P55 Smoothing of torque setpoint, hoisting gear

P60 Resolution of position sensor, hoisting gear

Calibration value for the hoisting gear position.
Default: -1 min: - 100 max: 100
P61 Offset of position sensor, hoisting gear

Calibration value for the hoisting gear position.

General information
5.3 Parameters
P62 Encoder increments per millimeter for hoisting rear

Default: 0 [1/mm] min: - 500000 [1/mm] max: 500000 [1/mm]
CAUTION
P63 Minimum position for positioning, hoisting gear

Smaller target positions are ignored. Please note that the limitation refers to calibrated target positions
(after conversion with resolution and offset).
P64 Position for hoisting gear VES speed lowering

Position where the hoisting gear must have attained the prelimit switch speed (P43). The position
where the hoisting gear is braked depends on the speed (dynamic prelimit switch). The parameter
acts only when P115 = 1 and the trolley is located on the landside (see P26).
P65 Hoisting gear waiting position

This parameter specifies the waiting position of the hoist. The hoisting gear waits at this position until
the bit "NO_WAIT_POS" has been set by the PLC.
P66 Minimum hoisting height, landside

Below the minimum hoisting height on the landside, the "bStart_Auto_OK" state bit is not set. If this bit
is used for starting the automatic, a start is not possible. If the state bit is not processed, only the
hoisting gear is operated below the minimum hoisting height on the landside at the automatic start,
then also the trolley.
P67 Minimum hoisting height waterside

Below the minimum hoisting height on the waterside, only the hoisting gear is operated at the
automatic start, then also the trolley.

General information
5.3 Parameters
P68 Position for hoisting gear VES speed hoisting

Position where the hoisting gear must have attained the prelimit switch speed (P43). The position
where the hoisting gear is braked depends on the speed (dynamic prelimit switch). The parameter
acts only when P115 = 1.
P69 Maximum position for positioning, hoisting gear

Larger target positions are ignored. Please note that the limitation refers to calibrated target positions
P70 Safe height on land

An automatic travel on land will always stop above this position. At start in this area, initially only the
hoisting gear is operated until the limit is exceeded.
Default: - 10000 [mm] min: - 10000 [mm] max: 200000 [mm]
P71 Travel clearance of hoisting gear to limit curve

Minimum travel clearance of the hoisting gear above the safety clearance of the limit curve. If a target
is below this limit curve, this parameter specifies the distance between the target position and the limit
curve.
P72 Safety clearance, hoisting gear

Safety clearance above the limit curve. This parameter is used to define the safety zone (smart
slowdown).
P74 Distance for automatic lowering

As of this distance to the target, lowering is performed with reduced speed (P49).
5.3.2.4 Sway control parameters

P80 Digital hoisting distance correction
Shift in the center of gravity of the load, with "Dig_Hoist_Dist_Corr" bit set.

General information
5.3 Parameters
Default: 0 [mm] min: -10000000 [mm] max: 10000000 [mm]

P81 Analog hoisting distance correction

Relationship between load mass and shift in the center of gravity.
Default: 0.02 [mm/kg] min: -70000 [mm/kg] max: 70000 [mm/kg]
P82 Weight of the load carrying device

Weight of the load carrying device to determine the shift in the center of gravity. If the load is the same
as the weight of the load carrying device, then there is no shift in the center of gravity.
Default: 12500 [kg] min: -20000 [kg] max: 20000 [kg]
P83 Upper limit for sway control

For a smaller (effective) pendulum length, the sway control will be disabled (E61).
P84 Lower limit for sway control

For a larger (effective) pendulum length, the sway control will be disabled (E61).
P85 Damping factor, trolley (deceleration)

Gain factor for the conventional sway control in all basic operating modes when decelerating. Large
values result in aperiodic transition characteristics, small values in overshoot.
P86 Damping factor, trolley (acceleration)

Gain factor for the conventional sway control in manual operation when accelerating. Large values
result in aperiodic transition characteristics, small values in overshoot. To achieve fast accelerations
operations, the value should be less than for deceleration.
P87 Damping factor for skew (deceleration)

Gain factor for the conventional sway control in all basic operating modes when decelerating. Large
values result in aperiodic transition characteristics, small values in overshoot.

General information
5.3 Parameters

Access code: 2 Display: Only for TLS (P197, selection 1 = ON)
P88 Damping factor for skew (acceleration)

Gain factor for the conventional sway control in manual operation when accelerating. Large values
result in aperiodic transition characteristics, small values in overshoot. To achieve fast accelerations
operations, the value should be less than for deceleration.
P89 Hoisting height offset for 20’ skew control

Offset for the conversion of the hoisting position to the effective pendulum length. The value is only
used for the skew control.
P90 Linear hoisting height factor for 20’ skew control

Linear gain factor for the conversion of the hoisting position to the effective pendulum length. The
value is only used for the skew control.
Default: 0,5 min: -1000 max: 1000

General information
5.3 Parameters
P91 Hoisting height offset for 30’ skew control

P92 Linear hoisting height factor for 30 ft skew control

Default: 0,85 min: -1000 max: 1000
P93 Hoisting height offset for 40/45’ skew control

P94 Linear hoisting height factor for 40/45’ skew control

Default: 1,2 min: -1000 max: 1000
5.3.2.5 General parameters

P100 Access code
Selection:
0 every user
1 commissioning engineers
2 service technicians
3 development engineers (password protected)
Access code for changing parameters.
Default: #1
P101 Parameter set locked during travel

Selection:
0 The active parameter set can be switched over during travel
1 The active parameter set can only be switched over at standstill
Default: #1

General information
5.3 Parameters
P102 Configuration
Selection:
0 ship unloader (without camera)
1 STS (with camera)
Default: #1
P103 Normalizing value

The parameter contains the normalizing factor for all speeds and accelerations that are transferred via
the field bus. If the parameter is set, for example, to 28,000, then a speed setpoint of –14,000
corresponds to half the negative maximum speed of the relevant axis.
Default: 32767 min: 10 max: 32767
CAUTION
This parameter is visible in the CeCOMM diagnostic tool, but does not apply for this product. All
relevant values are already transferred fully scaled in physical variables of the basic technology (see
Section 2.1.4.4).
P104 Diagnostics value

Depending on the set value, the diagnostics variable is assigned 10 and sent to CeCOMM.
0-2 limits, 3-5 setpoints, 6-8 actual values, 9-11 manipulated variables, 12-14 delayed manipulated
variables, 15-17 oscillation model, 18-20 camera measured values, 21 camera measurement, 26
setpoint-actual-value difference (position), 27 damping reduction factor.
Always in the sequence, position-speed-acceleration.
P105 Maximum inclined hoisting angle

If the inclined hoisting is greater than this angle, error E60 "Load stuck" is triggered. The evaluation is
performed by comparing the oscillation model with the camera measurement. The monitoring can be
deactivated by setting the parameter to values less than 0.6.
Default: 0 [°] min: 0 [°] max: 500000 [°]
P106 Spreader / container / grab width

The obstacles are increased in size by half the width left and right for the travel path calculation and
monitoring.

General information
5.3 Parameters
CAUTION
If the parameter is changed, the internal targets are initialized and all the learnt lanes are deleted.
Note
For P106 < 1000 mm, a switchover is made to the MODEL MODE. Because of the different
dimensions, smaller safety areas than on the real crane apply.
P107 Hoist offset to the spreader/grab

The limit curve is increased in height by the value of this parameter for the travel path calculation and
monitoring. This is useful when the hoisting gear position does not correspond to the lower edge of the
spreader/grab.
P108 Maximum container height

The height of the highest possible container. When the bit "Locking state of the spreader" is set, all
blocked regions (fixed and variable) are increased by this parameter value.
Note
For P108 < 1000 mm, a switchover is made to the MODEL MODE. Because of the different
dimensions, smaller safety areas than on the real crane apply.
P109 Automatic mode

Selection:
1 automatic travel only to land
2 for travel to land, a lane MUST be specified
This parameter only applies when no external targets are specified (bUse_Extern_Targets = 0 bit).
Default: #.2
P110 Language
Selection:
0- German
1 English
This parameter specifies the language used by the diagnostic software.
Default: #1
P111 Smoothing factor for actual speeds

General information
5.3 Parameters
This parameter can be used to smooth the determined actual speed. The factor acts on the actual
speeds of all axes. Small values cause more intensive smoothing; the maximum value 1.0 produces
no smoothing.
P115 Prelimit switch configuration

Deceleration of the trolley and the hoisting gear before the minimum or maximum position to VES
speed. The dynamic prelimit switches (P24, P27, P64, P68) are enabled and disabled.
Meaning:
0 dynamic prelimit switches deactivated, bits for prelimit switches active
1 dynamic prelimit switches activated.
P116 Maximum rotation angle for passive skew control

With passive skew control, the permissible rotation angle of the load after being put down corresponds
to this value.
Default: 0 [cgr] min: 0 [cgr] max: 10000 [cgr]
P117 Request for encoder synchronization

If the difference of the axis position between the encoder signal and the signal via PROFIBUS is
greater than this value, status bit no. 6 of the relevant axis is set and therefore an encoder
synchronization requested. As long as this value corresponds to the default value (=0), the bit is not
set.
CAUTION
5.3.2.6 Camera/reflector parameters

P120 Assignment of camera axes to drive axes
Selection:
1 Motion up or down corresponds to trolley travel.
2 Motion to the left corresponds to the forwards direction.
3 Motion up corresponds to the forwards direction.
The motions are evaluated as seen from the camera image in the "CeCOMM".
Default: #...

General information
5.3 Parameters
P121 Delay of camera data, trolley

Delay of the camera signal from the image recording until switching in to the oscillation model.
P122 Camera data delay for skewing

Delay of the camera signal from the image recording until switching in to the oscillation model.
P123 Gain of the camera measuring signal

Value for switching in the camera measuring signal to the internal oscillation model. The camera
measurement has no effect with a value of zero.
P124 Gain of the camera measuring signal while skewing

Value for switching in the camera measuring signal to the internal oscillation model. The camera
measurement has no effect with a value of zero.
Access code: 1 Display: Only for STS (P102, selection 1 = ON) and TLS
(P197, selection 1 = ON)
P125 Camera fixed - reflector rotated

Selection:
0 Slewing drive rotates camera and reflector (e.g. trolley slewing gear)
1 Slewing drive rotates reflector, but not the camera (e.g. TLS cylinder)
Mounting of the camera and the reflector with respect to the skew
Default: #1
P126 Upper limit for camera measurement

The camera measurement is deactivated for pendulum lengths shorter than this value.
5.3.2.7 Travel behavior parameters

P140 Transfer time for the actuator speed

General information
5.3 Parameters
Specifies the time required for the transfer of the actuator speed to the drive. It is approximately the
sum of the sampling times of the sway control and the PLC.
P141 Suppress opposite direction

As long as this percentage value of the maximum speed is not attained in manual operation, the drive
axis is only moved in the direction specified by the crane operator.
Default: 75 [%] min: 0 [%] max: 100 [%]
P142 Deceleration increase with countering

The deceleration is increased by this value when the speed setpoint and the actual speed have
different signs (countering).
P143 Acceleration reduction, fine travel

If the speed setpoint and the actual speed are less than 30% of the maximum speed, the set
acceleration is multiplied by this factor. The value applies for all drive axes.
Default: 0,5 min: 0,001 max: 1
P144 Deceleration reduction, fine travel

If the speed setpoint and the actual speed are less than 30% of the maximum speed, the set
acceleration is multiplied by this factor and used as deceleration setpoint. The value applies for all
drive axes.
Default: 0,5 min: 0,001 max: 1
P145 Variable acceleration for the time-optimized control

A variable acceleration range can be specified for the time-optimized control. The control tries to vary
the acceleration in such a way that simple ramps result. The acceleration is then in the range (100%-
value)*ASet_Was .. (100%+value)*ASet_Was or AMax.
with ASet_Was - Set acceleration without sway control (P7, P51)
Amax - Maximum acceleration (P5, P50)
Value - P145
Default: 10 [%] min: 0 [%] max: 100 [%]
P146 Activation speed of the sway control

General information
5.3 Parameters
If the absolute value of the speed setpoint is greater than this value, the sway control is activated after
expiry of the switch-on delay P147.A hysteresis of +- 5% is working to prevent . Warning E65 is active
as long as the speed has not been reached.
Default: 0 [%] min: 0 [%] max: 100 [%]
P147 sway control switch-on delay

The absolute value of the speed setpoint must be greater than the activation speed P146 at least for
this period so that the sway control is activated. Warning E65 is present if this period has not yet
elapsed.
P148 sway control switch-off delay

The sway control function is switched off after this period has expired if the switch-on conditions are
no longer satisfied.
P149 Drive switch-on delay, trolley

Switch-on delay of the converter, after which the brake is opened. If the value is less than 1, the delay
element is deactivated.
P150 Drive switch-on delay, hoisting gear

P151 Drive switch-on delay during skewing

P152 Conventional/time-optimized control, trolley

Selection:
1 Time-optimized control only for speed control
2 Time-optimized control only for automatic control

General information
5.3 Parameters
3 On-the-fly unloading permitted (only for GSU)

4 On-the-fly unloading with max. deflection (only for GSU)
5 Time-optimized control only for stopping (only for GSU)
If all options are "OFF", the conventional control is always active.
Default: #.....
P153 Time constant for current rise, trolley

The current rise and therefore the change in acceleration over time are often limited by the converter.
In order to take this delay into account when activating the oscillation model and the position control, a
first order delay element has been provided, whose time constant is set with this parameter. If the
value is less than 1, the delay element is deactivated.
P154 Time constant for current rise, hoisting gear

P155 Current rise time constant for sway control

P156 Permissible initial sway

Automatic positioning can only be started when the initial sway is less than this parameter. Error E62
is triggered if the initial sway is greater. The value refers to the calculated average load deflection for
acceleration operations. If 0% is set as permissible initial sway, then it is possible to start with every
initial sway.
Default: 0 [%] min: 0 [%] max: 200 [%]
5.3.2.8 Controlled variable parameters

P160 Position controller, trolley

General information
5.3 Parameters
P position controller for the automatic positioning. Negative values activate a target control instead of
the position control. The absolute value of a negative value determines the steepness of the
deceleration ramp. ABrake=fabs(P160)*P6
Default: 0,5 min: -1 max: 10
P161 Following error, trolley

Permissible deviation between the set and actual position during a travel operation in the "Positioning"
and "Hoist control" basic operating modes. If this value is exceeded, the travel operation is aborted
and an error message (E41) generated. If the value = 0 is set, this function is not active.
P162 Positioning accuracy, trolley

Tolerance within which a positioning operation should be completed.
P163 Position controller, hoisting gear

deceleration ramp. ADecel=fabs(P163)*P51
P164 Following error, hoisting gear

and "Hoist control" basic operating modes. If this value is exceeded, the travel operation is aborted
and an error message (E42) generated.
P165 Positioning accuracy, hoisting gear

P166 Position controller for skewing

deceleration ramp. ADecel=fabs(P166)*P225

General information
5.3 Parameters

P167 Following error for skew control

and "Hoist control" basic operating modes. If this value is exceeded, the travel operation is aborted.
P168 Positioning accuracy for skewing

Default: 20 [cgr] min: 1 [cgr] max: 200 [cgr]
P169 Permissible residual sway

Largest permissible load deflection after completion of a trolley motion. When the load deflection falls
below this value, the signal "Sway neutralized" will be set.
P170 Residual sway after time-optimized acceleration

The parameter specifies how large the swaying motion may be after a time-optimized acceleration
operation.
P169 is always used for stopping.
P171 Quality of the time-optimized control

This parameter specifies the quality of the time-optimized control. Higher quality reduces the
acceleration and deceleration times and increases the required CPU time.
5.3.2.9 TLS parameters

P180 Speed setpoint of the TLS cylinders
Cylinder speed when activating trim, list or skew.
P183 Maximum speed for TLS cylinders

General information
5.3 Parameters
Maximum cylinder speed that may occur with trim, list, skew and activated skew control.
P184 Speed for pressure 1/2 switchover

The signal for higher pressure is set above this speed.
P185 TLS switch-in for skew control

The manipulated variable determined for skew control is multiplied by this value and switched into the
TLS cylinder actuating signals.
Default: 1 min: -100000 max: 100000
P186 TLS speed for zero signal

If the control calculates an actuator speed that is less than this value, then zero and no direction is
output for the speed.
Default: 15 [%] min: 0 [%] max: 75 [%]
P187 Gain for the TLS cylinder positions

Calibration value for the TLS cylinder positions.
Default: 1 min: 0,0001 max: 200000
P188 Minimum TLS cylinder position

Limit for the TLS cylinder positions.
Default: -10000 [mm] min: -200000 [mm] max: 200000 [mm]
P189 Maximum TLS cylinder position

Limit for the TLS cylinder positions.
P190 Positioning accuracy of TLS cylinders


General information
5.3 Parameters
Default: 20 [mm] min: 0,01 [mm] max: 200000 [mm]

P191 Reduction of lowering actuator speed

The lowering speed of the TLS cylinders can be greater than the hoisting speed by this amount of
actuator speed. In this case, the actuator speed for the lowering should be reduced with this
parameter.
Default: 100 [%] min: -100 [%] max: 100 [%]
P192 Switch-off delay of the pump

The output signal for the pressure control is reduced by this set delay.
P193 Minimum pressure, normalized

The hydraulic cylinders start to move as of this output value.
P194 Trim limit

Limit of the difference between the left and right cylinder positions.
P195 List limit

Limit of the difference between the front and back cylinder positions.
P196 Skew limit

Limit of the difference between the diagonals A and B cylinder positions.
P197 Use trim/list/skew control

Selection:
1 Trim/list/skew control On
2 Use the same positions on the land- and waterside

General information
5.3 Parameters
If the TLS control is to be used, the slewing gear is used in conjunction with the TLS cylinders. It can
be specified whether the same TLS positions should apply on the land- and waterside or deviate from
each other.
Default: #..
P200 Zero position of cylinder A

Position that is approached when the command bit "Approach zero position" is set.
P201 Zero position of cylinder B

P202 Zero position of cylinder C

P203 Zero position of cylinder D

5.3.2.10 Slewing gear parameters

P220 Maximum actuator speed for skewing
Speed limit in cgr/s. The set value corresponds to the maximum attainable speed. The maximum
Default: 500 [cgr/s] min: 10 [cgr/s] max: 4000 [cgr/s]
Note
After confirmation of the parameter P220 , a prompt will be made whether the P221, P226, P225 and
P224 parameters should be updated. The updating is appropriate only when the speeds and
accelerations dependent on P220 have already been entered only P220 has to be adapted again.
For this "update", the P221, P226, P225 and P224 parameters will be changed in the same ratio as
P220.

General information
5.3 Parameters
P221 Positioning speed for skewing

This value corresponds to the maximum speed in the "Positioning" basic operating mode. In order to
allow a slight overshoot, a value of 90% of the maximum actuator speed (P220) should be set. Set
manually according to manufacturer or customer specifications. Record in order to check the speed
setpoint in Positioning mode.
Default: 450 [cgr/s] min: 10 [cgr/s] max: 4000 [cgr/s]
P222 Prelimit switch speed for skewing

Percentage speed value within the prelimit switches.
Default: 10 [%] min: 0 [%] max: 100 [%]
P223 Speed of rotation for zero speed signal

If the target position of the trolley has been reached and the actuating signal is less than
P223/100*P103, no further manipulated variable and therefore no further direction signal is output.
The brake can be closed.
Default: 3%
Default: 3 [%] min: 0 [%] max: 75 [%]
P224 Maximum acceleration for skewing

Acceleration limit in cgr/s². The set value corresponds to the maximum drive acceleration/deceleration.
The value should be approx. 50..100% above the set acceleration (P225). Input values less than 20
are interpreted as ramp time.
Default: 250 [cgr/s²] min: 0,1 [cgr/s²] max: 1000 [cgr/s²]
P225 Set acceleration for skewing

The set acceleration is an internal acceleration variable in cgr/s². It is effective not only in the
acceleration, but also in the deceleration phase. The set acceleration is attained with deactivated sway
control or time-optimized control. Input values less than 20 are interpreted as ramp time. Set manually
according to manufacturer or customer specifications. The value should be approx. 75% of the
maximum acceleration (P224).
P226 Acceleration without sway control

value. The value is used as minimum deceleration when the prelimit switch range is reached. Input
values less than 20 are interpreted as ramp time. Set manually according to manufacturer or customer

General information
5.3 Parameters
specifications. The drive must be braked with this deceleration from full speed at the prelimit switch
down to prelimit switch speed (P222) at the limit switch.
P227 Gain of the deceleration while skewing

Gain factor for the increase or decrease of the deceleration. The deceleration results from P225 *
P227, with countering from P225 * P227 * P142.
P228 Smoothing of torque setpoint for skewing

P229 Resolution of rotation angle sensor

Calibration value for the rotational position.
Default: 1 min: -100 max: 100
P230 Offset of rotation angle sensor

Calibration value for the rotational position.
Default: 0 [cgr] min: -100000 [cgr] max: 100000 [cgr]
P231 Encoder increments per millimeter for skewing

Default: 0 [1/mm] min: -500000 [1/mm] max: 500000 [1/mm]
CAUTION
P232 Minimum position for positioning for skewing

Smaller target positions are ignored. Please note that the limitation refers to calibrated target positions
Default: -5000 [cgr] min: -200000 [cgr] max: 200000 [cgr]

General information
5.4 Appendix
P233 Maximum position for positioning for skewing

Larger target positions are ignored. Please note that the limitation refers to calibrated target positions
Default: 5000 [cgr] min: -200000 [cgr] max: 200000 [cgr]
P239 Commissioning status

Information encoded bit-by-bit about which commissioning steps have been completed successfully.
Default: 0 min: 0 max: 2147483647
5.4 Appendix
5.4.1 CeCOMM commissioning software
5.4.1.1 Monitor menu tree

The menu assistance of the screens in the "Monitor" tab is explained using the first graphic. The
display screens (middle column) can be reached from the "main menu" with the keys "1" to "7". The
display screens, menus and additional functions listed in the right-hand column can be called from
each of these display screens.
1 Display kinematics
1 Display
2 Display Profibus Interface
kinematics
3 Display status of travel axes
2 Display Profibus
4 Display common bits
Interface 5 Display autocheck
3 Display status of 6 Display hoist control
travel axes 7 Display Trim/List/Skew
4 Display common B Fixed Blocked regions
bits G Display Variable Blocked regions
5 Display I commissioning menu
autocheck P parameters menu
6 Display hoist L Logger
control E Fault
7 Display H Fault History
Trim/List/Skew V Version Info
? Return to main menu
! Stop diagnosis
X Twistlock simulation
Space Return to main menu
ENTER Build a new display
B Fixed Blocked 1 Display blocked regions

General information
5.4 Appendix
Regions I Add blocked regions

C change blocked regions
D Delete blocked regions
S save all sets of parameters/areas
R reload parameters
F display interpolation points
ESC Return to last selected display – page 1 to 7
E Fault ESC Return to last selected display – page 1 to 7
? Help for selected fault
H Fault history
G Display Variable Any key Return to last selected display – page 1 to 7
Blocked Regions
H Fault History ESC Return to last selected display – page 1 to 7
E Fault
ENTER Return to last selected display – page 1 to 7
I commissioning 0 Set Configuration and Parameters
menu 1 set alignment of the camera
2 calibrate hoist high (TROLLEY)
3 calibrate hoist high (SKEW CONTROL)
4 simulate errors
5 determine speed limit
6 save all parameters
? help for selected commissioning step
L Logger H display first page
E display last page
B one page backward
F one page forward
S save logged signal sequences
P Parameters 1,2 Display trolley parameters 1,2 Display trolley parameters
menu 3,4 Display hoisting gear parameters 3,4 Display trolley parameters
5 Display sway control parameters 5 Display trolley parameters
6 Display general parameters 6 Display trolley parameters
7 Display camera parameters 7 Display trolley parameters
8 Display driveability parameters 8 Display trolley parameters
9 Display controller parameters 9 Display trolley parameters
10,11 Display TLS parameters 10,11 Display trolley parameters
12 Display skew drives parameters 12 Display trolley parameters

General information
5.4 Appendix
C Change parameters
D Set default values for all sets
F Search parameters
I Communication addresse
L Parameters/areas listing
N different parameters/areas set
R reload parameters
S save all sets of parameters/areas
Y copy parameters/areas set
T Title of set of parameters – only camera
? Help for parameter
V Version Info Any key Returne to last selected display

! Stop diagnosis Space Restart of diagnosis
X Twistlock X Stop Twistlock simulation
simulation
Fig. 5-13: Monitor menu tree

General information
5.4 Appendix
5.4.1.2 Analog signals of the path/speed time diagram

Table 5-2 Description of the analog signals

Trolley
VSet ext. trolley Trolley set speed specified from the master switch Right mm/s
VSet int. trolley Trolley set speed using the set ramps Left mm/s
VActuator trolley Trolley speed calculated by the oscillation model Left mm/s
VActual trolley Trolley actual speed Left mm/s
Trolley model Load deflection calculated by the model (deviation of Left mm
Trolley camera Load deflection recorded by the camera (deviation of Left mm
SSet trolley Position setpoint, trolley Right mm
SActual trolley Actual position, trolley Right mm
SDelay trolley Position after the set delays Right mm
VDelay trolley Actuator speed after the set delays Left mm/s
P104 Trolley Variable value that depends on the setting in the Right Variable
Parameters menu
Hoisting gear
VSet ext. hoisting Hoisting gear set speed specified from the master Right mm/s
gear switch
VSet int. hoisting Hoisting gear set speed using the set ramps Left mm/s
gear
VActuator hoisting Hoisting gear speed calculated by the oscillation model Left mm/s
gear
VActual hoisting Hoisting gear actual speed Left mm/s
gear
SSet hoisting gear Hoisting gear set position Right mm
SActual hoisting Hoisting gear actual position Right mm
gear
SDelay hoisting Position after the set delays Right mm
gear
VDelay hoisting Actuator speed after the set delays Left mm/s
gear
P104 Hoist Variable value that depends on the setting in the Right Variable
Parameters menu
Slewing gear
VSet ext. slewing Slewing gear set speed specified from the master Right cgr/s
gear switch
VSet int. slewing Slewing gear set speed using the set ramps Left cgr/s
gear
VActuator slewing Slewing gear speed calculated by the oscillation model Left cgr/s
gear
VActual slewing Slewing gear actual speed Left cgr/s
gear
Slewing gear model Rotation angle calculated by the model (deviation of Left cgr

General information
5.4 Appendix

Slewing gear angle Skewing angle recorded by the camera (deviation of Left cgr
SSet slewing gear Position setpoint, slewing gear Right cgr
SActual slewing Actual position, slewing gear Right cgr
gear
SDelay slewing Position after the set delays Right cgr
gear
VDelay slewing Actuator speed after the set delays Left cgr/s
gear
P104 Slewing gear Variable value that depends on the setting in the Right Variable
Parameters menu
5.4.2 Bibliography
Ref. 1: PROFIBUS and PROFINET, PROFIdrive Profile Drive Technology
PROFIBUS User Organization e. V.
Haid-und-Neu-Straße 7, D-76131 Karlsruhe
http://www.profibus.com
Order No.: 3.172 Version 4.1, May 2006
Ref. 2: SIMOCRANE Basic Technology V2.0 Operating Instructions
SIMOCRANE_Basic_Technology_de-DE.pdf, 06/2008 Edition
Ref. 3: SIMOTION D4x5 Manual
D4x5_Betreiben_de-DE.pdf, 08/2008 Edition
Ref. 4: SIMOTION D4x5 Commissioning and Hardware Installation Manual,
D4x5_Inbetriebnehmen_de-DE.pdf, 08/2008 Edition
5.4.3 Abbreviations
BT: Basic Technology
BW: Backward
CF: CompactFlash Card
CMS: Crane Management System
COP: Crane Operator Panel
CW: Clockwise
CCW: Counter-clockwise
DCC: Drive Control Chart
DN: Down
DS: Tandem Spreader
FW: Forward
GSU: Grab Ship Unloader
HO: Hoist

General information
5.4 Appendix
IO: Input/Output variables

LS: Landside
LH: Left hand
MCC: Motion Control Chart
RH: Right hand
RMG: Rail-Mounted Gantry Crane
RT: Run time
SC: Sway Control
ST: Structured text
STS: Ship to shore (Quayside Container) Crane
STW: Control word
SW: Software
TLS: Trim/list/skew
TO: Technology Object in SIMOTION; symbol for a moving axis
TR: Trolley
UP: Up
WS: Waterside
ZSW: Status word
5.4.4 Terminology (German/English)
English German English German

Backward Rückwärts Right hand rechte Seite
Boom Ausleger Ship-to-shore crane Containerbrücke
Clockwise Uhrzeigersinn Slew gear Drehwerk
Closing Gear Schliesswerk Sway Control Pendeldämpfung
Counter clock wise Gegenuhrzeigersinn Trolley Katze
Down abwärts Up aufwärts
Forward vorwärts
Gantry Fahrwerk
Gantry - Slave Fahrwerk - Slave
Grab Ship Unloader Greifkran, Schiffsentlader
Hoist Hubwerk
Holding Gear Haltewerk
Input/Output Eingabe-/ Ausgabevariablen
variables
Left hand linke Seite

Index
Access code General features............................................ 160
Camera measuring system ............................ 234 Internally learnt .............................................. 162
Sway Control system ..................................... 247 Internally learnt variable ................................ 162
Accessories Learn ............................................................. 162
Camera and reflector ..................................... 299 Transfer ......................................................... 161
Actual position value ........................................... 107 Brightness........................................................... 243
Actual speed ....................................................... 107 Calibration
Actuator speed .................................................... 256 Camera measurement................................... 241
Add-on Camera
Configuring .................................................... 197 Brightness ..................................................... 233
AddOn Connecting .................................................... 232
Import ............................................................... 86 Fine focus ...................................................... 232
Add-on DCC blocks ............................................ 108 Lens settings ................................................. 232
Add-on DCC library ............................................... 34 Set alignment ................................................ 257
Add-on FB library .................................................. 53 Camera image
Copying ............................................................ 96 Checking ............................................... 217, 236
Add-on system Live ................................................................ 218
Minimum configuration .................................. 121 Save .............................................................. 218
Alarm messages ................................................. 271 Camera measuring system
analog signals ..................................................... 340 Commissioning .............................................. 236
Application Configuring .................................................... 233
Sway Control for container cranes .................. 75 Fine adjustment ............................................. 241
Sway Control for ship unloader ....................... 74 Functions ....................................................... 228
Sway Control with TLS Control........................ 83 Interface ........................................................ 229
SwayControl with 2D-Trajectory and Bay Operating principle ........................................ 228
Scanning .......................................................... 76 Save parameters ........................................... 241
TLS Control...................................................... 81 Simulate errors .............................................. 241
Application error messages ................................ 274 Camera Measuring System ................................ 228
Application planning .............................................. 16 Camera measuring system commissioning
Auto configuration ............................................... 205 Requirements ................................................ 234
Automatic .................................................... 143, 156 Camera parameters
Basic operating mode ......................................... 129 Camera and reflector..................................... 300
Hoist control ............................................. 77, 134 Distance ........................................................ 304
Speed control................................................. 130 General 1 ....................................................... 306
Sway neutralization to load position .............. 136 General 2 ....................................................... 307
Sway neutralization to trolley position ........... 136 Manual setting ............................................... 241
Bay scanner ........................................................ 210 Characteristics
Bay Scanner values Sway Control ................................................. 249
Conversion..................................................... 126 Circuit diagram
Bay scanning ........................................................ 79 HUB ............................................................... 297
Blocked region ...................................................... 77 Closed-loop control structure ............................... 27
Blocked regions .................................. 134, 155, 159 Collision protection ..................................... 266, 273
Definition .......................................................... 77 Commissioning
Delete ............................................................ 162 2D-Trajectory................................................. 263
External variable ............................................ 160 Camera measuring system ........................... 236

Index
Hoist control ................................................... 265 Acceleration and deceleration ramps.............246

Positioning ..................................................... 263 Initial and final rounding .................................246
Sway Control system ..................................... 249 Limitation ........................................................247
TLS Control ................................................... 268 Minimum frequency ........................................246
Commissioning AddOn software Parameter sets ...............................................246
Requirements ................................................ 193 Preparing ........................................................246
Commissioning menu ......................................... 213 Speed controller .............................................246
Commissioning requirements Customization
AddOn software ............................................. 193 Add-on ............................................................108
Camera measuring system............................ 234 cylinder ................................................................166
Sway Control system ..................................... 244 Cylinder positions ................................................269
Commissioning software .................................... 199 Damping factor
Installing......................................................... 199 Setting ............................................................262
Commissioning steps DCC block
Camera measuring system............................ 237 DCC_SCCamera ..............................................50
Sway Control ................................................. 254 DCC_SCCommon ............................................35
Sway Control system ..................................... 254 DCC_SCDiag ...................................................52
Communication DCC_SCHoist ..................................................37
Checking PLC-SIMOTION D ......................... 247 DCC_SCObstacles ..........................................47
Ethernet ......................................................... 193 DCC_SCTargets ..............................................45
SIMOTION and CenSOR M .......................... 194 DCC_SCTLS ....................................................42
Communication test ............................................ 115 DCC_SCTrolley ................................................40
Complete system DCC blocks
Configuration ................................................... 15 Inserting............................................................98
Configuration Deceleration ........................................................256
Camera measuring system............................ 237 Definition
Complete system ............................................. 15 I/O peripherals ..................................................92
PROFIBUS ...................................................... 87 Message frame ................................................94
S7 .................................................................. 123 Definitions ..............................................................77
Sway Control system ............................. 138, 250 Deletion
Configuring Positions .........................................................268
Sway Control ................................................... 84 Dependency matrix ...............................................19
Connecting Determining the minimum window size ...............240
Camera .......................................................... 232 Diagnostic program .............................................199
Hub ................................................................ 232 Diagram ..........................................................219
Overview ........................................................ 231 Display screens ..............................................208
Reflector ........................................................ 232 Functions ........................................................203
Connection Diagnostic program main menu ..................208, 211
Basic technology and Add-on ........................ 102 Diagram ...............................................................219
TO objects and Add-on.................................. 106 Calibrate hoisting height.................................227
Consistency Characteristics ...............................................225
Checking ........................................................ 101 Menu tree .......................................................337
Content ................................................................... 5 Print ................................................................224
Control bits Record ............................................................219
Common ........................................................ 170 Recording cycle ..............................................220
Hoist............................................................... 173 Shortcuts ........................................................223
Obstacles ....................................................... 182 Telnet .............................................................227
Targets........................................................... 180 User interface elements .................................222
TLS ................................................................ 178 View................................................................224
Trolley ............................................................ 175 Web server .....................................................227
Control method X/Y display .............................................220, 226
Selecting ........................................................ 260 Zoom ..............................................................223
Conventional control ................................... 250, 260 Dimension drawing
Converter Camera...........................................................292

Index
Reflector ........................................................ 294 SIMOTION ....................................................... 88

Disclaimer of liability ............................................... 4 Height profile
Display screens Learning process ........................................... 163
Diagnostic program........................................ 208 Reset ............................................................. 162
Distance measurement ....................................... 241 Reset (delete) ................................................ 162
Double spreader ........................................... 79, 164 Help
Dynamic prelimit switch Diagnostic program ....................................... 206
Sway Control ................................................. 250 Hoist control........................................................ 134
Error .................................................................... 213 Activation ....................................................... 134
Simulate ......................................................... 259 Characteristics............................................... 134
Error list Commissioning .............................................. 265
Camera .......................................................... 274 Interruption .................................................... 149
Sway Control system ..................................... 277 Monitoring functions ...................................... 273
Error messages Sway control system parameters .................. 311
Sway Control ................................................. 274 Hoisting gear acceptance ................................... 152
Ethernet .............................................................. 193 Hoisting height
Execution system Calibrate ................................................ 258, 259
Integrating ...................................................... 113 Hoisting height range
FAQ Specifying ...................................................... 256
Sway Control system ..................................... 288 Hub
Faults .................................................................. 213 Connecting .................................................... 232
Faults history....................................................... 214 Hydraulic control ................................................. 167
FB_CommonAddOnToPLC .................................. 56 I/O address ranges ............................................... 91
FB_CommonPLCToAddOn .................................. 54 I/O peripherals
FB_HoistAddOnToPLC ......................................... 58 Definition ......................................................... 92
FB_HoistPLCToAddOn ......................................... 57 I/O-Variablen
FB_ObstaclesAddOnToPLC ................................. 70 kopieren ........................................................... 94
FB_ObstaclesPLCToAddOn ................................. 68 Immersion point .................................................. 157
FB_Receive_Analysis ........................................... 72 Import
FB_Send_Preparation .......................................... 71 AddOn ............................................................. 86
FB_TargetsAddOnToPLC..................................... 67 Infra-red filter ........................................................ 16
FB_TargetsPLCToAddOn..................................... 66 Installation
FB_TLSAddOnToPLC .......................................... 64 DCC library ...................................................... 86
FB_TLSPLCToAddOn .......................................... 62 Installing software ............................................... 199
FB_TrolleyAddOnToPLC ...................................... 61 Installing/mounting
FB_TrolleyPLCToAddOn ...................................... 59 Camera .......................................................... 230
Field weakening .......................................... 105, 149 Hub ................................................................ 231
File manager diagnostic program ....................... 218 Reflector ........................................................ 231
Following error .................................................... 247 Interface
Following error monitoring .................................. 272 Camera measuring system ........................... 229
Function blocks Diagnostic program ....................................... 204
Sway Control ................................................... 34 Introduction ........................................................... 13
Function module IP Address
Structure .......................................................... 25 Camera measuring system ........................... 233
Functional scope ................................................... 19 JAVA Runtime .................................................... 114
Functions Language
Diagnostic program........................................ 203 Camera measuring system ........................... 235
Overview .......................................................... 20 Diagnostic program ....................................... 205
Global variables .................................................... 29 Sway Control system..................................... 247
Basic technology.............................................. 32 Language files
Naming scheme ............................................... 31 Copying ......................................................... 114
TO objects ....................................................... 33 Laser ........................................................... 210, 267
Hardware configuration Laser scanner ............................................... 79, 210
SIMATIC .......................................................... 90 Learning

Index
Positions ........................................................ 267 Mathematical ..................................................249

Lens .............................................................. 16, 242 Override .............................................. 149, 150, 267
Focal length ..................................................... 17 Parameter
Lens settings Change ...........................................................212
Camera .......................................................... 232 Search ............................................................213
License key Parameter assignment / addressing ...........197, 233
Creating ......................................................... 115 Parameter list
Limit curve .................................................... 78, 161 CenSOR M .....................................................300
Display ........................................................... 214 Sway Control system .....................................308
Limit curve parameters ....................................... 265 Parameter set ..............................................197, 255
Limiting the search area ..................................... 244 Copy ...............................................................213
List ...................................................................... 166 List ..................................................................213
Load carrying device Load ...............................................................213
Compensate .................................................. 260 Save ...............................................................213
Load deflection ................................................... 209 Set default ......................................................213
Logic Switching ........................................................198
Brake signal ................................................... 125 Parameters
Mode-independent......................................... 125 Effectiveness ..................................................198
Travel signal .................................................. 125 Entering, editing .............................................198
Maintenance Saving ............................................................198
Camera .......................................................... 291 Parameters menu ................................................211
Reflector ........................................................ 291 Path curve .............................................................78
Maximum acceleration ........................................ 256 Pendulum length
MCC charts Effective..................................................209, 259
Copying............................................................ 97 Ping .....................................................................204
Measuring PLC program
Distance ......................................................... 229 Preparing ........................................................245
Offset ............................................................. 228 Polarities ................................................................34
Rotation angle ............................................... 229 Position ................................................................131
Measuring reliability Maximum, minimum .......................................256
Camera measuring system............................ 244 Position controller ................................................263
Message frame Position offset ......................................................156
Definition .......................................................... 94 Position parameters
Minimum speed .................................................. 262 Calculate ........................................................205
Minimum time ..................................................... 262 Position setpoint ..................................................104
Monitor Positioning ...........................................................131
Diagnostic program ....................................... 206 Abort ...............................................................131
Monitoring Activation ........................................................131
Automatic ....................................................... 273 Automatic .......................................................131
Normalizations ...................................................... 30 Positioning complete ...........................................106
Obstacles .............................................................. 77 Positioning range.................................................265
Offset Land ......................................................... 156 Permissible .....................................................265
Offset Water ........................................................ 156 Positioning speed ................................................256
ON delay ............................................................. 262 Prelimit switch speed...........................................256
On-the-fly unloading ........................................... 135 Pressure system..................................................270
Activation ....................................................... 133 Product Structure ..................................................18
Open grab ........................................................... 151 PROFIBUS
Operating conditions Configuration ....................................................87
Camera measuring system............................ 292 PROFIBUS address ..............................................87
Operating mode switchover ................................ 152 PROFIBUS connection
Operation Configuring .......................................................88
Diagnostic program ....................................... 200 PROFIBUS DP interface .....................................169
Option parameters .............................................. 309 Common input data ........................................169
Oscillation model Common output data......................................183

Index
Hoist input data .............................................. 173 Speed setpoint .............................................. 270

Hoist output data............................................ 187 Software
Obstacles input data ...................................... 181 Licenses .......................................................... 18
Obstacles output data .................................... 191 Software engineering ........................................... 21
Targets input data .......................................... 179 Software Structure ................................................ 21
Targets output data........................................ 191 Spare parts
TLS input data ............................................... 177 Camera and reflector..................................... 299
TLS output data ............................................. 189 Special parameters............................................. 316
Trolley input data ........................................... 175 Speed control ............................................. 130, 257
Trolley output data ......................................... 188 Activation ....................................................... 130
Project Speed limit
Transfer ......................................................... 114 Determine ...................................................... 260
Reflector................................................................ 16 Speed parameters
Connecting..................................................... 232 Calculate ....................................................... 205
Reflector type ...................................................... 241 Start cemgr ......................................................... 204
Determine ...................................................... 237 Status bits
Requirements.......................................................... 5 Common ........................................................ 184
Residual sway Hoist .............................................................. 188
Setting ............................................................ 262 Obstacles ...................................................... 192
S7 Targets .......................................................... 191
Brief description of blocks .............................. 124 TLS ................................................................ 190
Configuration ................................................. 123 Trolley ............................................................ 189
Structure ........................................................ 123 STS ....................................................................... 15
Safety guidelines .................................................... 3 Sway Control
Save image content ............................................ 204 Activating/deactivating................................... 142
Save position ...................................................... 267 Applications ..................................................... 74
SC Automatic .............................. 135, 142, 143, 156 Basic operating mode.................................... 129
End of a travel motion .................................... 147 Commissioning .............................................. 249
Manual hoisting motion .................................. 148 Configuring .............................................. 84, 197
Possible settings .................................... 148, 156 Deactivation................................................... 130
Start from manual hoist operation ................. 149 Fine adjustment ............................................. 260
Start mit Schlaffseil ........................................ 150 Priorities ........................................................ 166
Start of a travel motion................................... 145 TLS commands ............................................. 166
Start on the landside ...................................... 149 Sway Control configurations............................... 138
Start on the waterside .................................... 149 Sway Control system commissioning
SC Semi Automatic ..................................... 151, 159 Requirements ................................................ 244
SC Speed Control ............................... 138, 155, 168 Sway Control system interface description ........ 169
Control ........................................................... 138 Sway control system parameters
End of a travel motion .................................... 141 Hoist control .................................................. 311
Possible settings ............................................ 142 Sway Control system parameters ...................... 308
Start of a travel motion................................... 140 Camera and reflector..................................... 325
Scope of Delivery .................................................. 17 General 1 ....................................................... 322
SCOUT project Hoisting gear ................................................. 315
Transferring ................................................... 114 Save .............................................................. 260
Send text file ....................................................... 204 Slewing gear.................................................. 335
Set acceleration .................................................. 256 TLS ................................................................ 331
Setup Trolley ............................................................ 309
DCC library ...................................................... 86 SwayControl
Ship unloader ........................................................ 17 Activation ....................................................... 136
Signal characteristics .......................................... 116 System configuration ............................................ 14
Signal flow..................................................... 29, 116 System Overview.................................................. 13
Signal sequences ............................................... 245 Target generator ......................................... 135, 156
Skew ................................................................... 166 Target position .................................................... 131
Skew control ............................................... 167, 270 Time-optimized control ............................... 250, 260

Index
TLS AddOnMCC ......................................................25

Cylinder.......................................................... 271 CameraMCC ....................................................26
Move zero ...................................................... 271 Velocity monitoring ..............................................272
Reset ............................................................. 271 Velocity setpoint ..................................................103
Save zero....................................................... 271 Version
Skew control .................................................. 271 With camera .....................................................15
Speed limit ..................................................... 270 Without camera ................................................17
Speeds........................................................... 270 Versions of Sway Control ......................................15
Test ................................................................ 271 Weather protection enclosure .............................293
TLS commands................................................... 165 Window size ........................................................243
TLS Control......................................... 164, 165, 168 Windows menu functions
Activation ....................................................... 164 Diagnostic program: .......................................203
Trim ..................................................................... 166 Zero position
Twistlock simulation ............................................ 268 Approach/save ...............................................167
Unit


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Preface

Add-on Sway Control SIMATIC S7

Siemens AG Copyright © Siemens AG 2010

Siemens AG Copyright © Siemens AG 2010

Prerequisite (area of validity)

Hotline and Internet addresses

Siemens Internet address

SIMOCRANE Add-on Technology Sway Control

1 System Description .................................................................................................................................. 13

SIMOCRANE Add-on Technology Sway Control

2.2.2.8 FB_TLSPLCToAddOn ................................................................................................................. 62

SIMOCRANE Add-on Technology Sway Control

3.2 Mode-independent Logic ...........................................................................................................125

SIMOCRANE Add-on Technology Sway Control

4.2.1 General information................................................................................................................... 197

SIMOCRANE Add-on Technology Sway Control

4.6 Commissioning Requirements for AddOn Systems...................................................................250

SIMOCRANE Add-on Technology Sway Control

5.3.2 AddOn technology parameter list.............................................................................................. 315

SIMOCRANE Add-on Technology Sway Control

1.2 System Overview

1.2.1 General information

SIMOCRANE Add-on Technology Sway Control

Fig. 1-1: Sway Control logical structure

SIMOCRANE Add-on Technology Sway Control

1.2.2.1 Version with camera for container cranes

SIMOCRANE Add-on Technology Sway Control

Camera with lens system and infra-red filter

SIMOCRANE Add-on Technology Sway Control

Table 1-1 Measuring accuracy

Focal length of the lens 16 mm (standard) 25 mm

1.2.2.2 Version without camera for ship unloader

1.3 Scope of Delivery

SIMOCRANE Add-on Technology Sway Control

− Current firmware version and operating system

1.4 Product Structure

SIMOCRANE Add-on Technology Sway Control

1.5 Functional scope

Table 1-2 Overview of the AddOn modes

• Sway-controlled travel in manual • SC Speed Control Basic license

• Sway-controlled travel in all AddOn

The following dependencies of the Add-ons from other systems exist:

2D-Trajectory X o X Sway Control

SIMOCRANE Add-on Technology Sway Control

Table 1-4 Overview of the blocks in the Add-on DCC library

No. Function Brief description

SIMOCRANE Add-on Technology Sway Control

2.1.1 Software structure

SIMOCRANE Add-on Technology Sway Control

PROFIBUS – Communication between SIMATIC S7 and SIMOTION D

Global variables (ST)

MCC Chart „AddOn“

Send TLS MCC Chart „Camera“

Send Targets Receive Camera

Send Obstacles Send Camera

DCC Plan „SwayControl“

PROFIBUS – Communication via DP-Integrated to SINAMICS

Fig. 2-1: Software structure

SIMOCRANE Add-on Technology Sway Control

SIMOCRANE Add-on Technology Sway Control

Fig. 2-2: SwayControl for Hoist_1 structure

SIMOCRANE Add-on Technology Sway Control

2.1.2 Structure of a function module

Fig. 2-3: Unit "AddOn", program sequence "AddOnMCC"