Version 1.44
2012-05-10
VU 202
Waratah
Page 2:
VU 202 in cabin, Led F1- F8
Page 3:
Break point calibration
Page 4-5: VU 201A card, schematic
Page 6-8: Mounting
Page 9:
Cable number in crane cable
Page 10: Troubleshooting
Page 11: Circuit card
Page 12: Junctionbox in harvesting head
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Version 1.44
2012-05-10
VU 201A Adjustments Waratah
Function buttons on VU 202
Yellow button: Move to next function. Flashbulb F1 to F6 indicates
which are actuated. When F1 to F6 is off you are in working position.
Black button: Reduce parameter value.
Red button: Increase parameter value.
F1: Showing pulses from head cut out sensor.
F2: Showing diameter sender 1 (left). 310-999 (460) 270-999 (414)
Pushing black & red at same time will show volt input (0,5-4 V)
F3: Showing diameter sender 2 (right) 310-999 (460) 270-999 (414)
Pushing black & red at same time will show volt input (0,5-4 V)
F4: Breakpoint calibration (read instructions)
F5: Adjusting saw speed (0-100%)
F6: Harvesting head model 0=460, 1=414, 2=480C, 3=460 (standard
saw)
4 = 470, 5 = 250, 6 = 413.
To change model; hold red & black button until it has counted to 120
Then go down to right model.
Always turn off diesel engine doing this!!! It affects the tilt.
F7: Cutting control standard 350=0, two phase sender ab=1,
Standard 360,370=2, two phase sender ba=3.
F8: Diameter standard 0, Crossmeasured in Vu 202=1.
(Remember disconnect left or right sensor in maxi.)
F1+F2: Extra pressure knives open = faster knives open. Standard 10.
Remember length and diameter is normally adjusted in maxi!!
After starting machine you have to close head before opening!!
Or else you don’t have diameter reference.
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Version 1.44
2012-05-10
Breakpoint calibration
Alternative function on button F4
Touch yellow button until F4 is actuated.
1. Hold red and black button at the same time for one second and the
display will show 0.The program will lock on the actual breakpoint. With
red and black button you can now change value up or down on this
breakpoint. The result will be shown in the maxi computer. It will be
saved then you leave F4.
2. The basic curve for the actual head can always be brought back. Go
to F4 Hold both black and red button at the same time for ten seconds
and you will see 999 in the display. You can now release the buttons and
the basic curve is back.
Example
Under F4 the cross measured value to the Valmet is shown, from 0-999.
Different heads have different curves, for example if the diameter is
wrong at 100 mm you shall take a tree in the harvester head which will
be exactly 100 mm in the maxi.
You have to zero the computer by using button reset length and diameter
twice. You can see reset Length/Diameter.
Now you will see 100 mm in the maxi. You know that the tree is 90 mm.
(example).
Then go to F4 and hold both black and red buttons for two seconds and
you will see 0 in VU 202 display. Push the black button and look at the
same time in the maxi display - hold the black button until the maxi will
show 90 mm. Now you are done.
Push the yellow button several times until all the led lights are put out
(F1-F6), and the breakpoint is saved.
If you fail you can always go back to the basic curve (see above at #2)
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Version 1.44
2012-05-10
VU202 Waratah
Inputs from Valmet MHC
P1 Molex 12 pins
1
2
3
4
5
6
7
8
9
10
11
12
Led
GND (earth)
Saw signal
Tilt up
Knives close signal
Knives open signal
V7
V5
V3
V1
Rollers close signal
V8
Tilt down
Saw bar out
Saw home
V4
V2
(2 phase sender)
P2 Molex 14 pins
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Inputs Head and MHC
GND (earth)
Locking tilt
Saw bar home sender
Saw bar out sender
V9
IN1
IN2
IN3
Diameter sender 1
Analog 1
Diameter sender 2
Analog 2
24V supply output to 1 amp fuse
Input feeding forward
Input feeding back
24V supply output
D2A
D2B
4
left
right
Version 1.44
2012-05-10
P3 Molex 24pins
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Led/Outputs
GND (earth)
GND (earth)
GND (earth)
GND (earth)
GND (earth)
GND (earth)
GND (earth)
GND (earth)
GND (earth)
GND (earth)
GND (earth)
GND (earth)
Diameter 1A (Valmet right)
Diameter 1B(Valmet right)
Zero reference dia 1
Diameter 2B(Valmet left)
Diameter 2A(Valmet left)
Zero reference dia 2
Saw sender A
Saw sender B
Zero reference saw
Tilt floating
Pressure knife/roll. Open
Saw engine speed
1
2
3
4
5
6
7
8
9 (standard sender)
10
11
12
P4 Molex 4 pins
1
2
3
4
24V module supply
GND module supply
24V module supply
GND module supply
Same as MHC
Same as MHC
Same as MHC
Same as MHC
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Version 1.44
2012-05-10
Hydraulic installation
901.3 have pressure on the right side of machine. 901.4 have pressure
on left side of machine. The pressure has to be adjusted to 75bar,
because it’s no saw bar pressure from Valmet
Electric installation (901.3)
Before changing head disconnect x137 (901.3). Connect the Vu202 after
you connected crane cable. New system will fit MHC which will be placed
behind the chair, mounted under VBU. Use part nr. 6013. Drill is needed,
8,5 mm. X contacts will be placed in the right of gas/inch pedal. X
contacts will go against crane cable and VU 202 will be placed between
the door and Maxi computer. There is 2 M8 in the front. (Normally used
for steering in Germany) The last contact will go in X137(901.3). Have a
look in x137 so plus and minus will fit. Mount ground cable between
junction box and frame in harvesting head.
Electric installation (901.4, 911.5,931,941)
Before start changing head disconnect main switch. Cut crane cable 70
centimeter from cabin. Put the cut cable into the cabin. Mount contact on
cable (contact including).
Pin 1= White
Pin 2=Blue
Pin 3=Wire nr.1 (+24volt)
Pin 4=Wire nr2 and 3 (+ 24volt.)
Pin 8=Cable nr.4 (ground)
Pin 9=Wire nr.5 and 6 (ground)
This will fit contact X137 on VU202.
Crane cable is connected in X70, X71, X72, X73. These comes from
VU 202 system. Mount MHC behind chair on plastic cover on right side
Connect MHC to VU 202 system. Mount VU 202 under Maxi screen (use
p.n.6012). 941 mount VU 202 instead of CD box. Mount ground cable
between junction box and frame in harvesting head.
Maxi settings
Go to base settings/configuration. Waratah 414/460 will have 350
harvesting head. 480 will have 370. If you are using wrong head you can
change that by format head computer (service code).
Regarding machines 2007 or older: Before starting you can import
head .mas file from another unit if possible. To do this you have to have
.mas file on a USB flash drive. Place it in C:/data in maxi computer.
Then log in and go to production/copy files. Open pc on left side.
Open VBU on right side. Mark .mas file on left side until it turns yellow.
Push copy and it will be copied to VBU on right side.
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Version 1.44
2012-05-10
Next thing is to get the .mas file to head computer (service code).
Go out and in again to ground settings. Go to head settings/read settings
from file in VBU. Now the settings are OK.
Regarding machines 2008 or later (Maxi Explorer):
Import .mas file from USB flash drive.
On Valmet you can adjust the low pressure in computer. You have to log
by using service code. Go to base machine, machine settings. Low
pressure out around 54 % is normally 200 bars. All other settings will
done under head and calibration in maxi. In older 941 it will be found
under crane/system pressure. Here it should be set to 650 m.amp.
To adjust front knives, rear knives and roller pressure (service code)
Go to valve adjustment max. Push close and adjust.
When ready go to min, close head and adjust.
Saw control
There is a new sender in later machines.
In machines with programs from 3.12 and later (with XP).
And minimum 2.8.0 in headman. If possible use two phase sender.
We are using two phase sender for cutting control.
In VU there is a minifit contact marked S or T. Using Standard sender for
cutting control use S. For two phase sender use T.
Settings for sender is found under F7 in VU (program from 2011-03).
Saw control: Standard, (software -2010)
Check In 1 (saw home sender). The light turns on when saw is home and
lights turns out when saw is out.
Check In 2. The lights turns on and off about 16 times than saw bar is
going out. Use counter under F1 in VU202 (push yellow button once).
It should count to around 32 (supercut) 39 (standard cut) if it works.
Login by servicecode in maxi. Choose sensor type standard at
Calibrating/Measuring/Sawposition.
Go to calibration/Measuring/ Saw control/Manual test.
Testing saw has to be done with engine running.
Saw home = -101 and fully out +3400-3600. Has to be - before at home
position. If reversed change in VU202 P3 wires posision19 & 20 with
each other.
Program from 2011-03 adjust under F7 in VU, 0 or 2.
If still not Saw home after test; go to Calibration/Measuring/Calibration of
saw position.
First time you need to manually calibrate to home value -126 for Valmet
350 and -146 for Valmet 360, 370. Now saw should be home.
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Version 1.44
2012-05-10
Saw control: Two Phase (software from 2010-)
Check that in 1 (saw home sender) light then saw is home and not light
than saw is out. Check in 2 that it lights about 16 times when saw bar is
going out. Use counter under F1 in VU 202 (push yellow button ones).
Should count to around 32 (supercut) 39 (standard cut) if it works.
Login by service code in maxi. Choose sensor type two phase at
Calibrating/Measuring/Saw position.
Go to calibration/Measuring/ Saw control/Manuel test.
Testing saw has to be done with engine running.
Saw home = -12 and fully out +70-80. Has to be – before at home
position. If reversed change in VU 202 P3 wires posision19 & 20 with
each other. Program from 2011-03 adjust under F7 in VU, 1 or 3.
For calibrating:
Take a tree.
Go in to Calibrating/Measuring/Calibration of saw position.
Push saw button.
Saw bar will go without chain is moving to the tree. Hold it there and
enter saw position 0 and press enter.
Diameter
First check the VU 202. Close and open head. Hold button open until
head is open. Now it should be 999 in open position and going down
then closing. Left sender under F2 in VU 202 and right sender under F3
(Left sender is the sender you see on left side then you sit in cab with
saw bar against you. In maxi system it is reversed.)
If this is ok go in to maxi by using service code.
Go to calibration/diameter. Left and right should show 1302 in open
position and 100-300 in closed position*.
Look at left & right. If it starts with - in open you need to change wires in
VU 202. Left sender P3 16 &17 and right sender P3 13 &14.
At first calibration in maxi, use singlepoint or pipecalibration. Close head
and set it to 50 mm. Now you should see min and max diameter if open
and close. If not press button Reset length and diameter.
*) If you are using a 480 head, normal value for opening and closes are
around 1166 open and 0 closed.
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Version 1.44
2012-05-10
Cable number in crane cable and in head
Contacts in cranecable
X70
X71
X72
X73
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
1
2
3
1 + 24 volt to senders (fuse on black box)
2 Length puls 2
3 Length puls 1
4 Rotator left
5 Feeding forward
6 Feeding back
7 Saw engine
8 Tilt up
9 Tilt down
10 Feed rollers close
11 Knives close
12 Sender saw home
13 – for diameter 24/5 (negative)
14 Diameter 2 signal
15 Diameter 1 signal
16 Multitreehandling
17 Saw bar out
18 Bottom knives open
19 Bottom knives close
20 Tilt floating
21 Feed rollers open
22 Knives open
23 Colour 1
24 Colour 2
25 Measuring wheel out
26 Sender saw bar out
27 Rotator right
28 Prop pressure bottom knives
29 Prop pressure feed rollers
30 Prop pressure knives (green-yellow)
31 5 volt diameter senders
32 – volt diameter senders
33 Rotator floating
blue a
black b
y409
y490
y491
y484
y481
y487
y482
y492
410
sd2
sd1
y470
y456
y457
y487
y483
y493
y436
y482a
494a
y408
y457d
y482d
y492d
y485
Cablenumbers DC/DC
module in harvesting head (24 to 5 volt) and rotator floating
1 GND
connected to green/yellow in head connector (ground)
2 24 Volt
connected to number 1 in head (1-33 connector.)
3
4
5
6 Float rotator
connected to number 33 in head (1-33 connector )
7 Feed forward
connected to number 5 in head (1-33 connector)
8 Feed reverse
connected to number 6 in head (1-33 connector)
9
10
11 5 Volt Diameter connected to number 31 in head (1-33 connector)
12 GND Diameter connected to 13 and 32. Cable between. Not connected to ground.
Groundsettings for diametersenders. Adjust 0,5 volt then head closed.
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Version 1.44
2012-05-10
Cable number in crane cable - Troubleshooting
1 + 24 volt to senders Feeded from fuse on black box (left side on top) 1amp.
2 Length puls 2
Going to MHC K1:21
3 Length puls 1
Going to MHC K1:20
4 Rotator left
Going to MHC K2:1
5 Feeding forward
Going to MHC K2:9 and VU202 P2:12
6 Feeding back
Going to MHC K2:11and VU202 P2:13
7 Saw engine
Going to VU202 P3:24
8 Tilt up
Going to MHC K2:5
9 Tilt down
Going to MHC K2:7
10 Feed rollers close
Going to MHC K2:35
11 Knives close
Going to MHC K2:39
12 Sender saw home
Going to VU202 P2:3
13 – for diameter 24/5 (negative) Going to VU202 P2:1
14 Diameter 1 signal
Going to VU202 P2:6
15 Diameter 2 signal
Going to VU202 P2:7
16 Multitreehandling
Going to MHC K4:21
17 Saw bar out
Going to MHC K4:19 and VU202 P1:10
18 Bottom knives open
Going to MHC K3:17
19 Bottom knives close
Going to MHC K3:19
20 Tilt floating
Going to VU202 P3:22
21 Feed rollers open
Going to MHC K2:33
22 Knives open
Going to MHC K2:37 and VU202 P1:5
23 Colour 1
Going to MHC K4:5
24 Colour 2
Going to MHC K4:7
25 Measuring wheel out
Going to MHC K4:11
26 Sender saw bar out
Going to VU202 P2:4
27 Rotator right
Going to MHC K2:3
28 Prop pressure bottom knives Going to MHC K2:23
29 Prop pressure feed rollers
Going to MHC K2:25
30 Prop pressure knives
Going to MHC K2:21
31 5 volt diameter senders
Going to DC/DC in headbox cable 11
32 – volt diameter senders
Going to DC/DC in headbox cable 12
33 Rotator floating
Going to DC/DC in headbox cable 6
Cables from MHC can be tested in maxi.
Cables from VU 202 have led on every function.
VU 202 has same fuse as MHC
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Version 1.44
2012-05-10
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Version 1.44
2012-05-10
Junctionbox in harvester head
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