(load moment and area protection) telescopic boom cranes · 2 extension sensor the extension sensor...
TRANSCRIPT
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Altec LMAP (Load Moment and Area Protection)
Telescopic Boom Cranes
Calibration
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RCI-510 i
Contents
SystemComponents..............................................................................................................................................................1
Anti-TwoBlock..................................................................................................................................................................1
AreaAlarm..........................................................................................................................................................................1
BoomAngleSensor........................................................................................................................................................1
Display..................................................................................................................................................................................1
ExtensionSensor.....................................................................................................................................................................2
FunctionKick-Out............................................................................................................................................................2
PressureTransducers......................................................................................................................................................2
OperatorAlarms..............................................................................................................................................................2
LMAPDisplay............................................................................................................................................................................3
Calibration.................................................................................................................................................................................5
EnteringCalibrationMode...........................................................................................................................................6
ExtensionSensorSetup.................................................................................................................................................7
CheckingtheAngleSensorVoltage..........................................................................................................................8
AngleSensorSetup(PhysicalZero)...........................................................................................................................9
SpanningExtensionandAngleSensors............................................................................................................... 10
ZeroingtheSwingPotentiometer.......................................................................................................................... 12
DisablingtheSwingPot............................................................................................................................................. 13
EnablingtheSwingPotentiometer.............................................................................................................................
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RCI-510 ii
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Introduction
SystemComponents• LMAPDisplayUnit• LMAPComputerUnit• PressureTransducers• ExtensionReelwithlengthandanglesensors• AntiTwo-Block(ATB)switches• Cables
TheLoadMomentAreaProtection(LMAP)systemisintendedtoaidthecraneoperatorbycontinuouslymonitoringtheloadandwarningofanapproachtoanoverloadortwo-blockcondition.Cranefunctionsaremonitoredbymeansofhighaccuracysensors.Thesystemcontinuouslycomparestheloadsuspendedbelowtheboomheadwiththecranecapacitychartstoredinthecomputermemory.Atapproachtooverload,thesystemwarnsbymeansofaudibleandvisualalarms.Thesystemcanbeconfiguredtocausefunctionkick-outbysendingasignaltofunctiondisconnectsolenoids.
AntiTwoBlock(ATB)Aswitchmonitorstheapproachofthehookblockoroverhaulballtotheboomhead.Theswitchisheldinthenormalpositionuntilthehookblockoroverhaulballraisesaweightthatismountedaroundthehoistrope.Whentheweightisraised,itcausestheswitchtooperate.TheresultantsignalissenttothecomputerviatheextensionreelcausingtheATBalarmtooperateandfunctionkick-outtooccur.
AreaAlarmWhenset,thisalarmpermitstheoperatortodefinetheoperatingzonebyonlytwosetpoints.Theuseofthismethodofsettingresultsinagreatlyenhancedworkingarea,andalsoclearlydefinestheoperatingzone.
BoomAngleSensorBoomangleismeasuredbymeansofahighaccuracypotentiometer,amagneticallydampenedpendulumtopreventerraticvoltagechanges.Itprovidesavoltageproportionaltoboomangle.Theboomanglesensorismountedinsidethecableextensionreelassembly.
DisplayTheoperatorisprovidedwithacontinuousdisplayof:
• RatedLoad• ActualLoad• BarGraphshowingPercentageofRatedLoad• RadiusoftheLoad• BoomAngle• MainBoomLength• WorkingArea• CraneConfiguration
On-screenmessagesprovidetheoperatorwithvisualwarningsofconditionsthatoccurduringoperationofthesystem.
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ExtensionSensorTheextensionsensorprovidesanincreasingvoltageproportionaltotheextensionoftheboom.AcableattachedtotheboomheadprovidesalowcurrentelectricalpathfortheATBsignal.
FunctionKick-OutElectricallyoperatedsolenoidsdisconnectthecontrolleverfunctionsforboomhoistlower,telescopeout,andwinchupwheneveranoverloadoranATBconditionoccurs.
PressureTransducersTwopressuretransducersmeasurethepressureintheboomhoistcylinder.TheresultantTotalMomentsignalisprocessedtoprovideacontinuousdisplayoftheloadsuspendedbelowthepointoflift.
OperatorAlarmsThesealarms,whenproperlysetbytheoperator,definetheoperatingrange.Thisisachievedbymeansofminimumandmaximumangle,maximumheight,and/ormaximumlength.Thesealarmscanbeprogrammedforeachjobsiteandallowtheoperatortoworkinadefinedarea.
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LMAPDisplay
1. OverloadWarning–ThisredLEDilluminateswhenyoureachorexceed100%ofratedcapacity.Itisaccompaniedbysolidtonealarmandwhenmaximumratedcapacityisexceededwillresultinboomfunctionlockout.
2. ApproachingOverloadWarning–ThisamberLEDIlluminateswhenyoureachorexceed90%RatedCapacity.Itwillbeaccompaniedbyabeepingalarm.
3. PartsofLine–Displayscurrentnumberofpartsoflineinuse.
4. LoadonHook–Displaystheentirehookloadweightundertheheadoftheboom,includingcable,loadblock,loadhandlingequipment,andweightofloadhangingonhook.
5. PercentofRatedCapacityMeter-Showstheloadasapercentageofratedcapacity.Astheloadincreases,themeterlevelincreasestorepresentthepercentageoftheratedcapacityofthecrane.
6. RatedCapacity–Displaystheratedcapacityinthecurrentconfigurationbasedonthecraneloadcapacitychart.
7. ATBWarning–Warnsofapotentialtwo-blockconditionwithflashingLEDandaudiblealarm.
8. BoomLength–Displaysthecurrentboomlengthinfeetandtenthsofafoot.
9. BoomAngle–Displaysthecurrentboomangleindegreesandtenthsofadegree.
10.LoadRadius–Displaystheloadradiusfromcenterlineofrotation.
11.CraneSetup–ThesekeysareusedinthesetupprocesstoconfiguretheLMAPsystemtomatchthecurrentconfigurationofthecrane.
12.InformationWindow–Displayscranesetupandcalibrationinformationaswellaswarningmessages.
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13.ErectedJib–Enablestheselectionofthejibtobeusedontheboom.Selectsextendedorretractedjibwhencraneisequippedwithtwostagejib.
14.BasketOperation–Enablestheselectionoftheplatformformanbasketoperation.
15.OutriggerConfiguration–Enablestheselectionbetweenfullandmidspanoutriggers.
16.StowedJib–Enablestheselectionofthejibstowedontheboom.Alsousedtostowtheerectedjib.
17.WinchSelection–Enablestheselectionofthewinchifthecraneisequippedwithanoptionalsecondwinch.
18.AlarmCancel–Disablesaudiblealarm.Holdingdownthiskeyoverridesfunctionkick-out.
19.TestButton–Pressandholdthetestbuttontoinitiateasystemselftestandrundiagnostics.
20.OperatorAlarmSet–Enablesoperatoralarms.Whenanalarmhasbeenset,theLEDabovethisbuttonwillilluminateyellow.
WARNING
YOUMUSTUSETHECRANESETUPMODETOCORRECTLYSETTHELMAPSYSTEMFORPROPEROPERATION.THELMAPSYSTEMSETUPMUSTMATCHTHEACTUALCONFIGURATIONOFTHECRANESOTHATITWILLINDICATETHECORRECTHOOKLOADANDLIFTINGCAPACITY
OFTHECRANE.
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CalibrationTheLMAPsystemcontainsasetupcalibrationmodethatoperatesthroughthesystemdisplayconsole.Thesetupmodeprovidesameansofensuringthatthesystemsensorsarecorrectlypositionedandadjustedfollowingsysteminstallationorpartsreplacement.
Thisprocedureassumesthatinstallationofsystemcomponents,cabling,andhydraulicconnectionshavebeensuccessfullycompletedandchecked.
Thesetupprocedureinvolvesonlythesensorsmountedwithintheextensionreelonthesideoftheboom.
Itisimportantthateachstepofthisprocedureisproperlyfollowedforthesystemtoaccuratelyprovideload,ratedcapacity,warnings,andkick-outfunctions.
WARNING
ATALLTIMES,OBSERVESAFEPRACTICES.MAKESURETHATCRANECAPACITYLIMITATIONSAREUNDERSTOOD,ANDTHATTHECRANECAPACITYPLATEISFOLLOWED.DONOTEXCEED
MANUFACTURER’SSPECIFIEDLIFTINGLIMITATIONS.
RequiredTools• PhillipsScrewdrivers• DigitalLevel–Accurateto0.1°atlevel• Measuringtape(100feet)–fiber-typeintenthsoffeet
• DigitalVoltmeter
CraneConfigurationBeforestartingthesystemsetup,positionthecraneonfirmandlevelgroundwiththeoutriggersproperlyextendedandset.Itisrecommendedthatthecranebeconfiguredwithnostowedorerectedjib(bareboom)andreevedwithasinglepart-of-line.
Fullyretracttheboomandsetittozerodegrees(±0.1°)usingadigitallevel.
Removethereelingdrumcovertoexposethelengthandanglesensors.
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EnteringCalibrationModeThedisplaywillstepthrougheachsetupoperation,asrequiredbytheuser.Duringthesetupprocedure,thedisplayconsoleshouldbeplacedinapositionthatallowseasyviewingwhileadjustmentsarebeingmadewithintheboomextensionreel,andallowsforoperationofthedisplaybuttons.
Toentersetupdataitisnecessarytoputthesystemincalibrationmode.Onceincalibrationmode,youwillhavefive(5)secondstoenterthesecuritykeysequence.
Toaccesscalibrationmode:
1. HolddowntheTESTandSETkeyssimultaneously.Theaudiblealarmwillsoundandyouwillbepromptedtoenterthesecuritykeycode.
2. Enterthesecuritycodeinorder(1,2,3,4)asshown.
Thecomputerwillexecuteabriefselftestand,whenfinished,entercalibrationmode.
CheckingSensorDriveVoltageIMPORTANT!
MAKESURETOMEASUREANDSETALLVOLTAGESBEFORECALIBRATING.
1. Removetheextensionreelcover.
2. Usingadigitalvoltmeter,measurethevoltagebetweentheRED(TB1-4)andBLUE(TB1-1)wiresattheterminalblockmountedonthesensorbaseplateassembly.
3. Checkthatthevoltageisbetween4.7and5.3volts.
Voltagesoutsidetherangespecifiedabovewillindicateavoltagesupplyproblem,oraconnectionorshortcircuitproblem.
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ExtensionSensorSetupThefollowingproceduresdefinehowtoresetandcalibratetheextensionsensor,ifnecessary.Beforeanyoftheseproceduresareused,checkthatthereel-offcableislayeringcorrectly.
PhysicalZero
Itisnecessarytoensurethattheextensionsensorpotentiometeriscorrectlysettoitsminimum“zero”settingwhentheboomisfullyretracted.Thisensuresthatthesensorwillcorrectlymeasureoverthefulltelescopingrangeoftheboom.
1. Disengagethemaingearwheelconnectedtotheextensionsensorbypullingthesensorarminthedirectionshown.
2. Rotatethegearclockwiseuntilthesensorclutchdragsor,ifequippedwitha“balldenten”typeclutch,clicks.
3. Rotatethesensorcounterclockwiseexactly½turnandreleasethesensorarmtore-engagethegearsonthesensorarm.
4. Rotatethegearcounterclockwiseabouthalfaturnsettingthevoltageto0.2volts.Then,carefullyreleasethesensorarm,ensuringthatthevoltageremainsat0.2voltsasthegearsre-engage.
ZeroCalibration
1. Entercalibrationmode(seepage2).
2. Pressthekeyadjacenttoeither“MenuUp”or“MenuDown”until“02ZeroSensors”appearsintheinformationwindowattheright.
3. Pressthekeyadjacentto“02ZeroSensors”toentertheroutine.
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4. Pressthekeyadjacentto“ZeroNo.2=XX”tozerotheextensionsensor.
5. Pressthekeyadjacentto“YES!Calibrate!”tosettheextensionsensortozero.
6. Theretracedboomlengthshouldappearintheboomlengthwindow.
CheckingTheAngleSensorVoltage1. Verifythereadingonthedigitalleveliszerodegrees(0°).
2. Withadigitalvoltmeter,measurethevoltagebetweentheBLUEwire(TB1-1)andtheGREENwire(TB1-2).Withtheboomhorizontal,thevoltageshouldbebetween0.3and0.5volts.Ifthevoltageisincorrect,referto“AngleSensorSetup”onpage5.
3. Stillmeasuringthevoltageatthesamepoints,movetheexposedsideoftheanglesensorpendulumdownwards,andcheckthatthepotentiometerisoperatingbyverifyingthatthevoltageincreases.
4. Checkthatthependulummovesfreely,andwhenreleased,fallssmoothlybacktotheoriginalzerodegrees(0°)voltagereading.
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AngleSensorSetupThefollowingproceduresdefinehowtoresetandcalibratetheanglesensor,asrequired.
PhysicalZero
Itmaybenecessarytoensurethattheanglesensorpotentiometeriscorrectlysettoitsphysical“zero”settingwiththeboomatzerodegrees(0°).Thisensuresthatthesensorwillcorrectlymeasurethefullanglerangeoftheboom.
1. Verifythereadingonthedigitalleveliszerodegrees(0°).
2. Loosenthetwosecuringscrewsoneithersideofthesensorpotentiometerjustenoughtoallowthesensorpotentiometertobeturnedbyhand.Donotremovethescrewsanddonotputpressureontheterminalsexitingthesensor.
3. MeasuringthevoltagebetweenTB1-2andTB1-1,carefullyrotatethepotentiometeruntilthevoltagemeasures0.4volts.Rotatingthesensorcounterclockwisewillincreasethevoltage.Rotatingclockwisewillreducethevoltage.Onlyfineadjustmentsarerequired.Donottouchthependulumhangingbehindthesensorassembly,asthiswillaffectthereading.
4. Tightenthesecuringscrewsandcheckthatthevoltageremainsat0.4volts.
ZeroCalibration
1. Pressthekeyadjacentto“MenuUp”tozerotheanglesensor(No.3).
2. Pressthekeyadjacentto“ZeroNo.3=0”.
3. Pressthekeyadjacentto“YES!Calibrate!”tosettheanglesensortozero.
Whenyouhavefinished,pressthekeyadjacentto“Exit”toreturntothemainmenu.
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SpanningtheExtensionandAngleSensorsPressthekeyadjacenttoeither“MenuUp”or“MenuDown”until“03SpanSensors”appearsintheinformationwindowattheright.
WARNING
SETTINGSPANSONTHECRANEWILLREQUIREFULLEXTENSIONOFTHEBOOM.MAKESURETHECRANEISSETUPACCORDINGTOTHEMANUFACTURER’SOPERATIONMANUALTO
ENSUREMAXIMUMSTABILITY.ALSOMAKESUREALLBOOMEXTENSIONSANDLOADSARELIFTEDWITHINTHEAPPROPRIATELOADCHARTSANDLIMITS.FAILURETOCOMPLYWITH
MANUFACTURER’SLIMITSMAYRESULTINSERIOUSINJURYORDEATH.
Dimension“S”-Thisisthedistancebetweenthecenteroftheboompivotandthecenterofthesheavewiththeboomfullyretracted.
Dimension“T”-Thisisthedimensionbetweenthecenteroftheboompivotandthecenterofthesheavewiththeboomfullyextended.
ThespanoftheboomiscalculatedbysubtractingDimension“S”fromDimension“T”(T-S=span).
NumberEntry
Thedisplaydoesnothaveanumericalkeypadsowhennumbersarerequired,thedisplaywillchangetoenablenumberentry.
KeysBandDareusedtoscrollleftandright.The“cursor”willappearasflashing<>bracketsoneithersideofthenumber.KeyAisusedtoenterthenumber.KeyCisusedtoexitthenumberentrysubroutine.
Aseachnumberisselected,presskeyAtoenteritintothesystem.Thenumberwillthenappearinthe[]brackets.Uptofivenumbersmaybeentered.Whenenteringanegativevalue,enterthenumbersanddecimalfirst,thenentertheminussign.Ifyouenteranumberincorrectly,selectthe<backspaceandpresskeyA.Whenalldigitslookcorrect,presskeyCtocalibratethecompletenumber.
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Example:Toenterthevalue“-2.98”,dothefollowing:
1. PresskeyBorDuntilthenumber“2”isselected(indicatedbyflashing<>brackets)andthenpresskeyAtoenterthenumber
2. Selectthedecimal“.”thenpresskeyA.
3. Repeatthepreviousstepstoenterthenumber“9”and“8”.
4. Afterthenumbersareentered,presskeyBorDuntiltheminussign“-”isselectedandthenpresskeyA.
5. Ifthevalueiscorrect,presskeyCtoexit.
EnteringtheSpan
Oncethespanhasbeendetermined:
1. Pressthekeyadjacentto“SpanNo.2=X.X”.
2. Pressthekeyadjacentto“YES!Calibrate!”toenterthespan.
3. Usethenumberentryprocedureonpage6toenterthespan.
4. Withthedigitallevelstillattachedtotheboom,raisetheboomtoanangleofabout65°.
5. Pressthekeyadjacentto“SpanNo.3=X.X”.
6. Pressthekeyadjacentto“YES!Calibrate!”toentertheangle.
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7. Usethenumberentryprocedureonpage6toenterthenumberexactlyasshownonthedigitallevel.
Whenyouhavefinished,pressthekeyadjacentto“Exit”toreturntothemainmenu.
ZeroingtheSwingPotentiometerTheswingpotentiometerislocatedinthecollectorringassemblyunderthehydraulicswivel.Thejobofthepotentiometeristotrackthemovementoftheupperhalfofthecraneallthewayaroundtheswingcircle.Thisfunctioncanonlybezeroedinthestowed,orhouselockpositions,andthenumbersshouldcountup,whenrotatingtotherightorinaclockwisedirection.
1. Entercalibrationmode(seepage2).
2. Pressthekeyadjacenttoeither“MenuUp”or“MenuDown”untilmenu“04SwingPotentiometer”appearsintheinformationwindowattheright.
3. Pressthekeyadjacentto“04SwingPotentiometer”toentertheroutine.
4. Pressthekeyadjacentto“Zero=----”.
Theswingisnowzeroed.
5. Raisetheboomandswingitclockwise(right).The“Zero=XXX”shouldincrease.Ifthenumberdecreases,changethedirectioninthemenu.
6. Pressthekeyadjacentto“MenuUp”.
7. Pressthekeyadjacentto“Direction‘+’”.Thiswillreversetheswingdirectioninthecomputer.
8. Pressthekeyadjacentto“MenuDown”toreturntothe“Zero=XXX”sub-menu.Raisetheboomandswingitclockwise(right).The“Zero=XXX”shouldincrease.
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DisablingtheSwingPotentiometerInsomecases,itmaybenecessarytodisabletheswingpotentiometer.Forexample,iftheswingpotentiometerismalfunctioning,itcanbedisabledor“removed”fromthesystem,esentiallydisconnectedsothatthecomputerdoesnotreceivefalsereadings.
WARNING
REMOVINGTHESWINGPOTENTIONMETERISATEMPORARYSOLUTIONANDWILLDISABLEANYSWINGORWORKINGAREAALARMS.
1. Whileinmenu“04SwingPotentiometer”,pressthekeyadjacenttoeither“MenuUp”or“MenuDown”until“RemoveSwingpot?”appearsintheinformationwindowattheright.
2. Pressthekeyadjacentto“RemoveSwingpot?”.
3. Thecomputerwillaskyoutoconfirmthechoice.Pressthekeyadjacentto“yes”toproceed,orpressthekeyadjacentto“No”tocnacel.Pressthekeyadjacentto“Exit”toreturntothesub-menu.
4. Theinformationwindowwillshow“SwingPotRemoved”attheright.
Whenyouhavefinished,pressthekeyadjacentto“Exit”toreturntothemainmenu.
EnablingtheSwingPotentiometer1. Whileinmenu“04SwingPotentiometer”,pressthekeyadjacenttoeither“MenuUp”or
“MenuDown”until“Zero=----”appearsintheinformationwindowattheright.
2. Pressthekeyadjacentto“Zero=----”.
3. Theswingpotentiometerisnowenabled,referto“ZeroingtheSwingPotentiometer”onpage8tosettheproperzeropointfortheboom.
Whenyouhavefinished,pressthekeyadjacentto“Exit”toreturntothemainmenu.
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