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This operating manual and the examples provided for the product under description constitute protected information that is subject to the law of copyright. All rights are protected under the law. This operating manual may not be copied in whole or in part or otherwise reproduced without the prior consent of Hirschmann Automation and Control GmbH.
Trademarks
The use of generic names, trade names and trademarks etc. in this documentation cannot be taken to mean that such names are not protected by trademark and brand protection legislation and therefore open to use by anyone, even if this is not expressly stated
Attention
We hereby make express reference to the fact that any parts or accessories not supplied by us have not been tested or released by us. The installation and/or use of such products may therefore have a negative effect on the design properties of your device and thus impair active and/or passive safety. No liability can be accepted for damage caused by the use of spare parts and accessories manufactured by third parties.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Table of Contents
About this Manual Safety Information Warning Information and Symbols This sign points out a possible loss of warranty cover. Intended Use Requirements for Operating Personnel General Information Material List Warnings Startup Operating Console Calibration Procedure General information Set Angle Set Length Set Ratio (for systems with 2 pressure transducers (rod/piston) Set Radius Offset (optional) Set Deflection Calibration of pressure profiles Calibration of pressure profiles using the Standard method Calibration of pressure profiles using EasyCal method Refine the Load Indication Using Correction (optional) COPY Function Final check Menu Flow Chart Calibration Summary Table Error Code Listing Preventive Maintenance Annual Inspection Specifications 4 5 5 5 6 6 7 7 8 9 10 11 13 13 15 17 19 19 21 21 25 27 28 29 30 31 34 39 39 40
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Safety Information
Warning Information and Symbols
The following designations and symbols are used in the operating manual to indicate information that is especially important: This symbol refers to dangers involved in the activity under description that could possibly result in injury to personnel. Here your attention is drawn to dangers which could pose a threat to property, e.g. damage to the equipment or the environment. The hand with the pointing finger refers you to sections providing additional information and tips. This sign points out a possible loss of warranty cover. Make sure you read all the safety information in this documentation and comply with this information when using the system. Always keep these instructions in a safe place. Issue a copy to every operator. The control system may be operated only by hand. Never use pointed objects to depress keys. The system may no longer be operated if the device is damaged. It should be disconnected from the mains. The indicator must be protected against damp, liquids and dust, in particular, for as long as the display window is damaged. Always use mild detergents when cleaning the device. Solventcontaining, aggressive and abrasive detergents may not be used. On disposal of the indicator, the electronic assemblies must be disposed of as special waste in accordance with local regulations.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Intended Use
This system is built to recognised safety standards. However, the improper use of the device can endanger the life and limb of the user or of other persons and may result in damage to the equipment or other items. It may be used only for the intended purpose and must be in perfect technical condition. There should be no doubt that this system contains many electronic and mechanical components and therefore the possibility of a fault occurring cannot be completely ruled out. Faults that represent a potential safety risk must be remedied immediately. This system is designed solely for the tasks described in this documentation. It may not be used for any other purpose. Caution: this system cannot make up for any lack of on-the-job experience or judgment regarding the use of the equipment on the part of the operator. Responsibility for the entire operating process and any consequences arising therefrom rests solely with the operator. The manufacturer can accept no liability for damage or injury caused by improper or impermissible use of the system. The user alone bears the risk.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
General Information
The Load Moment Indicator System iVISOR Mark 4E/2 must be calibrated after completing system installation, crane modification, or anytime there is an indication of inaccuracy. The calibration will match the sensors installed on the crane. Prior to starting the calibration, it is advised to first read over this procedure in its entirety. The purpose of this manual is to provide calibration information required before operating the system. Refer to the Operators Manual for system description and console controls.
Material List
software EPROMs and calibration information package EPROM puller inclinometer 200' tape measure ft/meters digital multimeter complete with 2 sets of leads test weight; (Test loads are included with the EPROMs and calibration information). NOTE: To comply with the SAE J376 standards the test load must be to a known accuracy of 1%.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Warnings
Always refer to operational instructions and load charts that are provided by the crane manufacturer for specific crane operation and load limits. The Load Moment Indicator System MARK 4E/2 is not and shall not be a substitute for good operator judgement, experience, or use of acceptable safe operating procedures. The operator is responsible for operating the crane within the manufacturer's specified parameters. The crane operator shall ensure that all warnings and instructions provided by the manufacturer are fully understood, observed, and remain with the crane. Prior to operating the crane, the operator must carefully read and understand the information in the Operator's Manual so that he knows the operation and limitations of the Load Moment Indicator System MARK 4E/2.
BEFORE OPERATION OF THE CRANE, THE SYSTEM MUST BE CALIBRATED. ALL STEPS MUST BE FOLLOWED AND COMPLETED. TO PREVENT MATERIAL DAMAGE AND SERIOUS, OR EVEN FATAL, ACCIDENTS, THE CORRECT ADJUSTMENT OF THE SYSTEM HAS TO BE ENSURED BEFORE STARTING THE CRANE OPERATION.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Startup
Before taking the device into operation make sure you have read all the instructions issued by the manufacturer of the equipment in question with regard to the upgrade and use of the equipment. This manual and the manuals of the equipment manufacturer must have been read and thoroughly understood before starting work. All entries must be made in accordance with the actual condition of the equipment. If incorrect entries are made, the device will not function properly and will not afford the operator or the equipment protection in dangerous situations. Before making any adjustments to the system, always check the sensor and the power cable. The system may be adjusted and customised only by the customer service department or an authorised representative of Hirschmann Automation and Control GmbH. Incorrect adjustments can lead to inaccurate data indications or device malfunctions. All guarantee claims lapse in such cases.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Operating Console
1) 2) 3) 4) 5) 6) 7) 8) 9)
Display Area LED bargraph By-Pass Warning Light Load Moment Prewarning Light Load Moment Limit Light Alarm Light / Bypass Button "Anti-Two-Block" Down/Boom Length Button Program/"Buzzer" Button UP / "TARE" Button
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Calibration Procedure
Check and verify that the Load Chart in the enclosed booklet matches the Load Chart in the crane. If the Load Charts do not match, please contact your Hirschmann Automation and Control GmbH representative.
If the EPROMs are put into the sockets improperly they will be destroyed and new ones will have to be purchased. Install the EPROMs, which are received with the booklet by plugging them into the proper socket and in the proper direction, as shown above.
Turn on power to the system. The panel will display E: 1141, then press the button and the display will change to:
CODE
information. Push the or
ACCESS
The "ACCESS CODE" is included with the EPROMs and calibration buttons to change number for button to enter the respective
the proper menu digit and the digit and cursor to the next one.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
11
menu title blinks. After check summing EPROMs, RESET system and panel will return to the Operating Screen (see also the operation manual). With boom fully retracted and at "0" degrees, set minimum angle and length voltages to approximately 1.000VDC. Check with a digital level. Take care that the reel is mounted in a way that the pendulum of the angle sensor is close to its end- position when the boom is at "0" degrees angle. Angle voltages are checked with ground lead of voltmeter put on terminals X1.41-49 and the positive lead on terminal X1.56. Adjust voltage by loosening the three screws by the angle potentiometer and turning potentiometer until approximately 1.000VDC is reached. Length voltages are checked with ground lead of voltmeter put on terminals X1.41-49 and the positive lead on terminal X1.53. Adjust voltage by turning wiper arm (located behind white nylon gear and on the shaft of the length potentiometer) to approximately 1.000VDC.
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Attention
General information
Menu points are selected with the "NORM"). Then push the button. or button select (e.g.
Prior to all adjustments the crane must be on its outriggers without any inclination to the ground. Take care that during calibration the crane is never used outside its allowed operating conditions.
Set Angle
From the Operating Screen enter the Calibration menu by pushing the button then the button simultaneously.
If you come to the calibration menu the first time after poweringon the system, you will be asked to enter the access code, see page 11. Select "NORM" Select "ANGLE" Select "MINIMUM" Verify boom is at zero degrees or close to zero with a digital level. Note: If your length-and-angle sensor is LWG 154 or the anglesensor is type WGC, then go to a high angle, e.g. 78 degrees.
Confirm the actual boom angle digit by digit with the button or change with the angle. or button to the actual
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
13
Hoist the boom all the way up and measure angle, using a digital level. Note: If your length-and-angle sensor is LWG 154 or the anglesensor is type WGC, then boom down e.g. to zero degrees.
Select "MAXIMUM" Change the displayed value digit by digit to match the actual measured boom angle. Use the value of the digit and confirm with the and to change the button. For
Example, if the angle given by digital level was "0.5" degrees, then the display should read "00.5" before the pushed for the last time. Select "ADJUST" Note: If an error message Dyn. Range too low appears on the display, then check the voltage of the anglesensor at its analogue input at the MIN and the MAX position. The system requires, that the difference between MIN and MAX is at least 1 Volts. Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual. Boom down to "60" degrees, using crane angle indicator or digital level. button is
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Set Length
From the Operating Screen enter the Calibration menu by pushing the button then the button simultaneously.
If you come to the calibration menu the first time after poweringon the system, you will be asked to enter the access code, see page 11. Select "NORM" Select "LENGTH" Verify boom is at fully retracted and the potmeter of the LWG 154 cablereel is at its left end position. Select "MINIMUM"
Use the
and
proper value, which will be minimum boom length of the load chart; (same procedure as under "Set Angle"). Telescope the boom all the way out. Select "MAXIMUM"
Use the
and
proper value, which will be maximum boom length of the load chart; (same procedure as under "Set Angle").
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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Select "ADJUST" Note: If an error message Dyn. Range too low appears on the display, then check the voltage of the length sensor at its analogue input at the MIN and the MAX position. The system requires, that the difference between MIN and MAX is at least 1 Volts. Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual. Verify angle and length values with digital level and load chart lengths. Fully retract the boom. Check the cable reel when retracting to verify that the reel is spooling properly. If the reel is not spooling properly, adjust the first roller guide until spooling is correct.
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
If not available, measure the perimeter of the rod and divide by 3,14 in order to get Dr Measure the outer perimeter of the cylinder and divide by 3,14 to get Dp + 2 x T
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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From the Operating Screen enter the Calibration menu by pushing the button then the button simultaneously.
If you come to the calibration menu the first time after poweringon the system, you will be asked to enter the access code, see page 11. Select "SETUP" Select "RATIO"
Use the
or
to the calculated value. To control and finetune the Ratio, pick up a test weight and boom up to 60 degrees. While boom is stopped and load is steady, record ACT. LOAD indication. Note: It is not so important, if the loadvalue on the screen is not the right
value of the testweight. For setting the ratio, it is only important to see differences of the load readout between the moving and the steady boom.
or
buttons to adjust
the "ACT. LOAD" indication to the ACT. LOAD value referred to above. The Ratio is well adjusted, when there is nearly no difference of the load readout between steady boom and boom moving slowly up and down.
button to confirm.
Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual.
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
If you come to the calibration menu the first time after poweringon the system, you will be asked to enter the access code, see page 11. Select "SETUP" Select "RADIUS OFFSET" Measure actual radius. Then change RADIUS indicated to actual radius using the or buttons.
button to confirm.
Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual.
Set Deflection
Note: This step requires, that the load readout is within +/10% of the actual load on the hook. If the deviation is higher, then do the pressurecurve calibration (see next chapter) first. If you want to apply the EasyCAL Method, it is advised to repeat EasyCAL again after the first EasyCAL run and deflection setting.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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From the Operating Screen enter the Calibration menu by pushing the button then the button simultaneously.
If you come to the calibration menu the first time after poweringon the system, you will be asked to enter the access code, see page 11. Select "SETUP" Select "DEFLECTION" Select "OWN-WEIGHT" Telescope the boom all way out and boom up to 60 Measure actual radius with hook block only. Then change the readout under "own weight" until the RADIUS indication matches the actual measured radius. Use the buttons. or
button to confirm.
Measure actual radius with hook block + test weight at full boom length and 60 angle. Then change RADIUS indicated to actual radius using the or "UP/TARE" (9) buttons.
button to confirm.
Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual.
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
The pressure curve makes the conversion between length, angle and hydraulic pressure to calculate the load on the hook. Therefore, the accuracy of the pressure profile calibration determines the accuracy of the load measurement. There are two different methods to make the calibration, the Standard Method and the EasyCal Method. In the Standard method, you boom down with empty hook and with suitable testweights at all boomlengths which are foreseen (between 3 to 5 lengths). In the EasyCal method, booming down with testweight is required at only one length. The advantage here is the saving of time and the fact that only one testweight is necessary. As the system has to calculate the curves at the other lengths, the accuracy is better with the standard method where curves are directly measured. In the EasyCal Method, it is very important, that the radius is accurately known; see also page 16 under Set Deflection. It is strictly advised for both methods that the hydraulic oil is at operation temperature in order to have best results.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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From the Operating Screen enter the Calibration menu by pushing the button then the button simultaneously.
If you come to the calibration menu the first time after poweringon the system, you will be asked to enter the access code, see page 11. Select "MEASURE" Select "AUTOMATIC" Select "CLEAR" Select the shortest boom length. Select "EXIT" Select "MEASURE" Select "OWN-WEIGHT" Verify that boom is without load. Select the shortest boom length. Use the , and button to set all digits to the
proper value of hook block + deducts weight (same procedure as under "Set Angle"). After input of the last digits, the system is ready to record the pressure profile: Boom DOWN steady and slow to "0" degrees or minimum angle on the load chart. Before you stop booming down, push the button. This stops the recording.
Select a known test weight (load) for the known boom length (radius) that is within the load chart for the lowest boom angle. The larger the test weight, the better the pressure profile. Put the boom at "85" degrees or max. angle of the loadchart. Select "LOAD" Select the shortest boom length.
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Set load readout to the proper value, which will be the hook block + deducts + known weight. Boom down steady and slow to "0" degrees. Before completion of booming down, push the Select "EXIT" Select "CALCULATION" Select the shortest boom length. Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual. Pressure profiles at max. boom length. Fully extend the boom and pick up a know test weight which is within the loadchart of max. boom length. Verify pressure profiles are correct by checking the load indication at angle "0, 15, 30, 45, 60 and 75" with maximum boom length. If load indications are within 100 kg or 200 lb, skip to the next pre-programmed length. If indications are NOT correct, continue with the following procedure: Put the boom at "75" degrees or max. angle of the loadchart. Enter the Calibration menu. Select "MEASURE" Select "AUTOMATIC" Select "CLEAR" Select the longest boom length. Select "EXIT" Select "MEASURE" Select "OWN-WEIGHT" Verify that boom is without load. Select the longest boom length. button.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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Set load readout to the proper value, which will be the hook block + deducts weight. Boom down steady and slow, to "0" degrees or minimum angle on the load chart. Before completion of booming up, push the button. Select a known test weight (load) for the known boom length (radius) that is within the load chart for the lowest boom angle. The larger the test weight, the better the pressure profile. Pick up hook block + deducts + known weight less than the maximum capacity of the load chart, and put boom at "75" degrees or maximum angle. Select "LOAD" Select the longest boom length. Set load readout to the proper value, which will be the hook block + deducts + known weight. Boom down steady and slow, to "0" degrees or minimum angle on the load chart. Before completion of booming down, push the push the Select "EXIT" Select "CALCULATION" Select the longest boom length. Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual. button.
Pressure profiles at other boom lengths Repeat the pressure profile procedure with all pre- programmed boom lengths of the menu. Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual.
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Pressure profiles at the selected boom length. Extend the boom to the selected length at which you will make the calibration run with load. Pick up the known test weight which is within the loadchart of that boom length. Boom up to 85 degrees or maximum boom angle. From the Operating Screen enter the Calibration menu by pushing the button then the button simultaneously. If you come to the calibration menu the first time after poweringon the system, you will be asked to enter the access code, see page 11. Select "MEASURE" Select "EASYCAL" Select "FULL-MEASURE" Select "LOAD" Select the wanted boom length. Input of the Load: Use the , and button to set all digits to the proper value of hook block + deducts + testweight (same procedure as under "Set Angle"). After input of the last digit, the system is ready to record the pressure profile: Boom DOWN steady and slow to "0" degrees or minimum angle on the load chart. Before you stop booming down, push the "PROGRAM/BUZZER" (8) button. This stops the recording.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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Set down the testweight and boom up to 85 degrees or maximum boom angle. Select "OWN-WEIGHT" Select the same length as in the step before, which shall be the actual length of the boom. Input the own-weight load which is the hookblock and deducts weight. It is important that the own weight is not within 9501050 Kg because this could disturb the calculations. If the weight of the empty hook + deducts is within that range, use a small additional weight to increase beyond 1050 Kg. After input of the last digit, the system is ready to record the pressure profile: Boom DOWN steady and slow to "0" degrees or minimum angle on the load chart. Before you stop booming down, push the button. This stops the recording.
Select "EXIT" Select "OW-MEASURE" Repeat the ownweight measurements for the other lengths in the same way as under FULL-Measure. Note that all runs are done with empty boom. When all measurements at all boomlengths are done: Select "CALCULATION" Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual. It is strongly advised to control the accuracy of the loadreadout at all boomlenghts and angles. Corrections can be done with the refinement, see next chapter. Should at a certain boomlength the deviation between displayed and real load be so large that the correction is not satisfying, it is possible to run the standard method calibration with ownweight and testweight only at that length.
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
The following describes the correction procedure using P4, but holds for the other parameters as well. From the Operating Screen enter the Calibration menu by pushing the button then the button simultaneously. If you come to the calibration menu the first time after poweringon the system, you will be asked to enter the access code, see page 11. Select "SETUP" Select "CORRECTION" Select boom length at by pushing the push the button. or button and
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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Use the
or
indication until the "ACT. LOAD" equals the actual load = hook block + deducts weight. After correction is set, push the button to confirm.
Repeat the procedure with test weights for other boom lengths respectively. Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual.
COPY Function
The pressure profile calibration has to be made for each crane configuration, e.g. for the mainboom configuration and for jib configurations separately. The pressure curves of similar configurations (e.g. mainboom on outriggers and on wheels or mainboom (or jibs with same lengths and angles) with different counterweights) can be copied length by length:
From the Operating Screen enter the Calibration menu by pushing the button then the button simultaneously. If you come to the calibration menu the first time after poweringon the system, you will be asked to enter the access code, see page 11. Select "MEASURE" Select "COPY" Select the number of the source program, then select the length which you want to have the pressurecurve copied. Do the same for the destination. Before the curves are really copied, a confirmation screen will display your choice. If the entries are wrong, confirm the NO with the button. If it is ok, then turn the NO to YES with the arrow keys and confirm. After all copies are made, select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual.
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Final check
From the operating screen, check for all boom lengths and angles the load readout, the load moment indication and the function of prewarning and shut-off functions including A-2-B.
When approaching the load moment switch point (check load chart carefully), operate the crane with extreme caution to avoid any damage. After all indications and functions are proven to be correct, the EEPROM checksum must be set before switching off the system, see page 12.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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LED Brightness
Checksum
Reset
Exit
PRESSURE PISTON
CKSUM-PRG
EXIT
EXIT
PRESSURE ROD
CKSUM-EEP
MANUAL
RATIO
OWNWEIGHT
LENGTH
(Main Boom)
CKSUM-EP
AUTOMATIC
DEFLECTION
LOAD
ANGLE
(Main Boom)
EXIT
EXIT
CORRECTION
EXIT
EXIT
LENGTH
ADJUST
CALCULATION
START
OWNWEIGHT
ALL
MAXIMUM
CLEAR
DISPLAY
LOAD
EXIT
P1
MINIMUM
EXIT
EXIT
P2
EXIT
MEASURE
OWNWEIGHT
P3
EXIT
LOAD
P4
EXIT
EXIT
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
1.
WARNING: If the EPROMs are put into the sockets improperly they will be destroyed and new ones will have to be purchased. 2. 3. 4. 5.
Install System, Data I, and Data II EPROMS Enter Access Code: The ACCESS CODE Is included with calibration information. CHECKSUM NEW EPROMs: CKSUM EP CKSUM EEP CKSUM PRG RESET Position Boom At 0 mechanically adjust angle sensor to 1.0 VDC at X1:41 (GND) and X1:56 (angle signal) on the main board Page 11 Page 11 Page 12 Page 12
6.
Fully Retract Boom mechanically adjust length sensor Page 12 to 1.0 VDC at X1:41 (GND) and X1:53 (length signal) on the main board. Set Angle (refer to flow chart) select: NORM, ANGLE, MINIMUM (match display with actual angle) Boom to max angle MAXIMUM (match display with actual angle) ADJUST EXIT Page 14 Page 13
7.
8.
Set Length (refer to flow chart) select: NORM, LENGTH, MINIMUM (match display with actual length), boom to max length, MAXIMUM (match display with actual length), ADJUST, EXIT and fully retract boom. Set Ratio From the operating screen (refer to flow chart) Select: SETUP, RATIO, while boom is stopped and load is steady, Record the ACT. LOAD from the display, Boom down slow Adjust the displayed ACT. LOAD to match the ACT. LOAD recorded, and exit.
9.
Pages 15
Warning: Operator is responsible for operating the crane within manufacturers specified parameters.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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10.
Set radius offset refer to flow chart and select: RADIUS OFFSET, measure actual radius and record, change radius to actual radius, and EXIT.
Pages 15
11.
Page 16 Set deflection Refer to flow chart and select: DEFLECTION, OWN WEIGHT, measure actual radius with hook block only and record, change radius to actual radius, LOAD, , measure actual radius with load and record, change radius to actual radius, and EXIT Select a known load that is within the load chart for the specified boom length or radius. For pressure profiles, the load should be greater than 1 ton and allow the boom to have the greatest range of angle movement. For testing, the load should be at least 75% of the rated load as read from the load chart. Check hook block and/or test load at: 0, 15, 30, 45, 60, 75 are within 200lb. Note: Check the test load in crane configurations permitted by the load chart. If necessary, create pressure profiles using the boom lengths specified with calibration information. Use the same boom length throughout the following procedure and then repeating the procedure for each specified boom length. Refer to flow chart and select: MEASURE, AUTOMATIC, CLEAR Select boom length EXIT MEASURE, OWN-WEIGHT Select boom length Adjust the displayed load to match boom weight (hook block + deducts weight) Boom up steady and slow From the Operating Screen enter the Calibration menu by pushing the simultaneously. Pick the known load LOAD Select boom length Adjust the displayed load to match load (hook block + deducts + known weight) Boom up steady and slow From the Operating Screen enter the Calibration menu by pushing the simultaneously. EXIT CALCULATION Select boom length button then the button button then the button Page 16
12.
13.
Pages 17
14.
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
15.
Correction of minimum boom length load. Refer to flow chart and select: SETUP, CORRECTION Select boom length OWN WEIGHT, P4, ACT. LOAD indicates actual load = hook block + deducts EXIT LOAD, P4, ACT. LOAD indicates actual load = hook block + deducts + test weight. EXIT. Check load and radius indications and check load moment shut off. Correction of maximum boom length load. Refer to flow chart and select: SETUP, CORRECTION Select boom length OWN WEIGHT, P4, ACT. LOAD indicates actual load = hook block + deducts EXIT LOAD, P4, ACT. LOAD indicates actual load = hook block + deducts + test weight EXIT Check load and radius indications and check load moment shut off. If load, angle, or length measurements are incorrect, repeat calibration procedure.
16. 17.
Page 17 Page 18
Page 19
18.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
33
DESCRIPTION
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
DESCRIPTION
INVALID TELECONTROL TYP OVER FRONT WARNING TIRES OVER FRONT WARNING OUTRIGGERS HOIST MONITOR FRONT DRUM HOIST MONITOR REAR DRUM LIST ANGLE OUT OF RANGE TRIM ANGLE OUT OF RANGE WRONG PARTS OF LINE PRESET WINDSPEED 100% PRESET WINDSPEED 90% HOIST LIMIT SWITCH ERROR
SYSTEM ERRORS
1040 1041 1042 1043 1044 1045 1046 1047 DIVISION ERROR ILLEGAL INTERRUPT VECTOR WRONG PROGRAM EPROM CRC RTC NOT AVAILABLE DATA RECORDER RAM FAULT DATA RECORDER HEADER BLOCKS DESTROYED INVALID DATA RECORDER TYP (GLOBAL) INVALID DATA RECORDER TYP (HEADER)
35
DESCRIPTION
INVALID COUNTRY CODE PROGRAMMED INVALID LANGUAGE TEXT IDENTIFIER LENGTH NOPRGTE > # OF PROGRAM TEXT ENTRIES MAX. LOAD TABLE NOT AVAILABLE INVALID ERROR COUNT IN ML IDENTIFIER 0 UNAVAILABLE DIGITAL INPUT REFERENCE UNAVAILABLE DIGITAL OUTPUT REFERENCE PRE OPTION LIST OVERFLOW POST OPTION LIST OVERFLOW # OF OPTION OVERFLOW LENGTH CALCULATION IN LATTICE PROG. NOT POSSIBLE NOT ENOUGH TABLE ENTRIES IN LIST/TRIM OPTION TABLE INVALID DAC TYPE
USER ERRORS
1140 1141 1142 1143 1144 36 PROGRAM EPROM CHANGED DATA EPROM CHANGED EEPROM CHANGED ACTUAL AND PRE PROGRAM # NOT PERMITTED (TEXT XFER) DATA RECORD NOT AVAILABLE
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
DESCRIPTION
LENGTH ABOVE WHILE AUTO MESUARING LENGTH BELOW WHILE AUTO MESUARING
HARDWARE ERRORS
F000 F001 F002 F040 F041 F042 F043 F044 F045 F046 F047 F050 F051 F052 F053 SHUT OFF CIRCUIT ERROR 12V ERROR ADC TIMEOUT ERROR PARALLEL EEPROM ERROR (DATA FAULT) PARALLEL EEPROM ERROR (TIMEOUT) PARALLEL EEPROM ERROR (SERVICE IN USE) SERIAL EEPROM ERROR (READ) SERIAL EEPROM ERROR (WRITE) SERIAL EEPROM ERROR (VERIFY) SERIAL EEPROM ERROR (TIMEOUT) SERIAL EEPROM ERROR (SERVICE IN USE) SYSTEM TIMER ERROR TIMER LIST OVERFLOW EXTENDED TIMER LIST OVERFLOW NOTLE_EXT_MAX TO SMALL
FE00 .. FE0F ADC CHANNEL MIN. ERROR FE10 .. FE1F ADC CHANNEL MAX. ERROR FE20 FE21 FE22 FE23 FE24 FE25 FE26 FE27 FE28 FE29 FE2A FE2B FE2C FE2D FE2E FE2F FE30 ADC PRESSURE MIN. ERROR ADC PRESSURE MAX. ERROR ADC PRESSURE PISTON MIN. ERROR ADC PRESSURE PISTON MAX. ERROR ADC PRESSURE ROD MIN. ERROR ADC PRESSURE ROD MAX. ERROR ADC MAIN LENGTH MIN. ERROR ADC MAIN LENGTH MAX. ERROR ADC MAIN LENGTH 1 MIN. ERROR ADC MAIN LENGTH 1 MAX. ERROR ADC MAIN LENGTH 2 MIN. ERROR ADC MAIN LENGTH 2 MAX. ERROR ADC MAIN LENGTH 3 MIN. ERROR ADC MAIN LENGTH 3 MAX. ERROR ADC MAIN ANGLE MIN. ERROR ADC MAIN ANGLE MAX. ERROR ADC LUFFING JIB ANGLE MIN. ERROR
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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DESCRIPTION
ADC LUFFING JIB ANGLE MAX. ERROR ADC MAIN DMS MIN. ERROR ADC MAIN DMS MAX. ERROR ADC MAIN DMS 1 MIN. ERROR ADC MAIN DMS 1 MAX. ERROR ADC MAIN DMS 2 MIN. ERROR ADC MAIN DMS 2 MAX. ERROR ADC JIB DMS MIN. ERROR ADC JIB DMS MAX. ERROR ADC JIB DMS 1 MIN. ERROR ADC JIB DMS 1 MAX. ERROR ADC JIB DMS 2 MIN. ERROR ADC JIB DMS 2 MAX. ERROR ADC LUFFING JIB DMS MIN. ERROR ADC LUFFING JIB DMS MAX. ERROR ADC LUFFING JIB DMS 1 MIN. ERROR ADC LUFFING JIB DMS 1 MAX. ERROR ADC LUFFING JIB DMS 2 MIN. ERROR ADC LUFFING JIB DMS 2 MAX. ERROR
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Preventive Maintenance
This system consists of electronic and electrical components. Maintenance work may be carried out on the system only by service personnel of the company Hirschmann Automation and Control GmbH, by personnel authorised by the manufacturer or by personnel trained by Hirschmann Automation and Control GmbH. As even minor damage can significantly impair the efficiency of the device or even put it out of operation, the operator must ensure that the device is fully operational before the start of work each day.
Annual Inspection
At yearly intervals the system must be inspected by authorised service personnel. All checks and settings must be made in accordance with the statutory regulations.
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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Specifications
Supply voltage: Current consumption: Working temperature range: Relative humidity: Display: 12V DC (24V DC) +/-20% < 500mA DC -25C.-.+70C (-13F to 160F) Max. 95% / 40C (104F), not cond. Alphanumeric LC display, 2 lines of 20 characters, character height 8mm, backlighting Program-No., parts of line, radius and length in m or ft, resolution 10cm resp. 0.5ft, boom angle, resolution 0.5, actual and maximum load in t or lb, resolution 0.1t resp. 100lb Actual load, 0...100% Max. 8, input signal 0...8V DC or 4...20mADC Max. 5, input signal, 10 - 30V DC Standard 4, one changeover contact each, contact consumption 30V DC /5A By microprocessor, power-on-reset, watchdog, system error code IP 65 Directly, PG-connectors 200 x 100 x 60 mm
Display parameter:
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Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
Note:
Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009
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