Altec LMAP (Load Moment and Area Protection)

Telescopic Boom Cranes

Calibration

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.............................................................................................................................

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.