You are on page 1of 41

Adjustment Instructions

Load Moment Indicator

iVISOR Mark 4E/2

Adjustment Instructions Item No. 416324 Issue 07-2009

All rights reserved


Warranty
We reserve the right to make design changes or technical modifications to the product under description without prior notification. We reserve the right to amend this operating manual without prior notification. Hirschmann Automation and Control GmbH can accept no liability for any technical or printing errors or deficiencies in this operating manual. In addition, Hirschmann Automation and Control GmbH cannot be made liable for any damage directly or indirectly resulting from the use of the operating manual.

Copying restriction
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

About this Manual


This document is a constituent part of the system supplied by: Hirschmann Automation and Control GmbH, Branch Office Ettlingen 76275 Ettlingen / Germany In this documentation you will find information on starting-up, operating and maintaining the system. The Safety Information chapter tells you how warning information and symbols are used in this manual. You will also find information on the intended use of the system and the qualifications needed by the operatives.

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.

Requirements for Operating Personnel


Only appropriately trained personnel should operate this system, i.e. persons who: are familiar with the procedures for starting up and operating the system; have read and understood the documentation or have received the necessary training or instruction; know the accident-prevention regulations.

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

10

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

There after the panel will display:

CKSUMEP CKSUMEEP CKSUMPRG RESET


To checksum new EPROMs: PUSH button at EACH of these or buttons until

menu titles. To select a menu title, use the

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.

12

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

14

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

button to set all digits to the

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

button to set all digits to the

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

15

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.

Set Pressure piston side


Align this in the same way as for angle and length; also entering via the NORM menu. Minimum = 0 Bar is given by the sensors, when there is no pressure in the cylinder. For Maximum, disconnect the pressure sensor from the analogue inputs (e.g. 51, 52) and connect +5 Volts from terminals 2126 to the respective analogue input. Confirm Maximum with the nominal pressure of the sensor, e.g. 400 bar.

16

Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

Set Pressure rod side


Analogue in the same way as for piston side.

Set Ratio (for systems with 2 pressure transducers (rod/piston)


In most cases, the ratio is between 1,5 .. 2,5 It is very important that the ratio is correct. Try to read out the values of Dp and Dr from the cylinder drawing or spares catalogue of the crane.

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

Measure T, the thickness of the wall to calculate Dp to be used in upper formula.

Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

17

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

buttons to adjust the ratio on the display

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.

Boom down slowly and use the

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.

After the ratio is set, push the

button to confirm.

Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual.

18

Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

Set Radius Offset (optional)


Fully retract and put the boom at 60 degrees without load. 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 "RADIUS OFFSET" Measure actual radius. Then change RADIUS indicated to actual radius using the or buttons.

After RADIUS is set, push the

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

19

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

After RADIUS is set, push the Select "LOAD"

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.

After RADIUS is set, push the

button to confirm.

Select "EXIT" several times to come into the operating screen via the crane configuration menu; see also operating manual.

20

Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

Calibration of pressure profiles


Important note; please read before calibrating

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.

Calibration of pressure profiles using the Standard method


Pressure profiles at min. boom length. Fully retract boom to minimum length of the load chart, pick up a test weight and enter the operating screen. Verify whether the pressure profiles are correct by checking the load indication at angle "0, 15, 30, 45, 60 and 75" with minimum boom length. If load indications are within 100 kg or 200lb, skip to Step (Pressure profiles at max. boom length). If indications are NOT correct, continue with the following procedure: Fully retract and put the boom at "75" degrees or max angle of the loadchart. Put down the test weight.

Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

21

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.
22
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

23

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.

24

Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

Calibration of pressure profiles using EasyCal method


Depending on the testweight, which you have available, decide which length will be used to make the calibration run with load. It is strongly advised to calibrate with load at a combination of length and testweight, which creates a high loadmoment, i.e. high hydraulic pressure. If the testweight is small, select the largest length, if it is medium, then go to a medium length. Beside the general informations (see on page 17), it is important that the boom angle ranges during the calibration runs are large (optimum 900 degrees)

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

25

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.

26

Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

Refine the Load Indication Using Correction


(optional) After pressure profile calibration it is necessary to control the accuracy of the load readout at various lengths and angles. If the accuracy is within 3% of the maximum crane capacity at full load and with 200 Kg at empty hook, then this step can be skipped. If it is outside, then a load correction is advised. It is specially recommended when using the EasyCal Method. There are four parameters to be used to adjust the load readout: P1: P2: P3: P4: influences the loadreadout in the boomangle range of 9060 degrees influences the loadreadout in the boomangle range of 6030 degrees influences the loadreadout in the boomangle range of 300 degrees influences the loadreadout independently from the boomangle

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

Select "OWN-WEIGHT" Select "P4"

Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

27

Use the

or

buttons to change the percentage

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.
28
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

29

Menu Flow Chart


Access Code

NORM Analog Input Adjust

LED Brightness

Checksum

Measure Measures Boom

Service Analog and Digital Input

Setup Dynamic Menu Point

Reset

Exit

PRESSURE PISTON

CKSUM-PRG

EXIT

ANALOG INPUTS (1-4) (5-8)

EXIT

PRESSURE ROD

CKSUM-EEP

MANUAL

DIGITAL INPUTS (1-16)

RATIO

OWNWEIGHT

LENGTH
(Main Boom)

CKSUM-EP

AUTOMATIC

DIGITAL OUTPUTS (1-16)

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

30

Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

Calibration Summary Table


This table is a summary of the calibration procedure and is not recommended for the first time user. Use this procedure as reference after reading, completing the calibration procedure and becoming familiar with console operation.
STEP DESCRIPTION Check that load chart booklet matches load chart in crane REFERENCE Page 11

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

31

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.

Pages 17,18, 19, 20

32

Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

EXIT Return to the operating screen. Pages 17

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

Error Code Listing


ERROR CODE (HEX)
0001 0002 0003 0004 0005 0006 0007 0008 0009 000A 000B 000C 000D 000E 000F 0010 0011 0012 0013 0014 0015 0016 0017 0018 0019 001A 001C 001D 001E 001F 0020 0021 0022 0023 0024 34

DESCRIPTION

LMB ERROR CODE


HOIST LIMIT SWITCH BYPASS ERROR SHUT OFF BYPASS ERROR ILLEGAL MAX. LOAD TABLE IDENTIFIER MAIN LENGTH < TABLE ENTRY MAIN LENGTH > TABLE ENTRY RADIUS < TABLE ENTRY RADIUS > TABLE ENTRY ANGLE < TABLE ENTRY ANGLE > TABLE ENTRY RADIUS < MIN. SHUT OFF VALUE RADIUS > MAX. SHUT OFF VALUE ANGLE < MIN. SHUT OFF VALUE ANGLE > MAX. SHUT OFF VALUE HEIGHT < MIN. TABLE ENTRY HEIGHT > MAX. TABLE ENTRY ILLEGAL PROGRAM TABLE IDENTIFIER ILLEGAL PRESSURE TABLE IDENTIFIER WRONG PARTS OF LINE IN LOAD HOISTING LINE ILLEGAL FRICTION TABLE IDENTIFIER OUTRIGGER CONTROL COUNTERWEIGHT CONTROL OVERLOAD SWING AREA AXLE BLOCKING FRONT AXLE BLOCKING BACK MANUAL EXT. PIN PRESET ANGLE MAX. PRESET ANGLE MIN. PRESET RADIUS MAX. PRESET RADIUS MIN. PRESET HEIGHT MAX. PRESET HEIGHT MIN. PRESET LENGTH MAX. PRESET LENGTH MIN. PRESET LOAD MAX.

Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

ERROR CODE (HEX)


0025 0026 0027 0028 0029 002A 002D 002E 0031 003A 003B 1000 PRESET LOAD MIN.

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)

RANGE CHECK ERORS


1080 1081 1082 1083 1084 1085 1086 1087 1088 1089 108A 108B 108C 108D INVALID MAIN LOOP SEQUENCE # (NOSEQ) ERROR IMAGE NOT AVAILABLE INVALID ADC CHANNEL TYP (NOCRTE) INVALID ADC CHANNEL TYP (NOACCTE) INVALID SERVICE CONDITION CODE INVALID OPTION INVALID INPUT COMMAND INVALID DEFLECTION IDENTIFIER DATA RECORDER TYP NOT AVAILABLE INVALID PRESET IDENTIFIER INVALID LMB DATA IDENTIFIER OPTION TABLE OVERFLOW EXTERNAL ERROR TABLE NOT AVAILABLE EXTERNAL ERROR IMAGE NOT AVAILABLE

DATA PROGRAMMING ERRORS (EPROM)


Adjustment Instructions - Load Moment Indicator MARK 4E/2 Version 1.3 Item No. 416324 Status 07-2009

35

ERROR CODE (HEX)


10C0 10C1 10C2 10C3 10C4 10C5 10C6 10C7 10C8 10C9 10CA 10CB 10CD 10CE 10CF INVALID EPROM ID WRONG EPROM CRC

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

DATA PROGRAMMING ERRORS (EEPROM)


1100 1101 1102 1103 1104 1105 1106 1107 1108 1109 110A 110B 110C 110D 110E INVALID EEPROM ID WRONG EEPROM CRC WRONG EEPROM SIZE NOPRGTE <> NOPTE WRONG DEFLECTION TABLE LENGTH NO PROGRAM # PERMITTED (RANGE CHECK) OPTION SUBROUTINE POINTER NOT AVAILABLE (EPROM) OPTION TABLE POINTER NOT AVAILABLE (EPROM) OPTION TABLE POINTER NOT AVAILABLE (EEPROM) INVALID LENGTH CORRECTION TYP INVALID LENGTH CORRECTION TABLE LENGTH INVALID DATA RECORDER RAM SIZE INVALID MAX. # OF USER IDENTIFIERS WRONG PARTS OF LINE IN BOOM HOISTING LINE NOT ENOUGH TABLE ENTRIES IN LOAD OFFSET OPTION TABLE

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

ERROR CODE (HEX)


1145 1146

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

37

ERROR CODE (HEX)


FE31 FE32 FE33 FE34 FE35 FE36 FE37 FE38 FE39 FE3A FE3B FE3C FE3D FE3E FE3F FE40 FE41 FE42 FE43

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

38

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

39

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:

Tare: Analog inputs: Digital inputs: Relay outputs:

Supervision: Protection: Interconnection: Dimensions (L - B - H):

40

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

41