LMAP Calibration Manual Cover Skyazul...8. Boom Length – Displays the current boom length in feet...

Altec LMAP

Calibration Manual

Altec LMAP

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

NOTICE SkyAzúl makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and/or its fitness for a particular purpose. SkyAzúl will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing, performance, or use of this manual. This document contains proprietary information, which is protected by copyright, and all rights are reserved. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of SkyAzúl. SkyAzúl reserves proprietary rights to all drawings, photos and the data contained therein. The drawings, photos and data are confidential and cannot be used or reproduced without the written consent of SkyAzúl. The drawings and/or photos are subject to technical modification without prior notice. All information in this document is subject to change without notice.

REV DATE NAME DESCRIPTION

- 01/23/2016 SC ALTEC LMAP CALIBRATION MANUAL

SkyAzúl, Inc. 16 Walnut Street Middletown, MD 21769 Fax 301-371-0029 info@skyazul.com

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.........................................................................................................................13

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.

Altec LMAP Calibration Manual

SkyAzul, Equipment Solutions www.skyazul.com

ExtensionSensorTheextensionsensorprovidesanincreasingvoltageproportionaltotheextensionoftheboom.AcableattachedtotheboomheadprovidesalowcurrentelectricalpathfortheATBsignal.

FunctionKick-OutElectricallyoperatedsolenoidsdisconnectthecontrolleverfunctionsforboomhoistlower,telescopeout,andwinchupwheneveranoverloadoranATBconditionoccurs.

PressureTransducersTwopressuretransducersmeasurethepressureintheboomhoistcylinder.TheresultantTotalMomentsignalisprocessedtoprovideacontinuousdisplayoftheloadsuspendedbelowthepointoflift.

OperatorAlarmsThesealarms,whenproperlysetbytheoperator,definetheoperatingrange.Thisisachievedbymeansofminimumandmaximumangle,maximumheight,and/ormaximumlength.Thesealarmscanbeprogrammedforeachjobsiteandallowtheoperatortoworkinadefinedarea.

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.

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.

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.

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.

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.

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.

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.

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.

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.

7. Usethenumberentryprocedureonpage6toenterthenumberexactlyasshownonthedigitallevel.

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.

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.

EnablingtheSwingPotentiometer1. Whileinmenu“04SwingPotentiometer”,pressthekeyadjacenttoeither“MenuUp”or

“MenuDown”until“Zero=----”appearsintheinformationwindowattheright.

2. Pressthekeyadjacentto“Zero=----”.

3. Theswingpotentiometerisnowenabled,referto“ZeroingtheSwingPotentiometer”onpage8tosettheproperzeropointfortheboom.

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

SkyAzúl, Inc. 16 Walnut Street Middletown, MD 21769 Phone 301-371-6126 Fax 301-371-0029 info@skyazul.com www.skyazul.com

LMAP Calibration Manual Cover Skyazul...8. Boom Length – Displays the current boom length in feet...

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