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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 [email protected]
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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
ii
1
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
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ExtensionSensorTheextensionsensorprovidesanincreasingvoltageproportionaltotheextensionoftheboom.AcableattachedtotheboomheadprovidesalowcurrentelectricalpathfortheATBsignal.
FunctionKick-OutElectricallyoperatedsolenoidsdisconnectthecontrolleverfunctionsforboomhoistlower,telescopeout,andwinchupwheneveranoverloadoranATBconditionoccurs.
PressureTransducersTwopressuretransducersmeasurethepressureintheboomhoistcylinder.TheresultantTotalMomentsignalisprocessedtoprovideacontinuousdisplayoftheloadsuspendedbelowthepointoflift.
OperatorAlarmsThesealarms,whenproperlysetbytheoperator,definetheoperatingrange.Thisisachievedbymeansofminimumandmaximumangle,maximumheight,and/ormaximumlength.Thesealarmscanbeprogrammedforeachjobsiteandallowtheoperatortoworkinadefinedarea.
Altec LMAP Calibration Manual
SkyAzul, Equipment Solutions www.skyazul.com
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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.
Altec LMAP Calibration Manual
SkyAzul, Equipment Solutions www.skyazul.com
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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.
Altec LMAP Calibration Manual
SkyAzul, Equipment Solutions www.skyazul.com
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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.
Altec LMAP Calibration Manual
SkyAzul, Equipment Solutions www.skyazul.com
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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.
Altec LMAP Calibration Manual
SkyAzul, Equipment Solutions www.skyazul.com
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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.
Altec LMAP Calibration Manual
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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.
Altec LMAP Calibration Manual
SkyAzul, Equipment Solutions www.skyazul.com
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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.
Altec LMAP Calibration Manual
SkyAzul, Equipment Solutions www.skyazul.com
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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.
Altec LMAP Calibration Manual
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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.
Altec LMAP Calibration Manual
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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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SkyAzul, Equipment Solutions www.skyazul.com
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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.
Altec LMAP Calibration Manual
SkyAzul, Equipment Solutions www.skyazul.com
2
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 [email protected] www.skyazul.com