Manitowoc 16000 Lmi Operation Manual 6i5e71
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RATED CAPACITY INDICATOR/LIMITER OPERATION Model 16000 and 15000
TABLE OF CONTENTS Definitions .........................................................................2 General .............................................................................2 Rated Capacity Indicator/Limiter Components..................3 1 – RCL Display .........................................................3 2 – Main Display .........................................................3 3 – Warning Light .......................................................3 4 – Caution Light ........................................................3 5 – Display Touchpad Controls ..................................3 6 – Display 1 / Display 2 Buttons ................................3 7 – Enter / Exit Buttons ...............................................3 8 – Confirm Button .....................................................4 9 – Select Buttons ......................................................4 10 – Master Node Controller ......................................4 11 – RCL Receiver .....................................................4 12 – Boom Node Controller ........................................4 13 – Boom Angle Sensor............................................4 14 – Jib Node Controller.............................................4 15 – Luffing Jib Angle Sensor.....................................4 16 – Load Sensing Link ..............................................4 RCL Display Format..........................................................4 Screen Prompts .........................................................4 Menu Screen.....................................................................4 To Set a Number ...............................................5 Working Screen ................................................................5 Configuration Screen ........................................................6 Selecting Crane Configuration Items..........................6 Selecting Crane Configuration ...................................7 Calibration Screen ............................................................7 Angle Sensor Calibration Procedure ..........................8 Calibrate Boom or Luffing Jib ..............................8 Load Sensor Calibration Procedure ...........................8 Calibrate a Load Sensor......................................9 Diagnostics Screen .........................................................10 Camera Screen (Optional) ..............................................10 Load Link Installation ......................................................11 Wireless Load Link - PN A15345..............................11 Hard Wired Load Link - PN A15487................... 11 Replacing Batteries in Link (PN A15345) .......... 11 Wireless Load Link - PN A09683..............................12 Replacing Batteries in Link (PN A09683) ..........12 Wireless Load Link - PN A04237 or A04689 ............13 Replacing Batteries in Link (PN A04237 or A04689) 13
© 2006 Manitowoc Updated: 04-11-2006
F2108-1
RATED CAPACITY INDICATOR/LIMITER OPERATION
DEFINITIONS
GENERAL
Rated Capacity Indicator (RCI) — is a system of devices which automatically provides an audible/visual signal when the actual load approaches, reaches and/or exceeds the rated capacity value when applied to crane.
The purpose of this publication is to provide qualified operators with operating instructions for the Manitowoc RCL. The system is designed to aid the operator in identifying overload conditions, which can cause structural failure of the boom and jib or loss of stability (tipping).
Rated Capacity Limiter (RCL) — is a system of devices which automatically provides an audible/visual signal when the loading conditions approaches, reaches and/or exceeds the rated capacity value when applied to crane. When the actual load exceeds the rated capacity, the system supplies a signal to disable system. NOTE:
In this publication the Rated Capacity Indicator and Limiter information is combined, with the initials RCL representing both systems.
The limiter is turned on/off in RCI Fault Response Data Box on Configuration Screen. Fault response options are not allowed in some countries. In most of Europe it is illegal to disable the RCL alarms and limiter shut down. The fault responses can not be turned off if the crane has been programmed for use in these countries. If the RCL crane function lockout is enabled, the controller disables the following crane functions until the overload condition is corrected: •
Hoist up.
•
Boom down (or up if boom is raised above its maximum chart angle).
•
Luffing jib down (or up if jib is raised above its maximum chart angle).
WARNING Overload Hazard! The RCL has been installed on crane to aid operator. Presence of RCL on crane in no way substitutes for, or lessens, requirement that operator knowledge, experience, and judgment are required to ensure safe operation of crane. If RCL is not configured correctly, it will not properly sense load and alert operator to overload conditions. Before u s in g R C L , o p e r a t o r sh a ll r e a d a n d u n d e r s ta n d instructions in this publication.
F2108-2
The RCL GUI (Graphic Interface) screen is mounted on the front console in the operator’s cab. The graphic icons are designed to be universal for all languages. English or metric values are determined by the program number, typically English for domestic (USA) and metric for foreign countries. The RCL monitors signals from the load and angle sensors. These signals determine the loads suspended from the crane and the distance (radius) of each load from the centerline of rotation. The load and radius information for each drum is compared to the selected capacity charts and a total rated capacity of the crane is calculated. A rotating amber light and continuous tone horn are mounted on the outside of the operator’s cab to alert job site personnel to an overload or tipping condition.
RATED CAPACITY INDICATOR/LIMITER OPERATION
D16 RCL-1
1
3
2
4
13
10
11 12
16
5
6
9
7 8
Item 1 2 3 4 5 6 7 8
7
16
16
15
14
6
Description RCL Display Main Display Warning Light Caution Light Display Touchpad Controls Display 1 / Display 2 Buttons Enter / Exit Buttons Confirm Button
Item 9 10 11 12 13 14 15 16
Description Select Buttons Master Node Controller RCL Receiver Boom Node Controller Boom Angle Sensor Jib Node Controller Jib Angle Sensor Load Sensor Links and Transmitter
FIGURE 1
RATED CAPACITY INDICATOR/LIMITER COMPONENTS See Figure 1 for the following items. The RCL system is an electronic and mechanical load sensing system consisting of the following components:
1 – RCL Display The RCL display is on the left side of front console.
2 – Main Display The Main display is on right side in the front console. Some diagnostic information related to RCL operation is available on this display. See Section 3 in crane Operator’s Manual for operating instructions.
3 – Warning Light
D16 RCL-2
FIGURE 2
Glows red and an alarm comes on to alert the operator to an overload condition.
6 – Display 1 / Display 2 Buttons
4 – Caution Light
Use to choose which display is controlled by buttons 7, 8, and 9 below. The RCL is display 1 (See Figure 2).
Glows yellow and an alarm comes on to alert the operator to an approaching overload condition.
7 – Enter / Exit Buttons
5 – Display Touchpad Controls Contains all the screen controls required to operate the RCL and Main display screens.
Use these red Enter/Exit buttons to enter or exit a screen or to change the screen’s operating level. Use the red Enter button to enter a screen or go to the next screen level. Use the red Exit button to exit a screen or level. F2108-3
RATED CAPACITY INDICATOR/LIMITER OPERATION
8 – Confirm Button Use purple Confirm button to start certain test routines from the screen and to confirm data when required.
•
The RCL Display is item 1 and the Main Display is item 2.
•
The purple confirm prompt appears when the operator must start certain test routines from the screen and to confirm data when required.
9 – Select Buttons Use these green Select buttons to select screen images, icons or data boxes, and values or icons within data boxes.
MENU SCREEN
10 – Master Node Controller
See Figure 3 for following procedure.
Receives and sends information to and from all node controllers and the RCL display. The master node contains the main RCL program and all capacity chart data.
The Menu screen is the base screen for the RCL system. All other screens must be entered form this screen. Exiting from any screen will return to the Menu screen. The Menu screen show five icons and a data box.
11 – RCL Receiver
D16 RCL-3
2
1
6
RCL Receiver at boom top receives input signals from load link transmitters.
12 – Boom Node Controller Contains the boom angle sensor. Boom node controller sends the boom angle sensor signal to the master node controller.
13 – Boom Angle Sensor Boom angle sensor is located in the boom node controller. Sensor output is read by the boom node’s microprocessor.
14 – Jib Node Controller Controls the luffing jib angle sensor. Jib node controller sends the luffing jib angle sensor signal to the master node controller. 3
4
15 – Luffing Jib Angle Sensor Luffing Jib angle sensor is located in the jib node controller. Sensor output is read by the jib node’s microprocessor.
16 – Load Sensing Link Load links are attached either to wire rope dead ends or at the weight ball for single-part lines. Load links transmit signals to the RCL receiver.
RCL DISPLAY FORMAT Basic components for the Manitowoc RCL display is the Working, Configuration, Diagnostic, Calibration, Camera, and Number screens that are entered from the Menu screen. Exiting any of these screens will return to the Menu screen. The appearance and function of each screen depends on the screen level . Some screen levels show icons and/or data boxes that can be selected and used to change RCL parameters and/or to enter different screen levels.
FIGURE 3
Items shown on the Menu screen: 1.
Working Screen icon
2.
Configuration Screen icon
3.
Diagnostic Screen icon
4.
Calibration Screen icon
5.
Camera Screen icon
6.
Number data box
The Menu screen operates on two levels:
Level 1 — Selected screen icon or number data box is highlighted blue. Level 2 — number data box is highlighted red. To enter any of the five RCL screen listed above: 1.
In Level 1, use Select buttons to highlight icon that represents the screen to be entered.
2.
Press the Enter button to go to Level 2.
Screen Prompts
NOTE:
Screen prompts can appear on a selected screen if a fault condition exist or to prompt or confirm certain operator actions when required by the system. Prompt descriptions and icons are shown below.
3.
F2108-4
5
If screen is number protected and correct number is not set, the number data box is highlighted blue and the screen remains at Level 1.
Menu screen appears.
RATED CAPACITY INDICATOR/LIMITER OPERATION
To Set a Number
4.
luffing jib length (if configured with a luffing jib).
5.
Fixed jib length and offset (if configured with a fixed jib).
6.
Counterweight and stinger length (if configured with a Max-Er attachment).
7.
Optional Max-Er icon appears attachment is part of configuration.
8.
Linepull limit for load drum currently in use.
WORKING SCREEN
9.
Line parts for load drum currently in use.
See Figure 4 for following procedure.
10. Distance (radius) from center line of rotation to the center line of the load block or weight ball or the load drum currently in use.
1.
In Level 1, use Select buttons to highlight the number data box.
2.
Press Enter button to go to Level 2.
3.
Use Select buttons to set the number.
4.
Press Exit button to return to Level 1.
T h e Wo r k i n g s c r e e n s h o w s a l l t h e l o a d , c a pa ci t y, configuration, and rated capacity information required for operation of the crane. At start-up the RCL shows the Working screen. Press the purple Confirm button to acknowledge that capacity chart and basic crane configuration is correct before operating any drum. If the Confirm button is not pressed, drum operation in a direction that increases rated capacity will produce a RCL fault. A number is not required to enter the Working screen.
1.
Image of the basic crane configuration. The selected basic crane configuration determines the operating mode of the crane.
2.
Capacity chart number and selected capacity deduct for the load drum currently in use. 2
D16 RCL-4
13. Load and tare data box — shows suspended load and tare value for drum currently in use. NOTE:
12
4 13
5 6
3.
Tare is a visual aide only and does not effect the rated capacity calculation of the RCL. Rated capacity is always determined from the entered tare plus displayed load. To adjust the tare: a.
Press Enter button to go to Level 2.
b.
Use Select buttons to set the tare.
c.
Press Exit button to return to Level 1.
9
15
14. Capacity is the capacity chart’s maximum allowable load for the drum currently in use. Displayed capacity is always the least of the Manitowoc capacity chart or rope linepull limit. 15. Rated capacity triangle shows total rated capacity of the crane. The size of triangle increases as rated capacity of crane increases. Portions of triangle change color if rated capacity increases to the caution or maximum level:
11
1
8
Tare is a load value that is subtracted from displayed load so the operator can easily view load differences. For example: the weight of the hook block can be entered as a tare. The displayed load then shows only the weight suspended from hook.
10
3
7
Max-Er
12. Luffing jib angle (if configured with a luffing jib).
Level 1 — Load / tare data box (item 12) highlighted blue. The following items correspond to call outs in Figure 4.
a
11. Boom angle.
The Working screen operates on two levels:
Level 2 — Load / tare data box (item 12) highlighted red.
when
14
FIGURE 4
-
Green — indicates that rated capacity is at a safe level.
-
Yellow — indicates that rated capacity is now approaching the maximum level.
-
Red — indicates that rated capacity has exceeded the maximum level.
Boom length and luffing boom chart angle (if configured with a luffing jib).
NOTE:
When crane has a luffing jib, the RCL system automatically selects a capacity chart with a boom angle that closely matches the actual luffing jib boom angle. The capacity is de-rated if the actual luffing boom angle is too far from the selected chart’s boom angle. F2108-5
RATED CAPACITY INDICATOR/LIMITER OPERATION
CONFIGURATION SCREEN
6.
See Figures 5, 6, and 7 for following procedure. The Configuration screen sets the basic crane configuration and the individual RCL parameters for each load drum. A number may be required to enter the Configuration screen.
Load Sensor Data Box — selects load link TXID (6a). If a hard wired load link is used on boom or jib top, link point position – 1, 2, 3, or 4 must be selected (6b). Press the Enter button to go to Level 5 and select load link TXID.
NOTE: 7.
The Configuration screen contains data boxes and icons and operates on five levels.
Level 1 — Crane configuration image and icon shown. Crane configuration icon is highlighted red. Level 2 — Crane configuration image and drum data box shown. Drum data box is highlighted red. Level 3 — Crane configuration image and all data boxes shown. Selected data box is highlighted blue.
Some configurations do not require a load sensor.
RCL Fault Response Data Box — sets the RCL system’s response to an overload condition for the drum being configured. Symbols representing lockout, lamps, and audible alarms are shown in data box. The lockout area is blank if lockout (limiter) is turned off. The lamps and audible alarm area is blank if lamps and alarms (indicator) is turned off. Press Enter button to go to Level 4 to turn lockout on/off and select lamp/alarms on/off. Fault response options are not allowed in some countries and it is illegal to disable the RCL alarms and limiter shut down. The fault responses can not be turned off if crane is programmed for use in these countries.
Level 4 — Crane configuration image and all data boxes shown. Selected data box is highlighted red. Level 5 — Crane configuration image and all data boxes shown. Load sensor data box is highlighted green.
A fourth symbol for declaring the Drum Not Used is also selected in this box. All drums must be configured or declared not used when an RCL system is initially configured.
Selecting Crane Configuration Items The following items correspond to call outs in Figure 5. 1.
2.
1
Chart Number Data Box — selects the capacity chart for the load drum being configured. Once the basic crane configuration is selected, only capacity charts for that configuration can be selected in this box. Maximum capacity is always the least of the Manitowoc capacity chart or rope linepull limit.
2
7
8 10
Capacity Deduct Data Box — selects a deduct to the capa city chart (if required) for load drum being configured.
3 9
5 11
4
WARNING
6b
Tipping or Structural Hazard! Crane can be overloaded if deducts are not entered into RCL configuration screen. The RCL does not automatically include any deducts to stated capacity on Manitowoc charts. If a deduct is required, it must be manually set here to be included in the rated capacity calculation. See Manitowoc capacity chart in use to determine if a deduct is required. 3.
Chart Configuration Data Box — sets the specific crane configuration data — boom lengths, jib lengths, fixed jib, offsets for the load drum being configured and optional Max-Er counterweight/stinger length.
4.
Line Parts Data Box — selects the parts of line for the load drum being configured.
5.
Line Pull Limit Data Box — sets the single line pull limit for the load drum being configured.
NOTE:
F2108-6
Check the capacity chart Wire Rope Specification to determine the line pull limit.
D16 RCL-5
FIGURE 5
12 6a
8.
Upper Boom Point Data Box — selects upper boom point if part of basic crane configuration. This data box tells the RCL an upper point is being used by the drum being configured. If no upper point is possible, this box is grey and can not be selected.
9.
Drum Data Box — selects load drum configuration.
10. Crane Configuration Icon — configuration screen is selected.
indicates
crane
11. Crane Configuration Image — displays selected crane configuration (model 16000 shown in Figure 5). 12. Max-Er Icon — appears when optional Max-Er is configuration is selected.
RATED CAPACITY INDICATOR/LIMITER OPERATION
Selecting Crane Configuration
CALIBRATION SCREEN
See Figure 5, 6, and 7 for following procedure.
See Figure 8 for following procedure.
To configure the RCL:
The Calibration screen calibrates the load and angle sensors in RCL system. RCL configuration should be selected before calibrating any sensor. A number may be required to enter the Calibration screen. The Calibration screen has data boxes and operates on two levels.
1.
Press Enter or Exit buttons as required to go to Level 1. The crane configuration icon appears (see Figure 6).
2.
Use Select buttons to set the crane image that matches the current basic configuration.
NOTE:
The basic crane configuration set here determines crane operating mode.
Level 1 — Selected data box is highlighted blue. Level 2 — Selected data box is highlighted red. NOTE:
D16 RCL-6
Crane Configuration Icon
Crane Configuration Image
FIGURE 6 3.
Press Enter button to go to Level 2. Use Select buttons to highlight the load drum to be configured in drum data box (see Figure 7).
D16 RCL-7
The proper capacity chart and Configuration screen mu st be ena ble d befo re p erfo rming calibration procedures.
RCL calibrations should be checked frequently and should always b e che cke d be fo re an y n e ar-capaci ty lifts. Calibrations should be performed at the following intervals: •
First time using any load or angle sensor.
•
When any displayed angle is found to be in error by more than 2 degrees.
•
When any displayed load is found to be in error by more than 4 percent of capacity chart.
•
Yearly.
The following items correspond to call outs in Figure 8. 1.
Sensor data box — selects the load sensor or angle sensor to calibrate.
2.
Boom angle symbol — appears when a boom angle sensor is selected to calibrate.
3.
Luffing jib angle symbol — appears when a luffing jib angle sensor is selected to calibrate.
4.
Slope data box — shows slope calibration constant for the sensor being calibrated. This number should be recorded after a calibration. If the system loses calibration this constant can be manually restored in the slope data box. Do not alter the value in this data box unless restoring a lost calibration. 8 1 3 9
FIGURE 7 4.
When boom and load drum configuration is selected, press Enter button to go to Level 3.
5.
The complete crane configuration image screen appears as shown in Figure 5.
NOTE:
12
10 2
4 11
The RCL system will not allow capacity critical RCL parameters to be altered if any configured load sensor indicates a significant load on the hook.
6
6.
Only one load drum can be configured at a time. Press Exit button as required to return to Level 2
7
7.
Repeat above steps for all load drums.
D16 RCL-8
5
FIGURE 8
F2108-7
RATED CAPACITY INDICATOR/LIMITER OPERATION
5.
Intercept data box — shows intercept calibration constant for the sensor being calibrated. This number should be recorded after a calibration. If the system loses calibration this constant can be manually restored in the intercept data box. Do not alter the value in this data box unless restoring a lost calibration.
6.
High calibration data box — select to enter high calibration data.
7.
Low calibration data box — select to enter low calibration data.
8.
Distance (radius) — from center line of rotation to center line of load block or weight ball for load drum currently in operation. If crane is configured and the radius is known, radius can be used to calibrate angle sensors.
9.
NOTE:
6.
If calibrating with radius, use Select buttons to adjust displayed radius until it is same as known value. Or use Select button to adjust angle displayed in low calibration data box until it is same as the known boom or jib angle.
7.
Press Exit button to return to level 1.
8.
Use Select buttons to highlight high calibration data box.
9.
Position boom or luffing jib at a high angle. Press Enter button to go to level 2.
NOTE:
Line parts — Select for load sensor being calibrated.
10. Drum image — highlights load drum associated with load sensor being calibrated. 11. Crane configuration — image shows basic crane configuration. 12. Sensor status — shows state of the angle sensor.
Satisfactory angle calibrations can be completed with a range of low boom and jib angles. Best results are obtained with low angle set between 10 and 20 degrees.
Satisfactory angle calibrations can be completed with a range of high boom and jib angles. Best results are obtained with high angle set between 75 and 82 degrees.
10. If calibrating with radius, use Select buttons to adjust displayed radius until it is same as known value. Or use Select b utt on to a djust an gle disp layed in hig h calibration data box until it is same as the known boom or jib angle.
Angle Sensor Calibration Procedure
11. Press Exit button to return to level 1.
See Figure 8 for following procedure.
12. Record values shown in slope and intercept data boxes. Do not alter the value in this data box unless restoring a lost calibration.
The boom angle sensor calibrations can be performed in any order. It is not always necessary to do both low and high calibrations. For example, if the low calibration is known to be accurate only the high calibration should be performed. Measure angle with an accurate angle indicator on the centerline of the boom butt or by measured radius. If using radius to calibrate luffing jib angle sensor, boom angle must be calibrated first. Operating status of the selected load link sensor is displayed with icons on right side of screen: •
Selected angle sensor is operating normal if icon arrow is pointing to center of ± load bar.
•
Selected angle sensor is out of limits and has failed low if the icon arrow is pointing to minus end of load bar. The sensor must be replaced.
•
Selected angle sensor is out of limits and has failed high if the icon arrow is pointing to plus end of load bar. The sensor or wiring is faulty.
Calibrate Boom or Luffing Jib
Values shown in slope and intercept data boxes are the system’s internal calibration constants for selected sensor. If the system loses calibration these values can be manually restored in the slope and intercept data boxes. To restore slope and intercept calibration constants perform the following: a.
In level 1, use Select buttons to highlight slope or intercept data box.
b.
Press Enter button to go to level 2.
c.
Use Select buttons to adjust the value to previously recorded value.
d.
Press Exit button to return to level 1.
13. All calibrations are locked in when exiting back to level 1. If engine is shut down while at level 2 any new calibrations performed are lost and system reverts to last known calibration.
Load Sensor Calibration Procedure
1.
In level 1, use Select buttons to highlight sensor data box. Press Enter button to go to level 2.
2.
Use Select buttons to choose angle sensor to calibrate.
3.
An angle sensor with ID number 1 is boom angle sensor. ID number 2 is a luffing jib angle sensor.
It is not alwa ys nece ssa ry to d o b oth low an d hig h calibrations. Normally wireless load links only require a low calibration.
4.
Press Exit button to return to level 1. Use Select buttons to highlight low calibration data box.
NOTE:
5.
Position boom or luffing jib at low angle. Press Enter button to go to level 2.
Operating status of the selected load link sensor is displayed with icons on right side of screen:
F2108-8
See Figure 9 for following procedure.
Hard wired load links are calibrated the same as wireless load links.
RATED CAPACITY INDICATOR/LIMITER OPERATION
•
Selected link sensor is operating normal if blue antenna icon is displayed.
•
4.
Lift a light load and press Enter button to go to level 2.
NOTE:
Selected link sensor is not being received if yellow antenna icon has a red X through it. 5.
Use Select buttons to adjust load displayed in low calibration data box until it is same as known lifted load.
6.
Press Exit button to return to level 1.
7.
Record values shown in slope and intercept data boxes. Do not alter the value in this data box unless restoring a lost calibration.
Calibrate a Load Sensor 1. 2.
In level 1, use Select buttons to highlight sensor data box. Press Enter button to go to level 2.
Satisfactory Load calibrations can be completed with a range of light loads. Best results are obtained with line pulls between 3 to 10 percent of rated line pull.
Use Select buttons to choose load drum sensor to calibrate. Crane image shows load drum sensor (see Figure 9).
Values shown in slope and intercept data boxes are the system’s internal calibration constants for selected sensor. If the system loses calibration these values can be manually restored in the slope and intercept data boxes. To restore slope and intercept calibration constants perform the following:
8.
D16 RCL-9
3.
FIGURE 9
a.
In level 1, use Select buttons to highlight slope or intercept data box.
b.
Press Enter button to go to level 2.
c.
Use Select buttons to adjust the value to previously recorded value.
d.
Press Exit button to return to level 1.
All calibrations are locked in when exiting back to level 1. If engine is shut down while at level 2 any new calibrations performed are lost and system reverts to last known calibration.
Press Exit button to return to level 1. Use Select buttons to highlight the low calibration data box.
F2108-9
RATED CAPACITY INDICATOR/LIMITER OPERATION
DIAGNOSTICS SCREEN
3.
RCL state field — shows green and yellow triangular area that is a graphic representation of a capacity chart. Drum symbols shown in this field indicate radius and load state for each drum. Any drum symbols outside this field indicate that load drum is either off-chart, overcapacity, or both.
4.
Rated capacity triangle box — shows total rated capacity level of the crane. The size of the triangle increases as rated capacity increases. Portions of the triangle change color if rated capacity increases to caution or maximum level. Green indicates that rated capacity is at a safe l e v e l . Ye l l o w i n d i c a t e s t h a t r a t e d c a p a c i t y i s approaching the maximum level. Red indicates that rated capacity has exceeded the maximum load level.
5.
Sum state box — show a diagnostic number indicating flash memory status. The sum state indicates the information shown in Table 1.
See Figure 10 for following procedure. The diagnostic screen shows the overall state of RCL system as configured. Only sensors and data related to the configured system are shown. The diagnostic screen is viewonly and contains no selectable Icons or data boxes. A number is not required to enter diagnostic screen. The diagnostic screen operates on one level only. D16-RCL-10
4
1
3
Table 1 Sum State Numbers
2
Number
5
DIAGNOSTIC SCREEN
Description
0
Status Normal
1
Flash Entry Error (Chart Data)
2
Flash Entry Error (Capacity Data)
4
Configuration Data is not Confirmed
8
Calibration Data is not Confirmed
FIGURE 10
The following items correspond to call outs in Figure 10.
CAMERA SCREEN (OPTIONAL)
1.
Load sensor boxes — shows all load sensors that were configured to drums. Each box shows a symbol that identifies associated drum, signal from sensor, and individual rated capacity of the sensor.
The camera screen (not shown) displays camera options and items for selecting and operating. The camera option includes up to three different cameras to monitor drum spooling and back of crane.
2.
Angle sensor boxes — shows configured angle sensors. Each box shows a symbol that identifies sensor location as well as signal from sensor.
NOTE:
The camera screen is not available where Federal, State, or local laws prohibit the use of a camera screen operating on a RCL screen.
Use Select buttons to select camera screen the Menu screen. Press Enter button to access screen. Use Select buttons to select desired camera view. To exit screen, press Exit button until Menu screen appears.
F2108-10
RATED CAPACITY INDICATOR/LIMITER OPERATION
LOAD LINK INSTALLATION
8.
Check the part number on the load link to be installed and follow the procedure for that specific load link.
Replacing Batteries in Link (PN A15345)
A wireless load link is installed at the weight ball and a hard wired load link is normally installed at the boom top or jib top. NOTE:
If a wireless load link is attached to boom/jib top dead end, the antenna (opposite side of covers) must be facing toward crane.
Wireless Load Link - PN A15345 See Figure 11 for items in this procedure.
Replace power switch cover when link is operating correctly.
See Figure 11 for items in this procedure. Load links transmit counts to the receiver on boom. The receiver sends load information to boom node controller and master node controller. When the low battery threshold of a link is reached, a message is displayed to indicate that link battery pack must be replaced soon. To replace batteries:
The power is turned off when a new wireless load link is shipped from the factory. To turn load link power on, proceed as follows:
1.
Lower load line to ground to access link.
2.
Remove screws from battery cover (Item 4) of link.
1.
Remove power switch cover (Item 2) from link.
3.
Lift off cover and remove existing batteries.
2.
Press power on/off button (item 5). When link is powered up, red LED (Item 7) turns on for about one second.
4.
Replace with six D size Alkaline batteries.
5.
Reinstall battery pack cover on link.
3.
On RCL configuration screen (see Load/Limiter Alarm) set drums not used with configuration to Not Used.
6.
Screw battery pack cover to link.
4.
Select drums being used and enter in link Network ID (see Load Link Sensor Calibration Procedure).
5.
After 30 seconds link communication should be established.
6.
If link is not installed correctly a wireless system fault appears.
7.
Test switch is for testing communication between link and receiver. (factory use only). 3
P2341
Hard Wired Load Link - PN A15487 See Figure 11 for items in this procedure. Install wired link (Item 9) at boom top or jib top dead end with cable connector facing toward crane. Connect cable between boom or jib top node and hard wired link.
A15487
5
4 VIEW B Link with covers removed
8 2 Item
1
P2340
VIEW A Link With Covers Installed
1 2 3 4 5 6 7 8 9
Description Wireless Load Link ( Battery Pack Cover Six D-Cell Batteries Power Button Cover Power Button Test Switch (factory use only) Red LED Antenna (under cover) Hard Wired Link (boom/jib top)
7
6 9
VIEW C Hard Wired Link
FIGURE 11
F2108-11
RATED CAPACITY INDICATOR/LIMITER OPERATION
Wireless Load Link - PN A09683
NOTE:
See Figure 12 for items in this procedure. The power is turned off when a new wireless load link is shipped from the factory. To turn the load link power on, proceed as follows:
7.
If link is not installed correctly a wireless system fault appears.
Replace power/install cover when link is operating correctly.
Replacing Batteries in Link (PN A09683)
1.
Remove power/install cover (Item 3) from link.
See Figure 12 for items in this procedure.
2.
Press power on/off button (item 6). When link is powered up, LED (Item 7) turns on for about one second.
Load links transmit counts to the receiver on boom. The receiver sends load information to boom node controller and master node controller.
NOTE: 3.
Press install button (Item 5) and hold until LED stays on.
NOTE: 4. 5. 6.
When link is powered down, power is turned off so there is no indication on LED.
LED stays on until communication is established with RCL receiver.
On RCL configuration screen (see Load/Limiter Alarm) set drums not used with configuration to Not Used. Select drums being used and enter in link Network ID (see Load Link Sensor Calibration Procedure). After 30 seconds link communication should be established. Check that selected link LED is off.
2
1
P2204
To replace batteries: 1.
Lower boom/jib or load line to ground to access link.
2.
Remove screws from battery pack (Item 4) of indicated link.
3.
Lift off cover and remove existing batteries.
4.
Replace with six D size batteries.
5.
Reinstall battery pack cover on link.
6.
Screw battery pack cover to link.
4
1 2 3 4 5 6 7
Description RCL Load Link Battery Pack Cover Power/Install Cover D-Cell Batteries Install Button Power Button LED
5
7
Item
3
VIEW A Link With Covers Installed
2
P2205
When the low battery threshold of a link is reached, a message is displayed to indicate that the link battery pack must be replaced soon.
3
6 VIEW B Link With Covers Removed
P2206
VIEW C Power/Install Buttons
FIGURE 12
F2108-12
RATED CAPACITY INDICATOR/LIMITER OPERATION
Wireless Load Link - PN A04237 or A04689 See Figure 13 for items in this procedure. The power is turned off when a new wireless load link is shipped from the factory. To turn the load link power on, proceed as follows: 1.
Remove battery pack cover (Item 6) from link (Item 1).
2.
Turn cover over (View B).
3.
Connect plug (Item 4) to receptacle inside link.
4.
Move switch (Item 2) to ON (use pencil to move white switch).
NOTE
Not all battery packs have switch B.
5.
Move switch (Item 3) to RUN.
6.
Check that batteries are properly installed and secured in holders with straps.
7.
Securely reinstall battery pack cover when link is operating correctly.
1
Replacing Batteries in Link (PN A04237 or A04689) See Figure 12 for items in this procedure. Load links transmit counts to the receiver on boom. The receiver sends load information to boom node controller and master node controller. When the low battery threshold of a link is reached, a message is displayed to indicate that the link battery pack must be replaced soon. To replace batteries: 1.
Lower boom/jib to ground to access links.
2.
Remove screws from battery pack side of indicated link.
3.
Lift off cover and remove existing batteries.
4.
Replace with two D size and two 9 volt batteries (Item 5).
NOTE
Some past production links do not have 9 volt batteries.
5.
Reinstall battery pack cover on link.
6.
Screw battery pack to link.
P2037
2
VIEW A
P2034
VIEW C
3
6
5
+ + 4
+ – P2036
+
VIEW D
– 9-volt Batteries (not on all links)
Item P2035
VIEW B
1 2 3 4 5 6
Description Load Link Switch B - ON Switch C - RUN Plug A D-Cell Batteries Battery Pack Cover
FIGURE 13
F2108-13
RATED CAPACITY INDICATOR/LIMITER OPERATION
F2108-14
TABLE OF CONTENTS Definitions .........................................................................2 General .............................................................................2 Rated Capacity Indicator/Limiter Components..................3 1 – RCL Display .........................................................3 2 – Main Display .........................................................3 3 – Warning Light .......................................................3 4 – Caution Light ........................................................3 5 – Display Touchpad Controls ..................................3 6 – Display 1 / Display 2 Buttons ................................3 7 – Enter / Exit Buttons ...............................................3 8 – Confirm Button .....................................................4 9 – Select Buttons ......................................................4 10 – Master Node Controller ......................................4 11 – RCL Receiver .....................................................4 12 – Boom Node Controller ........................................4 13 – Boom Angle Sensor............................................4 14 – Jib Node Controller.............................................4 15 – Luffing Jib Angle Sensor.....................................4 16 – Load Sensing Link ..............................................4 RCL Display Format..........................................................4 Screen Prompts .........................................................4 Menu Screen.....................................................................4 To Set a Number ...............................................5 Working Screen ................................................................5 Configuration Screen ........................................................6 Selecting Crane Configuration Items..........................6 Selecting Crane Configuration ...................................7 Calibration Screen ............................................................7 Angle Sensor Calibration Procedure ..........................8 Calibrate Boom or Luffing Jib ..............................8 Load Sensor Calibration Procedure ...........................8 Calibrate a Load Sensor......................................9 Diagnostics Screen .........................................................10 Camera Screen (Optional) ..............................................10 Load Link Installation ......................................................11 Wireless Load Link - PN A15345..............................11 Hard Wired Load Link - PN A15487................... 11 Replacing Batteries in Link (PN A15345) .......... 11 Wireless Load Link - PN A09683..............................12 Replacing Batteries in Link (PN A09683) ..........12 Wireless Load Link - PN A04237 or A04689 ............13 Replacing Batteries in Link (PN A04237 or A04689) 13
© 2006 Manitowoc Updated: 04-11-2006
F2108-1
RATED CAPACITY INDICATOR/LIMITER OPERATION
DEFINITIONS
GENERAL
Rated Capacity Indicator (RCI) — is a system of devices which automatically provides an audible/visual signal when the actual load approaches, reaches and/or exceeds the rated capacity value when applied to crane.
The purpose of this publication is to provide qualified operators with operating instructions for the Manitowoc RCL. The system is designed to aid the operator in identifying overload conditions, which can cause structural failure of the boom and jib or loss of stability (tipping).
Rated Capacity Limiter (RCL) — is a system of devices which automatically provides an audible/visual signal when the loading conditions approaches, reaches and/or exceeds the rated capacity value when applied to crane. When the actual load exceeds the rated capacity, the system supplies a signal to disable system. NOTE:
In this publication the Rated Capacity Indicator and Limiter information is combined, with the initials RCL representing both systems.
The limiter is turned on/off in RCI Fault Response Data Box on Configuration Screen. Fault response options are not allowed in some countries. In most of Europe it is illegal to disable the RCL alarms and limiter shut down. The fault responses can not be turned off if the crane has been programmed for use in these countries. If the RCL crane function lockout is enabled, the controller disables the following crane functions until the overload condition is corrected: •
Hoist up.
•
Boom down (or up if boom is raised above its maximum chart angle).
•
Luffing jib down (or up if jib is raised above its maximum chart angle).
WARNING Overload Hazard! The RCL has been installed on crane to aid operator. Presence of RCL on crane in no way substitutes for, or lessens, requirement that operator knowledge, experience, and judgment are required to ensure safe operation of crane. If RCL is not configured correctly, it will not properly sense load and alert operator to overload conditions. Before u s in g R C L , o p e r a t o r sh a ll r e a d a n d u n d e r s ta n d instructions in this publication.
F2108-2
The RCL GUI (Graphic Interface) screen is mounted on the front console in the operator’s cab. The graphic icons are designed to be universal for all languages. English or metric values are determined by the program number, typically English for domestic (USA) and metric for foreign countries. The RCL monitors signals from the load and angle sensors. These signals determine the loads suspended from the crane and the distance (radius) of each load from the centerline of rotation. The load and radius information for each drum is compared to the selected capacity charts and a total rated capacity of the crane is calculated. A rotating amber light and continuous tone horn are mounted on the outside of the operator’s cab to alert job site personnel to an overload or tipping condition.
RATED CAPACITY INDICATOR/LIMITER OPERATION
D16 RCL-1
1
3
2
4
13
10
11 12
16
5
6
9
7 8
Item 1 2 3 4 5 6 7 8
7
16
16
15
14
6
Description RCL Display Main Display Warning Light Caution Light Display Touchpad Controls Display 1 / Display 2 Buttons Enter / Exit Buttons Confirm Button
Item 9 10 11 12 13 14 15 16
Description Select Buttons Master Node Controller RCL Receiver Boom Node Controller Boom Angle Sensor Jib Node Controller Jib Angle Sensor Load Sensor Links and Transmitter
FIGURE 1
RATED CAPACITY INDICATOR/LIMITER COMPONENTS See Figure 1 for the following items. The RCL system is an electronic and mechanical load sensing system consisting of the following components:
1 – RCL Display The RCL display is on the left side of front console.
2 – Main Display The Main display is on right side in the front console. Some diagnostic information related to RCL operation is available on this display. See Section 3 in crane Operator’s Manual for operating instructions.
3 – Warning Light
D16 RCL-2
FIGURE 2
Glows red and an alarm comes on to alert the operator to an overload condition.
6 – Display 1 / Display 2 Buttons
4 – Caution Light
Use to choose which display is controlled by buttons 7, 8, and 9 below. The RCL is display 1 (See Figure 2).
Glows yellow and an alarm comes on to alert the operator to an approaching overload condition.
7 – Enter / Exit Buttons
5 – Display Touchpad Controls Contains all the screen controls required to operate the RCL and Main display screens.
Use these red Enter/Exit buttons to enter or exit a screen or to change the screen’s operating level. Use the red Enter button to enter a screen or go to the next screen level. Use the red Exit button to exit a screen or level. F2108-3
RATED CAPACITY INDICATOR/LIMITER OPERATION
8 – Confirm Button Use purple Confirm button to start certain test routines from the screen and to confirm data when required.
•
The RCL Display is item 1 and the Main Display is item 2.
•
The purple confirm prompt appears when the operator must start certain test routines from the screen and to confirm data when required.
9 – Select Buttons Use these green Select buttons to select screen images, icons or data boxes, and values or icons within data boxes.
MENU SCREEN
10 – Master Node Controller
See Figure 3 for following procedure.
Receives and sends information to and from all node controllers and the RCL display. The master node contains the main RCL program and all capacity chart data.
The Menu screen is the base screen for the RCL system. All other screens must be entered form this screen. Exiting from any screen will return to the Menu screen. The Menu screen show five icons and a data box.
11 – RCL Receiver
D16 RCL-3
2
1
6
RCL Receiver at boom top receives input signals from load link transmitters.
12 – Boom Node Controller Contains the boom angle sensor. Boom node controller sends the boom angle sensor signal to the master node controller.
13 – Boom Angle Sensor Boom angle sensor is located in the boom node controller. Sensor output is read by the boom node’s microprocessor.
14 – Jib Node Controller Controls the luffing jib angle sensor. Jib node controller sends the luffing jib angle sensor signal to the master node controller. 3
4
15 – Luffing Jib Angle Sensor Luffing Jib angle sensor is located in the jib node controller. Sensor output is read by the jib node’s microprocessor.
16 – Load Sensing Link Load links are attached either to wire rope dead ends or at the weight ball for single-part lines. Load links transmit signals to the RCL receiver.
RCL DISPLAY FORMAT Basic components for the Manitowoc RCL display is the Working, Configuration, Diagnostic, Calibration, Camera, and Number screens that are entered from the Menu screen. Exiting any of these screens will return to the Menu screen. The appearance and function of each screen depends on the screen level . Some screen levels show icons and/or data boxes that can be selected and used to change RCL parameters and/or to enter different screen levels.
FIGURE 3
Items shown on the Menu screen: 1.
Working Screen icon
2.
Configuration Screen icon
3.
Diagnostic Screen icon
4.
Calibration Screen icon
5.
Camera Screen icon
6.
Number data box
The Menu screen operates on two levels:
Level 1 — Selected screen icon or number data box is highlighted blue. Level 2 — number data box is highlighted red. To enter any of the five RCL screen listed above: 1.
In Level 1, use Select buttons to highlight icon that represents the screen to be entered.
2.
Press the Enter button to go to Level 2.
Screen Prompts
NOTE:
Screen prompts can appear on a selected screen if a fault condition exist or to prompt or confirm certain operator actions when required by the system. Prompt descriptions and icons are shown below.
3.
F2108-4
5
If screen is number protected and correct number is not set, the number data box is highlighted blue and the screen remains at Level 1.
Menu screen appears.
RATED CAPACITY INDICATOR/LIMITER OPERATION
To Set a Number
4.
luffing jib length (if configured with a luffing jib).
5.
Fixed jib length and offset (if configured with a fixed jib).
6.
Counterweight and stinger length (if configured with a Max-Er attachment).
7.
Optional Max-Er icon appears attachment is part of configuration.
8.
Linepull limit for load drum currently in use.
WORKING SCREEN
9.
Line parts for load drum currently in use.
See Figure 4 for following procedure.
10. Distance (radius) from center line of rotation to the center line of the load block or weight ball or the load drum currently in use.
1.
In Level 1, use Select buttons to highlight the number data box.
2.
Press Enter button to go to Level 2.
3.
Use Select buttons to set the number.
4.
Press Exit button to return to Level 1.
T h e Wo r k i n g s c r e e n s h o w s a l l t h e l o a d , c a pa ci t y, configuration, and rated capacity information required for operation of the crane. At start-up the RCL shows the Working screen. Press the purple Confirm button to acknowledge that capacity chart and basic crane configuration is correct before operating any drum. If the Confirm button is not pressed, drum operation in a direction that increases rated capacity will produce a RCL fault. A number is not required to enter the Working screen.
1.
Image of the basic crane configuration. The selected basic crane configuration determines the operating mode of the crane.
2.
Capacity chart number and selected capacity deduct for the load drum currently in use. 2
D16 RCL-4
13. Load and tare data box — shows suspended load and tare value for drum currently in use. NOTE:
12
4 13
5 6
3.
Tare is a visual aide only and does not effect the rated capacity calculation of the RCL. Rated capacity is always determined from the entered tare plus displayed load. To adjust the tare: a.
Press Enter button to go to Level 2.
b.
Use Select buttons to set the tare.
c.
Press Exit button to return to Level 1.
9
15
14. Capacity is the capacity chart’s maximum allowable load for the drum currently in use. Displayed capacity is always the least of the Manitowoc capacity chart or rope linepull limit. 15. Rated capacity triangle shows total rated capacity of the crane. The size of triangle increases as rated capacity of crane increases. Portions of triangle change color if rated capacity increases to the caution or maximum level:
11
1
8
Tare is a load value that is subtracted from displayed load so the operator can easily view load differences. For example: the weight of the hook block can be entered as a tare. The displayed load then shows only the weight suspended from hook.
10
3
7
Max-Er
12. Luffing jib angle (if configured with a luffing jib).
Level 1 — Load / tare data box (item 12) highlighted blue. The following items correspond to call outs in Figure 4.
a
11. Boom angle.
The Working screen operates on two levels:
Level 2 — Load / tare data box (item 12) highlighted red.
when
14
FIGURE 4
-
Green — indicates that rated capacity is at a safe level.
-
Yellow — indicates that rated capacity is now approaching the maximum level.
-
Red — indicates that rated capacity has exceeded the maximum level.
Boom length and luffing boom chart angle (if configured with a luffing jib).
NOTE:
When crane has a luffing jib, the RCL system automatically selects a capacity chart with a boom angle that closely matches the actual luffing jib boom angle. The capacity is de-rated if the actual luffing boom angle is too far from the selected chart’s boom angle. F2108-5
RATED CAPACITY INDICATOR/LIMITER OPERATION
CONFIGURATION SCREEN
6.
See Figures 5, 6, and 7 for following procedure. The Configuration screen sets the basic crane configuration and the individual RCL parameters for each load drum. A number may be required to enter the Configuration screen.
Load Sensor Data Box — selects load link TXID (6a). If a hard wired load link is used on boom or jib top, link point position – 1, 2, 3, or 4 must be selected (6b). Press the Enter button to go to Level 5 and select load link TXID.
NOTE: 7.
The Configuration screen contains data boxes and icons and operates on five levels.
Level 1 — Crane configuration image and icon shown. Crane configuration icon is highlighted red. Level 2 — Crane configuration image and drum data box shown. Drum data box is highlighted red. Level 3 — Crane configuration image and all data boxes shown. Selected data box is highlighted blue.
Some configurations do not require a load sensor.
RCL Fault Response Data Box — sets the RCL system’s response to an overload condition for the drum being configured. Symbols representing lockout, lamps, and audible alarms are shown in data box. The lockout area is blank if lockout (limiter) is turned off. The lamps and audible alarm area is blank if lamps and alarms (indicator) is turned off. Press Enter button to go to Level 4 to turn lockout on/off and select lamp/alarms on/off. Fault response options are not allowed in some countries and it is illegal to disable the RCL alarms and limiter shut down. The fault responses can not be turned off if crane is programmed for use in these countries.
Level 4 — Crane configuration image and all data boxes shown. Selected data box is highlighted red. Level 5 — Crane configuration image and all data boxes shown. Load sensor data box is highlighted green.
A fourth symbol for declaring the Drum Not Used is also selected in this box. All drums must be configured or declared not used when an RCL system is initially configured.
Selecting Crane Configuration Items The following items correspond to call outs in Figure 5. 1.
2.
1
Chart Number Data Box — selects the capacity chart for the load drum being configured. Once the basic crane configuration is selected, only capacity charts for that configuration can be selected in this box. Maximum capacity is always the least of the Manitowoc capacity chart or rope linepull limit.
2
7
8 10
Capacity Deduct Data Box — selects a deduct to the capa city chart (if required) for load drum being configured.
3 9
5 11
4
WARNING
6b
Tipping or Structural Hazard! Crane can be overloaded if deducts are not entered into RCL configuration screen. The RCL does not automatically include any deducts to stated capacity on Manitowoc charts. If a deduct is required, it must be manually set here to be included in the rated capacity calculation. See Manitowoc capacity chart in use to determine if a deduct is required. 3.
Chart Configuration Data Box — sets the specific crane configuration data — boom lengths, jib lengths, fixed jib, offsets for the load drum being configured and optional Max-Er counterweight/stinger length.
4.
Line Parts Data Box — selects the parts of line for the load drum being configured.
5.
Line Pull Limit Data Box — sets the single line pull limit for the load drum being configured.
NOTE:
F2108-6
Check the capacity chart Wire Rope Specification to determine the line pull limit.
D16 RCL-5
FIGURE 5
12 6a
8.
Upper Boom Point Data Box — selects upper boom point if part of basic crane configuration. This data box tells the RCL an upper point is being used by the drum being configured. If no upper point is possible, this box is grey and can not be selected.
9.
Drum Data Box — selects load drum configuration.
10. Crane Configuration Icon — configuration screen is selected.
indicates
crane
11. Crane Configuration Image — displays selected crane configuration (model 16000 shown in Figure 5). 12. Max-Er Icon — appears when optional Max-Er is configuration is selected.
RATED CAPACITY INDICATOR/LIMITER OPERATION
Selecting Crane Configuration
CALIBRATION SCREEN
See Figure 5, 6, and 7 for following procedure.
See Figure 8 for following procedure.
To configure the RCL:
The Calibration screen calibrates the load and angle sensors in RCL system. RCL configuration should be selected before calibrating any sensor. A number may be required to enter the Calibration screen. The Calibration screen has data boxes and operates on two levels.
1.
Press Enter or Exit buttons as required to go to Level 1. The crane configuration icon appears (see Figure 6).
2.
Use Select buttons to set the crane image that matches the current basic configuration.
NOTE:
The basic crane configuration set here determines crane operating mode.
Level 1 — Selected data box is highlighted blue. Level 2 — Selected data box is highlighted red. NOTE:
D16 RCL-6
Crane Configuration Icon
Crane Configuration Image
FIGURE 6 3.
Press Enter button to go to Level 2. Use Select buttons to highlight the load drum to be configured in drum data box (see Figure 7).
D16 RCL-7
The proper capacity chart and Configuration screen mu st be ena ble d befo re p erfo rming calibration procedures.
RCL calibrations should be checked frequently and should always b e che cke d be fo re an y n e ar-capaci ty lifts. Calibrations should be performed at the following intervals: •
First time using any load or angle sensor.
•
When any displayed angle is found to be in error by more than 2 degrees.
•
When any displayed load is found to be in error by more than 4 percent of capacity chart.
•
Yearly.
The following items correspond to call outs in Figure 8. 1.
Sensor data box — selects the load sensor or angle sensor to calibrate.
2.
Boom angle symbol — appears when a boom angle sensor is selected to calibrate.
3.
Luffing jib angle symbol — appears when a luffing jib angle sensor is selected to calibrate.
4.
Slope data box — shows slope calibration constant for the sensor being calibrated. This number should be recorded after a calibration. If the system loses calibration this constant can be manually restored in the slope data box. Do not alter the value in this data box unless restoring a lost calibration. 8 1 3 9
FIGURE 7 4.
When boom and load drum configuration is selected, press Enter button to go to Level 3.
5.
The complete crane configuration image screen appears as shown in Figure 5.
NOTE:
12
10 2
4 11
The RCL system will not allow capacity critical RCL parameters to be altered if any configured load sensor indicates a significant load on the hook.
6
6.
Only one load drum can be configured at a time. Press Exit button as required to return to Level 2
7
7.
Repeat above steps for all load drums.
D16 RCL-8
5
FIGURE 8
F2108-7
RATED CAPACITY INDICATOR/LIMITER OPERATION
5.
Intercept data box — shows intercept calibration constant for the sensor being calibrated. This number should be recorded after a calibration. If the system loses calibration this constant can be manually restored in the intercept data box. Do not alter the value in this data box unless restoring a lost calibration.
6.
High calibration data box — select to enter high calibration data.
7.
Low calibration data box — select to enter low calibration data.
8.
Distance (radius) — from center line of rotation to center line of load block or weight ball for load drum currently in operation. If crane is configured and the radius is known, radius can be used to calibrate angle sensors.
9.
NOTE:
6.
If calibrating with radius, use Select buttons to adjust displayed radius until it is same as known value. Or use Select button to adjust angle displayed in low calibration data box until it is same as the known boom or jib angle.
7.
Press Exit button to return to level 1.
8.
Use Select buttons to highlight high calibration data box.
9.
Position boom or luffing jib at a high angle. Press Enter button to go to level 2.
NOTE:
Line parts — Select for load sensor being calibrated.
10. Drum image — highlights load drum associated with load sensor being calibrated. 11. Crane configuration — image shows basic crane configuration. 12. Sensor status — shows state of the angle sensor.
Satisfactory angle calibrations can be completed with a range of low boom and jib angles. Best results are obtained with low angle set between 10 and 20 degrees.
Satisfactory angle calibrations can be completed with a range of high boom and jib angles. Best results are obtained with high angle set between 75 and 82 degrees.
10. If calibrating with radius, use Select buttons to adjust displayed radius until it is same as known value. Or use Select b utt on to a djust an gle disp layed in hig h calibration data box until it is same as the known boom or jib angle.
Angle Sensor Calibration Procedure
11. Press Exit button to return to level 1.
See Figure 8 for following procedure.
12. Record values shown in slope and intercept data boxes. Do not alter the value in this data box unless restoring a lost calibration.
The boom angle sensor calibrations can be performed in any order. It is not always necessary to do both low and high calibrations. For example, if the low calibration is known to be accurate only the high calibration should be performed. Measure angle with an accurate angle indicator on the centerline of the boom butt or by measured radius. If using radius to calibrate luffing jib angle sensor, boom angle must be calibrated first. Operating status of the selected load link sensor is displayed with icons on right side of screen: •
Selected angle sensor is operating normal if icon arrow is pointing to center of ± load bar.
•
Selected angle sensor is out of limits and has failed low if the icon arrow is pointing to minus end of load bar. The sensor must be replaced.
•
Selected angle sensor is out of limits and has failed high if the icon arrow is pointing to plus end of load bar. The sensor or wiring is faulty.
Calibrate Boom or Luffing Jib
Values shown in slope and intercept data boxes are the system’s internal calibration constants for selected sensor. If the system loses calibration these values can be manually restored in the slope and intercept data boxes. To restore slope and intercept calibration constants perform the following: a.
In level 1, use Select buttons to highlight slope or intercept data box.
b.
Press Enter button to go to level 2.
c.
Use Select buttons to adjust the value to previously recorded value.
d.
Press Exit button to return to level 1.
13. All calibrations are locked in when exiting back to level 1. If engine is shut down while at level 2 any new calibrations performed are lost and system reverts to last known calibration.
Load Sensor Calibration Procedure
1.
In level 1, use Select buttons to highlight sensor data box. Press Enter button to go to level 2.
2.
Use Select buttons to choose angle sensor to calibrate.
3.
An angle sensor with ID number 1 is boom angle sensor. ID number 2 is a luffing jib angle sensor.
It is not alwa ys nece ssa ry to d o b oth low an d hig h calibrations. Normally wireless load links only require a low calibration.
4.
Press Exit button to return to level 1. Use Select buttons to highlight low calibration data box.
NOTE:
5.
Position boom or luffing jib at low angle. Press Enter button to go to level 2.
Operating status of the selected load link sensor is displayed with icons on right side of screen:
F2108-8
See Figure 9 for following procedure.
Hard wired load links are calibrated the same as wireless load links.
RATED CAPACITY INDICATOR/LIMITER OPERATION
•
Selected link sensor is operating normal if blue antenna icon is displayed.
•
4.
Lift a light load and press Enter button to go to level 2.
NOTE:
Selected link sensor is not being received if yellow antenna icon has a red X through it. 5.
Use Select buttons to adjust load displayed in low calibration data box until it is same as known lifted load.
6.
Press Exit button to return to level 1.
7.
Record values shown in slope and intercept data boxes. Do not alter the value in this data box unless restoring a lost calibration.
Calibrate a Load Sensor 1. 2.
In level 1, use Select buttons to highlight sensor data box. Press Enter button to go to level 2.
Satisfactory Load calibrations can be completed with a range of light loads. Best results are obtained with line pulls between 3 to 10 percent of rated line pull.
Use Select buttons to choose load drum sensor to calibrate. Crane image shows load drum sensor (see Figure 9).
Values shown in slope and intercept data boxes are the system’s internal calibration constants for selected sensor. If the system loses calibration these values can be manually restored in the slope and intercept data boxes. To restore slope and intercept calibration constants perform the following:
8.
D16 RCL-9
3.
FIGURE 9
a.
In level 1, use Select buttons to highlight slope or intercept data box.
b.
Press Enter button to go to level 2.
c.
Use Select buttons to adjust the value to previously recorded value.
d.
Press Exit button to return to level 1.
All calibrations are locked in when exiting back to level 1. If engine is shut down while at level 2 any new calibrations performed are lost and system reverts to last known calibration.
Press Exit button to return to level 1. Use Select buttons to highlight the low calibration data box.
F2108-9
RATED CAPACITY INDICATOR/LIMITER OPERATION
DIAGNOSTICS SCREEN
3.
RCL state field — shows green and yellow triangular area that is a graphic representation of a capacity chart. Drum symbols shown in this field indicate radius and load state for each drum. Any drum symbols outside this field indicate that load drum is either off-chart, overcapacity, or both.
4.
Rated capacity triangle box — shows total rated capacity level of the crane. The size of the triangle increases as rated capacity increases. Portions of the triangle change color if rated capacity increases to caution or maximum level. Green indicates that rated capacity is at a safe l e v e l . Ye l l o w i n d i c a t e s t h a t r a t e d c a p a c i t y i s approaching the maximum level. Red indicates that rated capacity has exceeded the maximum load level.
5.
Sum state box — show a diagnostic number indicating flash memory status. The sum state indicates the information shown in Table 1.
See Figure 10 for following procedure. The diagnostic screen shows the overall state of RCL system as configured. Only sensors and data related to the configured system are shown. The diagnostic screen is viewonly and contains no selectable Icons or data boxes. A number is not required to enter diagnostic screen. The diagnostic screen operates on one level only. D16-RCL-10
4
1
3
Table 1 Sum State Numbers
2
Number
5
DIAGNOSTIC SCREEN
Description
0
Status Normal
1
Flash Entry Error (Chart Data)
2
Flash Entry Error (Capacity Data)
4
Configuration Data is not Confirmed
8
Calibration Data is not Confirmed
FIGURE 10
The following items correspond to call outs in Figure 10.
CAMERA SCREEN (OPTIONAL)
1.
Load sensor boxes — shows all load sensors that were configured to drums. Each box shows a symbol that identifies associated drum, signal from sensor, and individual rated capacity of the sensor.
The camera screen (not shown) displays camera options and items for selecting and operating. The camera option includes up to three different cameras to monitor drum spooling and back of crane.
2.
Angle sensor boxes — shows configured angle sensors. Each box shows a symbol that identifies sensor location as well as signal from sensor.
NOTE:
The camera screen is not available where Federal, State, or local laws prohibit the use of a camera screen operating on a RCL screen.
Use Select buttons to select camera screen the Menu screen. Press Enter button to access screen. Use Select buttons to select desired camera view. To exit screen, press Exit button until Menu screen appears.
F2108-10
RATED CAPACITY INDICATOR/LIMITER OPERATION
LOAD LINK INSTALLATION
8.
Check the part number on the load link to be installed and follow the procedure for that specific load link.
Replacing Batteries in Link (PN A15345)
A wireless load link is installed at the weight ball and a hard wired load link is normally installed at the boom top or jib top. NOTE:
If a wireless load link is attached to boom/jib top dead end, the antenna (opposite side of covers) must be facing toward crane.
Wireless Load Link - PN A15345 See Figure 11 for items in this procedure.
Replace power switch cover when link is operating correctly.
See Figure 11 for items in this procedure. Load links transmit counts to the receiver on boom. The receiver sends load information to boom node controller and master node controller. When the low battery threshold of a link is reached, a message is displayed to indicate that link battery pack must be replaced soon. To replace batteries:
The power is turned off when a new wireless load link is shipped from the factory. To turn load link power on, proceed as follows:
1.
Lower load line to ground to access link.
2.
Remove screws from battery cover (Item 4) of link.
1.
Remove power switch cover (Item 2) from link.
3.
Lift off cover and remove existing batteries.
2.
Press power on/off button (item 5). When link is powered up, red LED (Item 7) turns on for about one second.
4.
Replace with six D size Alkaline batteries.
5.
Reinstall battery pack cover on link.
3.
On RCL configuration screen (see Load/Limiter Alarm) set drums not used with configuration to Not Used.
6.
Screw battery pack cover to link.
4.
Select drums being used and enter in link Network ID (see Load Link Sensor Calibration Procedure).
5.
After 30 seconds link communication should be established.
6.
If link is not installed correctly a wireless system fault appears.
7.
Test switch is for testing communication between link and receiver. (factory use only). 3
P2341
Hard Wired Load Link - PN A15487 See Figure 11 for items in this procedure. Install wired link (Item 9) at boom top or jib top dead end with cable connector facing toward crane. Connect cable between boom or jib top node and hard wired link.
A15487
5
4 VIEW B Link with covers removed
8 2 Item
1
P2340
VIEW A Link With Covers Installed
1 2 3 4 5 6 7 8 9
Description Wireless Load Link ( Battery Pack Cover Six D-Cell Batteries Power Button Cover Power Button Test Switch (factory use only) Red LED Antenna (under cover) Hard Wired Link (boom/jib top)
7
6 9
VIEW C Hard Wired Link
FIGURE 11
F2108-11
RATED CAPACITY INDICATOR/LIMITER OPERATION
Wireless Load Link - PN A09683
NOTE:
See Figure 12 for items in this procedure. The power is turned off when a new wireless load link is shipped from the factory. To turn the load link power on, proceed as follows:
7.
If link is not installed correctly a wireless system fault appears.
Replace power/install cover when link is operating correctly.
Replacing Batteries in Link (PN A09683)
1.
Remove power/install cover (Item 3) from link.
See Figure 12 for items in this procedure.
2.
Press power on/off button (item 6). When link is powered up, LED (Item 7) turns on for about one second.
Load links transmit counts to the receiver on boom. The receiver sends load information to boom node controller and master node controller.
NOTE: 3.
Press install button (Item 5) and hold until LED stays on.
NOTE: 4. 5. 6.
When link is powered down, power is turned off so there is no indication on LED.
LED stays on until communication is established with RCL receiver.
On RCL configuration screen (see Load/Limiter Alarm) set drums not used with configuration to Not Used. Select drums being used and enter in link Network ID (see Load Link Sensor Calibration Procedure). After 30 seconds link communication should be established. Check that selected link LED is off.
2
1
P2204
To replace batteries: 1.
Lower boom/jib or load line to ground to access link.
2.
Remove screws from battery pack (Item 4) of indicated link.
3.
Lift off cover and remove existing batteries.
4.
Replace with six D size batteries.
5.
Reinstall battery pack cover on link.
6.
Screw battery pack cover to link.
4
1 2 3 4 5 6 7
Description RCL Load Link Battery Pack Cover Power/Install Cover D-Cell Batteries Install Button Power Button LED
5
7
Item
3
VIEW A Link With Covers Installed
2
P2205
When the low battery threshold of a link is reached, a message is displayed to indicate that the link battery pack must be replaced soon.
3
6 VIEW B Link With Covers Removed
P2206
VIEW C Power/Install Buttons
FIGURE 12
F2108-12
RATED CAPACITY INDICATOR/LIMITER OPERATION
Wireless Load Link - PN A04237 or A04689 See Figure 13 for items in this procedure. The power is turned off when a new wireless load link is shipped from the factory. To turn the load link power on, proceed as follows: 1.
Remove battery pack cover (Item 6) from link (Item 1).
2.
Turn cover over (View B).
3.
Connect plug (Item 4) to receptacle inside link.
4.
Move switch (Item 2) to ON (use pencil to move white switch).
NOTE
Not all battery packs have switch B.
5.
Move switch (Item 3) to RUN.
6.
Check that batteries are properly installed and secured in holders with straps.
7.
Securely reinstall battery pack cover when link is operating correctly.
1
Replacing Batteries in Link (PN A04237 or A04689) See Figure 12 for items in this procedure. Load links transmit counts to the receiver on boom. The receiver sends load information to boom node controller and master node controller. When the low battery threshold of a link is reached, a message is displayed to indicate that the link battery pack must be replaced soon. To replace batteries: 1.
Lower boom/jib to ground to access links.
2.
Remove screws from battery pack side of indicated link.
3.
Lift off cover and remove existing batteries.
4.
Replace with two D size and two 9 volt batteries (Item 5).
NOTE
Some past production links do not have 9 volt batteries.
5.
Reinstall battery pack cover on link.
6.
Screw battery pack to link.
P2037
2
VIEW A
P2034
VIEW C
3
6
5
+ + 4
+ – P2036
+
VIEW D
– 9-volt Batteries (not on all links)
Item P2035
VIEW B
1 2 3 4 5 6
Description Load Link Switch B - ON Switch C - RUN Plug A D-Cell Batteries Battery Pack Cover
FIGURE 13
F2108-13
RATED CAPACITY INDICATOR/LIMITER OPERATION
F2108-14
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