Greer Company Page 1 of 27 MicroGuard 510 Retrofit Rated Capacity Indicator System Calibration and Testing for: Machine Model Serial Number Tester Date
Greer Company Page 2 of 27 Notice This document and all associated data are confidential. Copies of this document may not be distributed to third parties in any form without the prior written consent of the Greer Company and the crane manufacturer.
Greer Company Page 3 of 27 MicroGuard 510 Retrofit Rated Capacity Indicator System Table of Contents Introduction...5 Preliminary Checks...6 Boom Hoist Geometry...6 Miscellaneous Main Boom Data...7 Installation Checks...8 Pre-Tension Routine...8 Entering the Calibration Mode and Calibration Routines...8 00. Error Codes...9 01. Crane Data...9 02. Dimensions... 9-10 03. Extension Sensor...10 04. Angle Sensor...10 05. Swing Potentiometer...10 06. Pressure...11 07. /Moment... 11-12 08. Boom Deflection...13 09. Compensation...14 10. Erected Attachments...15 11. Auxiliary Head...15 12. Stowed Attachments...16 13. Digital Inputs...17 14. Enable Attachments...17 15. Enable Winches...17 16. Data Retrieval...17 17. Language Switch...17 18. Internal Data...17
Greer Company Page 4 of 27 MicroGuard 510 Retrofit Rated Capacity Indicator System Table of Contents continued Worksheets Main Boom Testing Worksheet... 18 Attachment Testing Worksheet...19 Attachment Tests...20-26
Greer Company Page 5 of 27 Introduction Congratulations on purchasing the new MicroGuard 510 Retrofit Rated Capacity Indicator System. This manual describes the calibration process for the MicroGuard 510 Retrofit System in an on-site situation, assuming that there is no prior knowledge of the geometry of the crane. This document also assists the calibration personnel in accurately obtaining the relevant measurements for the initial calibration and in developing a clear record of the measured dimensions and test results for review and/or comparison when changes are made. Recording this important data during the calibration process will ensure a structured, easy to follow calibration. Required Tools Digital volt/ohmmeter Inclinometer accurate to 0.1 (preferably a calibrated, digital style) Measuring tape (graduated in ft + 1/10 surveyor s tape) Hand tools MAX 23,500 6 i2,300 44.8 62.7 26.4 TEST ORs Full 9.7Klb Ctwt ERECTED 60' TELEJIB 17 o PICK FROM MAIN BOOM 360o AUXHD ON FRONT WINCH SET A B C D The MicroGuard 510 Display The keys that are identified above as A, B, C, and D will be used many times in the following procedures. Keys A and B are used to select from menus and to increase and decrease numeric values on the display. Key C is usually used to enter a finished number or enter a function via a menu. Key D is regularly used to exit a routine.
Greer Company Page 6 of 27 Preliminary Checks The following pages provide a list of measurements that must be double-checked for accuracy, if already in the MicroGuard 510 Retrofit System or if non-existent must be newly entered into the System. Any crane data supplied by the crane manufacturer in the crane application data sheet and stored in the crane capacity chip must be validated before calibration begins. To save time and ensure accuracy, two persons should carry out these measurements and should establish clear reference points during the measuring process. Measurements should be made using a tape graduated in 1/10 ft. Measured values should be entered in the boxes provided. Boom Hoist Geometry The boom should be in a horizontal position when measuring the distances shown below. L Boom Center Line Boom Pivot H Boom J * G Lower Pivot Upper Pivot Boom Hoist Cylinder Dimension L is the distance parallel to the boom centerline between the center of the Boom pivot and the center of the upper Boom Hoist cylinder pivot. Dimension J is the distance at 90 to the boom centerline between the center of the Boom pivot and the center of the upper Boom Hoist cylinder pivot. J is negative when the Boom pivot is above the upper Boom Hoist cylinder pivot and positive when it is below. Dimension G is the horizontal distance between the center of the Boom Pivot and the center of the lower Boom Hoist cylinder pivot. Dimension H is the vertical distance between the center of the Boom pivot and the center of the lower Boom Hoist pivot. * If the boom foot pin is above the Boom Hoist cylinder Upper Pivot (as shown in this illustration), dimension J is negative. Clearly indicate + or -.
GREER COMPANY Page 7 of 27 Miscellaneous Main Boom Data The following checks are for the main boom head sheave radius and swing offset. Swing offset is positive when the boom pivot is in front of the center of rotation, and negative when behind, as shown here. Measure the circumference of the boom hoist cylinder rod by wrapping a tape around the rod and reading the value. Enter the measured values in the boxes provided. Boom Pivot Top Sheave Boom Head Sheave Boom Hoist Cylinder Hd Shv radius Center of Rotation Swing Offset (negative) Winch Data Winch dimensions are required for compensation of moment arm created by the winch position. For winches mounted on the boom, dimensions are not required. Greer Company 1918 E. Glenwood Place, Santa Ana, CA 92705 Tel: (714) 259-9702 FAX: (714) 259-7626
GREER COMPANY Page 8 of 27 Installation Checks Check wiring and EPROM installations. Check swing switches, if fitted. Use the digital input monitor routine on the MicroGuard display to ensure that the switches operate correctly. Check the extension reel to ensure that the power spring clutch is engaged. If not, perform the pre-tension procedure below. Pre-Tension Routine Pre-Tensioning the cable ensures a steady, controlled cable line from the extension reel to the boom head. 1. Fully retract the boom. 2. Slowly rotate the Extension Reel clockwise until a click is heard, indicating that the power spring clutch inside the reel is engaged. 3. Turn the extension reel counterclockwise for 5 complete rotations. A temporary marker placed on the Extension Reel can facilitate the rotation count. 4. Physically prevent the Extension Reel from rotating until the cable is tied off on the boom head tie-off post. Entering the Calibration Mode and Calibration Routines To access the calibration routines, it is necessary to enter the Calibration Mode. To Enter the Calibration Mode, hold down the TEST and the ALARM SET keys for about 4 seconds. A message requesting the calibration entry code will appear. Use the keys to enter the following calibration code :ADBC Calibration entry is complete. If incorrectly entered, the display will return to the normal working screen. Once in the Calibration Mode, the following options are available. Use the left selection keys to display the desired option. Use the top right key to start the routine. To exit the calibration menu at any time, press the bottom right key, which will return the display to the normal working screen. 00 Error Codes Displays system information and error codes. 01 Crane Data Reset crane Personality data. 02 Dimensions Enter crane geometry and dimensions. 03 Ext n Sensor Set Zero and Span for extension sensor. 04 Angle Sensor Set Zero and Span for angle sensor. 05 Swing Potentiometer Set Zero and Direction for swing potentiometer. 06 Pressure Calibrate Lift Cylinder dimensions. 07 /Moment Calibrate and Moment of main boom. 08 Boom Defl n Calibrates Deflections for booms and attachments. 09 Compensation Sets Pressure Compensation when booming down. 10 Erected Attachments Calibrates Attachment Radii, Moments, and Dimensions. 11 Auxiliary Head Enter data for the Auxiliary Head. 12 Stowed Attachments Set dimensions for stowed attachments. 13 Digital Inputs View status of the digital inputs. 14 Enable Attachments Enable/disable attachments. 15. Enable Winches Enable/disable winches. 16 Data Retrieval View /Moment, Attachment and Pressure data. 17 Language Set Language for main display. 18 Internal Data View internal System data and variables. Greer Company 1918 E. Glenwood Place, Santa Ana, CA 92705 Tel: (714) 259-9702 FAX: (714) 259-7626
Greer Company Page 9 of 27 00. Error Codes This section allows viewing of several system operations. 1. System Error Codes (see Appendix for description). 2. Computer Serial Number (should match the number on the computer box). 3. The Crane Specific Applications File (created when the RESET key was pressed). 01. Crane Data From the calibration menu, this selection will display the status of the personality. If the system has been reset and is functionally correct, the Display will read: Personality is good. To recalibrate the entire system, the crane data Reset key MUST be pressed. This function will erase the personality memory, which stores crane specific data and dimensions; it will also copy any known data from the on-board ROM applications file to the working personality memory for use by the system. To reset crane data, simply enter the routine and confirm the reset command by pressing the keys indicated. 02. Dimensions This procedure will provide the current values for the crane dimensions listed below. Use the UP and DOWN keys to modify the displayed values. Procedure: 1. Enter Swing Offset value from worksheet. 2. Enter Ram L value from worksheet. 3. Enter Ram J value from worksheet. 4. Enter Ram G value from worksheet. 5. Enter Ram H value from worksheet. 6. Enter Rope Dimension L - winch [0] from worksheet 7. Enter Rope Dimension J - winch [0] from worksheet 8. Enter Rope Dimension G - winch [0] from worksheet 9. Enter Rope Dimension H - winch [0] from worksheet 10. Enter Rope Dimension L - winch [1] from worksheet 11. Enter Rope Dimension J - winch [1] from worksheet 12. Enter Rope Dimension G - winch [1] from worksheet 13. Enter Rope Dimension H - winch [1] from worksheet For winch dimensions, reference winch data diagram, page 7. 14. Enter Head Shv.Rad.value from worksheet. 15. Enter Rope Lim [0] maximum line pull for a single part-of-line. Enter Rope Lim [1] 16. Enter Max POL maximum parts-of-line allowed on the main boom.
Greer Company Page 10 of 27 17. Enter Scale a load multiplier, usually set to 1.0. 18. Set Offset Length between displayed value versus true value. 19. Enter New Root Length [0] Enter New Root Length [1] 03. Extension Sensor This routine is used to set the Zero and Span of the extension sensor. 1. Fully retract the boom and press the DOWN arrow key. The number next to the Zero Sensor label should go to Zero. 2. Fully extend the boom and measure the actual extension. 3. Press the UP arrow key to set the SPAN. Enter the actual extension when prompted. 04. Angle Sensor This routine is used to set the Zero and Span of the angle sensor. 1. Position the boom at 0 and press the DOWN arrow key. The number next to the Zero Sensor label should go to Zero. 2. Angle the boom up to 65-70. Press the UP arrow key to see the SPAN. Measure the actual angle with an inclinometer. Enter the new SPAN when prompted. 05. Swing Potentiometer The operator can zero the swing, set the direction, or remove the swing pot. When a duty chart cannot be found, it is usually due to an improperly calibrated swing.
Greer Company Page 11 of 27 06. Pressure The following routine uses a calibration load to compute the diameter of the hoist cylinder. Pick up calibration loads from the main boom with the computer correctly configured (i.e., winch in use, main boom, parts-of-line, etc.). If the diameter is already known or is easily measured, skip the calibration option and enter the value at the end of this routine. THIS DIMENSION IS CRITICAL AND MUST BE MEASURED TO WITHIN 1/10 th OF AN INCH. NOTE: Pressure cannot be calibrated until L, J, G, and H have been calibrated, otherwise an error message will flash on the screen during calibration. Calibration Routine 1. Examine the piston and rod-side pressures before entering the routine. Pressures can be reviewed in routine 15 Data Retrieval. The readings should show positive numbers from around 20 to 3000 PSI with the boom out of its cradle. When booming up, the piston-side reading should increase in value and the rod side value should not move. If this is not the case, switch the hydraulic hoses. 2. Enter the rod circumference from the worksheet. 3. The question, Perform Piston Dimension Calibration? will appear. If NO is selected, the system will ask for a manual entry of the piston diameter and then exit the calibration routine. 4. Enter the calibration load that will be lifted, including all shackles and hook weights. The load should be as large a mass as is safe for the crane to pick at a boom angle of around 60 and as far retracted as possible. If only small test loads are available, use a longer boom length. Example: 15550 lbs. should be entered as 15.55. 5. Pick up the calibration load and hold it steady to settle any fluctuations. Confirm the calibration. 6. Measure and enter the radius of the suspended load. 7. Set down the calibration load, allow it to settle, and then confirm the calibration. The routine will exit automatically. 8. Pick up the weight again. Check that the displayed load rises by the correct amount. The load may adjust itself a little for a few seconds. 9. Reenter the Calibration Mode and adjust, as appropriate. 07. /Moment The /Moment routine below calibrates the natural moment of the boom and the radius, taking into account its deflection under its own weight. Ensure that the boom configuration is set correctly, without erected attachments and the correct stowed attachments selected. If calibrating with a stowed attachment, check the relevant stowed data entered into the system via the 12-Stowed Attachments routine BEFORE calibrating the main boom.
Greer Company Page 12 of 27 07. /Moment continued Up to seven points may be stored; these points must include fully retracted and fully extended booms. Intermediate points should identify individual sections of the boom starting to telescope and/or other sections of the boom that stop telescoping as the boom is extended. For booms that exhibit an appreciable amount of flexibility or droop, it may be necessary to include an extra point to improve accuracy, especially if there is a long distance between obvious points of calibration. This is usually pertinent for long proportional booms, which may require a fully retracted and fully extended calibration. Some booms exhibit a sudden droop when nearing full expansion. Such a response may be due to the design and fitting of wear pads inside the boom, which allow sections to hang on each other when nearing the fully telescoped limit. Though this has little affect on main boom radius accuracy, the radius of a fly or jib may be affected by this characteristic. It is essential, therefore, to add an extra calibration point at about 90% of the boom extension. For each extension calibration, the system requires a stable measurement of the moment (via its own pressure sensors) and radius (via the calibration personnel measurements) at both high and low boom angles. Try to pick angles of 60 to 70 for high angles and angles as close to 0 as possible for low angles. Take care to accurately measure the radius at each calibration point. Using a single partof-line will aid this. When entering the Tare load in the calibration routine, it is beneficial to add a little weight to the hook. Adding 100 pounds (or 50 Kilos) will help guarantee a slightly positive load reading in all operating configurations. Calibration Routine for /Moment 1. Determine if this will be a brand new calibration or an existing calibration with changes. A new calibration will destroy all radius moment data previously calibrated. 2. Enter the tare-load, i.e. the weight of extras added to the boom like the hook-block, and rope and shackles. If there is a block and ball hanging, add both to tare. 3. Telescope to the required length and angle. Press the OK key when ready. Enter measured radius at these points of calibration. 4. Boom to the other desired angle and confirm, as above. 5. Store the calibration using the OK key. 6. Move to the next extension or exit using the bottom right key. 08. Boom Deflection The following procedure is used to quantify the amount that a boom or attachment bends when under load. The boom has its own bending factor called F and each jib combination can have its own independent F value. Before starting the procedure, the display will show the angle of the boom head under no load and under the current load.
Greer Company Page 13 of 27 Calibration Procedure The following procedure can be used for each fly/jib combination. Simply select the combination for calibration, reenter the routine, and follow the steps below. If direct entry of the F value is desired, simply press the key next to the Edit caption, enter the number, and skip to the next section. 1. Ensure that: the crane is configured to pick off the main boom. all stowed attachments are set correctly. there are no erected or unused attachments. 2. Fully extend the boom at a high angle greater than 60. 3. Lift a suitable calibration load. The load should induce significant deflection in the boom. 4. Begin the calibration by pressing the key next to the current F value. 5. Measure the loaded main boom radius and enter the value. It is helpful to add 0.1 ft or 0.1 m to the radius when entering the radius for boom deflection. This will create a slightly positive radius in most operating conditions. 6. Ensure that the new displayed radius matches (or slightly exceeds) the actual measured radius. 7. For attachment calibrations, have the attachment erected and used but with the boom fully retracted. Then follow the above procedure.
Greer Company Page 14 of 27 09. Compensation Often loads will change drastically when booming down; this can be compensated for in this routine. Two compensation speeds are allowed: Slow rate compensation and Fast rate compensation. The actual rate of boom movement is displayed when in this routine. 1. Enter the routine. Use the Next and Previous keys to select the desired compensation rate. 2. Select the rate using the Edit key and adjust the offset value by using the Increase, and decrease key. To see the effect, move the boom down. If the effect is too small, increase the compensation. It is customary to leave the slow rate compensation as zero, or a very small number and adjust the fast rate compensation to counter the booming down effect. 3. Press the Edit Activate key again to toggle back to the rate selection mode. 4. Exit the routine using the Exit key when finished. Note: Compensation ONLY switches in when booming down.
Greer Company Page 15 of 27 10. Erected Attachments For systems without pre-calibrated fly s, perform a calibration routine on each jib configuration. Upon starting the procedure, it is possible to enter the fly parameters manually, using an editor. This method of entry can be used to enter supplied pre-calibration data and may avoid the need to perform full calibrations; it can also be used to trim calibrations that are less than perfect. For each fly/jib combination, the system must gather data about the jib moment (through the pressure sensors) and the jib radius (taken from radius measurements by crane personnel). Data must be gathered at high and low angles and for a retracted and extended main boom for EACH configuration. Calibration Routine 1. Make sure the crane is configured to be picking off the jib to be calibrated. 2. Enter the main hook weight, if there is an unused hook picking off the main boom; otherwise enter 0.0. 3. Enter the weight of the fly hook and any other shackles and rope weights suspended from the fly pick point. 4. Telescope and boom the crane to the in/out and high/low angle positions. The system should display what it thinks the configuration is e.g. Tele d IN, Low Degs indicating that the system is gathering data with a retracted boom at a low angle. If this is incorrect, use the B key to bump the system into the correct configuration. 5. Each setting will display [not calibrated] next to it if it has not been calibrated and [calibrated] if it has. 6. For each of the 4 regions, enter the measured radius. 7. After all four data regions have been mapped; use the Calibrate key to store the calibration. The system will exit to the calibration menu automatically. 11. Auxiliary Head This routine allows the critical dimensions of the auxiliary head to be entered and viewed. Press the edit key to enter the following four values in the sequence below. Auxiliary Weight Offset Angle Center of G Auxiliary Length The weight of the auxiliary head. The auxiliary weight offset angle from the boom centerline. Approximate distance along the auxiliary head to its center of gravity. The length of the auxiliary head.
Greer Company Page 16 of 27 12. Stowed Attachments Use this routine to enter data for stowed attachments. Note that this information should be entered before performing a main boom radius/moment calibration, if it is to be calibrated with an attachment stowed! The required stowed jib data can be gathered as follows: Stowed Deduction Jib Weight Stowed G Stowed T Should be written on the chart or cab plate. Weigh it! Use weight gathered during the erected attachment calibration. Refer to Data Retrieval, Item 16 in this manual. Follow the steps in the Data Retrieval Routine. Balance jib on hook to find center point, compute distance from boom pivot to this center point when jib is stowed. As an approximation, use the halfway point along the jib. See diagram below. Measure from boom pivot to the centerline of jib when stowed. This should be a few inches. The number will be negative when the jib centerline is above the boom pivot (most likely). See diagram below. Horizontal ((G) and vertical (T) distances from boom pivot to center of gravity of jib. BOOM JIB CENTER OF GRAVITY BOOM PIVOT G T Calibration Routine 1. Enter the routine. Using the Next Jib and Previous Jib keys, select the stowed attachment to be calibrated. 2. Use the Edit key to enter new values for the stowed jib. 3. Press Exit key to exit the modify routine; calibrate the additional attachment.
GREER COMPANY Page 17 of 27 13. Digital Inputs Allows operator to view only the digital input status of the system. 14. Enable Attachments Allows the operator to enable or disable any attachment. 15. Enable Winches Allows the operator to enable or disable any winch. 16. Data Retrieval Allows operator to view or edit pressure, radius/moment and fly variables. The routine will ask the operator if he wants to edit each type of data. 17. Language Switch Switches language of main display from English to Spanish. Use the NEXT and PREVIOUS keys to make a selection. 18. Internal Data Allows the Engineer to view internal variables. Greer Company 1918 E. Glenwood Place, Santa Ana, CA 92705 Tel: (714) 259-9702 FAX: (714) 259-7626
Greer Company Page 18 of 27 Main Boom Testing Worksheet Following each main boom calibration, perform a series of tests that will sufficiently show the accuracy of the calibration in all working areas of the main boom. Test the unloaded boom, two different loads at three different lengths and three different angles for each length of main boom. Boom Length Angle Measur d Error Actual Error Notes
Greer Company Page 19 of 27 Attachment Testing Worksheet Attachment & Offset Main Boom Test # Test # Length Angle Measur d Error Actual Error
Greer Company Page 20 of 27 Attachment Tests Attachment & Offset Main Boom Test # Test # Length Angle Measur d Error Actual Error
Greer Company Page 21 of 27 Attachment Tests Attachment & Offset Main Boom Test # Test # Length Angle Measur d Error Actual Error
Greer Company Page 22 of 27 Attachment Tests Attachment & Offset Main Boom Test # Test # Length Angle Measur d Error Actual Error
Greer Company Page 23 of 27 Attachment Tests Attachment & Offset Main Boom Test # Test # Length Angle Measur d Error Actual Error
Greer Company Page 24 of 27 Attachment Tests Attachment & Offset Main Boom Test # Test # Length Angle Measur d Error Actual Error
Greer Company Page 25 of 27 Attachment Tests Attachment & Offset Main Boom Test # Test # Length Angle Measur d Error Actual Error
Greer Company Page 26 of 27 Attachment Tests Attachment & Offset Main Boom Test # Test # Length Angle Measur d Error Actual Error
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