GREER Company MicroGuard 510 Retrofit Use and care manual

MicroGuard® 510
Retrofit
Rated Capacity Indicator System
Calibration

MG510R Calibration i W450256 Rev A 06/07
Contents
Introduction......................................................................................................................................................................................... 1
Required Tools................................................................................................................................................................................... 2
Number Conversion ................................................................................................................................................................ 2
The MicroGuard®510 Display.................................................................................................................................................. 3
Command Entry......................................................................................................................................................................... 3
Number Entry ............................................................................................................................................................................. 3
Preliminary Checks and Measurements............................................................................................................................... 4
Boom Pivot Dimensions......................................................................................................................................................... 4
Winch Dimensions................................................................................................................................................................... 5
Boom Cylinder Dimensions.................................................................................................................................................. 6
Span Dimensions...................................................................................................................................................................... 6
Auxiliary Head Dimensions................................................................................................................................................... 7
Stowed Jib Dimensions.......................................................................................................................................................... 7
Installation Checks........................................................................................................................................................................... 8
Attaching the Anti Two-Block (ATB) Cable and Extension Sensor Zero.......................................................... 8
Entering Calibration Data ............................................................................................................................................................. 9
Menu 00 – Error Codes..................................................................................................................................................... 10
Menu 01 – Crane Data...................................................................................................................................................... 11
Menu 02 - Dimensions........................................................................................................................................................ 13
Menu 03 - Extension Sensor ........................................................................................................................................... 14
Menu 04 - Angle Sensor .................................................................................................................................................... 15
Menu 05 - Swing Potentiometer (if equipped)......................................................................................................... 16
Menu 06 - Pressure............................................................................................................................................................. 17
Menu 07 - Radius/Moment............................................................................................................................................. 20
Menu 08 - Boom Deflection ............................................................................................................................................. 23
Menu 09 - Compensation.................................................................................................................................................. 25
Menu 10 - Erected Attachments................................................................................................................................... 26
Menu 11 - Auxiliary Head................................................................................................................................................... 28
Menu 12 - Stowed Attachments.................................................................................................................................... 29
Menu 13 - Digital Inputs..................................................................................................................................................... 30
Menu 14 - Enable Attachments...................................................................................................................................... 31
Menu 15 - Enable Winches .............................................................................................................................................. 32
Menu 16 - Data Retrieval .................................................................................................................................................. 33
Menu 17 - Language............................................................................................................................................................ 35

MG510R Calibration ii W450256 Rev A 06/07
Appendix A - Measurement Record .................................................................................................................................... A-1
Fraction to Decimal Conversion Chart ....................................................................................................................... A-5
Appendix B - Computer Troubleshooting........................................................................................................................... B-1
Computer Internal Status Indicators ......................................................................................................................... B-1
Power Indicator States and Actions............................................................................................................................ B-2
Communication Indicator ................................................................................................................................................ B-2
Start-up Problems................................................................................................................................................................ B-3
System Schematic ............................................................................................................................................................... B-4
Terminal Block Positions and Functions.................................................................................................................... B-5
Suggested Swing Connection ......................................................................................................................................... B-6

MG510R Calibration 1 W450256 Rev A 06/07
Introduction
Congratulations on choosing the new MicroGuard®510 Retrofit Rated Capacity Indicator System.
This manual describes the calibration process for the MicroGuard®Retrofit Rated Capacity Indicator
System (hereinafter referred to as “the system”) in an on-site environment and assumes that there
is no prior knowledge of the geometry of the crane other than data provided by the manufacturer.
This document also assists personnel in obtaining necessary measurements for calibration and in
maintaining a record of the measurements and test results for review and/or comparison when
changes are made. Recording measurements and test results during the calibration process will
ensure an organized and easy to follow calibration.

MG510R Calibration 2 W450256 Rev A 06/07
Required Tools
1/4” nut driver or T15 Torx driver•
Digital or bubble level calibrated and accurate to 0.1° at level•
100 foot measuring tape: fiber type graduated in tenths of feet•
.9 1 ft .1 .2
10 11 1 ft 1 2 3
1.0′
1′-0″ 1′-1″ 1′-23/4″
1.1′ 1.23′
Typical Tape Measure
graduated in inches
Tape Measure
graduated in tenths
of a foot
Note: The computer calculates measurements in feet and tenths of a foot, so having the
correct measure will facilitate entering measurements.
Digital volt/Ohm Meter capable of measurements to three decimal places•
Number Conversion
If you are using a standard tape measure, the measurement must be converted into feet and tenths
of a foot. For example: a distance of 35’–6” would be entered into the system as 35.5 feet. Whole
inches can be easily converted by dividing by 12 (6/12=.5). Fractions of an inch are converted
by dividing the numerator by the denominator. For example: 1/4 inches would be entered as .25
(1/4=.25). Conversion of whole inches and fractions of an inch (for example 6-1/4”) are converted
by first converting the fraction to a decimal and then dividing by 12. In this case 6-1/4” is converted
to 6.25 and then divided by 12 which equals 0.520. Refer to the Fraction to Decimal Conversion
Chart on page A-5.
When entering weights, the number must be converted by moving the decimal three places to the
left. For example: a weight of 1,400 pounds would be entered as 1.4, and a weight of 300 pounds
would be entered as .300.

MG510R Calibration 3 W450256 Rev A 06/07
The MicroGuard®510 Display
Command Entry
The keys that are identified as A, B, C, and Dwill be used most for the procedures described in this
document and their function will vary depending on the routine being performed. Commands for each
routine will show in the information window as text adjacent to the keys. Follow directions for each
routine carefully.
Number Entry
The display does not have a numerical keypad so when numbers are required, the display will change
to enable number entry.
Keys Band Dare used to scroll left and right. The “cursor” will appear as flashing < > brackets on
either side of the number. Key Ais used to enter the number. Key Cis used to exit the number entry
subroutine.
As each number is selected, press key Ato enter it into the system. The number will then appear
in the [ ] brackets. Up to five numbers may be entered. When entering a negative value, enter the
numbers and decimal first, then enter the minus sign. If you enter a number incorrectly, select the
< backspace and press key A. When all digits look correct, press key Cto calibrate the complete
number.
Example: To enter the value “-2.98”, do the following:
Press key1. Bor Duntil the number “2” is selected (indicated by flashing < > brackets) and then
press key Ato enter the number
Select the decimal “.” then press key2. A.
Repeat the previous steps to enter the number “9” and “8”.3.
After the numbers are entered, press key4. Bor Duntil the minus sign “-” is selected and then
press key A.
If the value is correct, press key5. Cto exit.
TEST
SET
A C
B D
TEST
SET
A C
B D

MG510R Calibration 4 W450256 Rev A 06/07
Preliminary Checks and Measurements
The following pages provide a list of measurements that must be recorded and double-checked for
accuracy. If measurements exist in the system from a previous application, or if no measurements
exist, they must be entered into the system. Any data supplied by the crane manufacturer in the
crane application data sheet stored in the system must be validated before calibration begins. All
dimensions entered into the computer must be in feet and tenths of a foot.
Boom Pivot Dimensions
Boom Pivot
Boom Hoist Cylinder
Main Boom
Boom Hoist Cylinder
Upper Pivot
Boom Hoist Cylinder
Lower Pivot
H
L
G
J
The boom should be in a horizontal position (0°) when taking the following measurements. Use the
space provided in Appendix A to record the measurements:
Dimension “L” – The horizontal distance between the center of the boom pivot and the center of the
boom hoist cylinder upper pivot.
Dimension “J” – The vertical distance between the center of the boom pivot and the center of the
boom hoist cylinder upper pivot.
Note: If the Boom Pivot is above the boom hoist cylinder upper pivot the dimension is or negative.
Dimension “G” – The horizontal distance between the center of the boom pivot and the center of the
boom hoist cylinder lower pivot.
Dimension “H” – The vertical distance between the center of the boom pivot and center of the boom
hoist cylinder lower pivot.
USE THE SPACE PROVIDED IN APPENDIX A TO RECORD THE MEASUREMENTS.

MG510R Calibration 5 W450256 Rev A 06/07
Winch Dimensions
NSwing Offset
RSheave Radius
Centerline of
Rotation
Rear Winch
(1)
Front Winch
(0) J0
J1
G1
G0
H1 H0
L0
L1
Dimension “G0” and “G1” – The horizontal distance between the center of the front and rear winch
(respectively) and the center of the boom pivot.
Dimension “H0” and H1” – The vertical distance between the center of the front and rear winch
(respectively) and the center of the boom pivot.
Dimension “J0” and J1” – The distance between the top sheave and the centerline of the boom pivot
parallel to the horizontal boom plane (measurement may be identical).
Note: If the boom pivot is above the boom hoist cylinder upper pivot as shown in the illustration,
dimension “J” will be negative. Make sure to indicate a positive (+) or negative (-) value when noting
the measurement.
Dimension “L0” and “L1” – The distance between the centerline of the boom pivot perpendicular to
the horizontal boom plane and the center of the bottom sheave (measurement may be identical).
Dimension “N” Swing Offset – The horizontal distance between the center of the boom pivot and the
centerline of rotation.
Note: If the centerline of rotation is ahead of the boom pivot as shown in the illustration, the
dimension will be negative. Make sure to indicate a positive (+) or negative (-) value when noting the
measurement.
Dimension “R” Sheave Radius – The distance between the center and the outside edge of the bottom
sheave.
USE THE SPACE PROVIDED IN APPENDIX A TO RECORD THE MEASUREMENTS.

MG510R Calibration 6 W450256 Rev A 06/07
Boom Cylinder Dimensions
M
Dimension “M” –This is the distance measured around the outside of the cylinder rod, divided by 12.
USE THE SPACE PROVIDED IN APPENDIX A TO RECORD THE MEASUREMENTS.
Span Dimensions
mWARNING
SETTING SPANS ON THE CRANE WILL REQUIRE FULL EXTENSION OF THE BOOM. MAKE SURE
THE CRANE IS SET UP ACCORDING TO THE MANUFACTURER’S OPERATION MANUAL TO
ENSURE MAXIMUM STABILITY. ALSO MAKE SURE ALL BOOM EXTENSIONS AND LOADS ARE
LIFTED WITHIN THE APPROPRIATE LOAD CHARTS AND LIMITS. FAILURE TO COMPLY WITH
MANUFACTURER’S LIMITS MAY RESULT IN SERIOUS INJURY OR DEATH.
Dimension “S” - This is the distance between the center of the boom pivot and the center of the
sheave with the boom fully retracted.
T
S
Dimension “T” - This is the dimension between the center of the boom pivot and the center of the
sheave with the boom fully extended.
The span of the boom is calculated by subtracting Dimension “S” from Dimension “T” (T - S = span).
USE THE SPACE PROVIDED IN APPENDIX A TO RECORD THE MEASUREMENTS.

MG510R Calibration 7 W450256 Rev A 06/07
Auxiliary Head Dimensions
Centerline of Boom
Auxiliary Head Main Boom
Offset Angle
X.X°
USE THE SPACE PROVIDED IN APPENDIX A TO RECORD THE MEASUREMENTS.
Stowed Jib Dimensions
G
Balanced Pick Point =
Center of Gravity
Main Boom Jib Assembly
Dimension “G” - This is the distance between the center of the boom pivot and the center of gravity of
the stowed jib.
USE THE SPACE PROVIDED IN APPENDIX A TO RECORD THE MEASUREMENTS.

MG510R Calibration 8 W450256 Rev A 06/07
Installation Checks
Check wiring and EPROM installations (see Installation Manual for wiring schematic).
Check swing switches, if fitted. Use the digital monitor screen (located under Menu 13 – Digital
Inputs) on the MG510 to ensure that the switches operate properly. Digital input information for the
wiring is located on Pages 6 and 7 in the installation guide.
TEST
SET
Attaching the Anti Two-Block (ATB) Cable and Extension Sensor Zero
Check the extension reel to ensure that the extension sensor clutch is properly set for “0”, and the
spring is properly pre-tensioned by following the procedure below:
Fully retract the boom assembly and remove the reeling drum cover.1.
Slowly rotate the extension reel clockwise until you hear a “click”, indicating that the power2.
spring clutch is engaged.
Turn the extension reel counterclockwise five (5) complete turns and physically restrain it from3.
moving.
Remove enough cable from the drum (about three wraps = 10 feet) to reach the boom tip,4.
leaving enough extra cable to reach the two-block hardwire, and relieve the strain on the cable.
Pull the extension potentiometer downward against the tension spring enough the rotate the5.
gear clockwise until the potentiometer reaches the end of the travel and the clutch drags.
Pre-tensioning of the reeling drum is complete, and the sensor clutch is properly set for6.
calibration.

MG510R Calibration 9 W450256 Rev A 06/07
Entering Calibration Data
mWARNING
WHEN THE SYSTEM IS IN CALIBRATION MODE, AUTOMATIC OVERLOAD CONTROLS ARE
DISABLED. THE CRANE OPERATOR IS RESPONSIBLE FOR PROPER LOADING OF THE CRANE
WHILE PERFORMING CALIBRATION.
To enter calibration data it is necessary to put the system in calibration mode. Once in calibration
mode, you will have five (5) seconds to enter the security key sequence.
To access calibration mode:
Hold down the1. TEST and SET keys simultaneously. The audible alarm will sound and you will
be prompted to enter the security key code.
Enter the security code in order (1, 2, 3, 4) as shown.2.
TEST
SET
MicroGuard-510
Calibration entry security.
Enter correct key sequence.
1 4
3 2
The system is now in calibration mode and ready to receive calibration data. Use the keys adjacent to
the titles “Menu Up” and “Menu Down” to scroll through the following menus:
00 Error codes – Displays system information and error codes.
01 Crane Data – Used to reset and backup the crane personality data.
02 Dimensions – Used to enter the crane geometry dimensions previously recorded.
03 Extension Sensor – Used to set the zero point and span of the extension sensor.
04 Angle Sensor – Used to set the zero point and span point for the angle sensor.
05 Swing Potentiometer – Used to set the zero point and direction for the swing potentiometer.
06 Pressure – Used to calibrate the lift cylinder dimensions and load.
07 Radius/Moment – Used to calibrate the radius and moment for the main boom.
08 Boom Deflection – Used to calibrate deflection for the main boom and attachments.
09 Compensation – Sets rod side pressure compensation when booming down.
10 Erected Attachments – Used to calibrate the radii, moments, and dimensions of erected
attachments.
11 Auxiliary Head – Used to enter the dimensions of the auxiliary head.
12 Stowed Attachments – Used to enable or disable stowed attachments.
13 Digital Inputs – Used to view the status of digital inputs.
14 Enable Attachments – Used to enable or disable attachments in the system.
15 Enable Winches – Used to enable or disable winches in the system
16 Data Retrieval – Used to view radius moment, attachments, and pressure data as needed.
17 Language – Used to set the language for main display.
With the desired menu displayed, press the key adjacent to the menu name to select.

MG510R Calibration 10 W450256 Rev A 06/07
Menu 00 – Error Codes
TEST
SET
Menu Up 00 Error Codes
View System Error Codes Information
Menu Down Exit
This menu displays error code and system information.
Press the key adjacent to either “Menu Up” or “Menu Down” until “00 Error Codes” appears in the
information window at the right.
TEST
SET
Press the key adjacent to “00 Error Codes” to enter the routine.
The following information is displayed:
System error codes1.
Computer serial number (should match the number on the label on the enclosure)2.
Press the key adjacent to “Exit” to leave the routine or, press the key adjacent to “More” to view
additional system information. The following information is displayed:
TEST
SET
Crane specific file codes3.
When you have finished, press the key adjacent to “Exit” to leave the routine.

MG510R Calibration 11 W450256 Rev A 06/07
Menu 01 – Crane Data
This menu displays the status of the personality.
TEST
SET
Press the key adjacent to either “Menu Up” or “Menu Down” until “01 Crane Data” appears in the
information window at the right.
Press the key adjacent to “01 Crane Data” to enter the routine.
TEST
SET
If the system has been reset and is functioning correctly the display will read “Personality is Good”. If
there is no crane data present, or if the system has become corrupt, the display will read “Personality
not in use”.
To reset the entire system, the crane data reset key must be pressed. This function will erase the
personality memory which stores crane specific information and dimensions. It will also copy any
known data from the system chip (ROM) applications file to the working personality memory for use
by the system.
To reset crane data, press the key adjacent to “Reset Crane Pers. Data?”
TEST
SET
Then, press the key adjacent to “Yes! Calibrate!”, or to exit without resetting, press the key adjacent
to “No, Exit/Abort”.
The system will prompt you to “Enter Cal Seq...”, this is the same key combination used to enter
calibration mode. The system will show that it is “Calibrating...”.
When it has finished, it will return to the main routine menu. The display will read “Personality is
good”, indicating a successful transfer of data.
TEST
SET

MG510R Calibration 12 W450256 Rev A 06/07
The system also contains a backup function that allows the installer/calibrator to retain a copy of the
personality information after the unit is calibrated. This system consists of the following components:
System Program Chip (ROM)1.
Battery Backed RAM2.
Personality Chip3.
To back up the personality data, press the
key adjacent to “Backup Personality to RAM
Module”.
Then, press the key adjacent to “Yes!
Calibrate!”, or to exit without resetting, press
the key adjacent to “No, Exit/Abort”.
The system will prompt you to “Enter Cal
Seq...”, this is the same key combination used
to enter calibration mode. The system will
show that it is “Calibrating...”.
Pressing the button again after calibrating the backup will take you to the “Backup Personality from
Ram mode” where you select the option and calibrate the back up.
To copy the backup file to a blank personality chip:
Turn the system off and remove the existing personality chip.1.
Install the blank personality chip.2.
Turn the system on.3.
Press the select button and enter the security code.4.
The personality data will be copied from RAM to the new chip.
Note: The backup procedure is used at the end of all calibration steps or anytime a the current
personality is desirable. A copy of the personality data should be retained in case of computer failure.
System Program Chip Battery Backed RAM Personality Chip
IC16 IC17 IC18

MG510R Calibration 13 W450256 Rev A 06/07
Menu 02 - Dimensions
This menu is used to enter the physical dimensions of the crane that were previously recorded in
Appendix A.
TEST
SET
Press the key adjacent to either “Menu Up” or “Menu Down” until “02 Dimensions” appears in the
information window at the right.
Press the key adjacent to “02 Dimensions” to enter the routine.
Press the key adjacent to “Swing Offset X.X”.
TEST
SET
Enter the value for the swing offset. The only time this measurement will be positive, is if the boom
pivot pin is in front of the center of rotation. Use the keys adjacent to the numerical values at the
bottom of the window to scroll left or right and highlight each number. Use the key adjacent to “Swing
Offset” to enter the number. When complete, the menu will automatically change to enter the next
value. To skip to the next value, press the key adjacent to “Exit”.
Note: Numbers must be entered in feet and tenths (xx.xx). Make sure to enter a negative value where
appropriate.
TEST
SET
Continue entering the remaining values. After each value is entered, the menu will automatically
change to enter the next value. When all values have been entered, the main menu will be displayed.
When you are finished, press the key adjacent to “Exit” to continue, otherwise, press the key adjacent
to “Edit” to correct any of the values entered.

MG510R Calibration 14 W450256 Rev A 06/07
Menu 03 - Extension Sensor
This menu allows for entering the zero point and span of the extension sensor that were previously
recorded in Appendix A.
TEST
SET
Press the key adjacent to either “Menu Up” or “Menu Down” until “03 Extension Sensor” appears in
the information window at the right.
Press the key adjacent to “03 Extension Sensor” to enter the routine.
Press the key adjacent to “Zero Extension? = XXX”.
TEST
SET
The extension sensor is now zeroed.
mWARNING
BEFORE EXTENDING THE BOOM, MAKE SURE THE AREA AROUND THE CRANE IS SAFE. MANY
CRANES WILL TIP OVER IF THE BOOM IS EXTENDED HORIZONTALLY!!
Press the key adjacent to “Span Extension? X.X”.
Full extend the boom and then enter the
value for the span. Use the keys adjacent to
the numerical values at the bottom of the
window to scroll left or right and highlight
each number. Use the key adjacent to “Enter
Sensor Span” to enter the number. When
complete, the menu will automatically change to the previous menu. To exit the routine without
changes, press the key adjacent to “Exit”.
Note: Measurements must be entered in feet and tenths (xx.xx). If necessary, recorded
measurements must be converted before starting.
TEST
SET
When you have finished, press the key adjacent to “Exit” to return to the main menu.
T
S

MG510R Calibration 15 W450256 Rev A 06/07
Menu 04 - Angle Sensor
This menu is used to enter the zero point and span for the angle sensor. This is done using the digital
level.
TEST
SET
Press the key adjacent to either “Menu Up” or “Menu Down” until “04 Angle Sensor” appears in the
information window at the right.
Press the key adjacent to “04 Angle Sensor” to enter the routine.
With the boom in a horizontal position, press the key adjacent to “Zero Angle? = XXX”.
TEST
SET
TEST
SET
The extension sensor is now zeroed.
Press the key adjacent to “Span Angle? X.X”.
Raise the boom until the inclinometer reads 60° or slightly higher.
Enter the value for the angle from the inclinometer. Use the keys adjacent to the numerical values at
the bottom of the window to scroll left or right and highlight each number. Use the key adjacent to
“Enter Sensor Span” to enter the number. When complete, the menu will automatically change to the
previous menu. To exit the routine without changes, press the key adjacent to “Exit”.
Note: Measurements must be entered in degrees and tenths (xx.xx). If necessary, recorded
measurements must be converted before starting.
TEST
SET
04 Angle Sensor Exit>
Enter Sensor Span [0.00 ]
<0> 1 2 3 4 5 6 7 8 9 < . -
When you have finished, press the key adjacent to “Exit” to return to the main menu.

MG510R Calibration 16 W450256 Rev A 06/07
Menu 05 - Swing Potentiometer (if equipped)
This menu is used to enter the zero point and the swing of the swing potentiometer (if equipped).
TEST
SET
Press the key adjacent to either “Menu Up” or “Menu Down” until “05 Swing Potentiometer” appears
in the information window at the right.
Press the key adjacent to “05 Swing Potentiometer” to enter the routine.
The swing potentiometer is located in the collector ring assembly under the hydraulic swivel. The job
of the potentiometer is to track the movement of the upper half of the crane all the way around the
swing circle. This function can only be zeroed in the stowed, or house lock positions, and the numbers
should count up, when rotating to the right or in a clockwise direction. If no swing potentiometer is
present, calibration is not required.
Stow the boom in “road travel” mode. Press the key adjacent to “Zero = ----”.
TEST
SET
The swing is now zeroed.
TEST
SET
Next, raise the boom out of the rest and rotate to the right. The number by “Zero = 0” should
increase. If not, press the key adjacent to “Menu Up” and then press the key adjacent to “Direction =”
and the “+” will change to a “-” and the direction will be reversed.
TEST
SET
Press the key adjacent to “Menu Up” to view the Remove Swing pot command. This command can
be used in the event you want to remove the swing pot from the system. This is usually only used as a
troubleshooting tool and is not part of the calibration routine.
TEST
SET
When you have finished, press the key adjacent to “Exit” to return to the main menu.