GREER Company MicroGuard 586 User manual

MicroGuard ® 586 RCI Operation Manual 1 W458208C 05/11
MicroGuard® 586
Rated Capacity Indicator
System
For Industrial Cranes
Operation
Manual
Consider Yourself Warned™

MicroGuard ® 586 RCI Operation Manual 2 W458208C 07/2020
Table of Contents
Introduction ......................................................................................................................... 3
System Description ............................................................................................................. 4
Operator’s Display Console ................................................................................................ 6
Warning Alarm Indicators ............................................................................................... 6
Display Windows ............................................................................................................ 6
Push Buttons ................................................................................................................. 7
System Operation ................................................................................................................ 8
System Self Test ........................................................................................................... 8
Conguration Selection ....................................................................................................... 9
Normal Operation ........................................................................................................ 10
Approaching Overload ................................................................................................. 11
Maximum Capacity and Overload .............................................................................. 12
Two Block Warning ...................................................................................................... 12
Alarm Override ........................................................................................................... 13
Adjusting the Contrast ................................................................................................ 13
System Care ................................................................................................................. 14
Routine Checks and Maintenance .............................................................................. 14
Routine Checks and Maintenance .................................................................................... 15
Reel-Off Cable ............................................................................................................. 15
Routine Checks and Maintenance .................................................................................... 16
Hydraulic Connections................................................................................................. 16
Routine Checks and Maintenance .................................................................................... 17
Checking the Two-Block Warning Signals and Cutout of Machine Motions ................ 17
Routine Checks and Maintenance..................................................................................... 18
Load Test ..................................................................................................................... 18
System Fault Messages .................................................................................................... 19
Extension Reel Voltage Checks ........................................................................................ 21
Computer Internal Status Indicators .................................................................................. 22
Computer Replacement .................................................................................................... 24

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Introduction
The MicroGuard® 586 System is designed for use as an aid to crane operation.
Note: Do not use this system in place of a properly trained operator who is knowledgeable in safety
guidelines, crane capacity information, and the crane manufacturer’s specications.
This manual describes the setup, operation, and troubleshooting of the MICROGUARD® 586
Rated Capacity Indicator/Limiter System (hereinafter referred to as “the system”). Please make sure to
read, understand, and follow the contents and instructions contained within this manual.
WARNING!
IMPROPER INSTALLATION OF THIS SYSTEM MAY RESULT IN SYSTEM MALFUNCTION!
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System Description
The system, which includes a computer, an operator’s display console, an extension reel, and various
cables and sensors; and is designed to measure and display load weight, calculate and display maximum
capacity and percent of rated capacity, display code conguration numbers, and warn of an approaching
overload or two-block condition for each crane conguration.
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The computer provides all of the functions necessary to read the system sensors, work out computations,
and control the disconnect functions. In order to reliably calculate crane parameters, such as load and rated
capacity, and interpret the crane capacity chart and code conguration numbers, information dening the
physical characteristics of the crane has been loaded during factory setup.
Two hydraulic pressure sensors, housed in the computer assembly, measure the pressure in each side of
the boom lift cylinder. Other system sensors, mounted elsewhere on the crane, are connected to the com-
puter via electrical cables.
The reeling drum assembly measures the extended length of the telescoping sections of the boom and
enables calculation of load radius, load weight, and percent of rated capacity.
The anti two-block switch is used to signal a two-block condition.
The reel-off cable provides a path, from the boom head to the computer via the extension reel cable. This
path is used to send a two-block signal to the computer.
The extension reel cable provides a path to the computer for the two-block signal, the angle sensor, and the
extension sensor.
The boom angle sensor is housed within the reeling drum assembly and measures the angle of the boom.
The operator’s display unit translates data received from the computer and displays the actual load and
percent of rated capacity in the display console windows. Visual and audible warnings and alarms activate
when capacity limits are approached or exceeded, or when a two-block condition is encountered.
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Operator’s Display Console
Warning/Alarm Indicators
The red two-block lamp will illuminate when a two-block condition occurs (see “Two-Block
Warning” on page 12).
The yellow pre-warning lamp will illuminate at 90% of rated capacity (see “Approaching Overload”
on page 11).
When the load reaches or exceeds 100% of rated capacity, the red overload warning lamp will
illuminate along with the yellow pre-warning lamp (see “Maximum Capacity and Overload” on page
12).
Display Windows
The current rated capacity for the crane in the current conguration will be displayed in the rated
capacity window as well as the percent of rated capacity shown as a meter which progresses to
the right as the load increases (see “Normal Operation” on page 10).
The setup codes are shown in the setup code window, as well as the parts-of-line, and the stowed
jib option if available (see “Conguration Selection” on page 9).
The information window shows crane specic information regarding boom length, boom angle, and
load radius, along with the load on hook. In addition, information regarding any warnings or alarms
will be displayed in this window. If the system has any internal faults, it will display “!WARNING!
SYSTEM FAULT” in the information window. The specic fault messages can be viewed by
pressing the UP ARROW or DOWN ARROW key (see “System Fault Messages” on page 19).
Two-Block Pre-Warning Overload and Fault
Rated Capacity
Information
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Push Buttons
The SETUP key enables the operator to congure the system to match the actual setup of the crane.
Codes are present for:
• Stowed jib attachments; if no stowed options are available, this code will not appear.
• Crane conguration
• Number of parts-of-line
The ALARM OVERRIDE key is used to disable the audible warning and to override the function kick-out for
the current alarm condition.
The CONTRAST keys are used to adjust the lightness or darkness of the display area.
The DISPLAY MODE/SELECT keys are used to switch to different display formats showing various
combinations of boom angle, boom length, and radius. They can also be used as an UP ARROW or DOWN
ARROW key to scroll through menu selections.
Setup
Contrast Display Mode
Select
Alarm
Override
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System Operation
System Self-Test
When the system is turned on, it goes through a brief self-testing process.
All three alarm indicators will light up, all display windows will appear black, and the audible alarm will
sound.
The information display will then show the crane model and capacity chart number for the system
congured.
Following self-test, the system will go into the setup mode.
Refer to “Conguration Selection” on page 9 for setup instructions.
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Conguration Selection
Conguration selection is required upon system power up; however, it can also be entered anytime by
pressing the SETUP key.
Note: If no stowed jib options are available, this selection option is skipped.
The stages for selection, in no specic order, may include the following:
1. O/R or rubber
2. Erected attachment
3. Stowed attachment
4. Parts of line
The current stowed jib code will be ashing and the jib description is displayed in the information window.
To select a different stowed jib, press the UP ARROW or DOWN ARROW key to display the desired option
and press the SETUP/OK key to continue.
The current number of parts-of-line is now ashing.
To change the parts-of-line, press the UP ARROW or DOWN ARROW key to select the desired number
and press the SETUP/OK key to continue.
Note: Some congurations allow only single part-of-line operation. In these cases, the whole parts-of-line
selection phase will be skipped and the parts-of-line will be set to one (1).
Once the correct parts-of-line are entered, the system will exit the conguration mode and return to the
normal working screen.
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Normal Operation
Rated Capacity
Percent of Rated
Capacity
Actual Load Boom Angle Boom Length
Percent of rated capacity indicates how near the operation is to full capacity and overload. The percent of
rated capacity meter progresses to the right as the percentage increases. As long as the meter remains
within the normal (green-bordered) zone, the percent of rated capacity is within normal operating limits.
When the percent of rated capacity exceeds 60%, the rated capacity text will move to the left (see
“Approaching Overload” on page 11).
Rated capacity is the heaviest load that the crane can lift in the current crane position and conguration.
This value may be limited by the number of parts-of-line selected, or an erected attachment.
The actual load appears in the information window under the word “LOAD”. The actual load includes the
weight of the load plus the weight of everything hanging below the boom tip (hook block, etc.).
The boom angle appears in the information window under the word “ANGLE”. This shows the current
angle of the boom in degrees and tenths of a degree. Depending on the operation, the “ANGLE” display
will change to “RADIUS”, in which case the radius from the centerline of rotation to the center of gravity of
the suspended load will be shown in feet and tenths of a foot.
The boom length is displayed in the information window under the word “LENGTH”. This shows the current
length of the boom in feet and tenths of a foot. By pressing the UP ARROW or DOWN ARROW button, the
display can be changed to show “ANGLE” or “RADIUS”.
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Normal Operation (Continued),
If the system has any internal faults, it will display “!WARNING! SYSTEM FAULT” in the information
window. The specic fault messages can be viewed by pressing the UP ARROW or DOWN ARROW key
(see “System Fault Messages” on page 19).
WARNING!
THE OPERATOR MUST SELECT THE CORRECT CRANE CONFIGURATION FOR EACH
SETUP CONFIGURATION CHANGE. INACCURATE OR NON-SELECTION OF THE
APPROPRIATE CONFIGURATION WILL RESULT IN INCORRECT CALCULATIONS AND
READINGS OF THE ACTUAL LOAD WEIGHT AND PERCENT OF RATED CAPACITY.
PLEASE REFER TO “CONFIGURATION SELECTION” ON PAGE 9 OF THIS MANUAL.
Approaching Overload
Pre-Warning Lamp
The system continuously monitors the weight of the load suspended below the boom head. The system
compares this information with rated capacity data stored within the computer.
When the rated capacity of the conguration reaches 90%, the percent of rated capacity meter progresses
from the normal (green-bordered) zone into the caution (yellow-bordered) zone.
A pre-warning lamp will illuminate and an audible alarm will beep continuously. The message “!WARNING!
– PRE-ALARM” will ash in the information window.
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Maximum Capacity and Overload
Overload Lamps
When the rated capacity of the crane reaches 100%, the percent of rated capacity meter moves from the
caution (yellow-bordered) zone into the warning (red-bordered) zone.
The overload lamps will illuminate and an alarm will sound continuously. The message “!WARNING! –
OVERLOAD” will ash in the information window.
Crane motions (boom extend, boom down, swing and winch up) are cut in order to prevent damage to the
crane and the endangerment of persons near the lifting area.
Two-Block Warning
Two-Block Lamp
If the hook block comes into contact with the head machinery at the end of the boom, the two-block
lamp will illuminate and an audible alarm will sound continuously. The message: “!WARNING! TWO
BLOCKING” will appear in the information window.
Crane motions (boom extend, boom down, swing and winch up) are cut in order to prevent damage to the
crane and the endangerment of persons near the lifting area.
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Alarm Override
The alarm override button is used to temporarily disable current audible alarm conditions and to disable the
automatic motion cutout. This audible alarm will sound again following any subsequent overload or two-
block conditions, or any other alarm conditions.
To disable the audible alarm, press the ALARM OVERRIDE (CANCEL) key. Continue to hold the button
down for 5 seconds to cancel any existing motion cut outs. The ALARM OVERRIDE (CANCEL) key must
be held down to continue overriding the motion cut out.
WARNING!
THE ALARM OVERRIDE BUTTON SHOULD BE USED WITH CAUTION. AUTOMATIC
AUDIBLE ALARMS ARE PROGRAMMED AS A WARNING AGAINST OVERLOAD, TWO
BLOCK DANGERS, AND HAZARDOUS TIPPING CONDITIONS. THESE ALARMS ARE
TEMPORARILY SILENCED WHEN THIS OPTION IS ACTIVATED. MOTION CUTOUT MAY
ALSO BE DISCONTINUED.
Adjusting the Contrast
Changes in temperature and lighting conditions may require adjustment of the display contrast. Use the
CONTRAST keys to lighten or darken the display as needed.
Lighter Darker
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System Care
It is recommended that the system checks be carried out when using the MicroGuard® 586 Rated Capacity
Indicator/Limiter System.
1 Routine Checks and Maintenance
Items to Check before Each Shift or Crane Operation:
• Extension reel – reel-off cable to boom tip – extension reel cable to computer
• Hydraulic connections
• The anti two-block switch
• Checking the two-block warning signals and cutout of machine motions
MINIMUM MONTHLY CHECKS
• Load test
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2 Routine Checks and Maintenance Reel-Off Cable
Reel-Off Cable
Check Points:
• Carefully examine the reel-off cable for damage.
• Fully telescope the boom in and out. When extending or retracting the boom, ensure that the
reel-off cable is smoothly fed on and off the extension reel without drooping along the boom or
jumping, especially as the boom is telescoped in.
THE EXTENSION REEL SETTING IS FACTORY SET. IF THE REEL-OFF CABLE HAS BEEN
BROKEN, CALL THE SERVICE REPRESENTATIVE. DO NOT ATTEMPT TO REPAIR A
BREAK IN THE REEL-OFF CABLE WITHOUT CONSULTING WITH THE SERVICE
REPRESENTATIVE.
Computer Cable
Check Points:
• Ensure that the cable exiting from the extension reel and running down the boom and around its
pivot to the computer is free from damage. If this cable has been damaged in any way, it should be
carefully tested and may need to be replaced to ensure accurate transmission of signals.
WARNING!
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3 Routine Checks and Maintenance
Hydraulic Connections
The two hydraulic pressure sensors, mounted in the computer, measure the pressure within each side of
the boom hoist cylinder. The pressure sensors are connected to the boom hoist cylinder valve block by two
exible hoses. Both hoses are subject to the full hydraulic pressure contained within the upper and lower
sides of the boom hoist cylinder.
Check Point:
• Ensure that there are no hydraulic leaks at either connection end of both hoses. Check for signs
of wear or damage along the length of each hose.
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4 Routine Checks and Maintenance
Checking the Two-Block Warning Signals and Cutout of Machine Motions
The following test activates the anti-two-block warning signals and the valve controlling cut out of crane
motions to ensure proper operation. No other pre-existing alarm conditions may be active when performing
this test.
1. BEFORE PERFORMING THIS TEST, TURN THE CRANE POWER OFF AND THEN ON
AGAIN TO ENSURE THAT AN EXISTING TWO BLOCK WARNING AND/ OR MOTION
CUT HAS NOT BEEN OVERRIDDEN.
2. DURING THIS TEST, DO NOT USE THE CANCEL ALARM BUTTON TO CLEAR
AUDIBLE WARNINGS OR MOTION CUTS.
3. DURING THIS TEST, OPERATE THE CRANE MOTIONS WITH EXTREME CAUTION.
TEST FOR OPERATION OF TWO-BLOCK WARNINGS AND CUTOUT OF CRANE MOTIONS
1. Ensuring that power to the crane has been removed, place the anti-two block switch in the tripped
position. Wedge, clamp, tie, or otherwise immobilize the switch in the tripped position.
2. Power up the crane.
3. Check that the winch up motion as well as the boom down, boom extend, and swing left and right
motions are disabled. Audible and visual alarms on the operator’s display should become active.
4. Remove power to the crane.
5. De-activate the anti-two block switch.
6. Start the crane.
NOTE: This action should disable the audible and visual alarms on the operator’s display and activate the
boom motions.
WARNING!
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5 Routine Checks and Maintenance
Load Test
The best way to identify a possible problem in the system is to do a load test. The accuracy of the load test
is dependent upon accurate operation of all the sensors in the system and the correct conguration selec-
tion.
It is recommended that a load test be performed monthly.
WARNING!
IF IN DOUBT, SELECT THE CONFIGURATION AGAIN FOLLOWING THE STEPS OUTLINED
IN THE CONFIGURATION SELECTION.
Load Test Steps
1. Select a known weight of at least 20% of maximum rated capacity.
2. Calculate the weight of the total load, including the slings and sheave block, or downhaul.
3. Lift the weight, and record the load weight displayed on the MicroGuard® 586 operator’s display.
4. The load weight on the display unit should be between 0 to 10% higher than the load that was lifted.
EXAMPLE:
When lifting 5000 lbs., the display console window should read between 5000 and 5500 lbs.
WARNING!
A LOAD READING ON THE MICROGUARD® 586 OPERATOR’S DISPLAY CONSOLE THAT
FALLS OUTSIDE OF A 10% RANGE MAY INDICATE A SENSOR PROBLEM. CALL YOUR
SERVICE REPRESENTATIVE.
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System Fault Messages
When the system detects a fault, the red warning lamp will illuminate and the message,
"WARNING: SYSTEM FAULT" will ash on the display. When a more serious fault is detected, the mes-
sage, "WARNING: SYSTEM OUT OF SERVICE" will ash.
To determine the fault, press the UP ARROW or DOWN ARROW key once or twice. The information
window will display the related fault message. This message will appear for up to 20 seconds before the
display returns to its normal display mode. If the UP ARROW or DOWN ARROW key is pressed before the
20 seconds have elapsed, the display will automatically return to its normal display mode.
Fault messages that may appear on the display and the required corrective action follow:
Fault Message Corrective Action
Re-Select Crane Setup This message indicates that there is an error in
the crane setup, selection, or there is an internal
computer fault. Re-select the correct crane setup
code; the error should correct itself. If not, replace
the computer. Refer to “Computer Replacement,”
located on page 24 of this manual.
Check Extension This message indicates a problem with the boom
extension sensor.
1. Inspect/check cabling and connections from
computer to extension reel on the side of the
boom.
2. Inspect/check the extension reel-off cable for
damage.
3. Remove the extension reel cover to verify
operation of the extension reel. Refer to
“Extension Reel Voltage Checks,” located on
page 21 of this manual.
Check Angle This message indicates a problem with the boom
angle sensor.
1. Inspect/check cabling and connections from
computer to extension reel on the side of the
boom.
2. Remove the extension reel cover to verify
operation of the extension reel. Refer to
“Extension Reel Voltage Checks,” located on
page 21 of this manual.
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Fault Message Corrective Action
Check ATB Wiring This message indicates that there is an Anti Two-
Block wiring problem usually due to an electrical
short to the boom or a damaged cable.
1. Inspect/ check cabling and connections from
computer to extension reel on the side of the
boom.
2. Inspect/ check reel-off cable from extension reel
to boom tip and Anti Two-Block switch
connections.
3. Verify electrical signals for the two-block drive
and signal within the extension reel. Refer to
“Extension Reel Voltage Checks,” on page 21
of this manual.
Check FKO This message indicates a Function Kick-Out wiring
problem that is usually caused by a fuse or crane
circuit breaker failure. Remove the computer unit
lid and check the 10A fuse.
Replace the Computer This message indicates an internal fault in the com-
puter. In some cases, it may not be necessary to
replace the computer unit.
1. Remove the computer unit lid and check the
Internal LED status indicators located on the
computer circuit board.
2. Refer to Computer Internal Status Indicators on
page 22 of this manual.
System Fault Messages, (Continued)
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