Lmi Operation
Lmi Operation
03312008
11/15/2007
15/15/2007
Table of Contents
General ............................................................................. 1
Control Console Identification ........................................... 4
Display ....................................................................... 4
Select / Confirm Rocker ............................................. 4
Scroll Up / Down Rocker ............................................ 4
Limiter Key Switch...................................................... 4
Warning Light............................................................. 4
Caution Light.............................................................. 4
Display Contrast Switch ............................................. 4
Working Screen ................................................................ 4
GENERAL
The purpose of this publication is to provide qualified
operators with operation and calibration instructions for
Manitowoc Rated Capacity Indicator/Limiter (RCL).
These instructions only apply to Software Program Version
lmi 03_ or lmi 13_ and newer with front console 196285 or
A14717.
If first two digits of your Software Program Version are not
the same as listed above, contact your Dealer or the Factory
Crane CARE Customer Service for correct RCL publication.
The third digit or letter will vary from one crane to another.
The system is designed to aid the operator in identifying
overload conditions, which can cause structural failure of
boom and jib or loss of stability (tipping).
Language Screen....................................................... 5
Option Screen ................................................................... 6
Setup ................................................................................ 6
Configure LMI............................................................. 6
Select Multiple Sheaves............................................. 8
Calibrate RCL............................................................. 8
Calibrate Load Sensing Sheaves ........................ 9
Calibrate Boom Angle Potentiometers ................ 9
Calibrate Luffing Jib Angle Potentiometers ....... 10
Diagnostic Screen........................................................... 10
The RCL is an electronic and mechanical load sensing
system consisting of following components (see Figure 1):
CONTROL CONSOLE (with its own memory and processor)
mounted on front console in the operators cab.
P R O G R A M M A B L E C O N T R O L L E R ( c o n t r o l s c ra n e
functions) located behind operators seat.
LOAD SENSING SHEAVES located at boom and jib points.
See Figure 2 for identification of load sensing sheaves.
ANGLE SENSING POTENTIOMETERS located in junction
boxes on boom butt and, if equipped, on luffing jib butt.
RIN CONTROLLER (Models 111, 222, 222 Wagon, 888 and
999 only) remote controller that sends input signals from
load sensing sheaves and angle sensing potentiometers to
programmable controller.
WARNING
Overload Hazard!
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.
Some programming steps may have to be performed
before each lift. If RCL is not programmed correctly, it
will not properly sense load and alert operator to
overload conditions. Before using RCL, operator shall
read and understand instructions in this publication.
2007 Manitowoc
Published: 11-15-2007
Folio 1880v2-1
RAD:
12.5 M
NET LOAD: 100000 KGS
CHART: 1205B/70
PARTS [12]
FRONT DRUM
11
9
OFF
CONFIRM
ON
A
11
R
LIMITER
SELECT
7
5
11
4
11
Item
Identification
Control Console
2
3
4
Item
Identification
Select/Confirm Rocker
Display
Caution Light
Programmable Controller
Warning Light
10
11
A1013
11
12
2
CHART: 1205B/70
PARTS [12]
FRONT DRUM
RAD: 12.5 M
NET LOAD: 100000 KGS
MAX CAP: 110000 KGS
9
CONFIRM
10
SELECT
14
15
16
17
4
18
13
Item
1
Identification
Display
Item
7
Identification
Scroll Up/Down Switch
Item
Identification
13
14
Caution Light
Programmable Controller
15
Warning Light
10
16
Shutdown Switch
11
17
12
18
FIGURE 1
Folio 1880v2-2
OR
4
4
3
2
2
1
Item
Sheave Identification
FIGURE 2
Folio 1880v2-3
Hoist UP.
Boom DOWN.
NOTE
Display
The display contains the following screens:
Calibration screens.
NOTE
Folio 1880v2-4
Warning Light
Glows RED and a buzzer (in control console) comes on to
alert the operator to an overload condition.
Caution Light
Glows YELLOW and a beeper (in control console) comes on
to alert the operator to an approaching overload condition.
WORKING SCREEN
The WORKING screen (Figure 3) identifies current
configuration and displays load data for load drum being
operated. When operation is switched from one drum to
another, the WORKING screen automatically switches to
display load information for new drum, without having to
reprogram. Automatic switching can be turned off by
selecting DRUM Not Used when programming crane
configuration DRUM screen (Figure 9) See Operating
Controls manual for drum identification.
The WORKING screen appears when power is applied and
is turned ON. The program goes through a system test when
first turned ON. The message CONFIRM flashes until TOP
e n d o f C O N F I R M / S E L E C T r o c k e r is d e p r e s s e d t o
CONFIRM present configuration. If there are no changes,
the operator can start operating the crane without going to
any other screen.
A four-digit number and either one or two alpha characters
identify each capacity chart. A single alpha character (A, B,
etc.) identifies an ANSI (United States) approved capacity
chart. A single alpha character followed by an M (AM, BM,
etc.) identifies a metric or European approved capacity chart.
Units of measure displayed in WORKING screen
corresponds to type of chart selected:
80
000 LBS
50000 LBS
TARE
LOAD
Safe Working
Area
Percent of
Capacity Bar
Deduct
29500
RAD
CAP
Use Caution
Line
Pull
8200
80
29500
FT
LB
Maximum Load
Condition
FIGURE 3
Language Screen
Access language screen on working screen (Figure 4) by
pressing SELECT. The program cursor (>) appears next to
the LANGUAGE on screen. Scroll up or down to select
desired language. CONFIRM when desired language
appears to program the selected language on all screens.
>LANGUAGE
ENGLISH
SCROLL or CONFIRM
FIGURE 4
The working screen displays the following information:
Configuration is a coded representation of the crane/chart
configuration:
Jib offset (for fixed jib chart or boom chart with fixed
jib attached).
Folio 1880v2-5
OPTION SCREEN
[>Sheave 1 Configuration]
CALIBRATE ANGLE
CALIBRATE SHEAVE
CALIBRATE SHEAVES
FIGURE 5
SETUP
Configure LMI
The SHEAVE configuration screen (Figure 6) appears when
Configure LMI is selected on OPTION screen. The program
requires the operator to confirm all ten configuration screens
before returning to the WORKING screen. The program
cursor (>) appears next to first item on each screen. Select is
not active when programming in configuration screens. The
program automatically moves to next configuration screen
when TOP end of CONFIRM/SELECT rocker is depressed to
CONFIRM.
NOTE
>POINT
LOWER
SCROLL to Change
CONFIRM to Continue
FIGURE 7
On CAPACITY CHART configuration screen (Figure 8) the
program cursor (>) appears next to capacity chart number
(7941A in this example). Once this screen is selected, data
in bottom three lines changes automatically while scrolling
through possible chart configurations.
If you program data for any item without confirming it, data
will be lost when computer is turned off and previously stored
data will take effect when computer is turned back on.
The program will not allow any data to be changed if
corresponding load sensing sheave detects a line pull
greater than 3,300 lbs (1-1/2 Metric Tons).
A four-digit number and either one or two alpha characters
identify each capacity chart. A single alpha character (A, B,
etc.) identifies an ANSI (United States) approved capacity
chart. A single alpha character followed by an M (AM, BM,
etc.) identifies a metric or European approved capacity chart.
The chart configuration screen does not display units of
measure. Units of measure correspond to type of chart
selected:
[Drum 1 Configuration]
160
BOOM ANG
JIB1 ANG
JIB2 ANG
LIST
CRAWLER
CTWT
FIGURE 8
The following items are programmed for the selected chart
configuration:
CHART - is the chart number.
BOOM - is the boom length.
[>Sheave 1 Configuration]
CONFIRM to Continue
FIGURE 6
On POINT configuration screen (Figure 7) the program
cursor (>) appears next to the POINT selection. Only select
upper point when there is an upper point on the boom, fixed
jib or luffing jib. When configured with a fixed jib, the lower
point is generally selected.
Folio 1880v2-6
[>Sheave 1 Configuration]
>DEDUCT
0000 LBS
SCROLL to Change
FIGURE 12
On TARE configuration screen (Figure 13) the program
cursor (>) appears next to TARE selection.
>DRUM 2
[>Sheave 1 Configuration]
SCROLL to Change
>TARE
CONFIRM to Continue
0000 LBS
SCROLL to Change
LOAD
000000 LBS
CONFIRM to Continue
FIGURE 9
On PARTS configuration screen (Figure 10) the program
cursor (>) appears next to PARTS selection. Scroll up or
down as required to select and program desired parts of line.
[>Sheave 1 Configuration]
>PARTS
SCROLL to Change
CONFIRM to Continue
FIGURE 13
For an unknown tare value:
1.
2.
3.
4.
FIGURE 10
On LINEPULL configuration screen (Figure 11) the program
cursor (>) appears next to LINEPULL selection. Scroll up or
down as required to select and program required single line
pull for the selected drum and sheave configuration.
2.
3.
NOTE
CONFIRM to Continue
FIGURE 11
On DEDUCT configuration screen (Figure 12) the program
cursor (>) appears next to DEDUCT selection. Scroll up or
down as required to select and program desired deduct
value. As DEDUCT value is increased, the capacity value is
subtracted the same amount.
ON
SCROLL to Change
Load Limiter
OFF
CONFIRM to Continue
FIGURE 14
Folio 1880v2-7
*SINGLE SHEAVE
SUM SHEAVES
SUM SHEAVES
1 AND 2
3 AND 4
FIGURE 16
Check RCL calibration and calibrate if required, at the
following intervals:
FIGURE 15
If boom point load sensing sheaves 1 and 2 or luffing point
load sensing sheaves 3 and 4 are selected, rated line pull for
each sheave is compared to maximum. The sum of both
sheaves load is calculated for total percent of chart capacity.
Line pull or chart capacity that is closest to 100 percent rated
capacity is displayed in MAX CAP line on WORKING screen.
The MAX CAP line changes if another sheave load or total
rated capacity is closest to maximum capacity. The displayed
LOAD corresponds with displayed MAX CAP. If the program
is limited by maximum line pull, the LOAD and MAX CAP
shows that line pull.
Calibrate RCL
The calibration screens are used to calibrate load sensing
sheaves and boom/luffing jib angle sensing potentiometers.
T h e p r op e r ch art a nd cra n e co n fi gu r a t io n m us t b e
programmed and confirmed before performing calibration
procedures.
SCROLL or CONFIRM
Yearly
Folio 1880v2-8
2.
3.
4.
5.
6.
Turn off tare so that load lines, load block or weight ball,
and all rigging are included in calibration.
2.
3.
4.
5.
0 LBS
(MORE/LESS REQD)
Calibrate *BOOM
LOW ANGLE
HIGH ANGLE
000 V
82.0 DEGS
RAD
50 FT
08.74 VOLTS
CONFIRM to Return
CONFIRM to Return
FIGURE 18
FIGURE 17
7.
6.
7.
8.
9.
8.
9.
a.
b.
Folio 1880v2-9
1.
2.
3.
4.
5.
6.
82.0 DEGS
RAD
FT
08.74 VOLTS
CONFIRM to Return
FIGURE 19
7.
8.
9.
Folio 1880v2-10
DIAGNOSTIC SCREEN
Lmi 13
>BOOM
JIB
S999
VOLT
8.74
0.0
000000
DEG
+82.0
Mem 0
-86.0
Shv 1
Shv 2
Shv 3
Shv 4
0.00 V
0.00 V
0.00 V
0.00 V
FIGURE 20
Metric Ton
Voltage
0
0.50
4.5
2.25
7.2
3.30
9.0
4.00
10.8
4.70
Models: 888 and 999
Metric Ton
Metric Ton
0
6.8
9.5
10.9
13.6
Voltage
0.80
3.63
4.77
5.33
6.46
Voltage
0
4.5
7.2
9.0
10.8
0.50
2.25
2.95
3.30
4.00
Model 222HD with 1-1/4 inch (3,18 cm) rope use 777 columns.
Single part line pull at any sheave (S1, S2, S3, or S4).
Voltage
1.86
4.38
5.60
6.86
8.54
Voltage
1.48
2.31
4.80
7.32
8.72
Folio 1880v2-11
TABLE OF CONTENTS
General .......................................................................... 1
Personnel....................................................................... 1
Software Installation Requirements ............................... 1
Installing Program on Laptop ......................................... 1
Installing Software and Charts On Laptop ..................... 3
Downloading Software and Charts To Crane PC........... 4
Non-CAN bus Software........................................... 4
Installing Software Program rev00c.................. 4
Installing Software Program rev00f .................. 5
CAN Bus Software .................................................. 6
Installing Software Program rev00c.................. 6
Installing Software Program rev00f .................. 7
Rules-Discarding Files ................................................... 8
Documentation............................................................... 8
Software Installation Training......................................... 9
Field Software Installation............................................ 10
GENERAL
This publication provides qualified service technicians with
instructions for installing crane software and capacity chart
files on Manitowoc cranes equipped with an EPIC control
system either non-CAN bus or CAN bus.
SOFTWARE INSTALLATION
REQUIREMENTS
To successfully install crane software and capacity chart
files, the following items are required:
1.
2.
3.
4.
Click on New.
5.
Select Folder.
6.
7.
8.
NOTE:
MCC Controls
PERSONNEL
Crane software and capacity chart files must be installed
only by a qualified, trained technician as instructed in this
document.
MCC Controls
MCC Controls
MCC Controls
FIGURE 1
2007 Manitowoc
Rev. 05-15-2007
ST 167-1
2.
3.
9.
FIGURE 6
FIGURE 2
4.
5.
FIGURE 3
6.
10. Locate the MCC Controls folder on the C drive and click
OK (see Figure 7).
MCC Controls
FIGURE 7
11. Click on the Computer icon to proceed with the
installation of the download program into the MCC
Controls folder (see Figure 8).
FIGURE 4
7.
8.
MCC Controls
FIGURE 8
12. When asked to verify Program group, click Continue.
13. While in setup, a pop up screen may be displayed
indicating a newer file exists on your laptop. Click Yes to
keep your newer existing file.
14. The screen will indicate when setup is complete. Click
on OK.
FIGURE 5
ST 167-2
a.
b.
c.
d.
e.
1.
b.
c.
b.
Click on Settings.
c.
d.
e.
2.
Open crane software files. Right click MEC2.HEX (nonCAN bus) or Master.H86 (CAN bus) file icon.
3.
4.
5.
C/
FIGURE 9
17. Click Add/Remove button and existing program will be
removed from C drive of the laptop.
6.
7.
8.
9.
ST 167-3
6.
7.
8.
9.
10. Locate and click on Mec2.hex icon to select file and then
click on Open button (see Figure 12). The hex file will
now download the program. A screen displays bootstrap
information during download process and controls
application shows data address.
Front
Console
FIGURE 12
11. When laptop interface screen displays Process
Complete/Timed Out the screen closes automatically.
A1261
FIGURE 10
2.
FIGURE 11
3.
4.
5.
ST 167-4
FIGURE 13
14. Click on Open button to open file. Capacity charts will
now begin to load. While charts are loading the screen
6.
7.
8.
9.
ihx
mec2.hex
mec2.hex
1.
2.
FIGURE 16
11. Locate and click mec2.HEX icon to select file (see
Figure 16). The hex file will now download the program.
The screen will display Process Complete/Timed Out
when files are fully loaded and file closes automatically.
12. Go back to the Manitowoc Controls Interface - rev00f
screen (see Figure 15).
13. Select and press Load Charts button at bottom of
screen.
FIGURE 14
3.
14. A screen will drop down called Open (see Figure 17).
Imidata.ihx
FIGURE 17
FIGURE 15
4.
5.
ST 167-5
2.
3.
4.
5.
1.
2.
3.
4.
5.
6.
FIGURE 20
FIGURE 18
ST 167-6
6.
7.
8.
9.
FIGURE 23
FIGURE 21
2.
3.
10. Select and press Load Charts button in lower left part of
screen. A screen will drop down called Open.
11. Locate and open the crane model folder.
12. Select and click on candata.ihx icon to select file (see
Figure 22). Click on Open button to open file. Rated
capacity charts will now begin to load.
candata.ihx
candata.ihx
FIGURE 24
4.
FIGURE 22
13. When screen changes to indicate a Status bar that
programming is finished (Load Data in Address and
Close File), the charts will be fully loaded into the cranes
CAN bus system. Click Exit button on control interface
screen (see Figure 22) and disconnect download cable.
14. Scroll up or down on rated capacity screen and working
screen will return.
15. Check configuration screen to ensure system is
configured as it was before chart loading. Lift a few
different loads to determine if system is weighing load
correctly.
16. Right click on serial number folder, select delete on bar,
and click to remove folder from laptop.
b.
c.
d.
e.
f.
g.
h.
5.
6.
7.
ST 167-7
FIGURE 27
FIGURE 25
8.
9.
RULES-DISCARDING FILES
FIGURE 26
1.
2.
3.
4.
DOCUMENTATION
Field Software Installation Form OOSVFM045 (at end of this
document) must be completed and returned to Manitowoc
Cran e CARE Customer Service a t time of softwa re
installation. If the software is installed on more than one
crane, a form must be completed for each crane.
ST 167-8
Manitowoc Cranes
SOFTWARE INSTALLATION TRAINING
Date ________________
Dealer ________________________________
Branch ________________________________
Model Crane ___________________________
Serial Number __________________________
Software Version ________________________
Trainees
1. Name ______________________________________________________________
Telephone # _________________________________
E-mail address you wish to receive updates _________________________________
2. Name ______________________________________________________________
Telephone # ________________________________
E-mail address you wish to receive updates _________________________________
3. Name ______________________________________________________________
Telephone #_________________________________
E-mail address you wish to receive updates _________________________________
Instructed by:
_____________________________________________________________________
00SVFM044
10/24/02
ST 167-9
Manitowoc Cranes
FIELD SOFTWARE INSTALLATION
Date _______________
Dealer _____________________________________
Branch _____________________________________
Model Crane ________________________________
Serial Number _______________________________
Software Version _____________________________
_________________________________________________________________________
_________________________________________________________________________
00SVFM045
10/24/02