MARKLOAD SYSTEM 40 SERVICE AND INSTALLATION MANUAL 7332-40.pdf

MARKLOAD SYSTEM 40

SERVICE AND INSTALLATION

MANUAL

SYSTEM DESCRIPTION

The MARKLOAD SYSTEM 40 is a Microprocessor Controlled load indicating system.

The system measures and displays the actual weight lifted by the crane.

The MARKLOAD SYSTEM 40 consists of the following components:

The DISPLAY UNIT includes the power supply (12 to 24 VDC), the microprocessor and display electronics.

The SMART PREAMP board converts the load cell voltage to digital data that is sent down the crane boom to the display unit.. This board is mounted either inside the load cell or in a plastic box mounted near the load cell.

The display shows the load on the hook in units shown on the front panel below the numeric display (i.e. x1000 pounds).

The TENSIOMETER(S) is(are) used to measure the tension in a single part of line that supports the load the crane is lifting. The TENSIOMETER uses a load cell to convert the tension into an electrical signal read by the microprocessor.

Cabling is provided to connect the system components.

SYSTEM SPECIFICATIONS

LOAD DISPLAY ACCURACY +-2% of Maximum Rated Load

COMPONENT SPECIFICATIONS All system components are specified for use over ambient temperature range of –30 to 50C (-22 to 122F) without external adjustments.

IINPUT POWER REQUIREMENTS

Input voltage – 11-29 Volts DC Input current – less than ½ amp

INSTALLATION

The DISPLAY UNIT should be mounted so that the crane operator can easily view the display and access the buttons. The DISPLAY UNIT is weather resistant and may be mounted in any position.

Enclosures are tank tested to two atmospheres of pressure.

Power is supplied to the MARKLOAD SYSTEM 40 through the power cable extending from the

DISPLAY UNIT. Connect the red (positive) wire to 12 or 24 volts DC and the black (return) wire to DC ground. Verify that the voltage matches with the voltage rating shown on the DISPLAY

UNIT label.

Route all cables so that they do not interfere with any crane controls.

There are two (2) types of TENSIOMETERS that are typically supplied with the SYSTEM 40:

1. DEAD END TENSIOMETER

2. 3-SHEAVE RUNNING LINE TENSIOMETER

See installation drawings for details.

ADJUSTMENTS

• Adjustments are factory set at nominal levels. After installation the load readings MUST be verified with certified weights. Note that, if any signal (load(s), angle or length) falls above or below predetermined levels, an error indication will show on the display.

• Test personnel shall be thoroughly familiar with the system’s operation and shall check the system for all functions.

• The system test shall be conducted using an appropriately configured crane and specified load-rating chart.

• A minimum of two test loads should be employed. One should be as near as possible to the maximum value within the operating limits.

The other should be near mid range.

• After installation the load readings MUST be verified with certified weights known to within +-1%. Note that, if any signal (load(s), angle or length) falls above or below predetermined levels, an error indication will show on the display.

Important note: To quit from any setup procedure without changing the system settings simply turn the power switch off for several seconds.

PASSWORD ENTRY

password = 8600

When system setup is required (Zero and Gain Calibration) a password must be entered to access these functions.

When the or SET button is pressed the display will show 0000 for the password and the first digit will flash.

To enter the password, do the following:

- Press the button several times until the flashing digit shows the correct value for the first number of the password.

- Press the SET button to move to the next digit, which will now flash.

second number of the password.

third number of the password.

fourth number of the password.

- Now press the OK button. If the password is correct the display will now show the next setup information. If it is not correct the display will return to the normal operation display.

To quit at any time during setup or password entry just turn the power switch OFF. No permanent settings will be changed.

ZERO LOAD SETTING

Determine if the zero setting for the system should be done with the hook hanging or with the hook on the ground. The crane manufacturer’s lift charts should describe the correct zero setting depending upon whether the hook is considered part of the load. If this condition is not known, lay the block on the ground so its’ weight will be included in the displayed load.

1) Make sure the Parts of Line setting is correct. This value is shown when the power is turned on.

2) Press the SET button.

3) Enter the password and press OK.

4) S1 (S2 for Aux line) will appear on the display.

5) For Aux load zero Press the button until the display shows S3.

6) Press the OK button to accept set up option one for zero load setting.

7) The display will now flash 0000.

8) To accept this as your new zero load, press OK and hold it for at least two seconds until the display flashes a countdown from 9999 to 1111. If you do not hold the OK button until the countdown starts the setting will not be saved.

LOAD SETTING

The Zero Load Setting procedure should be followed before the load setting is performed.

All crane safety practices should be followed when performing this procedure.

1) Verify the “no load” reading.

2) Verify the parts of line setting.

3) Lift a known load.

A sufficient load must be lifted in order to calibrate the system correctly.

The crane should be set up to allow the following load to be picked up safely.

The certified load must be at greater than ½ of the Max single line pull working load times the current parts of line in use.

(Example: If max working single line pull for the wire rope is 25,000 and four parts of line are in use then -

½ times 25,000 times 4 = 50,000 … so at least 50,000 lbs. should be lifted for proper calibration.

4) Press the SET button.

5) Enter the password and press OK.

6) S1 will appear on the display.

7) Press the button once until the display shows S2.

8) For Aux load - Press the button once until the display shows S4.

9) Press the OK button to accept.

You will now enter the total load value (block, rigging, load…).

The value of the flashing digit can be changed by pressing the button.

10) The left most digit will now flash 0. To change the value of this digit press several times until the value is correct.

11) Press the SET button to select the next digit.

12) To change the value of this digit press several times until the value is correct.

13) Press the SET button to select the last digit.

14) To change the value of this digit press several times until the value is correct.

15) To accept this as your load, press OK and hold it for at least two seconds until the display flashes a countdown from 9999 to 1111. If you do not hold the OK button until the countdown starts the setting will not be saved.

16) Set the load down and lift it again to verify repeatability.

17) Lift another certified weight to verify system linearity.

ERROR CONDITIONS

• Minus sign ERROR o A minus sign (-) in the display signifies that the system is currently reading a value that is less than the current stored zero load value. The zero load procedure may be required.

• E2 ERROR

o The zero and load configuration values are stored in a special memory chip on the main circuit board. If this chip is damaged or scrambled the system will not read valid numbers. If this occurs the system will display an error message E2. If this message is displayed turn the power off for 5 seconds then back on. If the message returns try following the parts of line, Zero Load Setting, and Load

Setting procedures. If the system still shows the error message the chip is damaged and must be replaced and the system must be recalibrated. Contact

Markload for assistance

• E4 or E6 ERROR o The display unit was unable to communicate with the preamp board. There is most likely a bad connection or a faulty preamp board.. Contact Markload for assistance

• E7 ERROR

o The preamp board has not been initialized correctly. Turn the power off for several seconds then back on. If this error persists there is probably a bad connection. Contact Markload for assistance

• Over scale ERROR (E99.9) o When E99.9 is displayed the input signal is higher than can be shown on the display. This can be caused by crane overload or system problems. See troubleshooting page of manual.

TROUBLESHOOTING

• Display is Blank o Input voltage is out of range o Fault on the main board

• E99.9 is Displayed o Calibration of the system is faulty.

• Recalibrate the zero and load settings.

o Parts of Line set to wrong value

• Verify Parts of Line setting o Signal voltage is out of range

• Too much load on load cell

• Damaged signal cable

• Damaged load cell

• Preamp board damaged (if present)

• Moisture in preamp enclosure (if present) o Main board error

• System lockup

• Turn power off for 5 seconds

• Bad chip on main board

• Contact Markload for assistance

• E2 is Displayed o System configuration memory is corrupted

• System lockup

• Turn power off for 5 seconds

• Bad chip on main board

• Contact Markload for assistance

• Minus sign ERROR o Signal voltage is below normal range

• Zero Setting procedure may be required

• Too little load on load cell, (slack line)

• Damaged signal cable

• Damaged load cell

• Preamp board damaged (if present)

• Moisture in preamp enclosure (if present) o Main board error

• System lockup

• Turn power off for 5 seconds

• Bad chip on main board

• Contact Markload for assistance vlw

CERTIFIED

FIELD TEST REPORT

Owner: _______________________________________

Crane Manufacturer: _______________________________________

Markload System 40 Serial #: _______________________________________

Crane configuration: _______________________________________

Actual Load Lifted: _______________________________________

System 40 Load Reading: _______________________________________

Date: _______________________________________

Witness: _______________________________________

Test Procedures:

Known weight

Test load to be applied by suspending known weights accurate to +-1%. If the weights of all additional equipment such as blocks, slings, etc., are included in the test load, the total load shall be known to an accuracy of +-1%.

Fixed Anchor (Deadman)

Test load to be applied by hoisting against a fixed anchor or deadman equipped with a means for measuring loads accurate to +-1%. If the weights of all additional equipment such as blocks, slings, etc., are included in the test load, the total load shall be known to an accuracy of +-1%.

A copy of the current test record shall be available at all times.

S.O. NO. 23623

B.M. SERIES 2

AMD-2903

LOAD MONITOR ASSEMBLY Page 1 of 2

USCG ATON BARGE CRANECustomer:

PARTS LIST FOR:

APPLETON MARINE, INC.

Code ID NO. 70433

ITEM QTY PART NO. DESCRIPTION MAT'L / VENDER WT(LBS)

Date Run: 1/6/2020

Prep'd By: CEB

1.00 1 YMD-14180 DUAL HOOK LOAD MONITORING SYSTEM COMMERCIAL 120

2.00 2 MMD-7589 MOUNTING BRACKET ASTM A36 18

3.00 1 MMD-7591 MOUNTING PLATE NYLATRON 0

4.00 1 STUD-MOUNT POSITIONING ARM, MCMASTER

P/N: 1448N11

COMMERCIAL

5.00 2 THREADED INSERT #10-24NC (PEMM

ENGINEERING P/N: NFPC-024

300 SERIES

STN STL

6.00 8 HHCS: 5/8-11NC X 0.75 LG GRADE 5 STL

ZNC PLTD

7.00 4 NYLOC-HEX NUT: 5/8-11NC GRADE 5 STL

ZNC PLTD

8.00 4 HARDENED BEVELED WASHER: 5/8 DIA. ASTM F436 -

GALVAIZED

9.00 1 HEXNUT: M8 X 1.25MM AISI 316

STN STL

10.00 1 LOCKWASHER: M8 AISI 316

STN STL

11.00 4 SHCS: 5/16-18NC X 0.75 LG AISI 316

STN STL

12.00 4 LOCK WASHER: 5/16 DIA AISI 316

STN STL

13.00 2 FHCS: #10-24 X .75 LG AISI 316

STN STL

14.00 4 PHCS: #6-32 X .5 LG AISI 316

STN STL

15.00 4 LOCK WASHER: #6 AISI 316

STN STL

16.00 48

FT

MMD-6268 1.5" CABLE TRAY X 8 FT LENGTH AISI 316L

STN STL

S.O. NO. 23623

B.M. SERIES 2

AMD-2903

LOAD MONITOR ASSEMBLY Page 2 of 2

USCG ATON BARGE CRANECustomer:

PARTS LIST FOR:

APPLETON MARINE, INC.

Code ID NO. 70433

ITEM QTY PART NO. DESCRIPTION MAT'L / VENDER WT(LBS)

Date Run: 1/6/2020

Prep'd By: CEB

17.00 48 MMD-6269 1.5" CABLE TRAY COVER X 8 FT LENGTH AISI 316L

STN STL

18.00 12 MMD-6727 1.5" CABLE TRAY COVER CLAMP AISI 316

STN STL

19.00 18 HHCS: 3/8-16NC X .75 LG AISI 316

STN STL

20.00 18 LOCK WASHER: 3/8 DIA AISI 316

STN STL

21.00 12 HHCS: 1/4-20NC X .75LG AISI 316

STN STL

22.00 12 LOCK WASHER: 1/4 DIA AISI 316

STN STL

23.00 12 HEX NUT: 1/4-20NC AISI 316

STN STL

24.00 2 CABLE GLAND: 0.75" NPT

SOLID PLUG

SEALCON P/N: CD21-NP-BK

COMMERCIAL

25.00 2 LOCKING NUT: 0.75" NPT

SEALCON P/N: NN-21-BK

COMMERCIAL

26.00 2 YMD-9878 SEALING WASHER - 3/4" NPT TEFLON 0

CMD-316 Electrical Drawing