Load Moment Indicator System

OPERATION & INSTALLATION MANUAL

Model : LMI AT 355

Project: ONGC(Sagar Joyti, Sagar Ratna, Sagar Shakti)

Avalon Technologies (India) Pvt. Ltd.

Plot no 4,
105-106 Ramtekdi Industrial Area,
Hadapsar,
Pune: 411 013

Tel: +91-20-2681 1044 / 45 / 46

+91-20-3254 3254 / 3250 1012
Fax: +91-20-2681 1047

1
 INDEX

TOPIC PAGE No

INTRODUCTION 3

INTRODUCTION PRINCIPLE 4

BLOCK DIAGRAM 5

SYSTEM COMPONENT PLACEMENT 6

SYSTEM OVERVIEW 7

SYSTEM FEATURES 8

SYSTEM COMPONENTS 9

SYSTEM INSTALLATION 14

SYSTEM OPERATION 16

SYSTEM CALIBRATION 17

SYSTEM MAINTENANCE 20

WIRING DIAGRAM 22

TROUBLESHOOTING 24

PART LIST 27

2
 INTRODUCTION

Thank you for buying the AVALON LMI AT355 Load Indicator System
for your equipment. You have bought one of the most advanced and
reliable system, which will always help you in safe operating of your
equipment.
This manual contains all the information to understand the various
features of the system, operation, maintenance and trouble shooting.

IMPORTANT NOTE

Crane operations would be safe if the machine is properly set up,

properly inspected and maintained, used within the operational
limitations established by the manufacturer, and the load safely rigged.

Always use safe rigging practices. Remember that the key to crane
safety rests with a qualified operator who understands the equipment
limitations, knows how to interpret a load chart and, most importantly, is
experienced.

The Safe Load Moment Indicator System is an AID to the crane

operator. It can never substitute the operator’s good judgment,
experience and recommended safe crane operating practices. The
operator is solely responsible for safe operation of the crane.

The operator is advised to perform necessary checks / programming of

the Safe Load Indicator System before attempting each lift. If not done,
the system may not operate correctly and may fail to alert the operator of
any approaching overload condition. This manual should be thoroughly
read and understood before attempting the crane operation.

DISCLAIMER

The LMI, Safe Load Moment Indicator System or its manufacturer are
not responsible for any accident / mishap / loss of any kind because of
whatsoever reasons, which may arise during the crane operation.

3
Introduction Principle
AVALON’S CRANE AT 355 SYSTEM is an Electronic Safe load indicator
System for a mobile and Deck offshore cranes helps to avoid accidents
by displaying lifted load with visual & audible alarm before overload
condition approaches and on overload condition performs tripping
function.

Avalon’s Crane AT355 system uses a load sensor which is installed on

to the hoist wire rope. The load sensor output is proportional to the force
in the wire rope. The AT355 uses sophisticated electronic control circuit
to display the lifted load, boom length, boom angle, radius, capacity and
on programmed set points provides visual, audible warnings and activate
the tripping function. The set points can be set by the user without any
specific tools or aids.

4
Block Diagram

5
System Component Placement

6
7
 SALIENT FEATURES OF THE SYSTEM

 Designed keeping in mind the requirements of the crane operator,

provides all information simultaneously

 Simple but versatile product

 Suits all types of cranes, Modular design, system can be varied to

suit each customer’s requirement

 Latest technology using the Digital Signal Processing (DSP)

 Robust design optimized for harsh and severe environmental

conditions. All system components Encapsulated for environmental

protection

 Compact easy to read multifunctional alphanumeric backlit display,

requires minimum cabin space

 Site calibration facility

 Easy to install and maintain

 Minimal maintenance required

 Relay output for interfacing motion cut off facility (optional)

 Hook selection (Main or Auxiliary) and Tare facility

 Rugged power supply unit capable for varying input

AC input model: 85 VAC to 270 VAC

DC input model: 10 VDC to 30VDC

 Operating Temperature Range: 0C to 60C

8
SYSTEM COMPONENTS

1. Display Unit

6 5 4

The display unit is the main processor of the LMI system. The display
unit shows boom angle, lifted load, capacity, boom length and
percentage SWL bar and in percentage value
Display unit also having key pad with bypass key switch.

Display unit Components

1. Display 1
2. Keypad
3. Override key
4. Cable connector
5. Hooter
6. Display 2
7. LED’s

9
1 DISPLAY SCREEN 1

L- Actual Load (in tons)

C- Capacity
R- Radius (in meters)
A- Boom Angle (in degrees)

2
KEYPAD

DUTY / FALLS key:

In normal Mode it will display current duty and falls setting.
TARE / INCREMENT Key: In normal mode it work as the Tare
ON/OFF.(in ON position it will turn the crane lifted weight into zero.)
In calibration mode it will work as Increment  Key to increase the
value of a selected function.
MUTE key:
In normal mode it mutes the audible alarm.
In calibration mode it works as the decrement  Key to decrease the
value of a selected function.

FUNC/ESC: In normal mode

In calibration mode ESC key has two functions such as press once then
it will go to previous menu and if pressed continuously then it will EXIT
from the menu.
ENTER key:
In normal mode it will display the MAIN HOIST LOAD And AUX LOAD.
In calibration mode it saves the value of a selected function.

3
OVER RIDE KEY
Turn ON the bypass key while calibrating the data. Turn on the override
key, to bypass the
motion cut-off.

4 CABLE CONNECTOR

It is 10-core MS military grade connector. And connected to the display

unit from junction box.

10
5 HOOTER

6 DISPLAY SCREEN 2

L/C: percentage of the loading

l- Boom length
F- No of fall
D- Duty Number

7 LED’s

The six LED’s indicate the various load status conditions and warnings:
 ‘Overload’- crane is lifted more then its capacity
 Boom Up- when the crane crosses the maximum angle as per
the load chart.
 Boom Down- when the crane crosses the minimum angle as per
the load chart
 A2B Main- Indicates two block conditions of main hook
 A2B Aux- Indicates two block conditions of Aux hook
 Error – It will indicate when there is any error in input or any of
the above keys.

11
2. MAIN JUNCTION BOX
It processes the signal from sensors and gives the output.

3. Load Sensor

Measures line tension in hoist wire rope by deflecting

Wire rope through single-sheave pulley system.

12
4. Angle Sensor
Angle sensor measure the boom angle of the crane resistive type
sensing device. The angle sensor is designed to measures angle from 0
degree to 90 degree.

5. Cables
Display Cable, Signal cable, Power cable, Load Cable,
Angle Cable, Boom junction cable.

13
Installation of Components

Installation of the Dynamometer

S Method
No
1. Dynamometer is fitted on the hoist line wire rope between the wire rope
drum and the single pulley block.
2. The dynamometer is bolted with the clamps on the boom, either the
base section or the top section,
3. The hoist wire rope is running parallel to the boom, or else it is luffing
floating on the wire rope with one end tied to the boom using a
connecting rod with universal joint.

Installation of the Display Unit

S Method
No
1. The display unit is to be mounted inside the cabin in front of the crane
operator.

2. The display unit is supplied with a back plate the viewing angle of
display should be fixed before bolting the bracket.

3. Connect the cable provided with MS military grade connector to the

display unit. Carefully route the cable inside the crane cabin. Use “cable
ties” to tie the cable firmly inside the cabin.

14
Installation of the Angle Sensor

S Method
No
1. Angle sensor unit should be mounted on the boom close to the cabin. It can
be mounted on the right or the left side of the boom.

2. To mount the angle sensor unit, first mount the frame supplied. The frame
is to be bolted with clamp to the boom base section.
3. Then mount the angle sensor unit on the frame with the four screws
supplied.
4. Connect the cable provided with M.S military grade connector to the angle
sensor unit
5. The mounting position acceptable for the angle sensor unit is with its
connector side facing downward. This ensures the pendulum pointing to the
direction of gravity.
6. Carefully route the cable along the boom member, then from the boom butt
to the signal junction box. Use “cable ties” to tie the cable firmly to the
boom.

Installation of the Junction Box

S Method
No
1. Junction box should be ideally mounted inside the cabin with the
connectors/glands facing downwards.
2. In case the cabin space is restricted the control unit can be mounted
outside the cabin.
3. The control unit is supplied with a mounting frame. The frame has to be
first welded or bolted to the cabin.
4. The control unit should be mounted on the frame with four screws
supplied.

15
 SYSTEM OPERATION

OPERATING PROCEDURE

Switch ON the system Indicator will automatically show the release

version number, current date & capacity, crane and customer name for
few seconds.

Then the display indicates the current values of the crane parameters.

Duty Selection
The display indicates the duty cycle last selected. If this is the duty cycle
you would like to continue working then press ENTER key to select and
continue. But if you have changed the crane configuration then you
would probably need to change the duty cycle & or other parameters.

To change the duty, press DUTY key at power on followed by increment

 &/or decrement  keys to arrive at desired duty cycle number. Press
ENTER key to save the changes. After pressing ENTER the next
parameter displayed is FALL. This also can be altered using the
increment  & /or decrement  keys. After pressing ENTER key the
display indicates the current values of the crane parameters.

16
 SYSTEM CALIBRATION
LI system operates in two modes.
Normal mode: Normal operation as a load moment indicator.
Calibration mode: For calibration process.

LOAD (LOW & HIGH) CALIBRATION

For calibrating the Load follow these steps:

1. There is a display screen of MAIN MENU.

2. Press the Function key (F).
3. Press “ENTER” key. To carry on the calibration process and press
ESC key to EXIT.
4. Press increment ▲ key once and select Supervisory Settings.
5. Press “ENTER” key. And set the points by pressing increasing ▲ key
twice.
6. Press “ENTER” key. And select the Crane parameter.
7. Conform your selection by pressing “ENTER” key.
8. Press decrement ▼ key to set the low load value Zero, and fix the
crane angle at 45° and Hook should be rested on the ground.
9. Now turn ON the “OVER RIDE” key and press, “ENTER” key.
10. Turn off the override key
11. The Load (Low) calibration is over.
12. Press increment▲ key once and press “ENTER” key to enter into the
High load calibration.
13. Lift the known weight.
14. Press the increment ▲ key to set total load value.
15. Now turn ON the “OVER RIDE” key and press the “ENTER” key, this
will show the final value of the high load, and turn OFF the “OVER
RIDE” key.
16. High load calibration is completed.
17. Finally press “ESC” key to EXIT.

Note: Load value is the sum up of Actual load, Hook load, Sling load and D’shackle load.

17
 BOOM ANGLE CALIBRATION

The numerical display shows the current working angle in degrees by

the main BOOM ANGLE sensor.

For calibrating the angle follow these steps:

1. There is a display screen of MAIN MENU.

2. Press the Function key (F).
3. Press “ENTER” key. To carry on the calibration process and press
ESC key to EXIT.
3. Now press increment ▲ key and then press “ENTER” key.
4. Then press increment ▲ key till the display will show the system
calibration.
5. Press “ENTER” key.
6. Press increment ▲ key till the display will show the low angle.
7. Press “ENTER” key to enter into low angle calibration.
8. Press increment▲ key to set the low angle value zero degrees.
9. Confirm that the crane is at a ground level. Lower the boom at
zero degree.
10. Now turn ON the “OVER RIDE” key.
11. Then press “ENTER” key.
12. Low angle calibration is over.
13. Turn OFF the override key.
14. Now press increment ▲ key to select the HIGH BOOM ANGLE
and then press, “ENTER” key.
15. Take boom at Maximum working angle.
16. To conform angle, measure the radius as per the load chart.
17. Set the conformed angle value by pressing increment key.
18. Turn ON the “OVER RIDE” key and press “ENTER” key.
19. The boom calibration is over now. Turn OFF the OVERRIDE key.
20. Press “ESC” key to EXIT.

18
 SETTING THE SET POINTS
1. Press Function key (F).
2. Press ENTER key to switch into calibration mode.
3. Press increment ▲ key and then press ENTER key. To enter into
supervisory settings.
4. Press increment ▲key and then ENTER key twice to enter into
Main Hoist SP1
5. Set SP1 at 93% by using increment▲ & decrement ▼key.
6. Press ENTER key.
7. Press increment key once and press ENTER key to enter into
Main Hoist SP2.
8. Set SP2 at 97% by using increment▲ & decrement ▼ key.
9. Press ENTER key.
10. Press increment ▲ key once and press ENTER key to enter into
Main Hoist SP3.
11. Set SP3 at 100% by using increment▲ & decrement ▼ key.
12. Press ENTER key.
13. Press ESC key to EXIT.
Condition Visual Audible Term

When lifted load is  93% Flashing (First No audible Approach

of the SWL LED)

Long intermediate
When lifted load is  98% Flashing Alarm
of the SWL (First LED) beep

Short intermediate
When lifted load is  Steady Cut-off
103% of the SWL (First LED) beep

No Lift Zone
Long intermediate
When angle displayed is
Flashing (Second
beyond capacity chart beep
or third LED)
limits

Long intermediate ‘Anti-two

When two block situation Flashing (Fourth
reached or Fifth LED) Beep Block error’

19
SYSTEM MAINTENANCE
1. ROUTINE WEEKLY CHECKS

Junction Box:
The junction box should be kept free of accumulated dust, dirt, grease
etc. Rag and mild detergent solution can be used to keep the Control
unit clean. Do not use abrasives or stiff bristle brushes. Ensure that all
cable connectors are properly tight.

Display Unit:
The Display unit should be kept free of accumulated dust, dirt, grease
etc. Rag and mild detergent solution can be used to keep the power
supply unit clean. Do not use abrasives or stiff bristle brushes; it may
damage the display facial. If the display facial becomes dirty, clean it by
a non-abrasive cloth dampened with isopropyl alcohol or methyl spirit.
Be careful not to press the display window unduly. Ensure the display
cable connector is proper tight.

Load sensor:
The Load sensor is designed for heavy-duty use. Check the cable and
connector on the load sensor are in proper condition.

SMPS and UPS system:

Make sure that connection from crane electrical panel to the UPS are
properly connected

Cables:
Check all cables. Ensure that all cables are tied to the articulating arms
and booms. Check the places were the cable is entering the cabin.

Accuracy Check:
Check the accuracy of the load indicator by lifting a load of known.

20
CARE TO BE TAKEN WHILE DOING FOLLOWING

 PRESSURE CLEANING

Although all the system components are encapsulated, care should

always be exercised while cleaning the crane with pressure / jet water so
that none of the enclosure seals are damaged, allowing moisture in to
the control electronics.

 PAINTING

Do not paint any of the system components including cables. This

precaution should strictly be followed.

Monthly Checks:

Every month check all the LMI displayed readings, with the actual
readings.

1. Lift the known load and check displayed load.

2. Check the displayed radius with actual, It should be within the range.
3. Check Displayed SWL with load chart SWL should be same with
respect to radius.
4. Check A2B unit with alarm and cut-off.
5. Check motion cut-off of boom up, boom down and overload.
6. Check the hooter.

21
SYSTEM WIRING DIAGRAM

22
23
TROUBLE SHOOTING

The system is designed in such a way that isolating the source of error is
not very difficult. It is important to understand the system fault indication
to find out the source of error and take remedial action. A fault-finding
table is given below.
Symptom Possible Cause Corrective Action
No Power supply to Crane Check supply voltage to the
system
Internal fuse(159003) blown Check the fuse on the power
supply unit and replace it
with correct rating fuse, if
blown.

Display (Part no
Check the all input cable Make the proper
91624) not
connections to system connections.
functioning
Change the cable (part no
Fault in input supply cable
95112)
Fault in Power supply ( Part no Replace power supply unit in
87174 ) the power supply box
Fault in SMPS (Part No Change the SMPS
106005)
Change the UPS System
Fault in UPS system
(Part No72216).
Audible alarm (Part Replace the buzzer
Faulty buzzer in the control
no 182001)not
unit
sounding
Replace the display facial
LCD becomes dark Faulty LCD in the display unit
board (Part no 89255)

24
 Replace display cable(Part
Faulty display cable
Some or any keys no 180025)
not working Faulty Keypad in the display Replace the display facial
unit board (89255)
Loss of calibration data in Recalibrate the load
Wrong output
control unit indicator
Replace the Load Cell cable
Load indication Cable fault or broken
(Part no 95121)
displays incorrect
Replace the load cell
value. Faulty Load cell unit
unit.(Part no 91076)
Replace display cable
Junction box Faulty display cable
(180025)
working but display
Faulty display circuit board in Replace the display circuit
unit not working
the display unit board (Part no. 89111)
The connection between the Check the connection
Angle sensor and Control unit between Signal Junction
is open Box and Control Box and the
Display indicating Angle Sensor unit
Angle Cable Open
The signal voltage from Angle Adjust the angle sensor unit
sensor is too low. It should be (Part no. 91308) to get
more than 100mV. output more than 100mV.
Make appropriate
Check the connection in the
connections.
Display indicating signal junction box, 3rd wire is
Angle Cable Short connected properly
Replace the cable (Part No
Or the wire is shorted
95121)

25
 Check the connection
between Signal Junction
The connection between the Box (part no 92101), Boom
Load sensor and Control unit Junction Box (Part no
may open 92102) and Main junction
Display indicating box (part no 91715) and the
Load Cable Open Load Sensor unit (part no
The signal voltage from Load 91076)
sensor is too low. It should be Check for the connection in
more than 100mV the preamplifier box (part no
71411)

Make appropriate
Check the connection in the
connections
Display indicating signal junction box if wire is
Load Cable Short connected properly
Replace the cable (part no
Or the wire may be shorted
95121)

26
Part List

PART No. PART Description Qty

91624 Display AT355 1
91715 Main Junction Box 1
91076 Main Dynamometer 1
91076 Aux Dynamometer 1
91308 Angle unit 1
92113 Boom Junction Box 1
72216 UPS unit 1
71411 Load Preamplifier 1
89255 Display Facial 1
89111 Display circuit board 1
182002 Bypass key 1
182001 buzzer 1
106005 SMPS 1
106002 Battery 12v 1
196002 Transformer 1
57174 DC-DC supply card 1
180025 Display Cable 1
95140 Signal cable 1
95133 Boom junction cable 1
95121 Load cable 1
95121 Angle Cable 1
95112 Input supply cable 1
71807 Dynamometer mounting kit 1
159003 Fuse 2A 1

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