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Microguard RCI 510 Service Manual

1. COLLECTOR o G CRANE LIE 1 REAR OF WIRING 1 CRANE UPPER Hm wane CRANE CENTER HARNESS Dg ROD PRESSURE PORT PISTON PRESSURE PORT FIGURE 1 1 SYSTEM SCHEMATIC OVERVIEW SkyAz l Equipment Solutions www skyazul com 301 371 6126 5 of 67 SECTION 2 SECTION 2 PROBLEM FINDER This PROBLEM FINDER section is designed to aid in determining the location and type of problem experienced It is important to follow the recommendations within this section before contacting the Greer Company 2 SYSTEM SELF TES T un toes oe rci 1 7 2 2 DISPLAY CONSOLE PROBLEMS nn nn nn 8 2 3 FAULT REPORTING AND FAULT 9 14 2 3 1 GROUP A FAULT nnn nonae nana ada dod a aan 10 11 2 3 2 GROUP B FAULT 000 20000 0 00 12 2 3 3 GROUP C FAULT CODES uci aa 13 2 3 4 GROUP D FAULT tn r a a rn trne 14 2 4 NO FAULT CODE 15 17 2 4 1 ANTI TYVO BLOCK ALARM een aeta ina 15 2 4 2 DISPLAYED LOAD RADIUS 16 17 SkyAz l Equipment Solutions www skyazul com 301 371 6126 6 of 67 SECTION 2 2 1 SYSTEM SELF TEST When the power is turned on or when the TEST button is pressed during operation the c
2. EQUIPMENT SOLUTIONS MicroGuard RC510 SERVICE MANUAL NOTICE SkyAz l makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and or its fitness for a particular purpose SkyAzul will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing performance or use of this manual This document contains proprietary information which is protected by copyright and all rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of SkyAzul SkyAzul reserves proprietary rights to all drawings photos and the data contained therein The drawings photos and data are confidential and cannot be used or reproduced without the written consent of SkyAz l The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice SkyAz l Inc ul 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Fax 301 371 0029 info skyazul com SkyAz l Equipment Solutions www skyazul com 301 371 6126 TABLE OF CONTENTS MICROGUARD RCI 510 RATED CAPACITY LIMITER SYSTEM TROUBLESHOOTING MANUAL INTRODUCTION SERVICE DEDICA IION Z u t e etl ee tal tec e ER INSIDE FRONT COVER WHER
3. Loosen the two securing screws on either side of the sensor potentiometer just enough to allow the sensor potentiometer to be turned by hand Do not remove the screws and do not put pressure on the terminals exiting the sensor 3 Measuring the voltage between TB1 2 and TB1 1 see Figure 6 7 carefully rotate the potentiometer until the voltage measures 0 4 volts Rotating the sensor counterclockwise will increase the voltage Rotating clockwise will reduce the voltage Only fine adjustments are required Do not touch the pendulum hanging behind the sensor assembly as this will affect the reading 4 Tighten the securing screws and check that the voltage remains at 0 4 volts SECURING SCREWS TB1 1 SENSOR TB1 2 ANGLE DRIVE SIGNAL FIGURE 6 7 SENSOR BASEPLATE ASSEMBLY WIRING R XK s sr SkyAzul Equipment Solutions www skyazul com 301 371 6126 47 of 67 SECTION 6 6 9 2 ZERO CALIBRATION The computer must be able to identify where the ZERO point of the angle sensor has been set It is therefore necessary to calibrate the zero setting of the potentiometer Before continuing make sure that the mechanical physical zero has been properly set as described in Section 6 9 1 Using an inclinometer set the boom to 0 zero Enter the CALIBRATION MODE at the display console Refer to Calibration Mode Entry page 39 Select Command 02 SENSOR ZERO Select sensor No 3 Zero the angle sensor V N gt
4. TERMINAL BLOCK WIRING TERMINAL TB1 1 TB1 2 TB1 3 TB1 4 TB1 5 TB1 6 WIRE BLUE GREEN WHITE RED BROWN BLACK COLOR SIGNAL SENSOR ANGLE EXTENSION SENSOR ATB SIGNAL ATB FEED DRIVE DRIVE 4 Tuck unconnected remaining yellow and orange wires down into the shaft 5 Screw the slip ring assembly to the baseplate of the sensor assembly 6 Connect the brown wire on the slip ring assembly to TB1 5 connect the black wire to TB1 6 Strip wires if not already stripped 7 Note Ensure that the wires lay flat Ensure that there will be enough space to allow the slip ring arm to freely rotate 8 Checkthe wiring and then follow the procedures to set up both the angle and extension sensors later in this section SkyAz l Equipment Solutions www skyazul com 301 371 6126 54 of 67 SECTION 6 6 10 4 SIGNAL CABLE ASSEMBLY The SIGNAL CABLE ASSEMBLY provides interconnection between the extension reel sensors the Two Block switch and the system computer REMOVING THE EXTENSION REEL FROM THE BOOM 1 N Oo b o m Fully lower and retract the boom Disconnect the EXTENSION REEL CABLE from the Anti Two Block switch Gripping the extension reel cable firmly remove it from the tie off post Maintain a firm hold on the extension reel cable as the cable unwinds back onto the reel Secure the end of the extension reel cable to prevent unwinding Disconnect the signal cable at the distal end Unbolt the extension reel fr
5. This angle is then used to select capacity charts and operator swing alarms working area alarms In the event that the swing sensor fails the computer will be unable to select a valid capacity chart For fault diagnosis the swing sensor may be accessed by removing the cover of the collector at the cranes swing center See Figure 9 1 below For swing sensor replacement procedures consult factory service COLLECTOR SWING POT MG500 COMPUTER UNIT SWGA SWGB SWG DR AIN 4 AIN 5 SENSE anges DR BULKHEAD CONNECTOR CRANE WIRING HARNESS FIGURE 9 1 SWING SENSOR SCHEMATIC SkyAzul Equipment Solutions www skyazul com 301 371 6126 65 of 67 SECTION 9 9 2 CHECKING THE SWING SENSOR DRIVE VOLTAGE 1 Remove the collector ring cover to expose the swing sensor 2 With the system power turned on measure the voltage between terminal 1 of the swing sensor and crane ground The voltage should be between 4 4 and 4 8 volts 3 Measure the voltage between Terminal 3 of the swing sensor and crane ground The voltage should be between 0 2 and 0 5 volts Voltages outside of those shown in steps 2 and 3 indicate a problem with the swing sensor or cabling connections If voltages are incorrect proceed to SECTION 9 4 If voltages are correct proceed to SECTION 9 3 9 3 CHECKING THE SWING SENSOR OUTPUT VOLTAGE 1 Remove the collector ring cover to expose the swing sensor 2 With the system power turned on measure the
6. cable from the display console wire harness at the rear of the display console 4 Remove the remote bar graph from its bracket by loosening and removing the knob at each end of the remote bar graph Retain the knobs for reuse INSTALLATION OF REMOTE BAR GRAPH 1 Putthe new remote bar graph in position Reconnect and tighten the two knobs 2 Route the cable to the display console and connect the cable 3 Turn on the power and ensure that the remote bar graph operates correctly SkyAz l Equipment Solutions www skyazul com 301 371 6126 37 of 67 SECTION 6 EXTENSION REEL 6 0 ENTERING THE CALIBRATION 39 6 1 EXTENSION REEL 40 6 2 CHECKING THE REEL OFF CABLE LAYERING nennen nnn nnn 41 6 3 CHECKING THE EXTENSION SENSOR DRIVE VOLTAGE 42 6 4 CHECKING THE BOOM EXTENSION SENSOR VOLTAGE 42 6 5 EXTENSION SENSOR SETUP diee eee ies li o abies ea a Rae eua ar 43 6 5 PHYSICAL ZERO uec aded la epe ecc ee a a 43 6 5 2 ZERO CALIBRATION 2 eee iiec agio adv ah amas eve 43 6 53 SPAN CALIBRATION tcc atteinte eee e 44 6 6 CHECKING THE ANGLE SENSOR PENDULUM a a 45 6 7 CHECKING THE AN
7. illuminated the same brightness level up a ONE A missing or dimly lit indication points to a power supply problem Check the indicator chart below for repair actions Display Console ks Communications Power with the system power on O r 5 10 Relay Drive Power FIGURE 3 3 INTERNAL STATUS INDICATORS Indicator states Light OFF Q Light ON 10V 5VD 5VA BATT Check Crane power and circuit breaker VP power to display console shorted to crane ground Check display console bargraph cabling 10V relay power internal short or regulator failure Replace Computer 5VD digital power internal short or regulator failure Replace Computer BOMM vp SION ONE BATT 5VA analog power drive to sensors 2 C C 2 O Check extension reel connection inside reel 8 wiring to extension reel FIGURE 3 4 INDICATOR STATES 8 ACTIONS SkyAz l Eguipment Solutions www skyazul com 301 371 6126 22 of 67 SECTION 3 3 4 THE COMM INDICATOR The COMM indicator provides an indication of the success or otherwise of communication with the display console and of the running state of the computer program Carefully observe the COMM indicator and the display console at power on and through self test then use the following chart to help decide the course of action See Figures 3 2 and 3 4 to locate the position of the COMM indicator COMM INDICATOR indications at powe
8. the computer board provide communication of data between the computer unit and display console as well as bar graph unit if fitted These chips are pluggable and replaceable Replacement of the communications chip does NOT necessitate recalibration of the System It is unlikely that the communications chips will become damaged but in the event that the COMM indicator remains off at all times changing these devices may provide a solution See INTERNAL STATUS INDICATORS and the COMM INDICATOR in this section COMMUNICATIONS CHIPS REMOVAL 1 Turn the power off 2 Refer to Figure 3 2 Remove the chip from the computer board with a chip removal tool COMMUNICATIONS CHIPS INSTALLATION 1 Use an installation tool to insert the new chip into the socket 2 Ensure that the dot on the top of the chip is at the same corner as the IC1 IC2 legend on the circuit board 3 Ensure that all pins are properly inserted into the chip socket These pins are very easily bent WARNING When removing and installing chips ensure that the power is off Do not touch the chip pins unless vou are properly grounded Static electricity can damage the chips Always use a proper IC removal tool Use of screwdrivers fingers or other implements may damage the chip or seriously damage the circuit board Failure to have all pins inserted properly into the chip socket may cause damage to the System and the chip SkyAz l Equipment Solutions www skyazul com 301
9. the display contrast first On bracket mounted models only reposition the display console slightly The most commonly encountered problem is caused by reflections NOTE It may not be possible to correct this problem completely especially on flush mounted display consoles exposed to bright sunlight If the problem concerns the contents of one or more of the display screens refer to the PROBLEM FINDER FLOW CHARTS in SECTION 2 of this manual SkyAz l Equipment Solutions www skyazul com 301 371 6126 32 of 67 SECTION 4 4 3 2 BUTTONS THAT DON T RESPOND All button options are not available for use at all times Ensure that the non responsive button is programmed to respond at that point in the operation of the System Press the button in the center Pressing the printed symbol at one end may not activate the switch underneath Buttons that are damaged or have a surface that is worn may cause the switch underneath to operate improperly In this case refer to OPERATOR S DISPLAY CONSOLE REMOVAL AND INSTALLATION 4 3 3 CONNECTORS A SINGLE CIRCULAR CONNECTOR common to all display models is positioned on the rear of the display console On the bracket mounted style it is clearly visible on the rear of the housing On the flush mounted versions it is hidden behind the panel within the dash assembly This connector carries power and signals from the computer unit to the display console Examine this connector carefully It is possi
10. voltage between Terminal 2 of the swing sensor and crane ground The voltage should be between 0 2 and 4 8 volts 3 Measure the voltage between Terminal 4 of the swing sensor and crane ground The voltage should be between 0 2 and 4 8 volts Voltages outside of those shown in Steps 2 and 3 indicate a problem with the swing sensor or cabling connections If voltages are incorrect proceed to SECTION 9 4 9 4 CHECKING THE SWING SENSOR RESISTANCE 1 Disconnect the connector behind the collector ring 2 Measure the resistance between pins C and D of the connector on the swing sensor side The resistance should be between 2200 and 2800 ohms 3 Measure the resistance between pins A and B of the connector on the swing sensor side The resistance should be between 1800 and 2300 ohms NOTE Resistances outside of those shown in Steps 2 and 3 indicate a problem with the swing sensor or associated cable connections If resistances are incorrect replace the swing sensor and its cable SkyAz l Equipment Solutions www skyazul com 301 371 6126 66 of 67 SECTION 9 9 5 SWING SENSOR SETUP AND CHECKS The following procedures may be used to check or setup the SWING SENSOR Only two setup operations are required ZERO and DIRECTION Unlike other system sensors the swing sensor requires no span calibration to operate Span is automatically calculated by the computer 9 5 1 CHECKING AND SETTING ZERO The 0 zero angle of the upper structur
11. 1 amp TB2 2 terminal connections on the sensor arm FIGURE 7 4 SENSOR ASSEMBLY WIRING AND SLIP RING T r TE SkyAzul Equipment Solutions www skyazul com 301 371 6126 60 of 67 SECTION 7 5 With the A2B switch closed the resistance should be less than 300 ohms If not this suggests that the reel off cable A2B switch or one of the boom head connectors has an Open circuit 6 Open the A2B switch at the boom head by lifting the weight 7 Measure the resistance between TB2 1 amp TB2 2 terminal connections on the sensor arm 8 With the A2B switch open the resistance should be greater than 10 000 ohms If not this suggests that the reel off cable A2B switch or one of the boom head connectors has a short circuit SkyAzul Equipment Solutions www skyazul com 301 371 6126 61 of 67 SECTION 8 SECTION 8 POWER KICKOUT amp BOOM MODE OUTPUTS 8 1 POWER KICKOUT 8 BOOM MODE OUTPUTS 62 63 This section provides schematic outlines of outputs from the computer and is provided for information only Since most of these functions are contained within the computer design and crane wiring harness only limited fault diagnosis may be carried out The FKO fuse FS2 is described in SECTION 3 Iz NRI cA RNC vs a a SkyAzul Equipment Solutions www skyazul com 301 371 6126 62 of 67 SECTION 8 Computer Bulkhead Connector System System power Battery positive input from machine circuit breake
12. 32 4 2 DISPLAY CONSOLE MODELS aasan ite eher EE n etaed avia 32 4 3 CHECKING THE DISPLAY 5 32 33 4 3 1 READING THE LIQUID CRYSTAL 5 32 4 3 2 BUTTONS THAT DON T 33 4 3 3 CONNECTORS Airin EE 33 Loo Agshi 33 A 3 MOISTURE LE 33 4 4 REPLACING THE DISPLAY 2 34 rmcsr r r s a SkyAzul Equipment Solutions www skyazul com 301 371 6126 31 of 67 SECTION 4 4 1 DISPLAY CONSOLE OVERVIEW The OPERATOR S DISPLAY CONSOLE Figure 4 1 allows the user to see the crane values angle radius load etc and crane configuration selection The display also provides calibration functions used for testing and fault diagnosis 4 2 DISPLAY CONSOLE MODELS m O O 1 M ORs Full 9 7 Ctwt c ERECTED 60 TELEJIB 1790 AUXHD ON A s PICK FROM MAIN BOOM FRONT WINCH e J FIGURE 4 1 OPERATOR S DISPLAY CONSOLE 4 3 CHECKING THE DISPLAY CONSOLE The OPERATOR S DISPLAY CONSOLE is normally very reliable However when operated for extended periods under extreme conditions the console can become damaged The damage is not always apparent To help identify subtle faults that are sometimes difficult to find or that may be attributed mistakenly to other kinds of problems please review the following comments 4 3 1 READING THE LIQUID CRYSTAL DISPLAYS Always adjust
13. 371 6126 26 of 67 SECTION 3 3 6 PRESSURE SENSORS There are two PRESSURE SENSORS installed as part of a MicroGuard RCI 510 System Both pressure sensors are mounted within the computer unit and electrically connected to the computer board within One is connected to the PISTON side of the boom hoist cylinder via a flexible hose the other to the ROD side of the boom hoist cylinder via a flexible hose Both hoses are protected by velocity fuses within the boom hoist cylinder valve block on the end of the cylinder s The pressure sensor on the piston side is subject to the hydraulic pressure necessary to support the weight of the boom any attachments and the load The other sensor monitors the pressure necessary to control down motion of the boom The computer unit uses this information along with that from other sensors such as extension length and angle to compute the weight of the suspended load The maximum continuous working pressure for these devices is 250 bar 3625 PSI CHECKING PRESSURE SENSORS The pressure sensing system is factory calibrated therefore pressure sensors may not be individually A WARNING Both pressure sensors are factory pre calibrated and supplied as part of the computer unit Removal or replacement of these devices from the computer invalidates the warranty and will adversely affect the pressure calibration replaced Any serious problems will necessitate changing the whole computer unit 1 Boom f
14. 7 Upper Half Reel Off Cable Plugs into and Turns on Lower Half a f p Cable Ties Lower Half Aes Mounts to end of Extension Slip Ring Arm Reel Shaft Wires connect to 1 5 and TB1 6 on Sensor Baseplate Assembly FIGURE 6 9 SLIP RING ASSEMBLY kx rs sssrr r p SkyAzul Equipment Solutions www skyazul com 301 371 6126 51 of 67 SECTION 6 REMOVING THE SLIP RING ASSEMBLY 1 Remove the extension reel cover Holding the reel off cable on the arm of the slip ring cut the tie wraps Unscrew the reel off cable from TB2 on the arm of the slip ring Unscrew both Phillips screws that hold the lower half of the slip ring on the shaft remove the slip ring 5 Disconnect the two wires connecting the lower half of the slip ring assembly at TB1 5 and TB1 6 on the sensor baseplate assembly INSTALLING THE SLIP RING ASSEMBLY The new SLIP RING ASSEMBLY is pre lubricated with grease Do not wipe off lubrication 1 Attach the brown slip ring wire from the lower half of the new slip ring to TB1 5 on the sensor baseplate assembly Make sure that the brown signal wire is also correctly connected 2 Attach the black or white slip ring wire from the lower half of the new slip ring to TB1 6 on the sensor baseplate assembly Make sure that the black signal cable wire is also correctly connected 3 Screw the bottom half of the slip ring to
15. BLOCK 60 61 in sI m nt SkyAzul Equipment Solutions www skyazul com 301 371 6126 57 of 67 SECTION 7 7 1 ANTI TWO BLOCK FUNCTION OVERVIEW This section describes fault diagnoses of the Anti Two Block detection circuit For details of function kickouts including the Anti Two Block kickout refer to SECTION 8 The computer supplies a protected positive feed to the Anti Two Block switches at the boom jib head via the extension reel signal cable slip ring and extension reel off cable With the Anti Two Block weight hanging freely on the switch es the switch contact is closed and the signal return to the computer is high 6 25 volts When the weight is lifted by the hook block the switch contact is opened and the computer will sense a low signal input 0 volts from the A2B signal return Since the computer checks the protected feed voltage internally the system is capable of detecting a short circuit of the feed or the A2B signal return when the switch is closed to the crane chassis Fault codes are defined in SECTION 2 The Anti Two Block detection circuit is probably the most susceptible part of the System since it is carried through so many of the system components Often most problems with this circuit may be identified through inspection of cables switches and the extension reel Damage to these parts may result in continuous or intermittent A2B alarms SkyAz l Equipment Soluti
16. Before exiting the command check that the displayed value is between 4 and 4 6 9 3 SPAN CALIBRATION The computer must be able to treat measurements of the angle provided by the angle sensor It is therefore necessary to calibrate the SPAN of the angle potentiometer Before continuing ensure that the calibration zero has been properly set as described in SECTION 6 9 2 1 Boom up to a high angle at least 70 and measure the angle with an inclinometer 2 Enterthe CALIBRATION MODE at the display console Refer to Calibration Mode Entry page 39 3 Select Command 03 SENSOR SPAN 4 Select sensor No 3 5 Calibrate the angle span using the angle as measured in step 1 6 Before exiting the command check that the displayed value is between 0 1 and 0 1 of the value entered NOTE The required accuracy of measured angles is within 0 2 When taking boom angle measurements always use a good quality inclinometer Many inclinometers are only accurate at 0 level Ensure that a reliable position on the top of the boom is used to measure the angle and that the inclinometer will provide an accurate reading at 0 and at 70 SkyAzul Equipment Solutions www skyazul com 301 371 6126 48 of 67 SECTION 6 6 10 EXTENSION REEL REPLACEABLE PARTS The EXTENSION REEL is field serviceable in every respect except for the spring chamber extension reel surface and shaft assembly Failure of the recoil spring damage to the shaft or reel
17. E TOGO FOR HELP Sci u ya nal albo best m sab bbs M 4 SECTION 1 OVERVIEW amp PREPARATION e uuu a tubo dass rudu aaa has lana 5 SECTION 2 PROBLEM FINDER RR rio XISRKIRRSRR RR XA nik K 6 SECTION 3 COMPUTER UNIT uu 2 ccs eter nd a ra 19 SECTION 4 DISPLAY CONSOLE rere te eit ecient Eee ev Ree 31 SECTION 5 5 55 35 SECTION 6 EXTENSION dae r nu ona nr Ae ee ed Ma 38 SECTION 7 ANTI TWO BEOGCK FUNCTION a tii rte u lunch ha nh pu mau nn tno nha mre rne ar 57 SECTION 8 POWER KICKOUT amp BOOM MODE 62 SECTION 9 SWING SENSOR uu rna exe Speo Ex e ego SE e ER xa RH ER anus deb EK desk Ue SE de ER us EE eS RU EE de RH 64 SkyAz l Equipment Solutions www skyazul com 301 371 6126 3 of 67 WHERE TO GO FOR HELP When field repairs cannot be made without replacement of a part when troubleshooting advice is needed or when corrections to memory chips are reported one of the following support numbers should be called SkyAz l Inc 200 W Main Street Suite 2A Middletown MD 2176 Phone 301 371 6126 Fax 301 371 0029 www skyazul com info skyazul com SkyAz l E
18. ENDULUM Refer to Figure 6 5 below Push the pendulum downwards in the direction shown and ensure that it doesn t feel as if it is sticking Some resistance of movement may be encountered as the pendulum is moved however this is due to the magnets that provide the damping Release the pendulum and make sure that it returns with free but controlled movement directly back to its original position Push the pendulum downwards a few more times checking that it returns each time to its starting position NOTE If any sticking of the pendulum is encountered while performing the above checks ensure that there are no wires touching the pendulum or that other obvious problems are present If not it will be necessary to replace the sensor assembly Push in this direction Potentiometer Pendulum FIGURE 6 5 SENSOR ASSEMBLY SkyAzul Equipment Solutions www skyazul com 301 371 6126 45 of 67 SECTION 6 6 7 CHECKING THE ANGLE SENSOR DRIVE VOLTAGE 1 2 3 Remove the extension reel cover Using a digital voltmeter measure the voltage between the RED TB1 4 and BLUE TB1 1 wires at the terminal block mounted on the sensor baseplate assembly Check that the voltage is between 4 7 and 5 3 volts Voltages outside the range specified above will indicate an interconnection problem between the extension reel and the computer or a short circuit within the extension reel Check extension reel wiring within th
19. ERATOR S DISPLAY CONSOLE on the bracket in the cab by positioning it between the bracket legs and inserting and tightening the knob on each side of the console 2 Connect the electrical cable to the electrical connector on the rear of the console tt rr iSkyAz l Equipment Solutions www skyazul com 301 371 6126 34 of 67 SECTION 5 SECTION 5 REMOTE BAR GRAPH 5 1 REMOTE BAR GRAPH 36 5 2 CHECKING THE REMOTE BAR GRAPH eee eene 36 37 5 2 1 LAMPS PH RR 36 5 2 2 5 2 2 11 0 La P u su 36 5 2 3 CABLE AND 37 2 Mesi ice 37 5 3 REMOTE BAR GRAPH 37 vO a a SkyAzul Equipment Solutions www skyazul com 301 371 6126 35 of 67 SECTION 5 5 1 REMOTE BAR GRAPH OVERVIEW The REMOTE BAR GRAPH shown below displays the percentage of rated capacity of the crane The remote bar graph is mounted at the top of the cab front window in the operators line of sight User selectable levels of brightness are available on the device which is designed for reading under all lighting conditions Defective remote bar graphs cannot be serviced The remote bar graph is optional and is not used on all cranes Qh FIGURE 5 1 REMOTE BAR GRAPH 5 2 CHECKING THE REMOTE BAR GRAP
20. GLE SENSOR DRIVE VOLTAGE a 46 6 8 CHECKING THE ANGLE SENSOR 2 00 0 0 000040 46 0 9 ANGLE SENSOR SETUP niet eee ere a Pavese ec ees 47 0 9 1 PHY SICAL ZERO cocer erento rte ORE ee ee 47 6 9 2 ZERO CALIBRA T ION iere tense a alasan dde de e dev Re RR 48 6 9 3 SPAN CALIBRATION teta te rot e cene td Ee Read 48 6 10 EXTENSION REEL REPLACEABLE PARTS 49 56 6 10 1 EXTENSION REEL OFF 49 51 6 10 2 SLIP RING 51 52 6 10 3 SENSOR BASEPLATE ASSEMBLY nennen nennen 53 54 6 10 4 SIGNAL CABLE ASSEMBLY sene re rra nene nnne nnns 55 56 SkyAz l Equipment Solutions www skyazul com 301 371 6126 38 of 67 SECTION 6 6 0 ENTERING THE CALIBRATION MODE To perform the calibration sequences shown in this and in the following sections of this manual it will be necessary to access the Calibration Mode followed by entry of the Security Code 1 To access the Calibration Mode locate the Test and Set keys on the Display Console as shown below and press both keys simultaneously for about two seconds 2 Enterthe Calibration Security Code by pressing the keys identif
21. H The REMOTE BAR GRAPH is normally very reliable However when operated for extended periods under extreme conditions the device can become damaged The damage is not always apparent To help identify subtle faults that are sometimes difficult to find or that may be attributed mistakenly to other kinds of problems please review the following comments 5 2 1 LAMPS The LAMPS are LIGHT EMITTING DIODES LED s They are more reliable than standard incandescent bulbs and consume far less power LED operation can be checked at any time by the operator by pressing the test button on the operator s display console Always replace the entire bar graph unit if it is found to be faulty With the System powered there should always be at least one GREEN LED lighted the one furthest from the BRIGHTNESS CONTROL push button even when there is no load suspended The REMOTE BAR GRAPH LED s should track or echo the bar graph on the operator s display console at all times 5 2 2 BRIGHTNESS CONTROL There are four levels of brightness Holding the BRIGHTNESS CONTROL BUTTON continuously will cause the unit to automatically cycle through the available levels Release the button at any time to select the desired setting Alternately pressing and releasing the button will cause the cycle to progress through the four levels in sequence It is not possible to switch off the LED s using this control The currently selected brightness l
22. TION 1 m Ensure that the correct system chip is installed the computer Secure the computer unit to the cab wall with the mounting hardware Ensure that the electrical connections face downward Remove the two protective covers from the electrical bulkhead connector Connect the electrical connectors Remove the protective caps from the hydraulic ports Connect the base side pressure hose to the piston pressure port Connect the rod side pressure hose to the rod pressure port POWER UP AND CALIBRATION 1 Switch the crane power on and check that all LED check lights within the computer unit are illuminated Ensure that the COMMS LED is flashing and that the display console is operating CHECKS e With an inclinometer check the accuracy of the boom angle and the radius measurements and tape at four or five points Ensure that the hydraulic connections are secure and not leaking at the computer unit e Secure the computer lid and rain cover SkyAz l Equipment Solutions www skyazul com 301 371 6126 28 of 67 SECTION 3 THIS PAGE INTENTIONALLY LEFT BLANK rs T a SkyAz l Equipment Solutions www skyazul com 301 371 6126 29 of 67 SECTION 3 THIS PAGE INTENTIONALLY LEFT BLANK rs T a SkyAz l Equipment Solutions www skyazul com 301 371 6126 30 of 67 SECTION 4 SECTION 4 DISPLAY CONSOLE 4 1 DISPLAY CONSOLE OVERVIEW uu trt eere dene hh
23. VE FUSE protecting the power feed to the function kickout circuit is located on the circuit board within the unit The system program capacity chip known as the SYSTEM CHIP IC 16 COMMUNICATIONS CHIPS IC1 IC2 that communicate with the display console and are pluggable 3 5 1 FUNCTION KICKOUT FUSE FS2 The computer unit contains a REPLACEABLE FUSE illustrated in Figure 3 2 that protects the function kickout circuit and relay contacts in the event that a short circuit across the crane kickout solenoids occurs The fuse identified as FS2 on the computer board may be replaced in the event that system error codes indicate that the function kickout power feed is missing and it has been established that the crane circuit breaker is closed and power from the crane is present Before replacing the fuse make sure that any electrical shorts that may have caused the failure of the original fuse have been removed WARNING When removing and installing the fuse ensure that the crane power is turned off SkyAz l Equipment Solutions www skyazul com 301 371 6126 24 of 67 SECTION 3 3 5 2 SYSTEM CHIP 1 16 The computer unit contains a replaceable SYSTEM CHIP illustrated in Figure 3 2 The system chip identified as IC16 on the computer board contains program data capacity charts and calibration data for the crane and is a 28 pin dual in line DIL device This chip MUST MATCH the load chart in the crane Installat
24. ble for the pins and sockets within the connector halves to bend break or pushed back inside the housing On FLUSH MOUNTED DISPLAY CONSOLES VERTICAL MODEL ONE ADDITIONAL CONNECTION besides the circular connector is required The HORN DRIVE WIRE is a single black lead that should be attached to the black terminal on the rear of the display console housing 4 3 4 HORN On vertical FLUSH MOUNTED CONSOLES the HORN is outside the housing If there is a problem with the horn ensure that the HORN DRIVE WIRE is connected correctly to the black terminal on the rear of the display console housing Release the display console from its connections and pull it gently forward If the wire is intact and connected correctly and the horn is still not operating correctly the horn may need to be replaced If possible test the horn operation by temporarily installing another horn known to operate correctly 4 3 5 MOISTURE The DISPLAY CONSOLE offers protection against dust and water when correctly installed SkyAz l Equipment Solutions www skyazul com 301 371 6126 33 of 67 SECTION 4 4 4 REPLACING THE DISPLAY CONSOLE REMOVAL 1 Disconnect the electrical cable from the electrical connector on the rear of the OPERATOR S DISPLAY CONSOLE 2 Remove the defective operator s display console from the bracket in the cab by removing the knob on each side of the console Retain the knobs for future use INSTALLATION 1 Install the new OP
25. ce computer 013 X X X 014 X X X 015 X X X X 016 X Check crane circuit breakers then See SECTION 3 5 1 017 X X 018 X X 019 X X X 020 X X Replace computer 021 X X X 022 X X X 023 X X X X 024 X X Check crane circuit breakers then See SECTION 3 5 1 025 X X X 026 X X X 027 X X X X 028 X X X Replace computer 029 X X X X 030 X X X x 031 x x x x x SkyAz l Equipment Solutions www skyazul com 301 371 6126 12 of 67 2 3 3 GROUP C FAULT CODES GROUP FAULT CODES REPRESENT FAULTS DETECTED FOR INTERNAL COMPUTER MEMORIES The following chart details all the available codes in the left column and the actions to take in the right SECTION 2 column FAULT SERIAL CRANE RAM DUTY PROGRAM ACTION EEPROM 000 No Fault Fo NONE 001 002 Replace system chip 003 Follow SECTION 3 5 2 004 Replace computer 005 006 Replace system chip 007 Follow SECTION 3 5 2 008 X Reset crane data 009 X 010 X Replace system chip 011 X Follow SECTION 3 5 2 012 X Replace computer 013 X 014 X Replace system chip 015 X Follow SECTION 3 5 2 016 Reselect crane setup configuration 017 X 018 X Replace system chip 019 X Follow SECTION 3 5 2 020 X Replace computer 021 X 022 X Replace system chip 023 X Follow SECTION 3 5 2 024 X Reselect crane setup configuration Reset crane data 025 X X X 026 X X X Rep
26. d Single Layer Reel Off Cable FIGURE 6 1 EXTENSION REEL CUT AWAY DRAWING SkyAzul Equipment Solutions www skyazul com 301 371 6126 40 of 67 SECTION 6 6 2 CHECKING THE REEL OFF CABLE LAYERING The extension reel is designed to provide accurate measurement of boom extension when the REEL OFF CABLE forms a single flat layer across the surface of the extension reel as the boom is telescoped in and out Any stacking of the cable will cause extension errors as the boom retracts 1 Telescope the boom fully out and then fully in 2 Check that the reel off cable forms a flat single layer across the surface of the extension reel with each successive turn of cable laying next to the last If any stacking or build up of the cable occurs make sure that the first cable guide at the top of the boom root section is correctly aligned with the outside edge of the extension reel as shown in Figure 6 2 below Clean the reel off cable then lubricate it with a silicone oil Boom Root Section First Cable Guide Reel Off Cable Outside Edge of Reel FIGURE 6 2 EXTENSION REEL VIEWED FROM ABOVE mt s 22 2 SkyAzul Equipment Solutions www skyazul com 301 371 6126 41 of 67 SECTION 6 6 3 CHECKING THE EXTENSION SENSOR DRIVE VOLTAGE 1 Remove the extension reel cover 2 Using digital voltmeter measure the voltage between the RED TB1 4 and BLUE TB1 1 wires at the te
27. d alarms Accuracy of load radius length and angle is determined by the correct installation and maintenance of the system sensors Accuracy of load is governed by the radius accuracy and the extension angle and pressure sensors Accuracy of radius unloaded is governed by the extension and angle sensors Before continuing make sure that there are no system faults CHECK BOOM EXTENSION 1 First check that the boom is fully retracted 2 Check that the extension reel off cable is correctly layered as a single layer across the extension reel surface Any stacking of the cable will cause extension errors when the boom is fully retracted causing the System to exceed the 0 5 ft tolerance allowed by the computer for boom mode selection If the reel off cable is stacking on the reel see SECTION 6 2 3 Check the zero of the extension sensor at the fully retracted boom position Enter the Calibration Mode and use the SPAN command Select sensor 2 to view the extension value in feet The value of extension must be between 0 2 and 0 2 with the boom fully retracted If the extension value is incorrect follow the EXTENSION SENSOR SETUP procedure in SECTION 6 5 4 Fully telescope the boom and check that the displayed boom length value matches the maximum length of the boom If the length value is incorrect follow the EXTENSION SPAN procedure in SECTION 6 5 3 CHECK MAIN BOOM RADIUS NOTE The reguired accuracy of taped radiu
28. des press and hold the TEST button and wait for the system to complete the self test Do not release the TEST button Fault codes will now be displayed at the bottom of the text window for as long as the TEST button is held down FAULTS A000 BO DOO FIGURE 2 2 FAULT CODE DISPLAY SHOWN IN LOWER PORTION OF TEXT DISPLAY WINDOW There are four groups of FAULT CODES amp D The function of these groups and a complete listing of each code is provided on the following pages NOTE ALWAYS INVESTIGATE FAULTS IN THE B AND GROUPS BEFORE CONTINUING WITH A AND FINALLY D GROUP FAULTS SkyAz l Equipment Solutions www skyazul com 301 371 6126 9 of 67 SECTION 2 2 3 1 GROUP A FAULT CODES GROUP A FAULT CODES REPRESENT FAULTS DETECTED FOR ANALOG SENSORS NOTE CHECK AND REPAIR B AND C GROUP FAULTS BEFORE PROCEEDING WITH GROUP A FAULT FINDING SENSORS The following chart details all the available codes in the left column and the actions to take in the right column FAULT Swing Boom Extension Tdx 1 Tdx 0 ACTION CODE Sensor Angle Sensor Rod Piston Sensor Pressure Pressure 000 No Fault Found NONE 001 002 Replace computer 003 004 Follow SECTION 6 4 005 006 Replace computer 007 008 X Follow SECTIONS 6 6 through 6 8 009 X 010 X Replace computer 011 X 012 X Follow SECTION 6 3 013 X 014 X Replace computer 015 X SkyAzul Equipment Solution
29. e reel and at the boom foot base connector 6 8 CHECKING THE ANGLE SENSOR VOLTAGE 4 Using an inclinometer for verification place the main boom at a 0 zero angle then remove the extension reel cover With a digital voltmeter measure the voltage between the BLUE wire TB1 1 and the GREEN wire TB1 2 With the boom horizontal the voltage should be between 0 3 and 0 5 volts If the voltage is incorrect follow the ANGLE SENSOR SETUP PROCEDURE Still measuring the voltage at the same points move the exposed side of the angle sensor pendulum downwards and check that the potentiometer is operating by verifying that the voltage increases Check that the pendulum moves freely and when released falls smoothly back to the original 0 zero voltage reading as measured in Step 5 VA 2 T T f I l lI L TB1 1 SENSOR DRIVE TB1 4 SENSOR TB1 2 ANGLE DRIVE SIGNAL FIGURE 6 6 SENSOR BASEPLATE ASSEMBLY WIRING SkyAz l Equipment Solutions www skyazul com 301 371 6126 46 of 67 SECTION 6 6 9 ANGLE SENSOR SETUP The following procedures define how to reset and calibrate the ANGLE SENSOR as required 6 9 1 PHYSICAL ZERO It may be necessary to ensure that the angle sensor potentiometer is correctly set to its physical zero setting with the boom at 0 ZERO This ensures that the sensor will correctly measure the full angle range of the boom 1 Using an inclinometer set the boom to 0 ZERO 2
30. e should be set with the house lock engaged over front for all types of cranes Before continuing ensure that the upper structure is positioned over FRONT and the the house lock is engaged 1 Enter the CALIBRATION MODE at the display console Refer to Calibration Mode Entry page 39 2 3 Select Command 07 SWING SENSOR 4 Check that the angle value displayed is between 0 5 and 0 5 If not reset the zero by pressing the zero key 9 5 2 CHECKING AND SETTING DIRECTION 1 Enter the CALIBRATION MODE at the display console Refer to Calibration Mode Entry page 39 2 Select Command 04 SWING SENSOR 3 Remove the house lock and swing to the right Check that the angle value displayed increases from zero If not the displayed value will immediately jump to over 350 and continue counting down as the crane upper is swung to the right If this is the case press the direction key to reverse the calibrated direction of the sensor SkyAz l Equipment Solutions www skyazul com 301 371 6126 67 of 67 SkyAzul Inc 200 W Main Street Suite 2A ey Middletown MD 21769 Phone 301 371 6126 a PMENT SOLUTIONS Fax 301 371 0029 www skyazul com info skyazul com
31. en freeze with the message READ UNDERSTAND THE FOLLOWING ASMA MANUAL ANST ANSI B30 5 SkyAz l Equipment Solutions www skyazul com 301 371 6126 7 of 67 SECTION 2 OSHA REGULATIONS OPERATOR S MANUAL e The display segments will be set to and the red and amber and ATB lamps will be on All green configuration lamps will be illuminated IF ANY OF THE ABOVE INDICATIONS DO NOT OCCUR CONTINUE TO SECTION 2 2 DISPLAY CONSOLE PROBLEMS 2 2 DISPLAY CONSOLE PROBLEMS DISPLAY CONSOLE PROBLEMS are difficult to isolate because of the interaction between the display console and the computer unit Failure of either unit or interconnection of the two units causes malfunction of display console indications No FAULT diagnoses of other system problems can be carried out without the proper function of the display console and it s communication with the computer unit To solve problems using display console indications carefully observe the display console at power PROBLEM ACTION There are no display console indications at all Refer to SECTION 3 3 when power is turned on All displays remain blank and no lights are illuminated The load angle radius length and rated Replace display console capacity display windows do not show 488 8 or the bar graph display window has missing black segments during the self test The red or yellow indicator lights do not Replace display console illuminate during self test The displa
32. evel is not stored within the MicroGuard System when the power is switched off Therefore the brightness desired will have to be set again manually when the System is next used The remote bar graph always starts with the LED s set to MAXIMUM brightness SkyAz l Equipment Solutions www skyazul com 301 371 6126 36 of 67 SECTION 5 5 2 3 CABLE AND CONNECTOR The REMOTE BAR GRAPH uses a single cable to communicate with the computer unit and to carry power The cable is nonremovable and is a fixed length Excess cable should be stored not discarded when the unit is installed Extending this cable is not recommended There is a single connector on the far end of this cable This connector carries power and various signals between the computer unit and the remote bar graph Because of the nature of connectors it is possible for the pins and sockets within the connector halves to be damaged A pin may be bent broken or pushed back inside the housing 5 2 4 MOISTURE The REMOTE BAR GRAPH offers adequate protection against dust and water when correctly installed It is not possible however to fully protect the sensitive electronic assembly inside against pressure washing or heavy rainfall If this occurs the remote bar graph should be replaced 5 3 REMOTE BAR GRAPH REPLACEMENT REMOVAL OF REMOTE BAR GRAPH 1 Turn off the power 2 Remove the display console in order to access cabling in connectors 3 Disconnect the remote bar graph
33. ied below as 1234 in that sequence If the wrong Calibration Security Code number sequence is used or if the Calibration Security Code en try is not completed within 5 seconds the entry will be aborted and must be entered again THIS CODE WILL BE USED WHENEVER CALIBRATION IS REQUIRED IT IS HELPFUL TO MEMORIZE THESE KEY POSITIONS AS SHOWN IN FIGURE 6 0 BELOW 2 53 500 K ORs Full 9 7 10 Ctwt ERECTED 60 TELEJIB 179 AUXHD ON A m PICK FROM MAIN BOOM FRONT WINCH FIGURE 6 0 THE RCI 510 400 DISPLAY SkyAz l Equipment Solutions www skyazul com 301 371 6126 39 of 67 SECTION 6 6 1 EXTENSION REEL OVERVIEW The primary operation of the EXTENSION REEL is to measure the extension of the telescoping sections of the main boom The extension reel also includes an angle sensor to measure the main boom angle and an electrical slip ring which transfers the Two Block signal from the reel off cable to the system computer The extension reel is designed to provide a very accurate measurement of extension and angle It is important that the setting up and maintenance of these devices be properly carried out as per the procedures contained within this manual Incorrect maintenance will result in system calculation errors Reel Off Cable Signal Cable amp Connector Sensor Baseplate Assembly Extension Reel Spline r Mounting ssem y LG Baseplate Reel Off Cable Glan
34. ion of the system chip does NOT necessitate recalibration of the System but under certain circumstances may require a RESET CRANE DATA operation to be performed SYSTEM CHIP REMOVAL 1 Turn the power off 2 Referto Figure 3 2 Remove the chip from the computer board with a chip removal tool SYSTEM CHIP INSTALLATION 1 Use an installation tool to insert the new chip into the socket 2 Ensure that the notch in the chip points to the upper side of the computer unit opposite side to bulkhead connector and pressure ports 3 Ensure that all pins are properly inserted into the chip socket These pins are very easily bent WARNING When removing and installing chips ensure that the power is off Do not touch the chip pins unless you are properly grounded Static electricity can damage chips Always use a proper IC removal tool Use of screwdrivers fingers or other implements may damage the chip or seriously damage the circuit board Recommended chip removal and installation tools may be obtained from Newark Electronics Stock No 10F7494 and 10F7497 Failure to have all pins inserted properly into the chip socket may cause damage to the System and the chip SkyAz l Equipment Solutions www skyazul com 301 371 6126 25 of 67 SECTION 3 3 5 3 COMMUNICATIONS CHIPS IC1 2 The computer unit contains two replaceable COMMUNICATIONS CHIPS illustrated in Figure 3 2 The communications chips identified as IC1 and 2 on
35. it to the Anti Two Block switch 10 Follow the EXTENSION SENSOR SETUP PROCEDURE to set the potentiometer zero Recalibration of the extension span should not be necessary 11 Fully telescope the boom in and out at least twice ensuring that the reel off cable remains in a single flat layer on the drum surface and the length display on the display console is accurate with a fully extended or fully retracted boom Any stacking of the cable on the extension reel surface will cause measurement errors If this is the case it may be necessary to check that the first cable guide aligns correctly with the outside edge of the extension reel surface SkyAz l Equipment Solutions www skyazul com 301 371 6126 50 of 67 SECTION 6 12 Reinstall the cover of the extension reel ensuring that the O ring on the inside of the Extension Reel is intact 6 10 2 SLIP RING ASSEMBLY The main purpose of the SLIP RING ASSEMBLY is to provide an electrical path for the feed and switch signal return between the Two Block switch and the system computer It is unlikely that the slip ring assembly should ever require repair or replacement If such an event arises however both the upper and lower halves of the slip ring assembly must be replaced at the same time Failure of the slip ring assembly will most likely result in a continuous Two Block alarm For information on testing and checking the slip ring assembly refer to the Anti Two Block function in SECTION
36. l block on the slip ring support arm Loosen the gray cable gland mounted on the cheekplate Pull the existing extension reel off cable out through the cable gland INSTALLING THE EXTENSION REEL OFF CABLE 1 Loosen the strain relief on the cheekplate and feed the EXTENSION REEL OFF CABLE through the wall of the cheekplate Leave enough slack to work easily with the cable 2 If not already stripped remove 1 of the outer jacket of the cable with an X ACTO knife 3 Unravel the stainless steel braid and twist it into a single wire 4 Remove 1 4 insulation from the center wire The insulation bonded to the center wire is difficult to remove Remove small increments about 0 1 at a time with wire strippers 5 Connect the extension reel off cable to TB2 on the arm of the slip ring The braided wire connects to the black wire and the center core connects to the brown wire Using two cable ties tie the cable to the arm of the slip ring 6 Secure the extension reel off cable to the arm of the slip ring with 2 tie wraps 7 Adjust the cable to bend slightly from the strain relief to the slip ring Rotate the extension reel Ensure that the path of the new cable is unimpeded then tighten the strain relief 8 Wind the extension reel off cable onto the extension reel in a single layer 9 Set pre tension 5 turns counterclockwise Thread the extension reel off cable through the cable guides Attach the cable to the boom tie off post and connect
37. lace system chip 027 X X X X Follow SECTION 3 5 2 028 X X X 029 X X X X Replace computer 030 X X X X 031 X X X X X SkyAz l Equipment Solutions www skyazul com 13 of 67 301 371 6126 SECTION 2 2 3 4 GROUP D FAULT CODES GROUP D FAULT CODES REPRESENT FAULTS DETECTED FOR CAPACITY CHART SELECTION The following chart details all the available codes in the left column and the actions to take in the right column FAULT ACTION 000 No Fault Found NONE 001 X Re select CRANE SETUP Check other sensor faults first 002 Boom length is out of range for selected chart Check crane setup boom length and extension 003 Re select CRANE SETUP Check other sensor faults first 004 Swing to correct working area to select chart Check swing sensor zero position Follow SECTION 9 5 005 Swing to correct working area to select chart Check swing sensor zero position Follow SECTION 9 5 006 Re select CRANE SETUP Check other sensor faults first 007 Re select CRANE SETUP Check other sensor faults first SkyAz l Equipment Solutions www skyazul com 301 371 6126 14 of 67 SECTION 2 2 4 NO FAULT CODE PROBLEMS THIS SECTION ADDRESSES THOSE PROBLEMS THAT MAY OCCUR AND ARE NOT REPORTED BY THE COMPUTER FAULT CODE SYSTEM 2 4 1 ANTI TWO BLOCK ALARM A2B This section gives direction to fault diagnosis of A2B alarm problems For detailed information schematic and voltages refer t
38. noses of the boom sensors may be made at this terminal block Angle Sensor Shaft Mounting Collar Potentiometer amp Set Screw Extension Sensor Angle Sensor Gears amp Clutch Pendulum Extension Sensor Potentiometer Terminal Block TB1 FIGURE 6 10 SENSOR BASEPLATE ASSEMBLY rm a SkyAzul Equipment Solutions www skyazul com 301 371 6126 53 of 67 SECTION 6 REMOVING THE SENSOR ASSEMBLY 1 Remove the aluminum cover on the extension reel Unscrew the screws holding the slip ring to the mounting ring of the SENSOR ASSEMBLY Disconnect the brown and black wires Disconnect the signal cable wires to terminal block TB1 Using a 5 32 Allen wrench loosen the set screw that holds the baseplate on the shaft F N Remove the sensor assembly INSTALLING THE SENSOR ASSEMBLY Place the boom in a horizontal position when installing the SENSOR ASSEMBLY 1 Feed the wires coming out of the main shaft through the mounting collar on the sensor assembly 2 While pulling both extension sensor gears out against the spring slide the sensor assembly onto the shaft until the top of the shaft aligns with the top of the mounting collar Align the top edge of the assembly parallel with the boom 3 Tighten the set screw and release the gears allowing them to mesh with the extension reel spline Route the wires to the terminal block and hook up the wires as indicated below Refer to Figure 6 10 SENSOR ASSEMBLY
39. o setting when the boom is fully retracted This ensures that the sensor will correctly measure over the full telescoping range of the boom 1 Fully retract the boom Extension Sensor gear 2 With the cover of the extension reel removed disengage the main Extension gear wheel connected to the Sensor extension sensor by pulling the sensor arm in the direction shown Sensor Arm 3 Rotate the gear clockwise until the sensors clutch detonate starts to Move the sensor arm click At the next click stop in this direction to disengage the gear rotating the gear 4 Measure the voltage between TB1 3 and TB1 1 Figure 6 3 FIGURE 6 4 SENSOR ASSEMBLY 5 Rotate the gear counterclockwise about half a turn setting the voltage to 0 2 volts Then carefully release the sensor arm ensuring that the voltage remains at 0 2 volts as the gears re engage 6 5 2 ZERO CALIBRATION The computer must identify where the ZERO POINT of the extension sensor has been set see above It is therefore necessary to calibrate the zero setting of the potentiometer Before continuing ensure that the mechanical zero has been properly set See SECTION 6 5 1 Fully retract the boom Enter the calibration mode at the display console Refer to Calibration Mode Entry page 39 Select Command 02 SENSOR ZERO Select sensor No 2 Zero the extension sensor O fF wn gt Before exiting the command ensure that the displayed value is be
40. o SECTION 7 ANTI TWO BLOCK FUNCTION PROBLEM The Anti Two Block alarm is continuously ON Operating the switch at the boom head does not deactivate the alarm This problem suggests an open circuit between the computer A2B input and the A2B switch es or an open circuit between the computer A2B feed and the A2B switch es 1 Check extension reel off cable for damage 2 Make sure that the Two Block switches are correctly connected 3 Check the slip ring and wiring inside the extension reel 4 Check the signal cable from the extension reel to the computer Check connectors PROBLEM e The Anti Two Block alarm is continuously OFF safe De operating the switch at the boom head by lifting the A2B weight does not activate the alarm This problem suggests a short circuit between the computer A2B input and the computer A2B feed somewhere between the computer and the A2B switch es 1 Check extension reel off cable for damage 2 Make sure that the Two Block switches are correctly connected 3 Check the slip ring and wiring inside the extension reel 4 Check the signal cable from the reel to the computer Check connectors SkyAz l Equipment Solutions www skyazul com 301 371 6126 15 of 67 SECTION 2 2 4 2 DISPLAYED LOAD OR RADIUS ERRORS This section gives direction to fault diagnosis of load and radius errors as displayed on the display console Load or radius errors may give rise to early or late tripping of overloa
41. om the crane with a wrench REMOVING THE SIGNAL CABLE FROM THE EXTENSION REEL 1 2 3 Remove the cover from the extension reel Remove the slip ring on the baseplate of the sensor assembly Disconnect all wires from the sensor assembly EXCEPT for the 6 wires leading to the angle and extension sensor potentiometers To protect the sensors within the extension reel use two screws to temporarily reattach the cover of the extension reel Turn over the extension reel with cover attached exposing the back of the device With the wires still disconnected pull the SIGNAL CABLE out of the main shaft in the center of the reel This cable has a strain relief encircled with an O Ring creating a tight fit that seals out water NOTE If it is difficult to remove the cable use the Insertion Extraction tool from the FRONT of the extension reel to release the cable SkyAz l Equipment Solutions www skyazul com 301 371 6126 55 of 67 SECTION 6 INSTALLING THE SIGNAL CABLE 1 Unpack the new SIGNAL CABLE and ensure that the O ring on the strain relief is greased 2 With the back of the extension reel still exposed insert the end of the signal cable with the O ring into the mounting plate and down the shaft in the center of the reel 3 Seatthe strain relief with attached O ring as follows using the tool provided in the kit 4 Bend the cable to the side Position the hollowed out section of the tool on the strain
42. omputer and operator s display console perform a SELF TEST which as far as is possible verifies that the computer display console cables and all remote sensors are working properly During SELF TEST all display functions are activated allowing the operator to check whether or not all indicators are functional NOTE It is important that the indications shown during the SELF TEST are recognized and fully understood by the operator in order to aid in correctly determining computer and display communication problems 1 K ORs Full 9 7 10 Ctwt ERECTED 60 TELEJIB 170 AUXHD ON A ge PICK FROM MAIN BOOM FRONT WINCH FIGURE 2 1 THE DISPLAY CONSOLE For six seconds following power on or activation of the TEST button T the display will show the following indications e All display segments of the bar graph display B will be black ON e All display segments of the load angle radius length and rated capacity windows will be black ON showing 488 8 or 888 800 for load and capacity All green configuration lamps will be illuminated e The red LED indicators for overload and Anti Two Block will be illuminated The yellow LED indicator for pre warning will be illuminated e The audible alarm will sound in the crane cab e The display will now show the crane model chart number and the units of measurement along with the message SELF TEST IN PROGRESS e The display will th
43. ons www skyazul com 301 371 6126 58 of 67 SECTION 7 SLIP RING A2B SWITCH ES amp CONNECTOR REEL OFF CABLE E EXTENSION REEL AT BOOMIJIB HEAD SIGNAL CABLE EXTENSION REEL 8 WAY MG500 COMPUTER UNIT CONNECTOR BULKHEAD CONNECTOR CRANE WIRING HARNESS FIGURE 7 1 ANTI TWO BLOCK FUNCTION SCHEMATIC e SkyAz l Eguipment Solutions www skyazul com 301 371 6126 59 of 67 SECTION 7 7 2 CHECKING THE EXTENSION REEL OFF CABLE The outer braid of the cable carries the Anti Two Block feed to the switches If the cable sheath is damaged this may cause a short circuit to the boom chassis If this is the case a fault code above B 8 will be indicated See SECTION 2 3 2 The same fault code will be indicated if the A2B switch is closed and the inner core of the cable is shorted to chassis at some point in the wiring Carefully inspect the reel off cable for wear Check for signs of damage to the outer sheath of the cable Check for any signs of severe kinking or crushing of the cable 7 3 CHECKING THE ANTI TWO BLOCK CIRCUIT Before continuing ensure that connectors are correctly connected to the A2B switches at the boom head jib 1 Remove the extension reel cover 2 Disconnect the slip ring arm from the plug by pulling it away from the center of the reel 3 Close the A2B switch at the boom head by suspending the weight from it or pulling on the chain 4 Measure the resistance between TB2
44. pre calibrated and as such may not be separately replaced in the field FIGURE 3 1 THE COMPUTER UNIT r m wr 22 222 SkyAzul Equipment Solutions www skyazul com 301 371 6126 20 of 67 SECTION 3 3 2 COMPUTER UNIT LAYOUT Power and Communication Communications System Chip IC16 Indicators s Notch at Top Chips of Chip IC1 IC2 Piston Pressure Rod Pressure Bulkhead Connector Port Port FKO Fuse FS2 10A FIGURE 3 2 COMPUTER UNIT LAYOUT LID REMOVED _rmrss r rs a SkyAz l Equipment Solutions www skyazul com 301 371 6126 21 of 67 SECTION 3 3 3 INTERNAL STATUS INDICATORS The computer unit contains a row of indicators to aid in checking power supply and communications operation within the system Remove the lid of the computer and check these indicators Refer to the computer unit layout in Figure 3 2 5V Digital All the indicators are bright green light emitting diodes There Protected Machine Machine are five power indicators and one communication indicator COMM With the exception of the COMM indicator all 4 indicators should be
45. quipment Solutions www skyazul com 301 371 6126 4 of 67 SECTION 1 SECTION 1 OVERVIEW amp PREPARATION This Troubleshooting Manual for the MicroGuard RCI 510 Rated Capacity Limiter System manufactured by the Greer Company provides information and methods for isolating problems that may arise during operation of the System Some of these problems can be corrected in the field Other problems may require replacement of parts or a return of a part to the factory for servicing Service personnel should have prior training and experience in the procedure for operation and setup of this System The procedures in this manual where possible are based on crane operation and function A basic tool kit consisting of wrenches and screwdrivers flat and Phillips blades will be required to remove covers and units for inspection A digital multimeter DMM may be required The DMM must be capable of measuring DC voltage with a range of 0 volts to 50 volts and resolution of 0 1 volts Resistance range is 0 ohms to 2 megohms Low cost analog meters are not appropriate since the input impedance of these meters can give false readings TOM MUN NCC EEUU EMEN ANTI TWO BLOCK SWITCHES amp CONNECTORS BARGRAPH UNIT OPTIONAL oooooooooooooooo EXTENSION REEL SIGNAL CABLE CAB INTERNAL DISPLAY CONSOLE crane 1 WIRING BOOM JUNCTION BOX HARNESS SWING SENSOR 3 CABLE D
46. r System Power Ground i Battery negative Y3 Fuse 10A FKO Power H Feed from machine circuit breaker To Digital Input Tests presence of NC Function Kickout Power Overload Fault Relay contact NO Test Signals To Digital Input Tests for Open circuit relay contact Bypassed relay contact Function Kickout Circuit Crane Wiring MG500 Computer Harness NC Anti Two Block Relay contact To Digital Input NO Function Kickout Tests for a Output to machine Open circuit relay contact R1 solenoids Bypassed FKO circuit i FIGURE 8 1 POWER FUNCTION KICKOUT amp BOOM MODE SCHEMATIC rr Rs SkyAzul Equipment Solutions www skyazul com 301 371 6126 63 of 67 SECTION 9 SECTION 9 SWING SENSOR 9 1 SWING SENSOR OVERVIEW octets tet eerie dened nre a eda i gs 65 9 2 CHECKING THE SWING SENSOR DRIVE 66 9 3 CHECKING THE SWING SENSOR OUTPUT VOLTAGE eee 66 9 4 CHECKING THE SWING SENSOR 66 9 5 SWING SENSOR SETUP AND 67 9 5 1 CHECKING AND SETTING 7 67 9 5 2 CHECKING AND SETTING 67 rsrr s HBH SkyAzul Equipment Solutions www skyazul com 301 371 6126 64 of 67 SECTION 9 9 1 SWING SENSOR OVERVIEW The SWING SENSOR measures the angle of the upper structure of the crane relative to its carrier
47. r ON ACTION From the moment the power is applied the COMM indicator does not illuminate During and after the self test period of eight seconds the COMM indicator remains off The computer is not running Check status indicators See SECTION 3 3 Try to reset the system by powering off and on again Listen to the computer for the relays to click If they do not click replace the system chip If not successful replace the computer If the relays do click replace communication chips IC1 2 See SECTION 3 5 3 From the moment system power is applied the COMM indicator flashes at a fast rate and never stops The display console never goes to 4 normal display and displays 88 8 or 888 000 in the number display windows Communication with the display has not been made Check connector at rear of the display console At the moment power is applied the COMM indicator flashes briefly then switches off After a few seconds the COMM indicator starts to flash at a fast rate and never stops This is the normal operation of the communication between the computer and display console If there are any problems with indications on the display console go to SECTION 2 2 O a a SkyAzul Equipment Solutions www skyazul com 301 371 6126 23 of 67 SECTION 3 3 5 COMPUTER UNIT REPLACEABLE PARTS The COMPUTER UNIT contains three parts that may be replaced in the field A STANDARD 10 AMP AUTOMOTI
48. re the angle with the inclinometer Check that the displayed angle matches the inclinometer reading within 0 2 If the displayed angle is incorrect follow the angle span calibration procedure in SECTION 6 9 3 CHECK PRESSURE SENSORS The Pressure sensing system is factory calibrated therefore pressure sensors may not be individually replaced Any serious problems will necessitate changing the whole computer unit 1 Boom fully down until the boom hoist cylinder is fully retracted and on its stop 2 Loosen both hydraulic connections to the pressure sensors to guarantee zero pressure is present on the sensors 3 Enter the CALIBRATION MODE and use the PRESSURE MONITOR command to iew both sensor pressures and nett pressure 4 Checkthe PRESSURE values of both sensors The PRESSURE values should be between 75 and 75 PSI If not replace the computer unit 5 Check the NETT pressure This should be between 35 and 35 psi If not replace the computer unit gt 15 Pressure Monitor Temperature 23 Piston Pressure 8 gt Rod Pressure 5 Nett Pressure 11 EXIT FIGURE 2 3 PRESSURE MONITOR SkyAz l Equipment Solutions www skyazul com 301 371 6126 17 of 68 SECTION 2 THIS PAGE INTENTIONALLY LEFT BLANK m nErmW rr Fr Y MSkyAz l Equipment Solutions www skyazul com 301 371 6126 18 of 67 SECTION 3 SECTION 3 COMPUTER UNIT The COMPUTER UNIT SECTION defines troubleshooting techniques and limited replacement procedure
49. relief plug at the top of the shaft 5 With a hammer gently tap the top of the tool forcing the strain relief into proper position in the shaft Continue to tap gently until the strain relief plug will go no further 6 Turn over the extension reel and remove the cover 7 Connectthe wires to the terminal block on the baseplate as indicated below CABLE TERMINAL BLOCK TERMINAL TB44 1 TB1 2 TB1 3 TB1 4 TB1 TB1 6 WIRE BLUE GREEN WHITE BROWN BLACK COLOR SIGNAL SENSOR ANGLE EXTENSION SENSOR ATB SIGNAL ATB FEED DRIVE DRIVE 8 Tuck the unconnected remaining yellow and orange wires down into the shaft 9 Connect the brown wire from the slip ring assembly to TB1 5 connect the black wire to TB1 6 Strip wires if not already stripped 10 Screw the slip ring assembly to the baseplate of the sensor assembly 11 NOTE Ensure that the wires lay flat and toward the terminal connectors as shown in Figure 6 1 on page 40 Ensure that there will be enough space to clear the wires when the arm of the slip ring rotates 12 Replace the cover on the extension reel reinstall the extension reel SkyAz l Equipment Solutions www skyazul com 301 371 6126 56 of 67 SECTION 7 SECTION 7 ANTI TWO BLOCK FUNCTION 7 1 ANTI TWO BLOCK FUNCTION 2 2 58 59 7 2 CHECKING THE EXTENSION REEL OFF CABLE eee emen 60 7 3 CHECKING THE ANTI TWO
50. rminal block mounted on the sensor baseplate assembly 3 Check that the voltage is between 4 7 and 5 3 volts Voltages outside the range specified above will indicate an interconnection problem between the extension reel and the computer or a short circuit within the extension reel Check extension reel wiring within the reel and at connector J305 6 4 CHECKING THE BOOM EXTENSION SENSOR VOLTAGE 1 Fully retract the boom 2 Remove the extension reel cover 3 With a digital voltmeter measure the voltage between the BLUE wire TB1 1 and the WHITE wire TB1 3 4 With the boom fully retracted the voltage should be between 0 1 and 0 3 volts If the voltage is incorrect follow the EXTENSION SENSOR SETUP PROCEDURE 5 Still measuring the voltage at the same points telescope the boom out and check that the TB1 1 SENSOR DRIVE TB1 4 SENSOR potentiometer is operating by 1 3 EXTENSION verifying DRIVE that the voltage increases SIGNAL FIGURE 6 3 SENSOR BASEPLATE ASSEMBLY WIRING SkyAz l Equipment Solutions www skyazul com 301 371 6126 42 of 67 SECTION 6 6 5 EXTENSION SENSOR SETUP The following procedures define how to reset and calibrate the EXTENSION SENSOR if necessary Before any of these procedures are used check that the reel off cable is layering correctly SECTION 6 2 6 5 1 PHYSICAL ZERO It is necessary to ensure that the extension sensor potentiometer is correctly set to its minimum zer
51. s 3 1 COMPUTER UNIT OVERVIEW dea eda eit nisus 20 3 2 COMPUTER UNIT LAYOUT rra dva Lo oaa ee dot ra gei dad oe dati ee 21 3 3 INTERNAL STATUS INDICATORS 20 22 3 4 THE COMM INDICATOR 23 3 5 COMPUTER UNIT REPLACEABLE PARTS ene enne ne nenne 24 26 3 5 1 FUNCTION KICKOUT FUSE 52 24 3 5 2 SYSTEM CHIP IC16 u uu u uuu l u u u za vod akata z CURRERE 25 3 5 3 COMMUNICATIONS CHIPS 1 2 26 3 6 PRESSURE SENSORS ra adr ae raa t Cha xr ea quer Sau ra desta dex ae aa an 27 3 7 REPLACING THE COMPUTER 2 96 28 SkyAz l Equipment Solutions www skyazul com 301 371 6126 19 of 67 SECTION 3 3 1 COMPUTER UNIT OVERVIEW The COMPUTER UNIT shown in Figures 3 1 and 3 2 is the center of the System The computer unit provides all the necessary functions to read the sensors control computations disconnect functions and communicate with the display console internal bar graph The computer unit directly connects to the crane wiring harness via a 60 way bulkhead connector There are no wiring connections or screw terminals within the unit Contained within the unit are the two hydraulic pressure transducers required to sense pressure within the boom hoist cylinder These sensors and the computer are factory
52. s measurements is within 0 1 feet When taking radius measurements always use a good quality tape that does not stretch The tape should be graduated in feet and tenths of feet Always measure between the swing center of the crane and the hook line using a single part of line with the crane centered over front rough terrain crane or centered over rear truck crane 1 Fully retract the boom and make sure that the crane configuration is correctly set up 2 Boom up to about 45 and measure the radius The measured radius must match the displayed radius within 0 2 ft If it does not match continue to the CHECK BOOM ANGLE procedure If it does match continue to CHECK PRESSURE SENSORS Both procedures are on the next page SkyAz l Equipment Solutions www skyazul com 301 371 6126 16 of 67 SECTION 2 CHECK BOOM ANGLE NOTE The required accuracy of measured angles is within 0 2 When taking boom angle measurements always use a good quality inclinometer Many inclinometers are only accurate at 0 level Make sure that a reliable position on the top of the boom is used to measure the angle and that the inclinometer will provide an accurate reading at 0 zero and at 70 Fully retract the boom Using an inclinometer set the boom to 0 zero and check that the displayed boom angle value is 0 0 If the angle value is not 0 0 follow SECTIONS 6 6 6 9 1 and 6 9 2 Boom up to a high angle at least 70 and measu
53. s www skyazul com 301 371 6126 10 of 67 SECTION 2 2 3 1 GROUP A FAULT CODES continued FAULT Swing Boom Extension Tdx 0 ACTION CODE Sensor Angle Sensor Piston Sensor Pressure Pressure Follow SECTION 9 Replace computer Follow SECTIONS 6 3 6 4 amp 9 Replace computer Follow SECTIONS 6 7 6 8 amp 9 Replace computer Follow SECTIONS 6 3 6 4 6 7 6 8 amp 9 Replace computer X X X X X X X X X X X X X X X X gt x x x x x x Follow SECTIONS 6 3 6 4 6 7 6 8 amp 9 Internal Temperature Sensor Fault Replace Computer Unit _ a a SkyAzul Equipment Solutions www skyazul com 301 371 6126 11 of 67 SECTION 2 2 3 2 GROUP B FAULT CODES GROUP B FAULT CODES REPRESENT FAULTS DETECTED FOR INTERNAL ANALOG FUNCTIONS AND POWER FEEDS TO THE FUNCTION KICKOUT AND ANTI TWO BLOCK SWITCHES The following chart details all of the available codes in the left column and the actions to take in the right column FAULT FKO A2B DISPLAY ADC2 ADC 1 ACTION CODE POWER POWER CONSOLE INTERNAL INTERNAL FEED FEED FAULT FAULT 000 No Fault Found NONE 001 X 002 X 003 X X 004 X Replace computer 005 X X 006 X X 007 X X X 008 X See SECTION 7 009 X X 010 X X 011 X X X 012 X X Repla
54. surface and side plates requires complete replacement of the extension reel The following parts of the extension reel are field replaceable EXTENSION REEL OFF CABLE ASSY SLIP RING ASSEMBLY SENSOR BASEPLATE ASSEMBLY CABLE TAIL ASSEMBLY SIGNAL CABLE e COVER 6 10 1 EXTENSION REEL OFF CABLE The EXTENSION REEL OFF CABLE running from the extension reel to the main boom head carries the Anti Two Block signal from the switches at the main boom head aux head and erected jib fly The cable is made from stainless steel wire and a durable outer sheath Damage to the cable will often result in bad Two Block signals or bad measurement of boom extension If the cable has been broken or damaged in any way it can be field replaced Cable Ties Reel Off Cable TB2 FIGURE 6 8 REEL OFF CABLE CONNECTION THE EXTENSION REEL SkyAz l Equipment Solutions www skyazul com 301 371 6126 49 of 67 SECTION 6 REMOVING THE EXTENSION REEL OFF CABLE 1 V m Fully retract and lower the boom Then disconnect the REEL OFF CABLE from the Anti Two Block switch or connector Gripping the cable firmly release it from the tie off post Continue to grip the cable firmly while allowing it to fully wind back onto the extension reel Remove the extension reel cover Cut the 2 tie wraps that secure the extension reel off cable to the slip ring support arm Unscrew the extension reel off cable from the termina
55. the shaft with the two Phillips screws making sure that wires exiting through the center of the shaft are not trapped 4 Connect the extension reel off cable to TB2 on the arm of the slip ring The braided shield connects to the slip ring TB2 black wire and the center of the cable connects to the slip ring TB2 brown wire 5 Secure the extension reel off cable to the arm of the slip ring with two cable ties 6 Ensure that the slip ring is plugged in all the way 7 Replace the extension reel cover SkyAz l Equipment Solutions www skyazul com 301 371 6126 52 of 67 SECTION 6 6 10 3 SENSOR BASEPLATE ASSEMBLY The SENSOR BASEPLATE ASSEMBLY supports both the extension and angle sensors and provides interconnection between the sensors the Two Block switch signal to the slip ring and the signal cable to the system computer Electrical or mechanical failure of either the angle sensor or the extension sensor potentiometers may not be field repaired since the angle sensor pendulum is factory set on the potentiometer shaft and the extension potentiometer gear contains a protection clutch which is difficult to replace in the field In the event of failure of either of these items the whole sensor baseplate assembly must be replaced The terminal block TB1 mounted on the assembly provides wiring connection for all internal parts of the extension reel and the signal cable connecting the reel to the system computer Most electrical diag
56. tween 4 and 4 SkyAzul Equipment Solutions www skyazul com 301 371 6126 43 of 67 SECTION 6 6 5 3 SPAN CALIBRATION The computer must be able to treat measurements of distance provided by the extension sensor It is therefore necessary to calibrate the SPAN of the extension potentiometer Before continuing ensure that the calibration zero has been properly set as described in SECTION 6 5 2 page 43 1 Fully extend the boom 2 Enterthe CALIBRATION MODE at the display console Refer to Calibration Mode Entry page 39 3 Select Command 03 SENSOR SPAN 4 Select sensor No 2 5 Calibrate the SPAN value which is the fully extended boom length minus the fully retracted boom length 6 Before exiting the Command check that the displayed value is within 0 2 of the extension value calculated in No 5 above rr c nIp n r U SkyAz l Equipment Solutions www skyazul com 301 371 6126 44 of 67 SECTION 6 6 6 CHECKING THE ANGLE SENSOR PENDULUM The ANGLE SENSOR uses a copper PENDULUM mounted behind the sensor assembly In order to stop the pendulum from swinging uncontrollably during movements of the boom two magnets provide damping If problems with the angle sensor are suspected check that the pendulum and potentiometer are operating without restriction before continuing to check electrical operation and performing any calibration 1 2 3 Remove the extension reel cover Locate the P
57. ully down until the boom hoist cylinder is fully retracted and on its stop 2 Loosen both hydraulic connections to the pressure sensors to guarantee zero pressure is present on the sensors 3 Enter the CALIBRATION MODE and use the PRESSURE MONITOR command to view both sensor pressures and nett pressure 4 Checkthe PRESSURE values of both sensors They should be between 75 and 75 PSI If not replace the computer unit 5 Check the NETT pressure This should be between 35 and 35 PSI If not replace the computer unit 15 Pressure Monitor Temperature 23 Piston Pressure 8 Rod Pressure 5 Nett Pressure 11 FIGURE 3 5 PRESSURE MONITOR SkyAz l Equipment Solutions www skyazul com 301 371 6126 27 of 67 SECTION 3 3 7 REPLACING THE COMPUTER UNIT When changing the COMPUTER UNIT it is strongly recommended that the SYSTEM CHIP be replaced at the same time This ensures that the latest version of the chip is installed and guarantees that problems that may be caused by the existing chip are eradicated COMPUTER REMOVAL 1 2 3 4 5 Boom down all of the way so that the boom hoist cylinder is fully retracted or the boom is firmly in the boom rest Disconnect hydraulic connections at the computer unit Note which hose is connected to the piston and rod pressure ports Disconnect both electrical connectors at the computer unit Remove the hardware securing the computer to the cab wall COMPUTER INSTALLA
58. y console does not do the self test Replace display console No words or logical numbers ever appear after power is turned on The displays look jumbled with lots of missing segments The display console lights are lit Load angle Display console is OK radius length and rated capacity show 488 8 or 888 800 for load and capacity but the dis play window shows only a message Bad Refer to SECTION 3 4 communications with main computer Check connectors at rear of display console E E SkyAz l Equipment Solutions www skyazul com 301 371 6126 8 of 67 SECTION 2 2 3 FAULT REPORTING AND FAULT CODES SYSTEM FAULT CODES provide one of the most important ways to quickly locate and assess problems in the MicroGuard System Please review this section carefully Each time the system is turned on it goes through a self testing process lasting six seconds that automatically detects most faults in the system During normal operation a self test can be initiated at any time by pressing the TEST button on the display console Many fault conditions are detected without a system self test Faults detected in the system during the self test are indicated on the display console in the following Ways RED OVERLOAD LAMP will illuminate e The AUDIBLE ALARM will sound WARNING SYSTEM FAULT will be displayed at the bottom of the text window Fault codes may be displayed on the display console To view the co

Microguard RCI 510 Service Manual

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