Mipeg Safe Load Indicator Sagar Kiran Manual m2000nr

Aanderaa Data Instruments Document W-130 H00 623, Date 26.06.
06, Page 1 of 34

MIPEG

COMPUTERISED CRANE MONITORING
SYSTEMS

Mipeg 2000NR
Safe Load Indicator System
Operating & Maintenance Manual

SeaTrax
Model 4228 - Offshore Pedestal Crane

Sagar Kiran
ANCHOR ONGC SVR INTERNATIONAL

Aanderaa Data Instruments Document W-130 H00 623, Date 26.06.06, Page 2 of 34

Contents Page

SAFETY NOTES ............................................................................................................................. 4
General Description............................................................................................................................ 5
Operating Instructions ....................................................................................................................... 7
3.1 Brief Description of MIPEG 2000 Operation....................................................................... 7
3.1.1 Verification of Driver's Display Unit......................................................................................................... 7
3.2 Information presented on the Mipeg 2000 display............................................................... 9
3.2.1 Push Buttons on the Display..................................................................................................................... 9
3.2.2 Alarms .................................................................................................................................................... 10
3.3 Error handling...................................................................................................................... 10
3.4 Tare Function ....................................................................................................................... 10
Offline Instructions for Drivers Display Unit (DDU).................................................................... 11
4.1 Introduction........................................................................................................................... 11
4.1.1 Push Buttons in Offline Mode ................................................................................................................ 12
4.2 Calibration of Sensors........................................................................................................... 13
4.2.1 Direct calibration of Sensors................................................................................................................... 14
4.2.1.1 Calibration of sensors.......................................................................................................................... 14
Maintenance ..................................................................................................................................... 15
5.1 Introduction........................................................................................................................... 15
5.2 Scheduled Maintenance ........................................................................................................ 15
5.2.1 Calibration of Sensors............................................................................................................................. 16
5.2.1.1 Calibration of Boom Angle Sensor ....................................................................................................... 17
5.2.1.2 Calibration of Load Hoist Sensors ........................................................................................................ 17
5.2.2 Check and calibration of Pulley Compensation...................................................................................... 18
5.2.3 Set-up of Angle Limits (optional)........................................................................................................... 19
5.2.4 Checking of Crane Operation Inhibit Relays.......................................................................................... 20
5.2.5 Checking Crane Curves .......................................................................................................................... 20
5.3 Unscheduled Maintenance.................................................................................................... 21
5.3.1 Built In Test Equipment.......................................................................................................................... 21
5.3.2 Faults Indicated on Driver's Display....................................................................................................... 21
5.3.3 Faults Not Indicated on Driver's Display................................................................................................ 22
Technical description of the main parts .......................................................................................... 23
6.1 Computer Cabinet................................................................................................................. 23
6.1.1 Master II Card......................................................................................................................................... 24
6.1.1.1 Replacement of the Master II card....................................................................................................... 24
6.1.1.2 Set-up of a new Master II card............................................................................................................. 24
6.1.1.3 Strap J5 for Safe or Ex i ....................................................................................................................... 24
6.1.2 Power Converter Unit ............................................................................................................................. 24
6.2 Driver's Display Unit ............................................................................................................ 25
6.2.1 Introduction............................................................................................................................................. 25
6.2.2 Mipeg 2000 Drivers Display Characteristics......................................................................................... 25
6.3 Sensors.................................................................................................................................... 26
6.3.1 Load Hoist Sensor................................................................................................................................... 26
6.3.2 Boom Angle Sensor ................................................................................................................................ 26


APPENDICES Page

APPENDIX A: MIPEG 2000 ERROR MESSAGES................................................................................................ 27
APPENDIX B: MIPEG SPARE PARTS LISTING................................................................................................... 28
APPENDIX C : MIPEG DOCUMENTATION LISTING.......................................................................................... 28
APPENDIX D : MIPEG CERTIFICATE REFERENCE LIST................................................................................. 28
APPENDIX E: NECESSARY TEST LOADS / DATA FOR CALIBRATION........................................................ 29
APPENDIX F: MIPEG 2000NR CALIBRATION PROTOCOL FORM................................................................ 30
APPENDIX G: BOOM ANGLE / CRANE RADIUS RELATIONSHIP................................................................... 32
APPENDIX H: PROJECT SPECIFICATION........................................................................................................... 33
APPENDIX I : WIRING DIAGRAM........................................................................................................................... 34

FIGURES Page

Figure 2.1: MIPEG 2000 System Configuration ....................................................................................................... 6
Figure 3.1: MIPEG 2000 Driver's Display Unit.......................................................................................................... 8
Figure 3.2: PUSH BUTTONS on Display Unit ....................................................................................................... 12
Figure 3.3: Addressing table for parameters. ........................................................................................................ 13

This document is the property of Aanderaa Data Instruments A.S.
It must not be traced, copied, or exhibited to any third party without permission in writing.


8ECTON
1
SAFETY NOTES

1. Check and if necessary calibrate the boom angle sensor (Inclinometer) prior to
calibration of the load sensors.

2. Care should be taken when removing the sensor cover to gain access to the
sensor unit and its wiring. The sensor cover should be supported at all times when
the socket head retaining screws are removed. The sensor covers are heavy and if
their weight is allowed to hang on the internal wiring damage to the wires and
sensor could occur. On reassembly it is essential to use the correct torque figure
for the cover retaining screws.


8ECTON
2

General Description

The MIPEG 2000 crane load indicator system, comprise sensors fitted to the crane, a computer
cabinet and a display located in the crane cabin. Figure 2.1 shows a block diagram of the MIPEG
2000 system.

The load sensors provide frequency modulated electrical signals that are proportional to the
developed loads in the load hoist rope systems of the crane. An inclinometer provides boom angle
information that is used for calculation of the hook radius.

In operation the actual load lifted by the crane are automatically compared with corresponding data
related to the maximum permissible crane loading. The permissible and actual loads, together with
the actual, expressed as a percentage of permissible are displayed. If this percentage exceeds a
pre-set value, alarms and safety functions are activated.

The computer stores the required load-radius curves. These fixed crane parameters are stored in
the main computer's memory while the calibration of the crane is performed using known loads and
boom angle, or known calibration factors. This information is tabulated into the main computer
memory via push buttons on the Display unit.

MIPEG 2000 in standard version comprises the following main parts:

- Computer Cabinet (6.1)
- Driver's Display (6.2)
- Sensors (load and boom angle) (6.3)

A technical description of these main parts is given in Section 6. The numbers in parenthesis are
references to paragraphs for these descriptions.


Figure 2.1: MIPEG 2000 System Configuration

8ECTON
3

Operating Instructions

3.1 Brief Description of MIPEG 2000 Operation

MIPEG 2000 is a computerised crane safety system. It measures load and radius and indicates
safe or hazardous conditions.

It has three main parts; the computer cabinet, the driver's display unit and the sensors. The driver's
display unit is located in the crane driver's cabin, and its layout is shown in Figure 3.1.

MIPEG 2000 interfaces with the crane and prohibits some functions under dangerous conditions.
These crane operation relays and their functions are described in Appendix H. In addition, alarms
are given for loads exceeding the alarm limits of the safe working load.

It is recommended MIPEG 2000 to be constantly powered if possible, even during periods of time
when the crane is not in operation. No warm up time for the system is required, but the load
sensors will need 5-10 minutes after power on to achieve maximum accuracy and stability.

3.1.1 Verification of Driver's Display Unit

Before using the crane: Check that the LEDs back lighting the drivers display panel are illuminated
to show that MIPEG 2000 is powered up.

The back lightning can be adjusted if one keep the AUX button depressed and use the TEST
button to toggle the light intensity. Release the buttons between each setting.

Press the TEST button on the Drivers Display unit and confirm:
Operation of the analogue display of percentage safe working load by allowing the needle to
make at least one complete revolution.
Integrity of the WARNING (Yellow) and ALARM (Red) lamps on DDU - will light continuously.
Operation of display digits. Each segment of each window will show a figure eight with decimal
points being visible between each digit.
If everything is satisfactory proceed, otherwise call maintenance.

Press the 'AUX' button and confirm that the hoisting line is correct for the operating
configuration of the crane.
Confirm that the hoisting line is correct for the operating configuration of the crane. If
not, select correct hosting line by pressing the AUX and 'FALLS' buttons.

Verify that the correct 'Crane curve' is displayed.
If not, select correct crane curve by pressing the CURVE button.


Figure 3.1: MIPEG 2000 Driver's Display Unit

3.2 Information presented on the Mipeg 2000 display

STANDARD LAYOUT

The outer circular analogue scale shows percentage safe working load (%SWL).

The scale is divided into three parts, coloured:
green - for the range 0 - 85/95% SWL,
yellow - for the range 85/95 - 110% SWL, and
red - for the range >110% SWL.

The top Window shows the Hook Load.
This load will vary slightly as the amount of rope paid out varies. It also varies depending on
how the load is lifted; the smoother the lift the less the resultant fluctuation.

The left Window displays the Crane curve selected. See Appendix H for details

The right Window shows the Hook Radius.

The lower Window shows the Safe Working Load that is related to:
operating configuration of the crane
crane curve selected
radius of operation.

ALTERNATIVE INFORMATION

Window Information presented with AUX button depressed

Top Boom angle
Left Not used
Right Number of hoist falls registered in MIPEG
Lower Not used

3.2.1 Push Buttons on the Display

The PUSH BUTTONS have normally the following functions:

BUTTON FUNCTION

ACK Press this button to reset the Mipeg.
Spurious error will be disabled and satisfactory operation will continue.
Pressing this button when an overload will also stop the flashing light on the display.
TEST Press this button to check the function of the needle and LCD's.
AUX Press this button to activate the alternative information on the display.
CURVE Press this button to toggle between the different crane curves (sea curves).
AUX+FALLS Pressing these buttons will change the number of falls in the system.
AUX+TEST The back lighting can be adjusted if one keep the AUX button pressed and use the
TEST button to change the light intensity. Release the buttons between each setting.

3.2.2 Alarms

The visual and audible alarms warn of approaching danger. The WARNING (Yellow) light on Drivers
Display will flash and the buzzer inside the computer cabinet will sound when the load raised
reaches the warning limit at boom radius, crane curve and operating configuration of the crane. This
means that although a load may have been lifted at a given radius the alarm may come on as the
crane is boomed out beyond that radius and the crane capacity reduces.

To acknowledge an alarm, press the ACK button; the WARNING light will remain constantly lit until
the overload situation has decreased below the warning threshold.

The ALARM (Red) light on Drivers Display will flash when the load raised reaches the alarm. When
the ACK button is pressed; the ALARM light will remain constantly lit until the overload situation has
decreased below the alarm threshold and the WARNING light will remain constantly lit until the
overload situation has decreased below the warning threshold.

3.3 Error handling

If a detectable error occurs the MIPEG 2000 clears the operators display, and blinks an error
message 'ERxx' in top window; "xx" is two digits identifying the error. Operator should press 'ACK on
the Display Unit that then resets MIPEG. If it was a spurious error, satisfactory operation will
continue, otherwise call for maintenance.

See Appendix A for Mipeg 2000 error messages. The two digit error codes have an error explanation
with fault sources and references.

3.4 Tare Function

The zero setting of the hook load may vary due to length of rope payed out or weight of the slings in
use. A tare function has been implemented in the Mipeg 2000 to set the hook load read-out to zero,
prior to lifting operations.

The load read-out may be 'tared' by pressing the 'FALLS' button once. Another push on this button
will deactivate the tare function.

The tare function will only work below +/- 0.5Tonne/1000Lbs. * number of falls calculated from the
last zero calibration. The tare function will not change the zero frequency in the system.


8ECTON
4

Offline Instructions for Drivers Display Unit (DDU)

4.1 Introduction

The push buttons on the Display Unit are used to select the Offline Mode. When the TEST and
CURVE buttons are pressed simultaneously, the following data is displayed: (Note: This Mode is
disabled by a switch in the computer cabinet).

Window Data

Top Presented value of displayed parameter (Calibration value).

Left Parameter no. which contents presently displayed in upper window. Each parameter
to be displayed/changed in setting mode is tabulated and given a number according
to its position in the table. When change of parameter is required, the number is
found in the table given in figure 3.3 or in the calibration protocol, Appendix F.

Right Off (Offline)

Lower Frequency value read from sensor (for calibration).

4.1.1 Push Buttons in Offline Mode

When calibration or inspection of calibration data is required, the offline mode is selected by pressing
TEST and CURVE push buttons simultaneously. The push buttons then get a new function, shown in
Figure 3.2.

The PUSH BUTTONS have the following functions in the Offline Mode:

Button Offline Mode

UP Pressing this button will increase the last digit on the displayed parameter by one.
(ACK) Keeping the button continuously pressed will give a fast change in value. All
alterations are done in the bottom window. The new value will also be displayed in
the top window when accepted.

DOWN Pressing this button will decrease the last digit on the displayed parameter by one.
(TEST) (Details as above)

ENTER Pressing this button will put the changed parameter value into the system.
(AUX)

NEXT Pressing this button will give a step to the next parameter in the table. Its value and
(CURVE) no. are displayed in the upper and left window respectively. When one comes to the
end of the table, the system returns to the first entry, which also is the starting point
when entering offline mode.

READ Pressing these buttons, AUX and then TEST, will read the frequency from the
(AUX+TEST) appropriate sensor and display it in the lower window. This value can then be set in
the system as a calibration value by pressing AUX.

PREVIOUS Pressing this button will give a step to the previous parameter in the table. Its value
(FALLS) and no. are displayed in the upper and left window respectively.

Return to normal operation by pressing ACK and AUX simultaneously.

Figure 3.2: PUSH BUTTONS on Display Unit

4.2 Calibration of Sensors

Calibration of the system is performed in the following steps:

Use the TEST and CURVE push buttons to select Offline Mode.

The first parameter is now displayed in the left window and the present value/frequency are
displayed in upper window.

The parameters are organised as follows. See Appendix F for details.

Index number Parameter

1-4 Inclinometer
5-10 Whip Load Sensor
11-34 Main Load Sensor
39-40 Pulley Compensation, Main
41-42 Pulley Compensation, Whip
43-46 Angle limits

Figure 3.3: Addressing table for parameters.

Press the UP (ACK) or DOWN (TEST) button to increase or decrease the last digit on the display by
one.

Press ENTER (AUX) button to set the value in the computer.

Press NEXT (CURVE) or PREVIOUS (FALLS) button to go to another parameter. Ref. the
calibration protocol, Appendix F.

Repeat until all parameters are set as required.

Update all values in the calibration protocol form, Appendix F.

Return to normal mode by use of ACK and AUX push buttons.

4.2.1 Direct calibration of Sensors

The calibration points are organised as follows:

Cal. Point Load Sensors Inclinometer

0 Empty hook (0) 30
1 100% SWL 80
2 40-60% SWL N/A

Point 2 is the value for the second order calibration and should only be used when required. The second
order calibration is not activated if point 2 is set to zero.

4.2.1.1 Calibration of sensors

To calibrate a Sensor, one must know which Index to use, see Appendix F

Cal. Point 0 - The Zero calibration is done as follows:
Use TEST & CURVE buttons for Offline Mode.
Press CURVE to select the correct Index (see Appendix F).
Press AUX & TEST to read new value from Sensor. Wait.
Press AUX to confirm new calibration.
Press CURVE to go to next Index.
Use ACK (UP) or TEST (DOWN), enter the Y-value (see Appendix E for details):
0 Tonns/Lbs. for Load.
normally 30 degrees for Inclinometer.
The calibration values will be updated.
Press AUX & ACK to go back Online.

Cal. Point 1 - The maximum point (100%) calibration is done as follows:
Load lifted in Tonns/Lbs.
normally 80 degrees for Inclinometer.

Cal. Point 2 - The Midpoint (40-60%) calibration is done as follows:
Load lifted in Tonns/Lbs.

When the calibration is completed, one should write all calibration values into the Mipeg Calibration Protocol,
Appendix F.


8ECTON
5

Maintenance

5.1 Introduction

This section describes the maintenance procedures for MIPEG 2000 system. It is divided into two
parts:
- scheduled maintenance (5.2)
- unscheduled maintenance (5.3)

It is recommended that all repair work is performed by Aanderaa Data Instruments A.S, Bergen,
for the aspects of warranty related requirements.

5.2 Scheduled Maintenance
The maintenance schedule and instructions below should be followed rigorously to ensure
correct operation of the MIPEG 2000 system.

FREQUENCY

TASK

PERFORMED BY

INSTRUCTIONS

Prior to
Each shift

Verification of system operation

Crane driver

Perform check detailed in Section
3, 'Operating instructions for
crane driver

3 Monthly

Check calibration of load sensors and
inclinometer

Crane supervisor /
Maintenance engineer

See paragraph 5.2.1. below

Check integrity of crane operation
inhibit relays.

Crane supervisor /


6 Monthly

Check crane curves

Crane supervisor /


As required

Calibration of pulley compensation

Crane supervisor /

See paragraph 5.2.1.3. below

5.2.1 Calibration of Sensors

The sensors of Mipeg 2000 are carefully checked during installation and their initial calibration
constants are semi-permanently kept in the Mipeg 2000 non-volatile memory. Their output might vary
within certain limits due to temperature drift, ageing and changes in environmental conditions. If the
variation is too large, malfunction may occur, and a calibration must be performed.

The zero point drift of the load hoist sensor(s), i.e. the deviation from zero on the display reading with
empty hook is considered to be the most important factor to monitor. It must be kept in mind that the
zero point for this sensor(s) has been defined at 45 degrees boom angle and hook at deck level.
Deviation from zero in a no load condition might be caused by different length of hoisting rope payed
out.

The calibration constants could be set up in two different ways:
1. Normally one would use calibrated test loads or dynamometers for the force sensors and crane
radius marks on the deck for the inclinometer. The frequency is read from the sensor by MIPEG,
while the actual quantity, i.e. weight or angle, is keyed in on the Displays push buttons, as
described in paragraph 4.2.1.

2. It is also possible to enter both the frequency and the actual quantity from the Displays push
buttons. This method is used to enter old calibration constants; giving calibration values to MIPEG
which already are recorded in the calibration protocol, Appendix F. See paragraph 4.2.1.

A compensation for variation caused by an unlinear load sensor arrangement is included in the
MIPEG system. Calibration point 2 is set by the Display Unit buttons during calibration, in the same
way as point 0 and 1. If the compensation is not required, point 2 should be set to zero.

Cal. point 0: Empty hook / No load
Cal. point 1: 100% load
Cal. point 2: 40-60% of full load

The calibration protocol given in Appendix F should be followed whenever possible. Ensure that the
calibration points of the boom angle sensor are checked, and if necessary, calibrated before any other
sensor is calibrated.

5.2.1.1 Calibration of Boom Angle Sensor

Calibration of the boom angle sensor is recommended if the deviation between the real and the
indicated crane radius is greater than one metre.

It is recommended that two permanent calibration points are used, one at minimum radius using the
boom's end stop, the other point at approximately 30 degrees boom angle, i.e. 87% of maximum
radius. The two points must be marked on the deck as radius in metre.

As Mipeg 2000 always measures boom angle above horizontal, a calibration point at maximum
working radius is not recommended as a small inaccuracy in the radius can cause a significant
inaccuracy in the angle reading. This is because changes in boom angle in the range 0 to 20 degrees
will give a small change in radius of approximately 7%. Radius/angle relationships for calibration
purposes are given in Appendix G.

The calibration procedure for the boom angle sensor is given as follows:

Boom out to the outer radius mark on the deck.
With the hook on this mark, do a calibration of point zero as described in paragraph 4.2.1.
Type in the boom angle according to the table in Appendix G, or according to earlier recorded
data in the calibration protocol.
Boom in to the inner radius mark on the deck.
With the hook on this mark, do a calibration of point one similar to point zero.
Set MIPEG in Online state and check the two calibration points.
If not ok, go back to point a) and/or d) and make adjustments of point zero and/or point one.
If ok, go Offline and read back the new calibration data, see paragraph 4.2.
Make a record in the calibration protocol.

5.2.1.2 Calibration of Load Hoist Sensors

Calibration of the load hoist sensor(s) is recommended if the hook load reading in a no load condition,
i.e. boom angle at 45 degrees and hook at deck level, is outside the following limits:

Whip line: +/- 1Tonne/2000Lbs. (Optional)
Main line, Plural Falls: +/- 2Tonnes/4000Lbs.

Calibration requires calibrated test loads or a calibrated dynamometer to measure the test loads.
Recommended sizes of the test loads are given in Appendix E.

The calibration procedure for the load hoist sensor(s) is as follows:

Boom in/out to the radius that gives a boom angle given in Appendix E. See Appendix G for
radius/angel conversion.
Lower the empty hook to just above deck level.
Do a calibration of point zero as described in paragraph 4.2.1, function 'Calibration of Sensors'.
Type in zero as hook load.
Put on the test load and hoist it just above the deck level.
Do a calibration of point one similar to point zero.
Go back online and check the two calibration points.

Test with approximately 50% of SWL and verify if the Mipeg readout is acceptable. If not
calibration point 2 should be activated.

Do a calibration of point two as above.
Repeat the load test.
If the calibration is acceptable without point 2, the frequency and value for point 2 should be set to
zero.


5.2.2 Check and calibration of Pulley Compensation

The weight of the pulley on the load hoist sensors could cause a varying output from the load sensors
as the boom angle varies. A compensation for this is implemented on MIPEG. The parameters for this
compensation are stored as calibration parameters according to the following table.

HOIST LINE Index no. PARAMETER

Main 39 Weight parameter
40 Angle for maximum load value
Whip (Optional) 41 Weight parameter
42 Angle for maximum load value

The check of the pulley compensation is done as follows:

Set the values in index 39-42 to zero as described below.
Select Main hoist line first and repeat for Whip hoist line.
With the boom at maximum radius, position the empty hook just above the deck level. Keep
this hoisting line position during this test.
Boom in and note the displayed hook load values for every 5 Metre/15 Foot from maximum to
minimum radius.
Check the variations of the hook load values. If the variation exceeds 0.5Tonne/1000Lbs. for
whip line and 1Tonne/2000Lbs. for main line, a calibration as described above is required.

To disable the pulley compensation, set the Parameters to zero as follows:
Press CURVE several times to go to the Index 39
Use ACK (UP) or TEST (DOWN) to set to zero
Press AUX to confirm.
Press CURVE to go to Index 40, 41 and 42 and set all to zero

The calibration of the pulley compensation is done as follows:

The compensation are set in degrees of boom angle and weight of the pulley. Theses values could
be changed from the display unit as described below.


Use ACK (UP) or TEST (DOWN) to adjust the weight parameter values, Index 39 for Main
(and Index 41 for Whip) according to the following formula: Adjustment = (Variation / No. of
falls) / (1 - cos(A)), where: A=Boom angle difference for variation readout

Press CURVE to go to Index 40
Use ACK (UP) or TEST (DOWN) to set Index 40 for Main (Index 42 for Whip) to the angle
where the highest load value was during the test.

Use TEST & CURVE buttons to return to Offline Mode.

Repeat the test above and if necessary adjust the weight parameter values (Index 39 & 40) until
acceptable read-outs are achieved.


5.2.3 Set-up of Angle Limits (optional)

'Mipeg 2000 will activate a buzzer and/or output relays if the boom is outside the set angle limits.
See Appendix H for project details. The parameters for these limits are stored as calibration
parameters according to the following table:

LIMIT INDEX NO. Parameter

High Angle-1 43 High limit on
44 Low limit off
Low Angle-1 45 High limit on
46 Low limit off

These limits are set in degrees of boom angle and could be set from the display unit as follows:

Set-up of the High Angle Limits:
Use ACK (UP) or TEST (DOWN) to select the high angle limit, 'on value'
Use ACK (UP) or TEST (DOWN) to select the high angle limit, 'off value'
Press AUX & ACK to go back online.

Set-up of the Low Angle Limits:
Press CURVE several times to go to select the Index 45
Use ACK (UP) or TEST (DOWN) to select the low angle limit, 'on value'
Use ACK (UP) or TEST (DOWN) to select the low angle limit, 'off value'
Press AUX & ACK to go back online.


5.2.4 Checking of Crane Operation Inhibit Relays

Checking of the crane operation inhibit relays are recommended to be performed by the crane
supervisor every third month.

To test the overload outputs, one needs a hook load sufficient to create an overload condition. In
order to use a smallest possible load, one can set MIPEG in the highest sea condition. Pick a load
size according to the crane curves. With this load available, the check are done in the following steps:

Lift the load off the ground.
While watching the %SWL readings on the driver's display, boom out until it reaches the warning
limit. The yellow light should be activated. Boom out until it reaches the alarm limit. The red light
and the relay output(s) should now be activated.
Boom in and put the load down.

In addition to this, the output relays may be tested as follows:

MIPEG Nonoperational
Turn MIPEG power off. The horn and overload relays should be activated.

MIPEG Error
Simulate an error condition on MIPEG. The horn and overload relays should now be activated.

5.2.5 Checking Crane Curves

The tables of safe working loads (SWL) are permanently stored in the Mipeg 2000 memory and are
called crane curves. These are thoroughly tested during the commissioning of the crane. One should
therefore not expect any problems with the crane curves during operation, but it is recommended that
the crane supervisor checks the crane curves installed in Mipeg 2000 against the load- radius tables
available in the crane cabin twice a year.

The crane curve checking is done in the following steps:

With no load in the hook, hoist the boom to top position.
Set number of falls to the lowest implemented value.
Set curve to the lowest implemented value.
While reading radius and SWL from driver's display and comparing the readings with the
load-radius tables, lower the boom to maximum radius.
Change the curve to next lowest value and perform point d) while hoisting the boom to top
position.
Go through all crane curves for this number of falls, then change to next number of falls and go
through all curves, and so on until all combinations are checked.
If possibilities for more boom lengths are implemented, change to next boom length, and repeat.
After the checking of the crane curves is finished, set the parameter values for boom length,
number of falls and curve back to the correct values.


5.3 Unscheduled Maintenance
5.3.1 Built In Test Equipment.

The computer will start to execute once the logic supply (5V) reaches it's working level after power is
turned on to the system.

If the bus or timer checks fails, the program will signalise the fault condition and indicate an error
message on the display, see Appendix A. If all checks are passed the full system software is
initialised and starts its normal execution.

Different checks are continuously performed during normal system execution:

Sensor data limit checks
Processing data evaluation
Processing time control ("watch dog" function)
Evaluation of the crane's parameter set

These tasks are all contained in the software package called the Online BIT-functions. If any of the
checks fail this will lead to an immediate shut down of the system by use of the normal error exit and
indication, see paragraph 5.3.2.

5.3.2 Faults Indicated on Driver's Display

Fault recognised by the Mipeg 2000 system during run-time, will be indicated on the driver's display
by a flashing light in the WARNING and ALARM lamps and an error code in the upper window. The
horn will blow for 10 seconds and overload alarm will be activated.

When the crane driver acknowledges the fault, the fault indications on the driver's display will
disappear and the overload function will be deactivated. If, however, the fault is of a permanent
nature, the same indications will appear over again.

The fault may of course be located in the computer (and be of a major kind, ref. paragraph 5.3.1
above) or the cabling to the display may be damaged both of which will display a normal error
indication.

The error code will assist the maintenance engineer in locating the fault. Appendix A gives a list of
error codes with the probable fault source(s). When fault tracing, reference should be made into the
technical description where further details may found.


5.3.3 Faults Not Indicated on Driver's Display

Prior to faultfinding on this level, the Mipeg 2000 system should be given a power reset by turning power
off/on. These faults normally fall into the following categories:

FAULT

"Dead system", a typical power supply problem

Faults located in the Driver's Display prohibiting
normal error indication

Erratic behaviour, where parts of the system do
not operate properly or as specified.

The system does not follow the input switches

Horn or other outputs not functioning

FAULT SOURCE :

Trace the input power through fuses on TR1. If
24V dc present, check fuse located on the Master
II card.

If the error is strictly located to the display unit,
error indication by the use of the horn will still be
maintained. If not, reference to paragraph 5.3.1
should be made.

If a malfunction is established and no fault found
in the cabling a replacement of the display or
cards may be necessary, see paragraph 6.1.

Check the cabling of the switch or eventually
replace the Master II card, see paragraph 6.1

Check the cabling of the item or eventually
replace the Master II card, see paragraph 6.1


8ECTON
6

Technical description of the main parts

MIPEG 2000 in standard version comprises the following main parts:

Computer Cabinet (6.1)
Driver's Display Unit (6.2)
Sensors (load and boom angle) (6.3)

A technical description of these main parts is given in this section.

6.1 Computer Cabinet
The Computer Cabinet houses the Mipeg computer, zener barriers (EEx nC only), relays and terminal
rows for external cable connection.

EEx nC Certificated systems:

The cabinet is certified EEx nC and sealed to IP66. Dimensions: 380*380*210 mm. Weight:
approximately 30 kgs.

The computer cabinet has been found to comply with the IEC 79-15 1987 standard and has
successfully met the type verification and test requirements of this standard.

Systems in safe areas:

The cabinet is sealed to IP66. Dimensions: 380*300*210 mm. Weight: approximately 15 kg. The
computer cabinet has been found to comply with the IEC 79-15 1987 standard and has successfully
met the type verification and test requirements of this standard.

There are three fuses in the system:

Supply Location Fuse type

24 Vs Master II Card 1.0 A / 250V - 5*20 mm
24 Vs TR1 - no. 3 3.15 A / 250V - 5*20 mm
85-240 V ac TR1 - no. 1 2.0 A / 250V - 5*20 mm (in safe area)
85-240 V ac TR1 - no. 1 8.0 A / 250V - 5*20 mm (certificated systems)

WARNING:
FOR CONTINUED PROTECTION AGAINST FIRE
REPLACE WITH SAME TYPE AND RATING OF FUSES


6.1.1 Master II Card

The computer is built in microprocessor technology located on the Master II card. The Master II card
also contains power, sensor and interface logic. The cards are connected to the terminal rail through
connectors on the cards. These connectors can be split to make a quick replacement of cards.

The Master II card contains the following electronics:
microprocessor with program memory
volatile memory used to store the crane's parameter set
timing circuits
interface for three S-sensors
interface for the inclinometer
DC/DC converter for generation of the galvanic isolated power supply 5V, 12V
level detection circuits on logic (5V) and input (24V) power,
power protection circuits
fuse: 1A/250V - 5*20mm

6.1.1.1 Replacement of the Master II card
When replacement of the Master II card is found to be necessary one should always continue with the
same program unless this circuit (EPROM) is proven damaged.

The EPROM containing the program is found in socket U37. To remove this socket inserted
component, gentle insert a small screwdriver under the component and twist until component is free.
Insert carefully onto spare Master II card.

6.1.1.2 Set-up of a new Master II card
Prior to operation of the Mipeg 2000 system, a new Master II card has to be reset with default values
from the system program and old calibration values should be entered:
Reset the Prom parameters (please contact Aanderaa Data Instruments for this procedure)
Enter old calibration values from the Calibration protocol, ref. paragraph 4.2.

6.1.1.3 Strap J5 for Safe or Ex i
Due to the use of Zener barriers for Exi systems, the strap J5 on the Master II card has to be set in
different positions for a safe or Ex i.
SAFE: strap J5 in position towards the crystal
Ex i : strap J5 in position towards J14

6.1.2 Power Converter Unit
The Power Converter Unit is included inside the computer cabinet. The unit is a switching power
supply, coping with input voltage from 85 - 264 Vac. The output from the power unit to the Mipeg
2000 Master II card is nominal 24 Vdc.

The unit is in accordance with UL,CSA, TUV and VDE (IEC950). Noise terminal voltage is
conforming to FCC class B and VDE0871 class B. Proof pressure AC 3000V.


6.2 Driver's Display Unit

6.2.1 Introduction.

The Mipeg 2000 Driver's Display is a microprocessor controlled display designed for use in harsh
environment.

Information is presented by four LCDs and by an analogue needle. All LCDs and the display facia are
backlit by LEDs. The unit incorporates two alarm indicators (LEDs). Information to be visualised on
the display is transmitted from the computer on a serial interface line.

The Display Unit consists of three major parts all housed in an enclosure supplied with a cable
entry through a gland and terminal row:

A printed circuit board including the front plate and electronic components of the display.
A push-button panel mounted on the front plate. This panel consists of five push-buttons.
A connector for the PTU connection mounted on the bottom plate of the enclosure.

The back-light can be adjusted if one keep the AUX button pressed and use the TEST button to
change the light intensity. Release the buttons between each setting.

The display is mounted on a bracket fitting which enables the unit to be tilted in both the vertical and
horizontal planes. Selica Gel should be included inside the enclosure to prevent condensation of
water on the display front glass.

It is recommended that the Driver's Display is serviced by Aanderaa Data Instruments personnel.

6.2.2 Mipeg 2000 Drivers Display Characteristics.

Physical characteristics
Outer size: 225 x 200 x 60 millimetre
Overall weight: Approximately 3 kgs
Housing material: Aluminium given an epoxy resin finish.

Electrical characteristics
Supply Voltage: Nom. 7.5 Vdc
Supply current: Nom. 152 mA

External connections
Two pairs connected to a terminal row.
DC supply: DD+/-.
Serial communications line to/ from display: RS485 A/B

Environmental characteristics
Operating/Storage temperature: -20, +40 C
Sealing: to IP65


6.3 Sensors

MIPEG 2000 sensors are used to measure the following:

Loads in the hoisting lines, main and whip (optional)
Boom inclination relatively to horizontal plane

A technical description of each of the sensors is given in the following paragraphs.

6.3.1 Load Hoist Sensor

The load hoist primary sensor(s) is of S-band type. This primary sensor is MIG-welded to a
suspension part that also carries a pulley for the load sensing. The sensor measures the material
stress in the suspension part, which is proportional to the line load.

The output from the sensor is a frequency signal in the range 350-450 Hz. The resolution is typically
5Hz/tonne for one fall configuration. The sensor has two wire power/signal connection and is not
damaged by short or open circuits.

The primary sensor may be overloaded 5-10 times the nominal working range. This is far above the
yield strength of the material. The primary sensor is temperature compensated. The primary sensor is
sealed hermetically to SEN431614-k (MIL-STD-883A).

The sensor cover is sealed to protection index IP67. The sensor has been examined against the
requirements of the CENELEC standards EN50 014 and EN50 018 for flameproof enclosures and has
been approved for use in hazardous areas and to bear the marking EEx d IIB T6. The sensor cover
mounted on the sensor with four socket screws. These are tightened with a torque wrench to a torque
of 5 Nm. The flame gap area must be filled with an 'EExd' approved protection matter/grease, e.g. of
mark PBC.

To verify correct/undamaged cabling and sensor, a resistance measurement from the terminal row in
the computer cabinet can be done. Between disconnected cores, the resistance shall be
approximately 6 ohms (3 ohms in sensor plus cable). There shall be open circuits between cores and
drain, and between drain and chassis earth.

The load hoist sensor(s) has to be replaced as a complete unit.

6.3.2 Boom Angle Sensor

The Boom Angle Sensor is an inclinometer mounted in an EX d enclosure at the boom foot. The
inclinometer gives a voltage output in proportion to the boom angle (BAS+). Voltage supply to the unit
is 12Vdc (BAR+). The Inclinometer has a typical resolution of 30-35 mV/degree boom angle. The
sensor is not damaged by shorts or open circuits.

The unit is manually set to give approximately 4 Volt dc at zero degree boom angle if the unit is
installed facing towards the left hand side of the crane. At minimum radius the voltage will then be
approximately 7 Volts.

If the unit is installed facing towards the right hand side of the crane, it should manually be set to give
approximately 7 Vdc at zero degree boom angle. At minimum radius the voltage would then be
approximately 4 Volts.


APPENDIX A: MIPEG 2000 ERROR MESSAGES

CODE

Error Explanation, (fault sources & references)

19

Sensor fault, Moment sensor out of range.
(Cabling, sensor, Master II card).

20

Sensor fault, Whip hoist sensor out of range.
(Cabling, sensor, Master II card)

21

Sensor fault, Main Hoist sensor out of range.

23

Sensor fault, Inclinometer out of range.

25

Computer fault, Initializing error. (Master II card).

28

Computer fault, SWL-parameter error. (Master II card).

30

Computer fault, EEPROM/RTC read/write error (Master II Card)

31

Computer fault, EEPROM overflow (Master II Card)

50

Crane identity does not correspond to parameter set.

51

Both or none of the Main and Whip inputs selected.

9509
Or
0210

No communication between the computer cabinet and the display.
(Cabling, Display, Master II Card)

Datainstrument document W-130 H00 623, Date 26.06.06 Page 28 of 34

APPENDIX B: MIPEG SPARE PARTS LISTING

Cranes: SeaTrax Model 4228 : ONGC Sagar Kiran

Part Name Part no.

COMPUTER CABINET
Master II Card DI-130 P01 001

MIPEG 2000 DRIVER'S DISPLAY
Display Box/Front DI-130 P02 000
Mounting Bracket DI-130 P02 005

SENSORS
Main Hoist Sensor DI-112 P05 239
Whip Hoist Sensor DI-112 P01 225
Boom Angle Sensor DI-130 P05 003

APPENDIX C : MIPEG DOCUMENTATION LISTING

COMPUTER CABINET
S - 123 B01 002 Block Schematic, Master II card

DISPLAY
A-130 M02 000 General Assembly, Mipeg 2000 Driver's Display

SENSORS
I - 112 M05 239 General Assembly, Main Hoist Sensor
I - 112 M01 225 General Assembly, Whip Hoist Sensor
I - 130 M05 005 General Assembly, Inclinometer

APPENDIX D : MIPEG CERTIFICATE REFERENCE LIST

MIPEG Part Marking Certificate no.

Main Load Sensor Ex II 2 GD EEx d IIB T6 NEMKO 03 ATEX 304
Whip Load Sensor Ex II 2 GD EEx d IIB T6 NEMKO 03 ATEX 302X
Inclinometer Ex II 2 GD EEx d IIB T6 NEMKO 03 ATEX 303X


APPENDIX E: NECESSARY TEST LOADS / DATA FOR CALIBRATION


The following test loads/data are recommended for calibration:

Sensor

Number
of Falls

Calibration
Point

Cal. at
Degrees

Test value

Inclinometer

-

0
1

30
80

No test load

Whip Hoist

1

0
1

45

0 Lbs
11 800 Lbs

Main Hoist

2

0
1

50

0 Lbs
27 000 Lbs

Main Hoist

4

0
1

75

0 Lbs
56 000 Lbs

Main Hoist

6

0
1

80

0 Lbs
85 000 Lbs


APPENDIX F: MIPEG 2000NR CALIBRATION PROTOCOL FORM page 1 of 2


CRANE: ______________________________ Calibrated - Date/Sign. : _________________________

SENSOR

No. of Falls

Cal.
Point

Index
no.

Calibration
Parameters

Frequency / value

0

1

Volt

INCLINOMETER

-

0

2

Degrees

1

3

Volt

1

4

Degrees

0

5

Hz

0

6

Lbs

LOAD HOIST,

1

7

Hz

Whip
1
1

8

Lbs

2

9

Hz

2

10

Lbs

0

11

Hz

0

12

Lbs

LOAD HOIST,

1

13

Hz

Main
2
1

14

Lbs

2

15

Hz

2

16

Lbs

0

17

Hz

0

18

Lbs

LOAD HOIST,

1

19

Hz

Main
4
1

20

Lbs

2

21

Hz

2

22

Lbs

0

23

Hz

0

24

Lbs

LOAD HOIST,

1

25

Hz

Main
6
1

26

Lbs

2

27

Hz

2

28

Lbs

APPENDIX F: MIPEG 2000NR CALIBRATION PROTOCOL FORM page 2 of 2


CRANE: ______________________________ Calibrated - Date/Sign. : _________________________

PULLEY COMP.

-

0

39

Lbs

( Main )

0

40

Degrees

PULLEY COMP.

-

0

41

Lbs

( Whip )

0

42

Degrees

ANGLE LIMITS

-

0

43

Degrees

( High Angle-1 )

0

44

Degrees

ANGLE LIMITS

-

0

45

Degrees

(Low Angle-1 )

0

46

Degrees


APPENDIX G: BOOM ANGLE / CRANE RADIUS RELATIONSHIP


RADIUS = Distance from Centre of Pedestal to Jib Pin (+ Sheave radius for 1 Fall)
+ Boom Length * cos(@) + Offset Centerline * sin(@)

RADIUS for Whip line = 3.75 + 0.60 + 122.32 * cos(@) + 3.52 * sin(@)

RADIUS for Main line = 3.75 + 118.80 * cos(@) + 1.50 * sin(@)

Boom lengths:
Whip
1 fall
122.32
Main
2or> falls
118.8
Angle Radius Radius
0 126.7 122.6
5 126.5 122.2
10 125.4 121
15 123.4 118.9
20 120.5 115.9
25 116.7 112.1
30 112 107.4
35 106.6 101.9
40 100.3 95.7
45 93.3 88.8
50 85.7 81.3
55 77.4 73.1
60 68.6 64.4
65 59.2 55.3
70 49.5 45.8
75 39.4 35.9
80 29.1 25.9
85 18.5 15.6
90 7.9 5.2


APPENDIX H: PROJECT SPECIFICATION


Crane specification
BOOM LENGTH: 118.80 Feet
LOAD SENSORS: Whip Line 1 Fall
Main Line 2, 4 & 6 Falls

MIPEG 2000 Non Recording System
LOAD CURVES: PLF(Static) & SEA(Dynamic)
WARNING LIMIT: 95% SWL
UNITS: Lbs / Ft
COMPUTER CABINET: Rittal AE1030, Safe area.
POWER SUPPLY: 85 - 240V ac

DIGITAL INPUT SIGNALS to MASTER II CARD
J13-2 INP#a : ON / OFFLINE SWITCH (in TR1)
J13-1 INP#b : spare

DIGITAL OUTPUT SIGNALS from MASTER II CARD
J13-3 OUT#10 : 95% SWL & Angle Limits - BUZZER
J13-4 OUT#11 : 110% SWL Horn & BOI - R1
J15-6 OUT#12 : High Boom Angle - R2
J15-7 OUT#13 : Low Boom Angle - R3

APPENDIX I : WIRING DIAGRAM

Mipeg Safe Load Indicator Sagar Kiran Manual m2000nr

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mipeg Safe Load Indicator Sagar Kiran Manual m2000nr

Uploaded by

Copyright:

Available Formats

Aanderaa Data Instruments Document W-130 H00 623, Date 26.06.

5.3.1 Built In Test Equipment.

You might also like