The Greer Insight system is a crane operation aid that monitors load and warns of overload or two-block conditions. It is designed to be used by properly trained operators who are knowledgeable in safety guidelines, crane capacity information, and the crane manufacturer's specifications. The system compares the load suspended below the boom head to the crane capacity chart stored within its computer's memory. Upon approach to an overload, the system provides audible and visual warning signals. It can also be configured to cause function kick-out by sending a signal to function disconnect solenoids.
System Components:
- Display Unit: Provides the operator with rated capacity, actual load, a bar graph representation of actual load vs. rated capacity, radius of the load, boom angle, main boom length, working area, and crane configuration.
- Computer Unit: Processes data from sensors and manages system functions.
- Pressure Sensors: Two sensors measure pressure in the boom hoist cylinder (rod-side and piston-side pressure).
- Swing Sensor: Measures the angle of the boom relative to the chassis (if equipped).
- Reeling Drum Assembly: Contains extension and angle sensors.
- Anti-Two-Block Switches: Monitor the approach of the hookblock or overhaul ball to the boom head.
- Cables: Connect the various system components.
- Audible Alarm: Provides audible warnings for various conditions.
- Installation/Operator Manuals: Provide instructions for installation and operation.
Key Features and Usage:
Power-Up Self-Test:
Immediately after electrical power-up, the system performs a self-test for approximately 10 seconds. During this time, the display shows the rating chart number, units in use, and load. After the startup screen, the Crane Configuration page is displayed.
Home Display:
The Home Display shows real-time operational data. The Configuration Display can be accessed from the Home Display by pressing a dedicated button. The system retains the last configuration even after power is removed and re-applied, until reset by the operator.
Configuration Display:
This display provides a pictorial representation of the current system setup. Shaded areas contain green indicators and buttons to change setup selections. Green indicators illuminate to show the current selection. Once configuration is complete, the Home button returns the user to the Home display.
- Point of Lift and Parts of Line: Operators must always check the point of lift and parts of line after selecting the winch. The displayed load and capacity are based on the currently selected point of lift. The system does not allow lifting from more than one hook at a time.
- Outrigger Selection: Outrigger selections are made by pressing a circled button. Some cranes may not have the option to select different outrigger positions.
- Outrigger Position Sensing (OPS) (If Equipped): At power-up, the system reads OPS sensors and selects the corresponding chart, displaying a white arrow above the outrigger position.
- Correct Selection: A solid green indicator appears when selected and detected outrigger positions match.
- Incorrect Selection: The detected position flashes red, and the selected position is solid yellow. An audible alarm sounds on the main screen if the selected position is greater than the detected position (e.g., fully extended selected, but outriggers are intermediate or fully retracted).
- Parts of Line (POL): The POL button increments the current POL. Once the maximum parts of line for the equipment is reached, the indicator rolls over to one POL.
- Jib Options: Jib options are selected by pressing the jib button multiple times. If no options are available, "None" is displayed. The jib must be stowed before it is erected.
- Pick Long, Pick Short, Pick Main: These selections depend on the crane model.
- Stow (Stowed Jib): This group has one green indicator that illuminates when the jib is stowed on the boom. Pressing the Stow button scrolls through jib options. If no options are available, "None" is displayed.
- Winch: This group contains two green indicators for Front or Rear winch selection. If the crane has two winches, the operator must select the winch to be used for the lift before selecting parts of line for each winch.
- Operator Alarms: Accessed by pressing the operator alarm button.
Home Display Details:
- Outrigger Setting: Four green indicators show the selection of full, intermediate, and retracted outriggers. Selection is made from the Configuration display and is crane-dependent.
- Actual Load: Displays the total load, including slings, suspended below the lifting point.
- Cancel Alarm Button: Silences audible alarms for overload, ATB, outrigger position mismatch, or operator programmable alarms. The alarm remains canceled until the condition is resolved.
- Parts of Line Display: Shows the amount of line chosen for the selected configuration, adjustable from the Configuration screen.
- Information Button: Displays system-generated messages about software versions and fault codes when held.
- Rated Capacity Display: Shows the maximum rated capacity of the machine in the current configuration.
- Erected Jib Display: Shows selected jib options. If none, "None" is displayed.
- System Units: The system can display Metric or Imperial units.
- Anti-Two-Block (ATB) Indicator: Illuminates when the ATB Limit switch detects an approach to a two-block condition.
- Jib Stowed Display: Shows the stowed jib from the configuration screen. Length and offset of the jib in use are also shown on the Home Display.
- Boom Length Display: Shows the length of the main boom from the boom foot pin to the sheave pin of the main boom head machinery, in Imperial or Metric units.
- Pick Points, Pick Long, Pick Short, and Pick Main: Pick selection is made from the Configuration display screen.
- Configuration Button: Returns to the Configuration display screen.
- Boom Length Symbol: Shown to the right of the boom length display.
- Boom Angle Symbol: Shown to the right of the boom angle display.
- Load Radius Symbol: Shown to the right of the boom angle display.
- Swing Angle Symbol (If Equipped): Shown to the right of the swing angle display (not used on all models).
- Load Radius Display: Shown to the right of the load radius display.
- Swing Angle Display (If Equipped): Shows the swing of the boom (not used on all models).
- Boom Angle Display: Indicates the angle of the main boom relative to horizontal in degrees.
- Bar Graph: Indicates the actual load versus the rated capacity.
Reset Function Kick-Out:
If a function kick-out occurs (e.g., during rigging), the bypass (Cancel Alarm Button) can be used. Press and hold the button for 5 seconds to reset the relay; a second beep confirms the bypass. If a different alarm condition occurs while the relay is overridden, a new function kick-out will occur. The function disconnect relay resets to normal when the alarm condition is no longer present.
WARNING: When the function disconnect relay is reset via the Cancel Alarm Button, protection against the condition that caused the kick-out is no longer active.
Operator Programmable Alarms:
These alarms define the working range and can be set by the operator for minimum angle, maximum angle, maximum height, and maximum length for each job site.
- Accessing Alarms: Press the configuration button, then the operator alarm button. The information screen shows the current status of alarms. Default settings are -15° for minimum boom angle and 80° for maximum boom angle. Each button acts as a toggle switch (ON/OFF). Pressing the operator alarm button cycles through programmable alarms. The home button returns to the main screen. When set, an orange alarm appears.
- Setting Minimum Boom Angle Alarm: Move the boom to the desired minimum angle, then press the "MIN ANGLE" button. The display will show the set angle. Pressing it again cancels the setting and returns to the default -15°.
- Setting Maximum Boom Angle Alarm: Move the boom to the desired maximum angle, then press the "MAX ANGLE" button. The display will show the set angle. Pressing it again cancels the setting and returns to the default 80°.
- Setting Maximum Boom Length/Tip Height Alarms: Similar process to boom angle alarms, with dedicated buttons for "MAX LENGTH" and "MAX HEIGHT."
Swing Alarms (If Equipped with Swing Sensor):
These alarms define a working arc and an exclusion zone using two set points. The operator is visually and audibly warned when the swing travels one degree past either set point ("WARNING! – RIGHT SWING!" or "WARNING! – LEFT SWING!"). The alarm clears when the crane returns to the working area.
- Setting Swing Alarms:
- Press the configuration button, then the operator alarm button twice.
- Press "Next" adjacent to "SET LEFT AND RIGHT SWING ALARMS?".
- If an alarm is already set, press "LEFT SWING" and "RIGHT SWING" to turn them off.
- Swing the boom to the desired left swing point and press the "LEFT SWING OFF" button.
- Press "NEXT" to continue.
- Move the boom into the desired working area and press the "SET" button.
- Press "NEXT."
- Swing the boom to the desired right swing point and press the "OFF" button.
- The swing alarms are now set. Press "Exit" to return to the calibration menu.
WARNING: The swing alarm is a warning device; functions remain operational in the exclusion zone. Operators are responsible for setting alarms to maintain a safe working distance from obstacles. Reset alarms if the crane, obstacle, or load changes.
Work Area Alarms (If Equipped with Swing Sensor):
This alarm defines an imaginary vertical plane between two set points using the tip of the boom. When the plane is passed, a red warning indicator is displayed, an alarm sounds, and "!! EXCLUSION ZONE !!" flashes.
- Setting Work Area Alarm:
- Press the configuration button, then the operator alarm button twice.
- Press "NEXT" adjacent to "SET WORKING AREA ALARM?".
- To set a new swing area, the left and right points must be reset.
- Press the "LEFT POINT" and "RIGHT POINT" buttons to reset set points. The display will show "LEFT POINT OFF", "RIGHT POINT OFF".
- Rotate the boom to the desired left point (left of the obstacle) and press the "LEFT POINT" button.
- Rotate the boom to the right, avoiding the obstacle, or rotate to the left to avoid moving the boom through the exclusion zone.
- Press the "RIGHT POINT" button.
- The work area alarm set points are now set.
- To deactivate alarms, return to the screen displaying the left and right set points and press the "LEFT POINT" and "RIGHT POINT" buttons to toggle OFF.
NOTE: Both alarms must be set for proper function. If the procedure is aborted, alarms default to "OFF."
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