Part Number TW316

lillLLDTotcom

1A Varco Company

INSTALLATION, OPERATION, AND MAINTENANCE

DYNALINE TENSIOMETER
UDI GRU-SERIES

Manufacturers of Precision Instruments

Printed in U.S.A. September 1976

 Manual TW316 contains 14 pages as follows:

Cover .............................. March 1998

ii thru vi ............................. March 1998
lthru 10 ........................ September 1976

All product, brand, or trade names used in this publication are the trademarks or registered trade-
marks of their respective owners.

Information in this manual is subject to change without notice.

 IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals are
recommended methods of performing service operations. When these service operations require
the use of tools specially designed for the purpose, those special tools should be used as recom-
mended. Warnings against the use of specific service methods that can damage equipment or
render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.

...
September 1976 III
M/D TOTCO
 LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Martin-Decker TOTCO (“Company”) warrants to Buyer (‘Purchaser”) of new products manufactured or

supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and
workmanship defects, subject to the following exceptions:

A. Any product which has been repaired or altered in such a way, in the Company’s judgement, as to affect
the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company
authorized facility.

B. Any product which has, in the Company’s judgement, been subject to negligence, accident, or improper
storage.

C. Any product which has not been installed, operated and maintained in accordance with normal practice
and within the recommendations of the Company.

D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit
warranty claims directly to the manufacturer thereof.

The Company’s obligation under this warranty is limited to repairing, or at its option, replacing any products
which in its judgement proved not to be as warranted within the applicable warranty period. All costs of
transportation of products claimed not to be as warranted to authorized Company service facility shall be
borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by
Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company
may, at its sole option elect to refund the purchase price of the products, and Company shall have no further
obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts
provided under the terms of this warranty are warranted for the remainder of the warranty period of the
product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are:

A. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months
from date of shipment from Company, whichever occurs first.

B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.

No deviations from the Company’s standard warranty terms or period as stated herein will be honored unless
agreed to in writing by an authorized Company representative prior to acceptance of the order.

EXCLUSIVITY OF REMEDY AND LlMlTATlON OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS
WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR
BREACH OF ANY OF COMPANY’S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER,
WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON
WARRANTY, NEGLIGENCE, OR OTHERWISE.

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

iv September 1976
M/D TOTCO
,

TW316
YAR71ll YARTIW
DECUR TECHNICAL INSTRUCTION MANUAL OfCKER
ET q

TABLE OF CONTENTS

Section No. Title Page No.

I INTRODUCTION AND DESCRIPTION ................ 2
l-l. Introduction ............................ 2
l-3. Description ............................. 2
l-5. System Components ....................... 2

II INSTALLATION AND CALIBRATION ................

2-l. Pre Installation Set-Up ....................
2-3. Installation ............................
2-5. Calibration Set With Dynaline On Wire Rope .......

III MAINTENANCE AND TROUBLESHOOTING ............

3-1. Maintenance.. ..........................
3-3. Lubrication ............................
3-5. Wash Down ............................
3-7. Recharging the Load Cell ...................

LIST OF TABLES
Table No. Title Page No.
2-l. Dynaline Set-Up Information ...................... 4
3-l. Malfunction Isolation ........................... 9

LIST OF ILLUSTRATIONS
Figure No. Title Page No.
l-l. TypicalDynaline System . . . . . . . . . . . . . . . . . . . . . . . . 3
2-l. Dynaline Spacer and Calibration Detail . . . . . . . . . . . . . . . 4
2-2. Typical Dynaline System Indicator . . . . . . . . . . . . . . . . . .
2-3. Dynaline Sheave Removal and Tiatening Detail . . . . . . . . . ss
2-4. Typical Dynaline Installation Using a Wooden Plank
for Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-l. Dynaline Lubrication Points . . . . . . . . . . . . . . . . . . . . . . 8
3-2. System Loading Detail . . . . . . . . . . . . . . . . . . . . . . . .. . 10

5/77
 TW316
MAPflW YARTIR
QECKER TECHNICAL INSTRUCTION MANUAL
BECKER
a B

SECTION I
INTRODUCTION AND DESCRIPTION

l-l. INTRODUCTION

l-2. This manual contains installation and operation instructions relative to the MARTIN-DECXER
UDl6RU Series Dynaline Tensiometer. Read the appropriate section of this manual before
installing or operating this equipment. Insure that all personnel operating the wire rope
system and Dynaline are familiar with the procedures contained herein.

l-3. DESCRIPTION

1-4. The UD16RU Series Dynaline Tensiometer (hereinafter referred to as the Dynaline) provides
the operator with a visual indication of the wire rope single line load. The Dynaline system
consists of a tensiometer, force frame and hydraulic load cell connected to a direct reading
hydraulic indicator. The system is closed circuit hydraulic and no external power source is
required. A variety of spacer combinations are used to allow the Dynaline to be operated on
several wire rope sizes.

1-5. SYSTEM COMPONENTS

l-6. A typical UDlBRU Series Dynallne Tensiometer system consists of the following components:

a. TENSIOMETER: The tensiometer force frame contains three sheaves and a load
cell. The center sheave is removable and deflects to transfer force to the load
cell by way of connecting rods. As the wire rope passes through the force frame
it is deflected by the center sheave. The resultant force of the deflected wire rope
against the center sheave is transferred to the load cell by the connecting rods and
the cell load plate. The load cell transforms this force into a hydraulic pressure
signal which is read on the indicator direct reading dial.
b. HOSE: The hydraulic signal from the load cell is transferred to the indicator
through high pressure wire braided hose. Total hose length in these systems is
40 ft. Applications requiring greater lengths should use hard tubing in the fixed
portion of the transmission line.
C. INDICATOR: The indicator consists of a pressure gage with dial calibrated to
read directly in thousands of pounds of tension. A pulsation damper is also
included to dampen out pointer pulsations.
d. CALIBRATION CHAMBER: A calibration chamber, consisting of a cylinder and
piston on a threaded stem, is used to make volume adjustments. Volume adjust-
ment may become necessary to compensate for ambient temperature changes or
for system calibration checks. The calibration chamber is located on the indicator
mounting bracket and is connected to the indicator with copper tubing.
e. RECHARGING EQUIPMENT. Recharging equipment consists of a check valve
mounted at the calibration chamber, hand pump and MARTIN-DECKER W15
hydraulic fluid.

2 5/77
 Tw316
YAUTIN TECHNICAL INSTRUCTION MANUAL YARTIW
QECW
EnEn a

ATTACHES TO
BULIUIEAAD on
RIGID SmJcTUnL

CUTAWAV OF DYNA-LINE

Figure l-l. Typical Dynaline System

SECTION II
INSTALLATION AND CALIBRATION

2-l. PRE INSTALLATION SET-UP

2-2. Before the Dynaline is installed, it must be calibrated for the specific size wire rope being
used. This is accomplished by adding or removing spacers as shown in figure 2-l. The
four cap screws holding the side bars to the connecting rods come in two lengths. The length
used depends on the number of spacers installed in the unit. Spacer and cap screw combina-
tions are specified in Table 2-1. All sheaves for the UDl6RU-16 are grooved for 2 in. wire
rope. UD16RU-20 sheaves are grooved for 2-l/2 in. wire rope.

2-3. INSTALLATION

2-4. Once the Dynaline has been assembled as described in Table 2-1, insta.lI the Individual
system components as follows:
a. Mount the indicator in a location convenient to the operator.
b. Connect the indicator to the tensiometer element using the couplings and hi-
pressure hose provided.

3
 TW316
YAnfnl TECHNICAL INSTRUCTION MANUAL YARTIW
DECKER DECKER
61
SPAC~(Sn Ttilee;h& ~884~fSJREWS ’ ’

~~~~~~~

CALIBRATION SCREW SET CALIBRA~ON SCRJSW SET

IN CALIBRATION PO3lTION IN OPERATING POSlTION

Figure 2-l. Dynaline Spacer and Calibration Detail

Table 2-l. Dynaline Set-Up Information

UD16RU-16 wiD516RU-16 Tensiometer

UD16RU-20 w/D516RU-20 Tensiometer

4 5/77
 TW316
YARTIN MARTIN
QECKER TECHNICAL INSTRUCTION MANUAL QECKER
El r3

2-4. cont.
Note
The calibration set described in the following steps
should be performed before the Dynaline is installed
and again every 25 to 30 days that the system is in
continuous use. Whenever ambient temperature
changes of more than 30°F occur or when the system
is idle for several weeks, calibration setting is
recommended.
Tighten the calibration screws against the frame as shown in Figure 2-1, Detail A.
Z: Turn the indicator damper screw (figure 2-2) fully clockwise, then back it out
2-l/2 to 3 turns. If the damper screw becomes disengaged from the threads,
push it in and turn clockwise until the threads become engaged.
e. ’ Adjust the calibration chamber screw until the pointer reads approximately 10%
of full scale. Back the screw off until the pointer is in the lower half of the
black band (figure 2-2).
f. Repeat step e several times to exercise the load cell diaphragm.
g- Adjust the c&ration chamber screw until the pointer is at the top end of the black
calibration set band. This point is used to establish a positive reference point and
maintain correct realtionshlp between the three sheaves when the element is on the
line.
h. Unscrew the two calibration screws as shown in Figure 2-1, Detail B.
1. The Dynaline is now ready to install on the wire rope. Exercise care to insure
that the calibration chamber screw is not moved during installation.
1. Refer to figure 2-3 and remove the deflection sheave assembly from the force
frame.
k. When the DynaIlne is to be installed on horizontal lines, it may be most convenient
to set the element on top of the wire and install the deflection sheave assembly
from below.

Indicator
Calibration
J / Chamber
Screw
Mounting Bracket, / /

Lock Nut

Retainer Nut

poitier((\ 1II:F Check Valve

Calibration
Chamber

Stein

Figure 2-2. Typical Dynaline System Indicator

5
 lW316,
YARTQl MARTIN
QECKEK TECHNICAL INSTRUCTION MANUAL DECKER
El q

2-4. cont.
Note
The Dynaline may be operated either above or
below a horizontal line.
k. Tighten the deflection sheave into the operating position with the toggle nut shown
in figure 2-3. Insure that the side plates contact the force frame stops at one or
both sides as shown in figure 2-3, Detail A.
1. The Dynaline should be supported with a tie bar employing a universal action at
each end. The tie bar must be of sufficient length to allow for movement of the
wire line but it must not allow the unit to swing through an arc under slack wire
conditions and strike adjacent structures. The tie bar can be supplied by
MARTIN-DECKER or fabricated by the customer to suit a particular application.
m. When a Dynaline is to be mounted close to the deck or floor, a wooden plank
such as that shown in figure 2-4 should be installed.

2-5. CALIBRATION SET WITH DYNALINE MOUNTED ON WIRE ROPE

2-6. In order to calibrate a Dynaline that is already on the wire line, proceed as follows:
Tighten the calibrationscrews againstthe frame as shown in Figure 2-1, Detail A.
ba: Remove the top toggle nut and loosen the bottom nut until the center sheave can
be turned by hand (figure 2-3).
C. Turn the calibration chamber screw (figure 2-2) until the pointer reads
approximately 10% of full scale. Back off the screw until the pointer is in
the lower half of the black band.
d. Repeat step c several times to exercise the load cell diaphragm.
e. Adjust the cabration chamber screw until the pointer is at the top end of the
black calibration set band. This point is used to establish the correct relation-
ship between the three sheaves.
f. Loosen the calibration screws as shown in Figure 2-1, Detail B.
!3 Re-tighten the two nuts that secure the deflection sheave. The system is now
ready to use.
Note
Check the unit to insure that the side plates contact the
force frame stops at one or both sides (Figure 2-3, Detail A).

-CONTACT POINTS7

Figure 2-3. Dynaline Sheave Removal and Tightening Detail.

5/77
6
 TW316
YARTIN MARTIN
DECKER TECHNICAL INSTRUCTION MANUAL DECKER
q q

When a Dynaline element

is mounted close to the
deck or floor, install a
wooden plank as shown.

Figure 2-4. Typical Dynaline Installation Using a Wooden Plank for Protection.

SECTION III
MAINTENANCE AND TROUBLESHOGTING
3-l. MAINTENANCE
3-2. Routine maintenance such as lubrication and general cleaning should be performed regularly.
Refer to the appropriate paragraph for specific procedures.

3-3. LUBRICATION

3-4. Lubrication fittings are of the hydraulic type. Use the appropriate coupler. There are
five lubrication points on the element and four on the MARTIN-DECKER tie bar (figure 3-l).
These fittings must be lubricated weekly with any commercial E. P. C2 extreme pressure
grease. Whenever a system has been unused for any length of time, it must be lubricated
prior to being put into service.
3-5. WASH DOWN

3-6. Whenever a Dynaline is removed from service, it must be washed down with fresh water.
After the unit has been thoroughly washed, it should be blown dry with a high pressure air
hose and sprayed with WWO or equivalent to prevent corrosion. Lubricate the Dynaline
as described in paragraph 3-3.

5/77
 TW316
MARTIN MAllIN
DECKER TECHNICAL INSTRUCTION MANUAL
QECKEK
R R

Figure 3-l. DynaIine Lubrication Points.

3-7. RECHARGING THE LOAD CELL

3-8. Recharging will be necessary whenever the fluid level drops or when air gets into the system.
The load cell can be charged with or without the element mounted on the line.

3-9. When the system is being recharged with the element still on the line, set the calibration
screws as shown in Figure 2-1, Detail A and loosen the deflection sheave until it can be
turned by hand. Load the system as follows:
a. Assemble hand pump and swivel as shown in figure 3-2.
b. Remove the cap from the check valve at the indicator and connect the pump to the
check valve.
Note
Leave the swivel nut loose at this time. It will be
tightened in a later step.
C. Fill the pump bowl 2/3 full and stroke the pump until all air is purged at the
swivel nut. Once all air is purged, tighten the swivel nut.
Note
Keep the pump bowl at least 2/3 full at all times to
avoid introducing air into the system.
d. Pump fluid into the system until the gage indicates 10% of full scale.
e. Back the calibration chamber screw out while pumping fluid into the system and
maintaining a 10% of full scale reading.
Note
Stop adjusting the calibration screw once the piston
contacts the retainer nut. Further adjustment could
back the retainer nut out of its position.
f. Bleed the air from the system by loosening the bleed plug at the load cell
(figure 2-i). Bleed fluid until the pointer returns to the middle of the calibration
band.
43. Turn the calibration screw two turns inward. Pump additional fluid into the
system until all air is purged. Repeat as required.
5/77
 TW316
BARTIN MARTIN
DECKER TECHNICAL INSTRUCTION MANUAL DECKER
El q

3-9. cont.
h. Remove hand pump from the check valve and replace the check valve cap.
i. Unscrew the calibration screws as shown in Figure 2-1, Detail B and tighten
the center deflection sheave.

Calibration
.mber

Figure 3-2. System Loading Detail

Table 3-l. Malfunction Isolation
I Symptom Probable Cause Corrective Action

Indicator pointer Damper closed. Turn damper screw counterclockwise

does not move. (figure 2-2).

Extreme ambient temperature Recharge system and adjust volume

changes. screw per paragraph 3-7.

Loss of Fluid. Check for leak in hydraulic system.

Repair and re-charge as required.

Air in system. Bleed and recharge per paragraph 3-7.

Indicator pointer Partially closed damper. Open damper slightly.

sluggish.

Indicator pointer Damper open too far. Close damper slightly.

erratic.

5/77 9
 Tw316
MARTIN TECHNICAL INSTRUCTION MANUAL MARTIN
OECKEl DECIIER
El a

Table 3-l; cont.

Symptom Probable Cause Corrective Action,

Indicator reads Fluid level low Recharge as required.

abnormally low
when picking up Dynaline not installed on wire Install per paragraph 2 -3.
load. rope properly.

Gap between the floating Check gap. Should be approximately

sheave guide block and force 3/16 in. under load. Perform calibra-
frame is in excess of the tion set procedures per paragraph 2-3.
required gap.

Line will not Tie bar misallignpled. Dynaline Insure that tie bar is properly aligned.
rewind on drum not following line properly.
properly.

Indicator reading Wrong size wire rope. Check that the unit has the correct
incorrect. spacers for the size wire rope being
used (paragraph 2-l).

10