LiftlogXL Installation and User Manual
Contents
1. ssssssssesssesesee esent ennt nenne ness ens 14 3 3 5 Connecting Load Sensor Inputs sessssssesee seen eene enne enne nnns 15 3 3 6 Connecting the Fault Output essssesssssseeeeeee eene eee ennnnts 17 COMMISSIONING DETAILS o5 eee eee eene o in een eo ao een oe ate e at eU a een sera een sess een sss pras rans KSEE 18 4 1 Installing and Launching the FSU Application sees enne 18 4 1 1 FSU Program Installation esses sees eene enne 18 4 1 2 Installing the FSU application esses eee nene 18 4 1 3 Launching the application retener ee e ker a e nva 18 4 2 Connecting to the Device eter eti dire re oid ead raain IA RE RE raa Re eaa pee ea a 19 4 3 Checking for Firmware enemies en nennen nennen nnns 19 AA Checking the Date Time deett eoe inpr texte trie re dee i rnv doe rs otra 20 4 5 General Tab car aee P t e Robbe ste i deas t o P dade rose coe dde 21 4 5 1 Setting Equipment Name 2 0 0 eee cece cece ee eeeeeaaece cece eeeeeaaaaeceeeeeeeseesaaaeceeeeeseeeeaaaeess 21 45 2 Upload Data to the Compultert ener rea pn enean sen teda aura sa ganan 21 4 6 Main and Aux Hoist Configuration eene enne nnne nnns 21 4 6 1 Input SelectiQni ucc cei ORRO 22 O CASWA Pty Ltd 2013 4 6 2 Using Removing a HoistNet Input essere nnne nnns 22 4 6 3 Using the LiftlogXL with a ControlPro2. esesseeseeeeeenenennnen nnne nnns 23 46 4 Checking the Gain ziii erret tanen aite ni page ta dnte na pe nau a Ernie ea nane aa bend 24 4 6 5 Calibrating the Logger sss eene ena 24 4 6 6 Resetting the Calibration cider bete riven certian ee aae ade ee nante soon 24 4 7 COMMS TaD oiriin Gaver ecdaeeeas E EE EEE adie taati vedas 25 4 7 1 BG CONPIBUFATI ON ienn era rene aiaa ca dra deae edendis 25 CASE ecc Dr EE 25 4 9 Inputs and LImilte coudre betonen Secreto eter coepere detur aea A E gage ua det vade Devis 26 4 8 1 Tuning Sensitivity and Noise Immunity ceessssseeeeee eene 26 49 OVERIOAGS EE 27 4 9 1 Main AUX and Combined ceceessssccececessesscnececececessesssaeeeeeescesseseeaeeeeeeseessesneaeees 27 4 9 2 Overload Sensitivity iocis tripode echte rea ue ehe Dna puede aaia 27 49 3 LOCK OU tee oU RU E ers tue ud wens E putes te vases ken rave E ade 27 4 10 SD Card ManaBeme nt occi edes odo seeds od dente pde deba dod oe hien aea qe Ra Eae dee sd C dune d Td n nagd aa it 28 4 10 1 Test SD Card eerie bait eee E HRS ee e ERR ERR EP REF Ne nis REL EV ONES 28 4 10 2 Reformat SD Card eiie eite acie eiie eth tae cevanegeeavanceuseseaccotsoavieests 28 5 ROUTINE MAINTENANCE irre enses kd oreet n eau a E REPERI ENS P SR FUR EXN PER ERAS ERE a oL ES PER rea EUR Eoo ENESESSE 30 6 OPERATING LIFTLOG XL iccscsccsssssnsssvsececesticnnsssvevessesscaneassesees dessinnaieveosesse
3. SOLE DIGITAL Liftlog AL Advanced Crane Data Logger Model LL300 Version 2 0 Connected Overload G MESS Liftlog com au m TEELE T A a sail bas i ai aA PIEJSIDIBIODUOUCIBlODIO V1 6 29 07 2013 CASWA Pty Ltd 2013 TNTELLIGENCE MADE SIMPLE CONTENTS i jdii i 4 1 1 iftlog XE Versions oe E e reca etes i rebar Rie on e tert ris di Rs 4 SPECIFICATIONS c 5 2 1 Operational Specifications eese eene eene enne nennen nnn erret nn 5 2 2 Physical Specifications sosser eneen an eE eae ss e eA aE a AE EEEa aE 5 2 3 Electrical Specifications iei e de rete e este cg patte rdg eren 6 2 4 Communication Specifications cesses eee enne en nennen nnne nennen 6 INSTALLATION DETAILS o esser sss s sensor o een r osea pora Y SUR R SERES PRR ERR STAR ERR SUR P YRES rere RR S PR Ray Rau 7 3 1 Prior to Installation roter tercer teet ra Lee rab rese it radi esatto Sia 7 3 2 Inserting Changing Your SIM Card sse nennen nnne nnne nnn nennen nennen nn nnnns 7 BS WinME DEtallS ERROR SMS 7 3 3 1 Terminals cit rre tete ueni teo e Een A EEE Een see Rae EESE Eee 8 3 3 2 Connecting the Power Supply esssssseseeseeeene eene enne enne nennen nnns 11 3 3 39 Connecting Motion INPUTS eer URS RR eS RU Es Re saves AUNRE RR ERR Ne NER AREAREN 13 3 3 4 Connecting Limit Inputs
4. 48 Inputs and Limits These two tabs show the status of each of the Liftlog XL s input signals They are intended to be used to confirm the correct wiring of the unit When a signal is detected the respective box will be checked 4 8 1 Tuning Sensitivity and Noise Immunity Very short duration events are often caused by noise these may appear as very short duration input events To remove these from the logged data set adjust the value in the Ignore inputs shorter than dropdown box The default output is 200mS shortest option Selecting a longer time period will reduce the likelihood of recording spurious noise events but also increases the risk that legitimate inputs will be erroneously ignored Therefore it is recommended that this value only be increased when the current value is known to be insufficient at removing known noise events O CASWA Pty Ltd 2013 gnore inputs shorter than 200mS t SOLE DIGITAL G Littlogxt General Main Aux Comms Inputs Limits Overloads SD gt Main up down T fast Aux up down T fast Motion north west fast east south Misc I Ax3 T Ax2 aux v log Auxon change Ignore inputs shorter than 100mS G Liftiogxt General Main Aux Comms Inputs Limits Overloads SD gt Main V up down J fast Aux up down T fast Motion north west fat east south Misc Ax3 Ax2 aux I lo
5. iy 25 1 27 33 GND Figure 5 Connecting Motion Inputs CASWA Pty Ltd 2013 13 Page SOLE DIGITAL 3 3 4 Connecting Limit Inputs There are two input pins for each limit input e g Pins 45 and 46 for the Main hoist SidePull limit Each input pair should be connected across the limit switch or chain of limit switches to be monitored All limit inputs are voltage independent and typically configured to be normally closed i e any voltage across these terminals keep the limit from activating For example the Main Hoist SidePull limit would be connected as follows LiftlogXL MAIN hoist SidePull Sensor 45 MAIN SidePull 46 MAIN SidePull Figure 6 Connecting Limit Inputs 9 CASWA Pty Ltd 2013 14 Page SOLE DIGITAL 3 3 5 Connecting Load Sensor Inputs The Liftlog XL supports two load sensor inputs marked MAIN and AUX of various types a Strain gauge input e g CASWA rope clamp load cell b 4 20mA input c 0 10V input d ABUSLIS Q F1 or F2 inputs The load sensor for the MAIN hoist is connected to pins 1 7 the load sensor for the auxiliary hoist connects to pins 28 34 3 3 5 1 Strain gauge input When using a strain gauge load cell to measure the load on either the MAIN or the AUX hooks all four wires from the strain gauge need to be connected For the MAIN hook these should be connected as follows LiftlogXL Red 4 XCite Green Whi
6. i Read Query the device ID l Write Set the device ID Device ID s are limited to 18 characters z Read Query the zero parameter The zero value is used to calculate the actual load See the C and r commands Write Set the zero parameter c Read Query the cal parameter The cal parameter is used to calculate the actual load See the C and r commands C Write Set the cal parameter In normal operation the cal parameter would be set as follows e Send the r command to get the raw reading from the load pin in it s unloaded state e Send the Z command to set the zero parameter e Apply a known load to the pin e Sendthe r command to get the raw reading from the load pin e Sentthe C command to set the calibration value to Rawunloaded zero Known Load in 100Kg units on Read Query the overload setpoint parameter This parameter is stored in 100Kg units eg 3 5mt is expressed as 35 It is used by the device to determine when an overload occurs On Write Set the overload parameter wn Read Query the inverted status of a setpoint output A return value of 1 means the output is normally open Wn Write Set the inverted status of a setpoint output io Write Reboot the device This command is usually only used to load new firmware onto the device O CASWA Pty Ltd 2012 SOLE DIGITAL Example Send v lt CR gt Rcv 1 02b CR Send h lt CR gt Rcv 2 CR Send HO CR Send
7. Each command must be followed by a carriage return lt CR gt ASCII 13 Where the command is a query command no arguments are sent and the device will respond with a single line except for the u and E commands the requested value in ASCI text followed by a lt CR gt Where the command is a set command an argument may be included between the command and the lt CR gt Where numbers are sent or received they are sent as clear text eg 1234 Where a number represents a load eg the o and O commands and the logged data returned by the u command it is expressed in 100Kg units Eg 3 5mt would be sent and received as 35 Where a number represents an elapsed time eg in the logged data returned by the u command it is expressed in 0 1second units Eg 35 4 seconds would be sent as 354 Where dates time values are sent or received they are sent in the format dd mm yy hh mm Hours are in 24 hour clock format Leading zeros must be used Eg 3 8 07 13 30 is an invalid datetime and should be sent as 03 08 07 13 30 CASWA Pty Ltd 2012 34 Page Communication commands Command R W Description v Read Query the firmware version number Read Display a summary of all settings Read Query the input mode O Analog 1 Q Link 2 Frequency H Write Set the input mode r Read Query the raw loadpin reading The lifted load may be computed from this value as Raw Zero Cal See the C command
8. shown on the Main Aux screen The connection Input status will also be shown m C 420mA C HOV C mV C AbusQ C AbusF HoistNet Bound to Liftlog RoperHoist 1 connected NB You will need to ensure that the originating HoistNet device s load signal has been calibrated correctly To unbind a Liftlog XL from a HoistNet device or to change the bound device press the Bind button on the Load screen and then select lt Unbind gt on the popup box 4 6 3 Using the LiftlogXL with a ControlPro If your LiftlogXL device is connected to a Konecranes ControlPro and you want to use the calibration settings stored on the ControlPro rather than calibrating with test weights press the Control Pro button A dialog box will appear asking you to confirm this action r e This will configure this input chanel for connection to a Konecranes WES Control Pro 0 10V signal Press lt OK gt to confirm Another dialog box will appear m c x CASWA Pty Ltd 2013 23 Page SOLE DIGITAL Enter the capacity of the hoist in tonnes and press lt OK gt Your device is now calibrated and you will not need to zero or calibrate this hoist in order to use this Liftlog NB You need to have selected the mV mA V input type 4 6 4 Checking the Gain Irrespective of the indicated load which is determined from the calibration the signal indicator bar below the load display shows the a
9. 36 Drive voltage for 4 20mA sensor 24V 37 AUX2 Opto isolated limit input can be used for any limit function 38 AUX2 39 AUX1 Opto isolated limit input can be used for any limit function 40 AUX1 41 Opto isolated side pull input for AUX Hook Connect across up inputs on SidePull 42 SideWise signal processor SidePull AUX 43 Top Limits Opto isolated ultimate limit input for AUX Hook 44 Top 45 Opto isolated side pull input for MAIN Hook Connect across up inputs on SidePull 46 SideWise signal processor SidePull MAIN 47 Top Limits Opto isolated ultimate limit input for MAIN Hook 48 Top 49 Fault2 AUX hook load limit output 48 240VAC 4A NO NC 50 Fault2 51 Fault1 MAIN hook load limit output 48 240VAC 4A NO NC 52 Fault1 CASWA Pty Ltd 2013 SOLE DIGITA SOLE DIGITAL 3 3 2 Connecting the Power Supply Liftlog XL is designed to operate from 24 240VAC grounded neutral Note Series 1 units could only operate from 48 240VAC It can also operate from 12 48VDC however this is not preferred as load limits cannot be used in this configuration For more information on driving the Liftlog XL from a DC power source contact tech caswa com Liftlog XL requires constant power so that it can maintain a connection to the 3G GPRS network Do not connect the unit after the K1 or E Stop relay Doing so will cause erratic behaviour and premature failure of the Liftlog XL elec
10. Description Min Typ Max Units Vin Supply voltage 24 250 VAC 12 48 VDC lin Supply current 40 100 mA Vlimit Overload relay voltage 60 VAC l mit Overload relay current 0 5 2 V Viimit Limit Switch input voltage 60 VAC Lense mv load sensor sensitivity 0 5 10 mvV V Rin Input impedance of 0 10V input 1500 Ohms log 24V output current 100 mA Operating temperature 40 gsr Je Notes 1 Power supply ve and GND pins are at chassis GND OV potential 2 Extended operation at maximum temperature will reduce the life the device 24 Communication Specifications Communications between the device and a host is usually via a Bluetooth radio link The Bluetooth device name will be set to the Crane ID the PIN is OOOO For more details on the communication protocol used to communicate with the Liftlog XL see Appendix A O CASWA Pty Ltd 2013 3 INSTALLATION DETAILS 3 1 Prior to Installation Before installing your Liftlog XL device visually inspect the unit and check that a the case is not damaged and fits together securely b terminals are secure c terminal numbering is as per section 3 3 1 i e stickers have been correctly placed If you have chosen to install your own SIM card then this should be inserted now Details are provided in the following section The antenna can also be screwed into the front terminal now 32 Inserting Changing Your SIM Card Remove the lid from the unit by releasing the clips at each e
11. Flashes every 3 seconds once connected Overload LED Illuminates for a couple of seconds on start up Flashes briefly once a second at other times to indicate normal operation Illuminates continuously when either hoist exceeds it overload limit 6 2 Accessing Your Data Open a web browser e g Internet Explorer and type in the URL you have been given into the address box If you have not received a URL web address that can be used to connect to your data please contact tech caswa com A screen similar to the following will appear that reflects all cranes with Liftlog XL devices installed for which you have access rights If the individual pieces of equipment are not visible click on the icons on the left hand side to show the equipment belonging to that group site equipment class etc EJ aces pack manage sous BBTBLATE B BOX Sxcespctcomau x al CAS Australia website 5 desktop ini WB DS Lib eBay Hits E http www mockridge co E My EBay Play Free Games Your Company Name amp Logo Events s i Mi Settings Summary B A Jj CD1 Ground 25 5T e 2 CD1 Jib 6 3T A CASWA Pty Ltd 2013 31 Page SOLE DIGITAL Select the name of the crane hook you wish to interrogate A variety of information is available via this screen to extract data and further configure the device s reporting features Events data This shows the date time mm dd yyyy format type of event and if an AccessPack is
12. North South travel is fast N S Fast 17 AC input indicating South Travel South 18 AC input indicating North Travel North 19 AC input indicating AUX Hook up down is fast Fast 20 AC input indicating AUX hook lowering Down AUX 21 AC input indicating AUX hook raising Up 22 AC input indicating MAIN Hook up down is fast Fast 23 AC input indicating MAIN hook lowering Down MAIN 24 AC input indicating MAIN hook raising Up 25 Neutral OVAC power connection OV AC 26 Live 48 240VAC power connection 24 240V AC 27 Shield OV GND O CASWA Pty Ltd 2013 0 10V input for AUX hook from loadcell pin amplifier or Konecranes Control 28 0 10V pro Return connection for AUX hook 4 20mA strain gauge mA load cell pin or 29 4 20mA output from load display Excitation voltage 3 3V for AUX hook strain gauge mv load cell pin red 30 XCite wire on RC 3 or RC 5 rope clamps 31 ve sense input for AUX Hook strain gauge mV load cell pin green wire on RC 3 or RC 5 rope clamps AUX ve sense input for AUX Hook strain gauge mV load cell pin white wire on 32 RC 3 or RC 5 rope clamps GND negative reference for mV mA and V sensors black wire on RC 3 or RC 33 GND 5 rope clamps 34 Connection for AUX hook to gnd on an ABUS LIS Q Link 35 Connection for AUX hook to terminal Q F1 or F2 on an ABUS LIS Q Link
13. also installed on the equipment the name of the responsible person using the crane at the time of the event Logs This shows the full list of all logged events recorded by this LiftlogXL Data includes date time hook 1 or 2 tons lifted sec duration of event direction of motion and if an AccessPack is also installed on the equipment the name of the responsible person using the crane at the time of the event Settings This tab allows the user to set what type of events will trigger an automatic email These settings do not affect what data is recorded Summary This tab displays summary graphs indicating how the crane hoist is being used 6 2 1 Downloading Data To download events or log data select the desired tab Press the Excel icon that is located just under the table on the right hand side Another window will then pop up for you to select desired date range for your data Select the start and end dates using the calendars Press the lt Save gt button You will be asked for a location to save the data The format of the downloaded Log data is provided in Appendix D CASWA Pty Ltd 2013 32 Page 8 TROUBLESHOOTING Fault Intermittent connection between XL and Link2 during commissioning Cause Intermittent power supply SOLE DICIT A r go gug 8 Fix Ensure power has not been supplied after the K1 or E Stop relay If so rewire to supply constant power Failure to do so will c
14. purchase 4 5 2 Upload Data to the Computer Clicking the Upload button brings up a dialog asking where to save the data Enter the required file name usually the crane name or serial number Make sure the Location entry is set to Storage card and press Save Progress is indicated on the MAIN screen Time to download depends on the number of lifts and can be up to 20 minutes 46 Mainand Aux Hoist Configuration G Liftlogxt General Main Ax Comms Inputs Limits Overoads sp gt If your Liftlog XL device has been preconfigured only available with Abus inputs or you are using a HoistNet load signal which must be calibrated then you will not need to calibrate the Liftlog XL All other types of Liftlog XL inputs must be calibrated Unless you are connecting the device to a Konecranes ControlPro and elect to use the already calibrated ControlPro settings this process will require test weights The process to configure the Main and Aux hoists is identical as are the configuration screens Click on the Main or Aux tabs to bring up the load settings screens CASWA Pty Ltd 2013 21 Page SOLE DIGITAL 4 6 1 Input Selection Select the button that corresponds to the input you have connected to the Liftlog XL For connection details see section 3 3 5 Hint If the Auxiliary input is not used it is strongly recommended that its input selection be set to 4 20mA a
15. ally downloaded in real time using GSM 3G GPRS or WIFI connectivity Liftlog XL is particularly well suited to users seeking an integrated enterprise solution for crane monitoring and management high risk applications requiring increased oversight of crane operation and dual hoist or process cranes 11 Liftlog XL Versions Liftlog XL V2 devices are marked with a serial number that begins with a 2 e g 2 001 2 974 If you have a Liftlog XL with a two or 3 digit serial number that is smaller than 200 e g 72 196 you have a V1 device and you should refer to the Liftlog XL V1 Installation and User Manual O CASWA Pty Ltd 2013 2 SPECIFICATIONS 21 Operational Specifications Parameter Description Min Typ Loi Maximum number of logged events Fiog Frequency of logged events Tiog Duration of a logged event 1 M max Maximum loggable load 2 2 Physical Specifications Overall length mm 157 Overall width mm 86 Overall height mm 58 Weight kg 0 3 Mounting Screwed or 30mm DIN rail Electrical connections 56 x screwed terminals Detailed dimensions of the Liftlog XL case are provided in the following diagram where all dimensions are shown in mm SOLE DIGITAL Max 10 000 000 4 30000 100 Figure 1 Case Dimensions CASWA Pty Ltd 2013 Units Hz Sec mt 23 Electrical Specifications SOLE DIGITA p g pu NH X Parameter
16. ate Faulty Link2 very rare Check that the Green Power LED is illuminated If not check power is connected correctly as per section 3 3 2 Move laptop closer to the LiftlogXL Power cycle the LiftlogXL Check if possible to connect to another CASWA device If not then replace Link2 Connection between XL and Link2 lost when E Stop is pressed Incorrectly connected power supply after E Stop relay Ensure power has not been supplied after the K1 or E Stop relay If so rewire to supply constant power Failure to do so will cause the electronics to fail very quickly Red LED not flickering during service but Green Power LED is on System failure probably due to stopping a firmware update mid stream Very rare Return to manufacturer for repair No data visible on website but all LEDs indicating correct operation Incorrect name or serial number on Liftlog XL or in database Check that Serial Number matches that on the outer case If problem persists contact tech caswa com and supply details of device s Equipment name and Serial Number No email notifications of crane events No events set to trigger an email Incorrect email settings Check settings on website settings tab Check settings on website settings tab O CASWA Pty Ltd 2013 6 SOLE DIGITAL Appendix A COMMUNICATION PROTOCOL The host sends single character commands to the device to write or query parameters
17. ause the electronics to fail very quickly Blue LED not flashing No data being sent Incorrect APN No GPS signal SIM Card expired Connect with FSU and verify the information contained under the Comms tab Check if mobile phone coverage is available at specific location inside cabinet Check antenna is connected securely but not over tightened If antenna has been over tightened the internal wiring may need to resoldered Open case to check Check account Erratic load readings Noise on input signals Check shielding on load cell and VSD cabling Noise on unused channels Set Aux load type as 4 20mA Inputs on all the time Active and neutral reversed Check the power wiring Inputs flickering Ground on LiftlogXL not at OV Noise on cables typically when the cable runs are long or there is a noisy VSD Measure between the chassis and one for the LiftlogXL gnd terminals correct active and neutral wiring ground control voltage transformer secondary or ground liftilog Fit 1Kohm 1W termination resistors between the input terminal and gnd No load indicated Wrong input selected Load input wired wrong Insufficient gain Refer to section 4 6 5 to calibrate the input Refer to section 4 6 5 to calibrate the input Refer to section 4 6 5 to calibrate the input No Bluetooth connection between XL and Link2 XL is not powered up Insufficient range XL in confused st
18. bsolute magnitude of the input signal Before undertaking a calibration check the magnitude of the signal at near full load It should be approximately 70 8096 of the full scale reading If the signal is too large the signal indicator will turn red and you should reduce the amplification applied to the signal by moving the gain slider to the left If the signal is less than half of full scale then increase the amplification by moving the gain slider to the right 4 6 5 Calibrating the Logger With no load on the hook press the Zero button After a brief pause the indicated load will show zero Do not be concerned if the indicated load changes or is slightly higher than zero in this state the indicated load is very sensitive to both electrical noise and very small changes in applied load Next lift a known load with the crane Ideally this load should be gt 80 of the crane s lifting capacity Note In practice it is often not possible to arrange test weights for every install Provided the input amplification has been set correctly 5 2 2 then an acceptable calibration may be performed with 30 50 of the cranes capacity However if this is done the Liftlog XL should then be recalibrated when the crane is next subject to a full load test Change value With this known load lifted press the Cal button The FSU application will prompt you to enter the load Do so and press OK Load on hook t After a bri
19. continue If the Lockout control is set to a non zero value when the indicated load exceeds lt Overload gt Lockout a special alert will be sent and the fault output will not close This effectively disables the crane until it can be inspected and put back into service NB The locked state can only be cleared by unchecking the Locked checkbox An Example Crane capacity 10t Overload set to 11t CASWA Pty Ltd 2013 27 Page Lockout set to 2096 Indicated load Liftlog XL behaviour gt 11t and lt 13 3t An overload alert is sent and lifting is disabled until the indicated load drops below 11t gt 13 3t An additional locked out alert is sent and lifting is disabled until a technician re enables it by clearing the Locked checkbox 410 SD Card Management Select the SD Card tab to bring up the following screen G Liftlogxt Erase the onboard memory card deleting all lift Reformat Card data Configuration and load calibration will not be affected Write a small file to the card and read it back to Test Card check for errors 4 10 1 Test SD Card To test the card and verify that the LiftlogXL device it is correctly writing data to and reading data from its internal SD card press the lt Test Card gt button A popup box will appear informing you of whether the Test Passed or Failed If the test fails it is recommended that the SD card be removed and replaced to ensu
20. d be left blank Carrier APN USERNAME PASSWORD Telstra prepaid telstra internet Optus Business yesbusiness Telstra 3G as telstra m2m supplied by CASWA CASWA Pty Ltd 2012 36 Page 6 SOLE DIGITAL Appendix C FSU SYSTEM REQUIREMENTS The minimum requirements for operating CASWA s Field Service Utility FSU and Link 2 Bluetooth modem are e Laptop computer running Windows XP SP3 or later e One Spare USB port e Microsoft NET framework 3 5 CASWA Pty Ltd 2012 37 Page Appendix D DATA FILE FORMAT SOLE DIGITAL Data is recorded each time a motion is detected a contactor closes Each datum set contains 1 An PWN Date Time based on the logger s internal clock when a user connects to the logger via Bluetooth using the FSU software the time is compared to the time on the laptop and can be reset Operator only used if a logger is bound to an AccessPack Hook 1 main 2 Aux 3 Both hooks Load from load cell other input in tenths of a tonne Duration of motion in tenths of a second Motion code type of motion as shown in the following table Motion m fo wme SSCS fa Wes CS 8 MoveEast Note If a combined motion is detected then the sum of the individual motions is recorded e g Move Up and Move Fast 144 5 O CASWA Pty Ltd 2012 38 Page
21. ed The new firmware will be installed on the device DO NOT switch off the computer or remove the LINK2 modem until this is complete doing so may leave the Liftlog XL in an unrecoverable state Alternatively press Not now to update firmware at a later time NB If you did not see this window then your device already has the most current firmware 44 Checking the Date Time After checking for firmware the FSU application verifies whether the Liftlog XL has the same date time as your computer If the times are not the same the following pop up window will display on the screen Date Time Warning The Date Time on this device is 01 01 80 11 31 Would you like to set it to 03 11 11 15 31 H Press lt Yes gt to update the devices date time or press lt No gt to leave the date time on the device as it is NB If you did not see this window then your device has the same date time as your computer CASWA Pty Ltd 2013 20 Page SOLE DIGITAL 45 General Tab Liftlogxt Ea 4 5 1 Setting Equipment Name SSD OE NE ER RE E Equipment Logged moves The only configurable item on the General page is the boma SEES Equipment ID This text can be up to 18 characters long and it is used to identify the crane in the reporting BEGIN system Whilst any name may be used it is highly Firmware recommended that the XL be named according to the poo registration details provided at the time of
22. ed 8 or 34 for the MAIN and AUX hoists respectively Connecting a signal for the MAIN hoist is depicted as follows ABUS LIS LiftlogXL Q F1 F2 7 Q Link 4 8 Q Link Figure 10 Connecting a Q Link Input 3 3 6 Connecting the Fault Output The two fault outputs marked Fault1 and Fault2 are normally closed relays which open when an overload is detected They are typically wired in series with the UP contactor coil On a dual hoist crane an interposing relay may be required if both hoists are to be inhibited For example connecting up the Fault2 output LiftlogXL 49 Fault2 50 Fault2 y KxUP Figure 11 Connecting the Fault Output 9 CASWA Pty Ltd 2013 17 Page SOLE DIGITAL 4 COMMISSIONING DETAILS Liftlog XL is designed to be commissioned using a laptop computer You will need a CASWA LINK 2 Bluetooth Modem and the Field Service Utility FSU software application loaded on a laptop 41 Installing and Launching the FSU Application 4 1 1 FSU Program Installation Ensure that your computer is switched on connected to the internet and that the minimum required software versions are installed see Appendix B for minimum system requirements Ensure that the LINK 2 modem is installed and that the drivers have loaded 4 1 2 Installing the FSU application The latest LINK 2 FSU software Link 2_FSU can be downloaded from http www soledigital com au Link2 html You should chec
23. ef pause the indicated load will match the load on the hook 4 6 6 Resetting the Calibration Under some circumstances it may be necessary to erase the calibration of a hoist Warning IF YOU ERASE THE CALIBRATION THEN YOU WILL NEED A TEST WEIGHT TO SET IT AGAIN CASWA Pty Ltd 2013 24 Page To reset the calibration for a hoist tap the button NB Resetting the calibration of one hoist MAIN or aux does not affect the calibration of the other 41 Comms Tab 4 7 1 3G configuration G Liftlogxt General Main Aux Comms inputs Limits Overloads SD Card This tab allows the configuration of the 3G Aceesspoint APN connection used to send data telstra m2m The values for APN UserID and Password are usually provided by the company supplying the SIM card If the SIM card is provided by CASWA then the settings are Connecting APN telstra m2m UserlD blank Password blank 4 7 2 Link Status Text at the bottom of the window will read either Connecting Connected or Online depending on the state of the 3G connection After power on the Liftlog XL will take up to two minutes to establish a connection to the 3G network Once connected any motion of the crane will cause the status to change to Online On the right of the window is a signal strength meter NB This meter is only updated when the Liftlog XL status is Connected CASWA Pty Ltd 2013 25 Page
24. g Auxon change Ignore inputs shorter than rooms l La General Main Ax Comms Inputs Limits Overloads SD gt Main up down J fast Aux up down T fes Motion north Aux3 v log Aux on change 26 Page 4 9 Overloads The Overloads tab contains configuration settings for the behaviour of both Main Aux and Combined overloads G Littlogxt General Main Aux Comms Inputs Limits Overloads SD Card Main Aux Combined 4000 t 200b t 4000 t Fault Contacts N O C N C Crane locked Lockout emp 10 additional overload 4 9 1 Main Aux and Combined In each of these boxes enter the required overload in tonnes If only one load input is connected it is recommended that the Aux and Combined overload be left at their default values 4 9 2 Overload Sensitivity Moving this slider changes the period of time that the hoist must be in an overload state before an overload event is triggered It should always be set as far to the left as practical Where electrical noise K1 contactor closures are important to test a rough runway or high vibrations are triggering false overload events move the slider to the right to decrease the sensitivity 4 9 3 Lockout When an overload occurs the fault output of the Liftlog XL opens When the load is reduced to a safe level there is a delay of 3 seconds after which the fault output closes and allows lifting to
25. k this location regularly for updates 4 1 3 Launching the application Double click on the FSU program icon amp CASWA Pty Ltd 2013 18 Page 42 Connecting to the Device The FSU will scan for Bluetooth enabled devices This process takes approximately 10 seconds when complete a list of all CASWA devices within range will be displayed AirWay unconfigured TrafficLite unconfig LiftlogXL2 unconfig Link 2 Liftlog unconfigured ME sonde HiBeam Display Look again If a particular Liftlog XL unit is not found ensure it is powered up and press Look again to repeat the search Version 2 Liftlog XL devices are differentiated from version 1 devices by a II superimposed over the device icons NB The Bluetooth link between the Laptop using a Link 2 and a Liftlog XL has a range of approximately 200m Double Click on the Liftlog XL you wish to configure 4 3 Checking for Firmware After you have selected your desired Liftlog XL a connection will be made and the software will check if the device has the current firmware If a new firmware version is available the following window will pop up 9 CASWA Pty Ltd 2013 19 Page An update for this devices software is available Would you like to upgrade this device now Current firmware version 10 9 New firmware version 11 0 Press Update to update the Liftlog XL to the latest available firmware version recommend
26. nd to reveal the internal circuit boards Locate the SIM card socket on the upper circuit board and insert a data SIM card into the socket shown Push the card in fully so that it engages For details on what SIM cards are compatible with Liftlog XL see Appendix B Communication Options Replace the cover 3 3 Wiring Details For the Liftlog XL to operate the following must be connected as a minimum a Power supply plus b 1ormore inputs motion limit or load cell The following additional types or inputs are optional e Upto 15 motion inputs and or e Upto9 limit inputs and or e Upto2 load cells of any type and or e 2 Fault outputs O CASWA Pty Ltd 2013 Please note that the terminals of Liftlog XL have changed slightly for different versions of the product Label descriptions have also been altered slightly Sticker orientations showing terminals for Liftlog XL devices with serial numbers that start with a 2 i e numbers greater than 199 are as follows 55 A A O BS og wo o SidePull SidePull WO OAS AS OS OPS SG OPA SC OSS O PV OVOYVOVOPOYO 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Power 0 Connected Overload im it 2 oo ori Liftlog com au Q 1 234567 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 ORCMCRESESECRESECRECRECGEQRN 7 Soo M X Dy iE no I lt gt e Figure 2 Ver
27. r lt CR gt Rev 354 lt CR gt Send i lt CR gt Rev crane34 lt CR gt Send Icrane45 lt CR gt Send z lt CR gt Rev 34 lt CR gt Send Z23 CR Send c CR Rev 11 lt CR gt Send C9 lt CR gt Send 01 lt CR gt Rev 35 lt CR gt Send 0140 lt CR gt Send w2 lt CR gt Rev 1 lt CR gt Send W20 lt CR gt Send lt CR gt 35 Page SOLE DIGITAL Appendix B COMMUNICATION OPTIONS When purchasing a SIM card for use with the Liftlog XL system please ensure 1 The pre or postpaid plan includes data access Voice only SIM cards will not work with the Liftlog XL 2 That you obtain the network name User ID and Password required for connection to the carriers network Many carriers do not require a User ID or Password However at a minimum most require that you configure the Liftlog XL with the network name Details on how to do this are provided in this User Guide B 1 How Much Data When choosing a mobile service plan for use with Liftlog XL select the one with the lowest available monthly data limit A VERY busy crane will generate around 1 megabyte of data per month Some carriers offer low cost options for telemetry applications It is worth investigating these B 2 Australian Carriers A list of Australian mobile network service providers and some suggested network name user ID and Password combinations are provided below Blank entries in the table mean that the entry shoul
28. re it is seated securely The test process should then be repeated If the card fails again then a reformat may be necessary 4 10 2 Reformat SD Card If necessary it is possible to delete all loading history from the LiftlogXL device by formatting the SD card A typical example of where this is useful is when the test process has not been successful or if the data logger is moved from one crane to another and prior data on the device is no longer applicable 9 CASWA Pty Ltd 2013 28 Page SOLE DIGITAL Configuration and load calibration settings are not affected by reformatting the card To delete change these settings go to sections 4 5 through 4 9 of this manual Hint Prior to reformatting it is recommended that data be downloaded from the device as detailed in section 4 5 2 To erase the onboard memory card press the lt Reformat Card gt button You will be asked to confirm the action CASWA Pty Ltd 2013 29 Page SOLE DIGITAL 9 ROUTINE MAINTENANCE There is no routine maintenance required for this device 9 CASWA Pty Ltd 2013 30 Page SOLE DIGITAL 6 OPERATING LIFTLOG XL 6 1 Operating Status The Liftlog XL is fitted with 3 LEDs labelled Power Connected and Overload These are visible from the front of the unit Power LED Illuminates whenever power is applied to the unit Connected LED Flashes quickly while a GPRS 3G connection is being established
29. s this input is relatively insensitive to electrical noise If this is not done motion data for this crane will often appear to be erroneous as the sum of both hoists is displayed By default the input type for the Main Hoist is set to mV whilst the Aux is set to 4 20mA 4 6 2 Using Removing a HoistNet Input Liftlog XL devices are now compatible with CASWA HoistNet This means that they can obtain their load signal wirelessly from any other HoistNet enabled device eliminating the need for long cable runs between the load cell and data logger NB HoistNet was first enabled in FSU version 10 7 If you do not see the HoistNet option then you are running an old FSU version Download and reinstall the lastest version of CASWA FSU You may also need to update the firmware on your Liftlog XL To receive a load signal via HoistNet select the G Littlogxt HoistNet input and then press the lt Bind gt General Main Aux Comms Inputs Limits Overloads so gt button Input Unbound A box will appear asking you which HoistNet enabled device you want to connect to HoistNet amp Jp js Select the device that has the load signal to be Zeleta Device to bindin used and press lt OK gt The popup box will close CASWA Pty Ltd 2013 22 Page SOLE DIGITAL The name of the bound HoistNet device will be G Liftiogxt General Main Aux Comms inputs Limits Overloads SD gt
30. sion 2 Sticker Orientations SOLE DIGITA The following table describes each terminal on Liftlog XL units that have serial numbers starting with a 2 i e greater than 199 Terminal EM Nuber Description Label Negative reference for mV mA and V sensors 1 GND black wire on RC 3 or RC 5 rope clamps 2 ve sense input for MAIN Hook strain gauge mV load cell pin i white wire on RC 3 or RC 5 rope clamps 3 ve sense input for MAIN Hook strain gauge mV load cell pin green wire on RC 3 or RC 5 rope clamps Excitation voltage 3 3V for MAIN hook strain gauge mv load cell pin red 4 XCite wire on RC 3 or RC 5 rope clamps Return connection for MAIN Hook 4 20mA strain gauge mA load cell pin or MAIN 5 4 20mA output from load display 6 0 10V input for MAIN hook from loadcell pin amplifier or Konecranes Control 0 10V j Pro 7 Connection for MAIN hook to terminal Q F1 or F2 on an ABUS LIS Q Link 8 Connection for MAIN hook to Ground on an ABUS LIS Q Link 9 Drive voltage for 4 20mA sensor 24V 10 Aux1 T Auxiliary inputs 1 3 can be used for any function e g magnets twist locks Au etc All are AC inputs across the range 48 240VAC 12 Aux3 13 AC input indicating East West motion is fast E W Fast 14 AC input indicating West Travel West 15 AC input indicating East Travel East 16 AC input indicating
31. ssiscadesvsssedesseseaavsnss 31 6 1 Operating Status cccisscsc M 31 6 2 Accessing Your Dataisscdcce sscccssvesteeecchavecesevsndeatetueceeetusdusetcnedeneonsessnatctaedvesteateoasdhatecerdvergnetenece es 31 6 241 Downloading Dat 2 tette oen pte oret vac bincen cabvbeacaatoncen Rada auda 32 B TROUBLESHOOTING res sior see sete i sober eo eo tea AE EE PEREe E ER EXE RE EE REEL E Re ERA RE EP ERR Po scosscsiscsavsseassoess 33 Appendix A COMMUNICATION PROTOCOL ee eeeeee eene nennen nenne nennt nnns ns nn nunt nnns 34 Appendix B COMMUNICATION OPTIONS eeeeeee eene eene n nenne nennt nnns nanus nnne 36 Bil How MUCH Data oh ar eret eee a Ee ERE Ea ee eant ue NC n epe Reve S FAR Re Eee Reus 36 B 2 Australian CartiIers ine conie rape ihe etre batcee res det guides taa eee sb ud euet ea ngo degna 36 Appendix C FSU SYSTEM REQUIREMENTS cene eene nn ns nn n nennt nn 37 Appendix D DATA FILE FORMAT 38 CASWA Pty Ltd 2013 SOLE DIGITAL 1 OVERVIEW Liftlog XL is an advanced remaining life and load limiting data logger for cranes It can simultaneously monitor two hoists and in addition to logging vertical lifting motions also supervises long and cross travel Overloads and dangerous usage will trigger immediate email or SMS alerts Data is automatic
32. te Black Notes Colour codes are for CASWA supplied rope clamp load cells Figure 7 Connecting a Strain Gauge Input The AUX hook can be connected in the same way using pins 30 to 33 CASWA Pty Ltd 2013 15 Page SOLE DIGITAL 3 3 5 2 4 20mA load sensor input When using a 4 20mA signal to monitor the load connect the load sensor between pins 5 and 9 for the MAIN hoist and pins 29 and 36 for the AUX hoist LiftlogXL 4 20mA Load Sensor a on MAIN hook Figure 8 Connecting a 4 20mA Input 3 3 5 3 0 10V Load Sensor When using a 0 10V signal to monitor the load e g Konecranes ControlPro connect the load sensor between pins 1 or any other pin marked GND and 6 for the MAIN hoist and pins 33 and 28 for the AUX hoist LiftlogXL 6 0 10V 0 10V Signal for MAIN hook 7 External device Amp etc 4 Figure 9 Connecting a 0 10V Load Input 9 CASWA Pty Ltd 2013 16 Page SOLE DIGITAL 3 3 5 4 ABUS LIS Q or Frequency Input Liftlog XL will also accept a load signal from either the Q F1 or F2 terminals of an ABUS LIS This has the advantage of not requiring a separate calibration of the load signal In this scenario the load signal from the ABUS LIS marked as Q F1 or F2 is connected into the Q Link terminal on the LiflogXL pin marked 7 or 35 for the MAIN and AUX hoists respectively whilst the ABUS LIS ground is connected into the Q Link terminal pin mark
33. tronics 3 3 2 1 Using an AC Power Source To connect an AC source from 24 240VAC wire active and neutral as follows LiftlogXL 24 240VAC Active 24 240VAC Power Supply OV Neutral 25 OVAC 26 24 240VAC Notes All pins marked as GND are connected internally to pin 25 OVAC Figure 3 Connecting an AC Power Source 9 CASWA Pty Ltd 2013 11 Page 3 3 2 2 Using a DC Power Source To connect a DC source from 12 24VDC wire active and neutral as follows LiftlogXL 12 24VDC 9 36 24V 12 24V DC Power Supply OV Neutral 25 27 OVAC Notes All pins marked as GND are connected internally to pin 25 OVAC Figure 4 Connecting a DC Power Source It is important to remember that when powering the Liftlog XL from a DC source that it may not be possible to use the load limiting functions of the Liftlog XL as the outputs only switch AC CASWA Pty Ltd 2013 12 Page 3 3 3 Connecting Motion Inputs Motion input pins Aux1 Aux2 Aux3 E W Fast West East N S Fast South and North must be connected to GND or OVAC pins 1 25 27 33 by a set of voltage independent contacts Where spare or auxiliary contacts are not available on the MAIN contactors small relays must be employed For example the DOWN and UP inputs on the Auxiliary hoist would be connected as follows To existing control circuitry LiftlogXL 20 Aux DOWN 21 Aux UP
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