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GS550 Palm User Manual - Load Systems International

1. Operation 15 Operation Screen Menu Rigging ok n aana eee 6 ine Chart Mai nBoom Figure The chart wizard follow steps 1 through 5 to select the capacity chart Display Settings Program the display for operator preferences in menu 3 Display Settings Weight Units Important The steps of boom length load radius and rated capacity may differ on rated capacity charts prepared in different units for the same crane The weight units for load display may be selected according to operator preference Length units are associated with weight units by default see the table below 1 Press Menu Next Next Enter to go to menu 3A Weight units 2 Use Up and Down to select the weight units for load display 3 Press Next to advance to the language adjustment page or press Exit twice to return to the operation display Table Weight Units Unit Notes Equivalent Weight Length Unit Pound Ib 1 lb 0 4536 kg Foot ft Kilogram kg 2 205lb 1kg Metre m Short ton T United States 2000 lb 907 2 kg Foot ft Long ton T United Kingdom 2240 Ib 1016 kg Foot ft Tonne t International System Sl 2205 Ib 1000 kg Metre m 16 The GS550 System Language Future versions of the GS550 will include different display language options 1 Press Menu Next Next Enter Next Next to go to menu 3B Display language 2 Press Next to advance to the contrast adjustment
2. e Verify the boom and jib angles permitted by the rated capacity chart selected If the lockout relay is inverted this alert will occur when voltage is detected on the wire when safe t If the lockout relay is inverted this alert will occur when voltage is not detected on the wire in alarm 10 The GS550 System Alert Description The boom or jib angle is under the minimum angle permitted by the selected Main angle chart For charts determined by radius only this message will occur when the below chart minimum radius is greater than the maximum radius permitted by the chart e Verify the boom and jib angles permitted by the rated capacity chart selected Limit Set hoist limits Press Limit to access the limit menu The limit menu displays the limits for each sensor in the sensor list on successive pages Use Next to scroll from one limit to the next Use Up and Down to adjust a limit When using the GS550 as a load indicator without programmed crane specific rated capacity charts the load limit is typically set to the lesser of the rope limit the hoist limit and the maximum allowed capacity as determined from the capacity charts When using the GS550 as a rated capacity indicator with programmed crane specific rated capacity charts the load limit is typically set to the lesser of the rope limit and the hoist limit Tip Press Up and Down simultaneously to return a limit to the factory default setting The facto
3. 5 System Line Rigging Settings Diagnostic 3A Select weight 3B Select 3C Adj ust 3D Adjust LCD 3E Adj ust units language lights contrast backlight Sensor 5B Radio 5C Lockout 5D Display 5E Digital Input Diagnostic Diagnostic Diagnostic Diagnostic Diagnostic 5B1 Back 582 Last 32 5B3 Search 5E4 Blue ground noise sensors for sensors wire On 5C1 White 5C2 Green 5C3 Orange wire test wire test wire test 5D1 Ti me 5D2 Clock 5D3 Power 5D4 Display 5D5 GS550 id and date battery test Supply volt temperature number Figure Open access menus default factory settings Parts of Line The load sensor often shares the weight with multiple parts of line For accurate load indication the GS550 must be programmed for the number of parts of line 1 Press Menu Enter to enter menu 1 Parts of Line 2 Use Next and Back to select the load sensor typically sensor number one is associated with sheave one the main hoist and sensor number two is associated with sheave two the auxil lary hoist etc 3 Use Up and Down to adjust the number of parts of line 4 Press Enter to save any changes and then press Exit twice to return to the operation display Rated Capacity Indicators The GS550 can be programmed to assist the operator by indicating the working load limit WLL from the crane specific rated capacity charts according to the angle and radius information re ceived from the boom mounted sensors 14 The GS550 Syst
4. 4H Password Settings 4H1 Set administrator password 4H2 Set user password 4H3 Tare menu password protection 4H4 Limit menu password protection 4H5 Info menu password protection 4H6 System start up password protection 4H7 Parts of Line menu password protection 4H8 Chart Rigging password protection 4H9 Display Settings password protection 4H10 Sensor List password protection 4H11 Sensor Calibration password protection 4H12 Radius Settings password protection 4H13 Chart Settings password protection 4H14 Memory Banks password protection 4H15 Data logger password protection 4H16 Lockout Settings password protection 4H17 Network Options password protection GS550 Menu Outline 79 4H18 System Diagnostic password protection 5C Lockout Diagnostic 4H19 Alarm Bypassed protection 5C1 White wire status and self test 41 Network Options 5C2 Green wire status and self test 411 Display mode 5C3 Orange wire status and self test 412 Set up sensor repeater 5D Display Diagnostic 413 Last repeater programmed 5D1 Time and date 414 Install update 5D2 Time clock battery test 5D3 External power supply voltage 9 System Diagnostic 5D4 internal temperature 5A System Sensors Diagnostic 5D5 GS550 base station identification number 5B Radio Network Diagnostic ero Gono portable Paltaly eve 5B1 Radio network background noise 5D7 Radio certification and frequency 5B2 List last 32 sensors received SE Digital
5. Important Replace all four batteries of the anti two block switch at the same time Unchanged batteries will reverse polarity severely reducing battery life Important Protect the interior of the anti two block switch from dirt and humidity at all times 1 Remove the anti two block from the crane and clean off dust and grime Important Do not unscrew the white nylon hex bolt of the antenna Important Do not unscrew the small screw to the left of the antenna 2 Place the anti two block on the edge of flat surface Use the adjustable wrench to unscrew the large white nylon hex bolt of the wire rope about one half inch 3 Carefully remove the plunger assembly without separating it from the cover and place it ona clean and dry surface 4 Slide out the four batteries 5 Insert the four new batteries following the positive negative schema printed on the back of the sensor 6 Replace the plunger assembly Correctly align the bottom cover before screwing in the white nylon hex bolt of the wire rope Tighten well 7 Pull and release the wire rope the light emitting diode LED on the bottom of the sensor should flash red 8 Reinstall the anti two block switch 9 Test the anti two block system for alarm and lockout before use Figures Changing GS050 batteries Actual battery life will vary greatly depending on the application the frequency of use the age and quality of the batteries
6. Load Systems International User Manual The GS550 System Document Part Number GM550 Version 2004 Revision B yi PI 701020 30 40 50 60 70 80 90 100 110 2 Block mu ae Wu ob mw Wiee Load WWW LOADSYSTEMS COM Enalnesrad weighing solutions for crane and lifting application Table of Contents MOGUO Nai 5 OVNI Wii 5 VEESIO MI COMPADII rata dacaa 5 Sais 5 OPAO er 7 DISPO ada 7 KOUE CTY Sta Dase 8 Sensor Status LIONE id os 8 marea PO oa 8 A A tie acy anda nunc aqewe site A ameneucnceh ates ate 8 Menu SY SCCM 1s E E E E E AE E E N A EEE 11 MSME NE E E rai oca 12 Menu Navigations ista 12 PassWord Protecto aaa r A oneateeauni ase eancaeraaat 13 Ment AV OUR cane id 13 PARSONS ad 14 Rated Capacity IMalcatoS nidad 14 DISpla Progr erinacea T A 15 Chane RIGGING siria ica 15 CTA VV IZ AG aio 15 DSENA ESE a e N E E aio 16 MV UIA E aan O 16 LANA 6 camer ae eae een rece a ee ee ee rere ne eee re ent eer re 17 ORINA 17 CONTAS airada 17 BAC KIC IVG Modena 17 AB le ajaj UIC cs AE O A a 17 SVSECM Sensors Dl Ian OS ME 17 Radio NetWork Diagnostic 18 ESEKOUE DIa gno IE iia 19 Display DISgnOS Hi 19 Digital TPUT DIINO SC ii hiateseiniar ee aawecest tina alate eae ce ea aa anaes 19 Stala ON iins a 20 DISPla GSIS li ai 20 Mounting brackets sic 20 Antenna POSION a O 21 Power Supply and Lockout Connection occococccconocconenionononcononconencanoncnnonenronenconenraneninnos 22 LOCKOUESetUInds sui 23 Pass
7. the sensor list 58 The GS550 System How to Remove a Sensor from the GS550 1 Determine the sensor to be removed If more than one sensor of the same type has been added to the sensor list then determine the radio identification number id of the sensor to be removed before proceeding This number between 10000 and 99999 is engraved on the sen sor 2 Press Menu Next Next Next Enter Enter to go to menu page 4A1 3 Press Next repeatedly to advance to the page of the sensor list showing the id of the sensor to be removed 4 The sensor id should flash press Next the sensor type should flash this means it is adjust able Use Up and Down to select No sensor This will remove the sensor from the sensor list but retain the sensor id Tip Press Next and Back simultaneously to remove the sensor from the sensor list The id number will revert to 0 and the sensor type will revert to No Sensor 5 Press Enter to save any changes made to the sensor list 6 Press Exit three times to return to the operation display Sensor list position Sensor radio id number 4A1 No 1 id GO No sensor Sensor type Figure Menu page 941 the sensor list Network Options Listen Only Mode When the GS55O0 is started it normally wakes up the sensors in the sensor list and takes control of them The last display started that is programmed for a sensor becomes that sensor s network controller This means
8. Direct Fax 281 664 1390 Email sales loadsystems com YO2 Saif Zone P O Box 7976 Sharjah United Arab Emirates Tel 971 6 557 3814 Fax 971 6 557 3815 Email sales loadsystems com 4495 boul Wilfrid Hamel bureau 110 Qu bec QC GIP 257 Direct Phone 418 650 2330 Direct Fax 418 650 3340 Email sales loadsystems com 9223 Solon Rd Suite A Houston TX 77064 Toll Free Phone 888 819 4355 Direct Phone 281 664 1330 Toll Free Fax 888 238 4099 Direct Fax 281 664 1390 Email techsupport loadsystems com LSI Contact Information 85 Load Systems International
9. Transfer Data Logger Files from the PDA to a Personal COMpUtET scseseeeeseeereeeeees 65 Trouble Shooting PDA Communication ISSUES ccceceeeeeeeeeeeeeeeeeeeeeaeeaeeeeseeaeseeseeaeeeteaees 66 Date LOGGE VIEWER o o ete ee eae 67 Installation on a Personal COMPUTED ccccccssersecsusecercesueeeeureeeeeausuecrseeauseeureesareenseensens 67 QUICES ta 67 FUI Repo tua ol 68 WIN REDO ista 68 MeN CO ancora 70 Replacing Sensor Batters ini 70 Replacing Anti Two Block Switch Batterles coococconcccocionionenconcanoncononnonconnnnonranenrennaninnons 71 Replacind a Sensor AMENNA arras MMi a 72 Edda Colla d 73 Reading ACCUFACY serrit a a aA 73 Load TESUNO dino 74 A O 74 Certification NOTES visi rai A 75 Model NUmDerS scudo 75 FCC and IG Instructions tothe User anni 76 Notes for CSA Class I Division 1 and 2 Rated Equipment sccscscsscsesereeeeeseeeeeeeetseeesens 77 CE Declaration OF Conforman OS 78 5550 Ment OUN casa 79 69530 Menu Local uurassiviamassiaa rita da 81 Table of Contents iii LSI PRODUCTWARRAN TV ccccccccccecscccccsccccesccensaceeessueeensaenensnnengags 83 LSLE Conta Mor mann rial 85 IV The GS550 System Introduction Overview The GS550 system includes the cabin mounted GS550 radio display and compatible crane mounted sensors The GS550 creates a two way radio network with the sensors to bring required lift data to the operator Hoist load boom and jib angles boom length wind
10. 10 20 30 40 50 60 708090100110 2Block Mays iS Load ves WWW LOADSYSTEMS COM uu Bar graph Keypad Infrared communication port Figure GS550 front view mem 19 2 150001 Dee pr Figure GS550 load display Operation 7 Liquid Crystal Display Detailed lift data and system information is displayed here The liquid crystal display LCD can be adjusted to facilitate viewing in varied lighting conditions See the Display Settings section of this manual Sensor Status Lights Detailed lift data and system information is displayed here The liquid crystal display LCD can be adjusted to facilitate viewing in varied lighting conditions 2 Block The red 2 Block alarm light comes on when a programmed anti two block switch is in alarm The green M main and A auxiliary anti two block radio status lights stay on when the GS550 has a reliable radio communication link to all programmed anti two block sensors The radio status lights flash green when communication is intermittent or absent The M re fers to the first anti two block sensor programmed in the sensor list The A refers to all other anti two block sensors programmed in the sensor list Load The red Load alarm light comes on when a load sensor is in overload The green M main and A auxiliary load radio status green lights stay on when the GS550 has a reliable radio communication link to all programmed sensors The radio status
11. 14 Verify accurate list and trim angle indication Operation Display SO ERE RRRRREREREAA i i K 4 Installation pias een PE IWA l l 4B Sensor Calibration Enter user password aaa 4B1 Automatic value calibration wizard ae AL 4B1A No x id Gxxxxx l L ee as E E eyes ee aS 1 Communi cating with remote sensor I ee a ee i a eee Trim calibration wizard Press Next 1 4 Known trim angle 0 6 4 4 Press Enter to Save calib in sensor Figure Trim angle calibration Installation 53 Rope Payout RopePayout Rope speed Figure Rope payout display Figure Rope payout on a line rider Typically the rope payout sensor is factory installed on the line rider load sensor Alternatively the rope payout sensor may be installed on an appropriate sheave Power supply must be provided to the rope payout sensor A GS550 display can then be programmed to communicate with the sensor and to indicate rope payout length and rope speed Rope Payout Calibration Procedure N 1 Mechanical Set Up Hoist up to reel in the wire rope fully Install the rope payout system Verify that the rope payout sensor is programmed in the sensor list menu 4A1 Zero the rope payout length in the Tare menu see Operation Display GS550 Keypad Tare in this manual Hoist down to pay out a known length of wire rope for example 20 feet 6 Verify the rope payout indicated matches the actual length of
12. GC005 GC012 GC018 GC035 GC060 calibration wizard GC100 and GCi70 eee hae er This procedure requires two known weights The first light weight should be about 10 of load sensor capacity and not F RNR a waa OS y less than 5 The second heavy weight should be over remote senspr 50 of capacity and absolutely not less than 25 aede 1 Press Menu Next Next Next to go to menu 4 wizard Press Next Installation 2 Press Enter Next to go to menu 4B Sensor Calibra 1 9 Enter actual parts of line 1 tion 3 Press Enter to go to the password page edo e 4 Use Back Next Up and Down to enter the user pass word and then press Enter to go to 4B1 Automatic 3 9 Lift known Value Calibration Wizard load No 1 xxxx 5 Press Enter to go to 4B1A 4 9 Adjust actual 6 Use Back and Next to select the load sensor and then poe OS E IBA press Enter to confirm communication with the sensor is possible 5 9 Lift known l load No 2 XXXX 7 Press Next to start the wizard e 8 Use Up and Down to adjust the actual parts of line on the a load sensor and then press Next 9 Note the units that will be used during the calibration de a ee t wizard and then press Next 10 Lift the first lighter known load and then press Next en a e 11 Use Up and Down to adjust the load value displayed to equal the actual known load lifted and then press Next 9 9 Press Enter to 12 Lower the first load lift t
13. S panel connection alternatively bolt the black wire to the body of the machine with a Y inch or 5 16 inch bolt The ground con nection must be strong enough to sustain 3 amperes Connect the red wire to a fused accessory source rated at least 3 amperes that sup Black wire plies 12 or 24 volts when the crane is on The GS550 will automatically detect the voltage level and adjust itself Crane Power Battery 12 V or 24 V Supply Figure Connection without lockout Lockout number 1 if required connect the white wire to a Bosch relay coil Connect the other terminal of the relay to the ground When operating properly the white wire will energize at the battery positive level Troubleshooting if no voltage is present on the white wire remove the load connected to the lockout Current over 1 5 amperes on the white wire triggers an auto re settable fuse Current flow will resume several seconds after the short circuit is eliminated Lockout number 2 if required the green wire functions in the same way as the white wire see above The green wire lockout signal could be triggered by a different set of alarms than the other lockout wires See the Lockout Settings sub section of this manual Yellow cable To valve coil if normally closed is required Cd Battery 12 V or 24 V To valve coil if normally open is Crane Power Supply a required Figure Connection with white wire lockout
14. SUOL 24W SWEGO sud Buoj suo yoye spUunod suun JUDIS AA SDIASP LD DIA pau SU Ul POON Peyo PUD Somos e660 DIOP JO pod pau uBisSp JoqIdUSID M LU SAS Op ADM OM 150 53 suol jog ONE Un LJ o psEbn y jayoog woy sjqoysnipy 200 4Squunu oy puUWJSJUD 3 9b gt 9D dal pey C 352 M WOT SUWAE SDEO TARAA 9 HGILYNEELH WY I a HL bi 13 MORAS HALA gt A THOU RSA Sas JHA WS aS Led Rl ME JO MASA BALA SARA DO HOW Aaa iy WOT l 1H TWUNPOR NOS OMY ASI dd 39404 JOUR SEU US Oy goes 51 JUD Sy UI POLL SSUDUI Ul SID SUOISUSLUIp py AOSSSD9U 3D 5149193 Z AU juudjooy 424209 Woy 27 Installation Load Cell WARNING Capacity and safety factor for load cells and adapter plate assemblies are calculated for load along the intended axis of load vertical with the assembly hanging free side loading may cause load cell and adapter plate assembly to fail causing load to drop Lifts must be rigged such that the load cell and adapter plate assembly hang free and not be subjected to side loading Important The load cell antenna must not be in contact with metal Important The load cell antenna must have a clear line of sight to the GS550 display Important The load cell antenna must point to the left or to the right of the boom it must not point directly to or away from the GS550 display 1 Install load cell bushings Assembly of the load cell and adapt
15. To reduce potential radio interference to other users the antenna type and its gain should be so chosen that the equivalent isotropically radiated power e i r p is not more than that permitted for successful communication Antenna List LSI P N TAO11 Description 14 wave monopole MFG Load Systems International FCC ID QVBGS050 IC 7076A ICGS050 RF Exposure Warning This product complies with FCC IC radiation exposure limits set forth for an uncontrolled environment To comply with RF exposure requirements the unit must be installed and op erated with 20 cm 8 inches or more between the product and your body This product may not be collocated or operated in conjunction with any other antenna or transmitter This device has been designed to operate with the antennas listed below and having a maximum gain of 3 0 dB Antennas not included in this list or having a gain greater than 3 0 dB are strictly prohibited for use with this device The required antenna impedance is 50 ohms To reduce potential radio interference to other users the antenna type and its gain should be so chosen that the equivalent isotropically radiated power e i r p is not more than that permitted for successful communication Antenna List LSI P N TAO11 Description 14 wave monopole MFG Load Systems International Notes for CSA Class I Division 1 and 2 Rated Equipment WARNING Understand manual before operation WARNING Replace batteries only in area
16. accurate WARNING Rated capacity radius and tip height based on information from angle and boom length sensors that are not correctly installed will not be accurate Tip To ensure communication sensors must be at least six feet from the GS550 display How to Add a Sensor to the GS550 1 Determine the radio identification number id of the sensor to be added This number between 10000 and 99999 is engraved on the sensor 2 Press Menu Next Next Next Enter Enter to go to menu page 4A1 3 Advance to the next empty sensor position in the sensor list Press Next repeatedly until the LCD shows No sensor on the bottom line Up to 32 sensors may be added to the sensor list 4 The id number should flash this means it is adjustable Use Up and Down to program the sensor id Tip Press Up and Down simultaneously to make the sensor id number jump directly to 15000 Press Up and Down simultaneously again to make the sensor id number jump directly to 10000 Press Up and Down simultaneously a third time to make the sensor id number jump directly to 0 5 Press Next 6 The sensor type No sensor should flash this means it is adjustable Use Up and Down to select the sensor type 7 Press Enter to save any changes made to the sensor list 8 Press Exit three times to return to the operation display Sensor list position Sensor radio id number 4A1 No 1 id G11023 Load cell Figure Menu page 4A1
17. advance to the lockout level adjustment page or press Exit three times to return to the operation display Lockout level All programmed and rated capacity limits and two block can generate a lockout signal when the lockout level is reached By default the lockout wires carry crane power supply voltage as long as the display is in safe condition to inverse lockout polarity see menu page 4G8 When a lockout level is reached voltage is be cut on all lockout wires linked to the lockout condition see menu pages 4G4 through 4G7 The proportion of a limit that must be reached to trigger lockout is the lockout level The default factory setting for the lockout level is 105 1 Press Menu Next Next Next Enter Next Next Next Next Next Next Enter Next Next to access menu 4G3 Lockout level 2 Use Up and Down to adjust the lockout level 3 Press Next to advance to the white wire lockout trigger adjustment page or press Exit three times to return to the operation display Lockout triggers Different events can be programmed to cut voltage on the lockout wires of the yellow cable Each lockout wire can be linked to a different combination of lockout conditions 1 Press Menu Next Next Next Enter Next Next Next Next Next Next Enter Next Next Next to access menu 4G4 White wire lock out trigger 2 Select which alarm conditions will trigger lockout
18. and recommended Bosch relay 22 The GS550 System 5 Lockout number 3 if required the orange wire functions in the same way as the white and green wires see above 6 Optional Lockout number 4 if purchased with the fourth lockout option the blue wire will function in the same way as the white and green wires see above 7 Connect the yellow cable to the GS550 The connector is waterproof and well rated for external environments Simply connect the cable to the display and gently tighten the nut Do not put a kink in the yellow cable where it enters the connector any bend in the cable at the base of the connector must not be so severe as to break the internal connections where the cable meets the connector Orange wire Green wire Red wire White wire Blue wire Black wire La i A r a ia rd q z E mr at a 5 l a Figure GS550 power supply connector Figure Power supply cable part N2 LB006 Table Power and Lockout Connection Wire Colour Function Black Negative ground Red Positive 12 or 24 volts crane power supply White Lockout No 1 Green Lockout No 2 Orange Lockout Ne 3 Blue Optional 4 lockout or digital input Lockout Settings Warning alarm and lockout control is programmed in this menu The GS550 can be programmed to generate alarms and lockout for almost all programmed limits and two block Furthermore warnings are generated when approaching programmed load limits and r
19. be collocated or operated in conjunction with any other antenna or transmitter This device has been designed to operate with the antennas listed below and having a maximum gain of 2 0 dB Antennas not included in this list or having a gain greater than 2 0 dB are strictly prohibited for use with this device The required antenna impedance is 50 ohms To reduce potential radio interference to other users the antenna type and its gain should be so chosen that the equivalent isotropically radiated power e i r p is not more than that permitted for successful communication Antenna List LSI P N TA001 LSI P N TA008 Description 1 4 wave monopole Description 12 wave dipole MFG Linx Technologies MFG Nearson P N ANT 916 CW QW P N S467AH 915S FCC ID QVBGS000 IC 7076A 1CGS000 RF Exposure Warning This product complies with FCC IC radiation exposure limits set forth for an uncontrolled environment To comply with RF exposure requirements the unit must be installed and op erated with 20 cm 8 in or more between the product and your body This product may not be collocated or operated in conjunction with any other antenna or transmitter 76 The GS550 System This device has been designed to operate with the antennas listed below and having a maximum gain of 3 0 dB Antennas not included in this list or having a gain greater than 3 0 dB are strictly prohibited for use with this device The required antenna impedance is 50 ohms
20. etc Maintenance 7 1 Replacing a Sensor Antenna The GS series sensor antenna part number TA011 is identified by a blue coated tip The TAO11 is replaceable Heavily damaged antennas ripped out sheared off wire exposed and fraying etc should be replaced to ensure communication between the sensor and the cabin mounted display unit Figure TAO11 GS series sensor antenna The following items are necessary to successfully replace the sensor antenna e one new antenna with white nylon hex bolt e one wrench 7 16 inch e an electrical insulating compound This procedure may be followed without removing the sensor from the crane if it is safe to do so If removed an angle sensor must be re calibrated during reinstallation for correct angle display see the angle sensor installation section of the user manual Important The interior of the sensor must be protected from dust grime and water at alltimes If it rains during the procedure an umbrella or other suitable means of protection should be used Place the crane boom jib or ball hook such that the sensor is safely accessible Clean dust grime and water from the sensor Identify the short black whip antenna and the white hex bolt securing it Inspect the antenna for signs of obvious physical damage Carefully unscrew the white nylon hex bolt completely and slide it up the antenna a IS Pictures Removing the antenna 6 Grip the antenna by the base of the black p
21. in accordance with the warranty services procedures described below WARRANTY SERVICES PROC EDURES In order to benefit of the above mentioned warranty the purchaser shall notify LSP s customer service or LSI s authorized distributor or representative originally responsible for the sale of the Products within the Warranty Period in order to obtain a Return Authorization Number A proof of purchase of the Product such as an invoice or a receipt certifying the validity of this warranty shall be presented in order to obtain warranty services In any event even if a Return Authorization Number is provided to purchaser LSI reserves the right to inspect the damaged Product or part before the final decision of repairing or replacing the defective Product or part The defective Product or part shall be returned to LSI or its designated service representative accompanied by the Return Authorization Number with prepaid shipping charges at the address mentioned below The purchaser must insure the shipment or accept the risk of loss or damage during the shipment Purchaser shall also pay any tariff or duty applicable to the return of defective part or Product LSI will at its option repair or replace the Product or part returned to LSI or to its designated service representative LSI owns all parts removed from a repaired Product If LSI repairs a Product its warranty is not extended If LSI replaces a Product the replaced Product is warrantied for the r
22. lift Wedge socket to loaded cable 28 The GS550 System Angle Sensors for the Boom or Jib WARNING Keep the angle sensor away from the boom and any connecting metal struc tures when welding the metal lugs to the boom Proximity to welding may cause permanent damage to the angle sensor and prevent accurate angle indication Mounting Procedure The GS010 series angle sensors can be turned on by starting up the GS550 display to which they are programmed The angle sensor can then assist in levelling itself with the red and green LED Boom Angle sensor Boom centreline Figure Angle sensor level with the boom side view Boon Angle sensor Figure Do not mount the angle sensor with its top bottom axis more than 15 from vertical front view 1 Determine the angle sensor position Angle sensor Boom Figure Angle sensor top bottom axis within 15 of vertical front view Cabin Angle sensor Boom Figure A wedge used to mount the angle sensor with its top bottom axis within 15 of vertical front view a The GS010 01 boom angle sensor can be mounted on either side of the boom b The GS010 02 360 angle sensor must be mounted on the left side of the jib c The angle sensor must be level with the boom centreline d The top bottom axis of the angle sensor must be within 15 degrees of vertical Installation 29 e The angle sensor must have a clear line of sight to t
23. menu 5 System Diagnostic System Sensors Diagnostic 1 Press Menu Back Enter Enter to go to menu 5A1 2 Use Back and Next to select the sensor 3 Press Enter to see sensor data Operation 17 V XXXxXxXx T xx x P xx R Internal temperature Power received by the display Figure Sensor diagnostic data 4 Press Enter to get the sensor firmware product and version numbers Sensor type Angle sensor B0012 2 0 0 0 Product number Version number Figure Sensor firmware product and version numbers 5 Press Exit five times to return to the operation display Radio Network Diagnostic 1 Press Menu Back Enter Next Enter to go to menu 5B1 Radio network back ground noise WARNING The list of last 32 sensors received includes all functioning GS series sen sors within range Programming a GS550 display for sensors from a different system will disable that system and render indication by both systems inaccurate 2 Press Next to go to menu 5B2 List last 32 sensors received a Press Enter to access 5B21 the list of the last 32 sensors received Sensors are shown with their radio id number and the sensor type b Use Up and Down to scroll through the list c Press Exit to return to menu 5B2 3 Press Next to go to menu 5B3 Search for sensors a Press Enter to launch a sensor search After searching the display automatically reverts to 5B21 the list of the last 32 sen
24. on the white wire 3 Add the lockout codes for the selected alarms together to find the lockout trigger num ber 4 Use Up and Down to adjust the white wire lockout trigger number 5 Press Next to advance to the next wire trigger menu page and repeat steps 2 through 5 or press Exit three times to return to the operation display Table Default Triggers Lockout Wire Default Trigger White 4301 Green 34 Orange 32767 The GS550 System Table Lockout Codes Condition Maximum wind speed Minimum angle Maximum angle Overload Not used Maximum radius Maximum length Two block Maximum wind gust Maximum rope payout Examples Maximum wind speed Maximum angle Overload Maximum length Two block Maximum tip height Default white wire trigger 128 912 o hh 64 128 4096 4301 Condition Minimum slew Maximum slew Maximum tip height Maximum imbalance factor Minimum slack rope Minimum list angle Maximum list angle Minimum trim angle Maximum trim rope Maximum radius Minimum angle Default green wire trigger Code 1024 2048 4096 8192 16384 32768 65536 131072 262144 32 2 34 Lockout relay inversion By default the lockout wires carry crane power supply voltage as long as the display is in safe condition When lockout is triggered voltage is cut on the lockout wires linked to the lockout condition Warning Inverting lockout relays will allow crane operation in the event
25. page or press Exit twice to return to the operation display Light Intensity Adjust the intensity off the LEDs light emitting diodes to facilitate viewing in bright sunlight or in reduced visibility 1 Press Menu gt Next Next Enter Next Next to go to menu 3C Light intensity adjustment 2 Use Up and Down to adjust the intensity of the lights 3 Press Next to advance to the contrast adjustment page or press Exit twice to return to the operation display Contrast Adjust the LCD contrast to optimize visibility 1 Press Menu Next Next Enter Next Next Next to go to menu 3D LCD con trast adjustment 2 Use Up and Down to adjust the display contrast 3 Press Next to advance to the backlight adjustment page or press Exit twice to return to the operation display Backlight Mode Adjust the LCD backlight control mode to conform to viewing and power supply conditions 1 Press Menu gt Next Next Enter Next Next Next Next to go to menu 3E Backlight mode 2 Use Up and Down to select the backlight control mode The LCD backlight can be always on always off or on a four second timer In the four second timer mode the backlight will come on for four seconds when any button is pressed 3 Press Next to advance to the backlight adjustment page or press Exit twice to return to the operation display System Diagnostic Diagnose system failures with the sub menus of
26. the GS550 display fails Operating a crane without a functioning anti two block system and load and angle indication ts dangerous and may be against the law Exceptionally the lockout relay can be inverted so that lockout wires carry no voltage in safe condition and carry crane power supply voltage when in a triggered lockout condition In this case if the display fails crane functions will not lockout 1 Press Menu Next Next Next Enter Next Next Next Next Next Next Enter Back to access menu 4G8 Lockout relay inverted 2 Use Up and Down to switch between yes and no 3 Exit three times to return to the operation display Password Settings Three levels of access are available administrator operator and public The administrator pass word is required to change the operator password In the event both the administrator and the operator passwords are lost please call your LSI representative Menus accessible from the operation display can be individually protected by the operator password 1 2 Press Menu Next Next Next Enter Next Next Next Next Next Next Next to access the menu 4H1 Set administrator password 4H1 Set administrator password Press Next three times to advance to the set user password page or to change the administrator password use Up and Down to adjust the flashing letter and then use Next to advance to the ne
27. the alarm until the next two block event or simulation If the switch has not been programmed to the display this should be done before proceeding to step 2 See the sub section How to Add a Sensor to the GS550 in this manual 2 Position the sensor mounting bracket To ensure that the sensor can pivot securely on the mounting bracket throughout the full range of boom angle the mounting bracket must be posi tioned at a 30 from horizontal with the boom parallel to the ground and such that the locking pin of the mounting bracket points up Bolt or weld securely lt Boom Tip G Pivot center Figure Bracket footprint and orientation All dimensions are in inches Up to 8 in 20 cm diameter Boom base gt Mount bracket below and behind sheave centre Figure Anti two block switch placement on a telescopic boom If the head sheave diameter is between 8 and 16 inches 20 41 centimetres then two mounting brackets will be required to permit both live and dead end mounting 32 The GS550 System 8 16 in 20 41 cm diameter Boom base gt Mount bracket 4 in 10 cm below sheave centre Figure Anti two block switch placement for live end mounting on a lattice boom 8 16 in 20 41 cm diameter Boom base gt Mount bracket 4 in 10 cm in front of the dead end pin Dead end pin Figure Anti two block switch placement for dead end mounting on a lattice boom For live end mounting on multiple sheave blocks
28. the scope of LSI s obligation LSI does not warrant that the business results obtained from the use of the Products will be appropriate or adequate for the purchaser EXCLUSION The above mentioned warranty does not cover and shall not apply to e any shipping charges to LSI or an designated service representative as well as the technician out of pocket expenses including traveling lodging and meal expenses if any e the damages caused during the transport or the move of the Products e damages caused by accidents abuse misuse a force majeure or external cause e Products altered modified or repaired not expressly authorized by LSI e any cost damage or expenses for field labor or any other expenses related to or arising from the re placement of defective parts e Products used for pile driving wire rope activated clamshell or dragline applications If pur chaser uses the Products for pile driving wire rope activated clamshell or dragline application the warranty will automatically become null and void LIMITATION OF LIABILITY To the maximum extent permitted by applicable law in no event will LSI be liable to the purchaser or any third party for any indirect special consequential incidental or exemplary damages whatsoever including but not limited to loss or revenue or profit lost or damaged data business interruption or any other pecuniary loss whether based in contract tort or other causes of action even if LSI has b
29. wire rope paid out If not then follow Rope Payout Calibration Procedure Ne 2 pe i Rope Payout Calibration Procedure N2 2 Correct with the GS550 If rope payout indicated does not match actual rope payout and if it is not possible to easily correct by following Rope Payout Calibration Procedure Ne 1 then follow this procedure This procedure requires hoisting up to fully reel in the wire rope and then hoisting down to pay out a known length of wire rope For accurate calibration the known length paid out must be accurately measured 1 Press Menu Next Next Next to go to menu 4 Installation 54 The GS550 System 2 Press Enter Next to go to menu 4B Sensor Calibration 3 Press Enter to go to the password page 4 Use Back Next Up and Down to enter the user password and then press Enter to go to 4B1 Automatic A ee Value Calibration Wizard a gt 4 Installation 5 Press Enter to go to 4B1A A a 6 Use Back and Next to select the rope payout sensor 148148 Sensor Calibration and then press Enter to confirm communication with the fe sensor is possible nter user password 7 Press Next to start the wizard 8 Note the units that will be used during the calibration men 7 Automatic value wizard and then press Next calibration wizard 9 Hoist up pay in the wire rope and then press Next l 4B1A No x id GXXXXX 10 Use Up and Down to adjust the actual wire rope payout Rope payout leng
30. 00 000 Ib capacity load cell for Europe 170 000 Ib capacity load cell for Europe Load Transmitter With Pigtail 6 in for Europe Load Transmitter w pigtail amp pull up for Omy balanced cell for Europe Anti Two Block Transmitter for Europe Boom Angle sensor for Europe 360 Angle sensor for Europe List Angle sensor for Europe Angle sensor with Length input for Europe Wind Speed sensor for Europe Anti Two Block sensor for Europe standard GS display for Europe 55550 Display Spanish for Europe GS550 Display for Manitowoc for Europe 5550 Display for Shutilelift for Europe 5550 Display Spanish for Shuttlelift for Europe to which this declaration refers conform to the relevant standards or other standardising documents Wireless EN 300 220 3 V1 1 1 2000 09 EMC EN 301 489 3 V1 4 1 2002 08 Qu bec June 26th 2007 Dave Smith President 78 The GS550 System GS550 Menu Outline 1 Parts of Line 2 Crane Rigging 3 Display Settings 3A Weight units 3B Display language 3C Light intensity 3D LCD contrast 3E Backlight mode 4 Installation 4A Sensor List 4A1 Sensor type and radio identification number 4A2 System selected configuration number 4A3 Configuration number selection mode 4B Sensor Calibration 4B 1 Automatic value calibration wizard 4B2 Manual parameter calibration 4B3 Reset sensor parameters 4C Radius Settings 4C1 Boom length 4C2 Slew offset 4C3 Height offset 4C4 Boom de
31. 1 Determine placement Find a clear mounting position on the left side of the first lowest section of the boom The mounting position should be close to the base of the boom at least ten feet three metres from the tip of the first section and where the cable reel won t obstruct free boom movement at all boom angles and slew positions Furthermore the reel must be placed such that the cable has a clear straight line to the end of the last section at all boom lengths 36 The GS550 System KT Boom at 0 degrees from horizontal T Welding pads level and in line with the boom at 0 degrees Welding pad holes 2 in apart centre to centre Welding pad holes tapped 16 lt Boom tip Boom base Figure Cable reel mounting position 2 Mount the welding tabs They must be placed parallel to each other with 16 Y inches between the holes centres Install the tabs such that they create a level mounting position in line with the boom at 0 degrees Tip When factory installed the GS011 angle length sensor transmitter is integrated to the LS101 cable reel with the angle sensor zeroed If the cable reel is installed perfectly level on the boom at 0 degrees the angle sensor of the GSO11 will also be zeroed Minor adjustments to the angle sensor within plus or minus two degrees are possible after cable reel installation 3 Attach the reel to the welding tabs with the bolts provided The reel should be orientated with
32. 1 8 Confirm current feet metres o 4 8 Extend boom to max length xXxxx x 5 8 Adjust actual boom length xxx x 6 8 Calib Result 8 Trim 7 8 Calib Result XX X Scale X XXXX 8 8 Press Enter to save calib in sensor Figure The boom length calibration wizard 11 12 13 14 15 16 Press Menu Next Next Next to go to menu 4 Installation Press Enter Next to go to menu 4B Sensor Calibra tion Press Enter to go to the password page Use Back Next Up and Down to enter the user pass word and then press Enter to go to 4B1 Automatic Value Calibration Wizard Press Enter to go to 4B1A Use Back and Next to select the length sensor and then press Enter to confirm communication with the sensor is possible Press Next to start the wizard Note the units that will be used during the calibration wizard and then press Next Fully retract the boom and then press Next Use Up and Down to adjust the length value displayed to equal the actual fully retracted boom length and then press Next Fully extend the boom and then press Next Use Up and Down to adjust the length value displayed to equal the actual fully extended boom length and then press Next Note the new trim value and then press Next Note the new scale value and then press Next Press Enter to send the new calibration to the length sensor Press Exit three times to return to th
33. 2 Press Next repeatedly to advance to the next available sensor position usually follow ing the four load sensors 3 Determine the sum load cell id number For example id 1234 to indicate the sum of load sensors Ne 1 Ne 2 Ne 3 and Ne 4 or id 34 to indicate the sum of load sensors Ne 3 and No 4 4 Use Up and Down to adjust the id number 5 Press Next 6 The sensor type should flash use Up and Down to select the sensor type Sum load cell 7 Press Enter to save any changes 8 Press Next to program the imbalance sensor or press Exit three times to return to the operation display 9 Adjust the sum maximum limit in the limit menu Imbalance Systems programmed for four load sensors and four load sum indication can be programmed with an imbalance sensor to warn against uneven load distribution or against unwanted rope payout if one corner of the load touches down before the others Installation 49 Imbalance factor limit The imbalance factor is the percent difference between the load on one load sensor and the average load on the other three The imbalance factor is calcu lated for each of the four load sensors and then compared to an adjustable limit The de fault imbalance factor limit is 15 Imbalance minimum limit Imbalance is not calculated when the four load sum is below the imbalance minimum limit Adjust this limit to avoid generating an imbalance alarm under minimum load conditions for example wi
34. 20 Deduct 0 0 Figure Radius settings Installation 41 Basic Radius Parameters for a Lattice Crane Jib mounting point Jib offset angle Sheave radius menu 4C19 Your measurement Sheave head length perpendicular menu 4C17 The distance from the head sheave centre to the boom centreline Your measurement Boom Length menu 4C1 The distance from the boom base pin to the head sheave centre Crane centre of Your measurement rotation Slew offset menu 4C2 The distance from the boom base pin to the crane centre of rotation If the boom base pin is behind the centre of rotation this value will be negative Your measurement Figure Basic radius parameters for a lattice crane 42 The GS550 System Basic Radius Parameters for a Telescopic Boom Crane Sheave head length perpendicular menu 4C17 e The distance from the head sheave centre to the boom centreline Your measurement Boom length the distance from the boom base pin to the head sheave centre Sheave radius menu 4C19 Your measurement Slew offset menu 4C2 e The distance from the boom base pin to the crane centre of rotation Y e Ifthe boom base pin is behind the centre of rotation this value will be negative Crane centre of rotation Your measurement Figure Basic radius parameters for a telescopic boom crane Installation 43 Advanced Radius Parameters Typical sheave heads e Sh
35. G5 GS550 base station identification Ne 5D5 GS550 battery level charging 5D6 H Height offset 4C3 I Info menu password protection 4H5 Install update 414 Installation 4 Intermediate boom length tolerance 4D7 Jib length 4C13 Jib mounting point parallel 4C1 1 Jib mounting point perpendicular 4C10 Jib offset 4C8 Lattice extension length 4C15 Lattice extension offset 4C9 LCD contrast 3D Light intensity 3C Limit menu password protection 4H4 List last 32 sensors received 5B2 Lockout Diagnostic 5C Lockout level 4G3 Lockout relay inverted 4G8 Lockout Settings 4G GS550 Menu Locator 81 Lockout Settings password protection 4H16 Luffing jib length 4014 Manual length 4C16 Manual parameter calibration 4B2 Memory Banks 4E Memory Banks password protection 4H14 Network Options 4l Network Options password protection 4H17 No load deflection 4C7 O Operation mode 4D1 Orange wire status and self test 5C3 Orange wire lockout trigger 4G6 Out of charts default working load limit 4D3 Parts of Line 1 Parts of Line menu password protection 4H7 Password Settings 4H R Radio FCC IC or CE and frequency 5D7 Radio network background noise 5B1 Radio Network Diagnostic 5B Radius Settings 4C Radius Settings password protection 4H12 Radius tolerance 4D9 Reset sensor parameters 4B3 Restore factory configuration 4E7 Retracted boom length tolerance 4D6 S Searc
36. GICAUON eenia 49 MDAC anita 49 SICK RODO correer O 50 istand TIM ANGIE SMSO cinarita a a a ean ace teteaea eeas 51 Programming the GS550 for List and Trim Indication cocconcococionicnonioncanoninninnoninnannon 52 MOUNINO MSTUCUIOAS ssis 52 List and Trim Angle Calibration Procedure ssssssssssssnsnsnsnnnnrnrnnnrnrnnnrnrnrnrnrnnnrnrnrnrnrenne 52 O A a eae eaes 54 Rope Payout Calibration Procedure N9 1 Mechanical Set UD cocccccconncccconanoncncananonnnons 54 Rope Payout Calibration Procedure N 2 Correct with the GS550 cccesssseeeseeeeeeeesenes 54 RODE Payout LIMA ESs 5 an ani n 55 Data LO o e ea 56 The GS550 System Recording MOdeS aii 56 Date Ana TM 57 The Sensor Uta a 58 How to Add a Sensor TO the GS550 iaa 58 How to Remove a Sensor from the GS550 s ssssssserssersrsrsrsrsrsrernnnnenennnnnnnnnnnenenenennns 59 NetWork ODUONS citadas 59 ste OMY Mode ina 59 PROD bo 60 Wireless Sensor Update cia 61 Portable DOWNIOIA TOO iiiviiaain rs 62 Installing PDA SOWA enn 63 Transteriinda FIGS uree da isal 63 Transfer Firmware Files from a Personal Computer to the PDA ococcocociononiononcanononconos 63 Transfer Firmware Files from the PDA to a GS550 ccccsecseeeeeeeseeeeseeeeseeseeetensenseeeneees 63 Conserve GS550 Configuration When Updating Firmware oococcococconoccccononconencanonennononos 64 Transfer Data Logger Files from the GS550 to the PDA cccecseceeeeteeeesseeseesesesereetaees 64
37. Input Diagnostic 5B3 Search for sensors 5E4 Blue wire status 80 The GS550 System GS550 Menu Locator A Adjust date 4F2 Adjust time 4F3 Alarm Bypassed protection 4H19 Alarm level 4G2 Automatic value calibration wizard 4B1 Backlight mode 3E Blue wire digital input status 5E4 Blue wire lockout trigger 4G7 Boom angle tolerance 4D10 Boom deflection 4C4 Boom length 4C1 Boom top length 4C5 Boom top offset 4C6 C Chart Rigging password protection 4H8 Chart Settings 4D Chart Settings password protection 4H13 Clear configuration memory banks 4E8 Configuration number selection mode 4A3 Copy configuration to memory bank A 4E1 Copy configuration to memory bank B 4E2 Copy configuration to memory bank C 4E3 Copy memory bank A to current configuration 4E4 Copy memory bank B to current configuration 4E5 Copy memory bank C to current configuration 4E6 Crane capacity chart interpolation 4D2 Crane Rigging 2 Data Logger 4F Data logger mode 4F 1 Data logger password protection 4H15 Deduct 4C20 Digital Input Diagnostic 5E Display Diagnostic 5D Display internal temperature 5D4 Display language 3B Display mode 411 Display Settings 3 Display Settings password protection 4H9 Enable start section 4D4 Enable stop section 4D5 Extended boom length tolerance 4D8 External power supply voltage 5D3 G Green wire status and self test 5C2 Green wire lockout trigger 4
38. Word SCUUINGS ica 25 Datasneetanaa ads 27 COAG CEM A tua a a a Deel 28 Angle Sensors Tor the BOOM OF Dira 29 MOuntna Procede 29 Angle Calibration Procedure N 1 Mechanical Set Up oococcoccccocionccconiononnoniononnonianonnons 30 Angle Calibration Procedure N 2 Correct with the GS550 occococconiocccconcononnonianonionianons 30 Antl T WO BIOGK SWITCH GSO50 o 31 Length Sensor Cable Realice 35 MAXIMUM BOOM EXUCMSION SS 36 M nting the Cable Realia nia 36 Boom Length Calibration Procedure N 1 Mechanical Set Up occococcccocconancnconencanononss 38 Boom Length Calibration Procedure NY 2 Correct with the GS550 cccecseseceesereeeeeens 38 FR GUNS Ue a capa eae vert E veica eas wd san ae ane 40 Radius Verification and ACJUStMENK ccsccscseceeseececeecsececcecerenececutsueaecatsereneensuesecseratens 40 RAGES SECHIN SiS 41 Basic Radius Parameters for a Lattice Crane cccccceccecseeeeeeeeeseeeeeeeeaeeeeeeeaeegeseeeeeaeeenags 42 Basic Radius Parameters for a Telescopic BOOM Crane cccscecsecseseeeeeeeeeeeseeeeeeeenereeness 43 Advanced Radius Paraimeters isa 44 Wireless Wind Speed Sensor GSO20 cccccssscessecuresceusesseeusuecesseuseeausecuueesausesseeusareenseeees 45 Wireless Load PINS si as 47 LEPOTE EPOLS INAP do 47 Load Pin Transmitter GSOO I iaa aateahicnes vane a 47 Load Pins Line Riders and Compression Cells Calibration c cccscssesesessevseseeeeenseneeerenes 48 FOU PONCE s a a a 49 sum Oa IN
39. and other factors t Repeater battery life estimated for standard product using new factory specified batteries correctly installed Individual results will not vary with of intensity of use individual results may vary with environmental conditions and other factors 60 The GS550 System Clear a sensor repeater 1 Ot ea ee Press Menu gt Next Next Next Enter Next Next Next Next gt Next Next Next Next Enter Next Next to go to menu 413 Menu 413 details the last repeater programmed When no repeater has been programmed the menu 413 displays the message No repeater registered To shut down the last repeater programmed press Enter The following messages will be displayed briefly Removing network path Initializing network To shut down additional repeaters repeat step 2 Press Exit three times to return to the operation display Important Test all system functions after setting up or removing a repeater Shut off and then restart the GS550 within one minute the 2 Block and Load M and A flashing radio status lights should remain solid Wireless Sensor Update It is possible to send a firmware update to a sensor using the GS550 menu 414 For more infor mation on installing a sensor update refer to the field service guide How to Update the Firmware of a GS Series System document part number GM550 011 provided with the firmware update k
40. ar icon to start HotSync Once started HotSync will connect the PDA with Hel the PC and update files from each Direct Serial Figure The Palm HotSync page Transfer Firmware Files from the PDA to a GS550 1 On the PDA start the LSI Firmware software a Press the house icon to go to the Home menu b Select the LSI Firmware icon from the Home menu Portable Download Tool 63 2 On the GS550 display press and hold Bypass while starting the display The display will enter a safer mode and allow firmware updates 3 Align the infrared ports of the PDA and the GS550 about 6 inches 10 centimetres apart 4 Onthe PDA send the file LSiFirmware D a Select a firmware or chart file to send from the ive LSI Firmware file list Send b Press Send The GS550 will display Sena Transferring Ren am el When the transfer is complete the PDA gener Charts Config ates a short musical alarm and the GS550 dis plays the version identification of the newly installed GS550 firmware 5 Repeat steps two through four to transfer any additional files Figure The Palm LSI firmware list Tip For advanced users only To conserve the GS550 configuration during a firmware upaate read the section that follows Conserve GS550 Configuration When Updating Firmware The LSI Firmware PDA Software can conserve the actual old system configuration including the sensor list and radius parameters when updating firmware i
41. ated capacity when applicable Warning level When gross load regardless of tare value approaches the maximum limit for a load sensor the red overload alarm light will flash The maximum limit for a load sensor is lower of the operator set limit Limit Menu or the WLL if rated capacity indication is used The proportion of a limit that must be reached to trigger the overload warning is the warning level The default factory setting for the warning level is 90 1 Press Menu Next Next Next Enter Next Next Next Next Next Next Enter to access menu 4G1 Warning level 2 Use Up and Down to adjust the warning level Installation 23 3 Press Next to advance to the alarm level adjustment page or press Exit three times to return to the operation display Alarm level All programmed and rated capacity limits and two block will generate an au dible alarm when the alarm level is reached In the event of two block or overload the ap propriate alarm light will light solid Other alarms will generate an intermittent alarm message on the LCD The proportion of a limit that must be reached to trigger an alarm is the alarm level The default factory setting for the alarm level is 100 1 Press Menu Next Next Next Enter Next Next Next Next Next Next gt Enter gt Next to access menu 4G2 Alarm level 2 Use Up and Down to adjust the alarm level 3 Press Next to
42. ck rope sensor compares the sum load to an adjust able slack rope minimum limit When the sum load goes below the slack rope limit a slack rope alarm is generated The slack rope limit is usually adjusted to less than the weight of all rigging below the load sensors The default slack rope minimum limit for is 1000 pounds or kilograms depending on load display units Program the slack rope sensor 1 Press Menu Next Next Next Enter Enter to go to the sensor list menu page 4A1 2 Press Next repeatedly to advance to the next available sensor position usually follow ing the four load sensors the sum load sensor and the imbalance sensor 3 The id can be left at 0 press Next 4 The sensor type should flash use Up and Down to select the sensor type Slack rope sensor Only one slack rope sensor is required to calculate slack rope for all four load sensors 5 Press Enter to save any changes Press Exit three times to return to the operation display 7 Adjust the slack rope minimum limit in the limit menu o List and Trim Angle Sensor The GS010 03 is a two axis angle sensor designed to detect both list and trim angle Minimum and maximum limits for list and trim angle are adjustable in the display The display will generate an alarm if the limits are exceeded and can be programmed to generate lockout Furthermore list and trim angle can be used to control rated capacity chart selection where required example ba
43. d cell readings on operation If the bolt head is bent or sheared verify the transmitter box fits tightly to the load cell link before contacting LSI for replacement bolts Dow Corning dielectric grease 4 74 The GS550 System Certification Notes Model Numbers The model numbers for product certified by the Federal Communications Commission FCC United States of America Industry Canada IC and the European Community CE can be found in the table below Table Model Numbers FCC and IC Certified CE Certified GC005 GC005 CE GC012 GC012 CE GC018 GC018 CE GC035 GC035 CE GC060 GC060 CE GC065 GC065 CE GC100 GC100 CE GC170 GC170 CE GS001 GS001 CE GS002 GS002 CE GS005 GS005 CE GS010 01 GS010 01 CE GS010 02 GS010 02 CE GS010 03 GS010 03 CE GS011 GS011 CE GS020 GS020 CE GS050 GS050 CE GS550 GS550 CE GS550 03 GS550 07 GS550 07 CE GS550 08 GS550 08 CE GS550 09 GS550 09 CE GS550 10 GS550 10 CE CSA The designator CSA added to the model numbers in the table above indicates CSA certification Examples GC012 CSA GC012 CSA CE Certification Notes 75 FCC and IC Instructions to the User This equipment has been tested and found to comply with the limits for a class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energ
44. data required by the wind speed report feature of the Data Logger Viewer software Automatic variation A record is added when load increases by more than the operator adjusted percentage When the automatic variation data logger mode is selected on menu page 4F1 see step 3 above press Next to go to page 4F11 and then use Up and Down to adjust the variation threshold Automatic peak In the automatic peak mode the data logger analyzes the measured weight and records the peak value only One threshold per load cell must be adjusted When the weight drops by more than the peak threshold the peak weight is recorded Only one event is recorded for each pick when the threshold is adjusted correctly When the automatic peak data logger mode is selected on menu page 4F1 see step 3 above press Next to go to page 4F11 and then use Up and Down to adjust the peak threshold for the first load cell Press Next to repeat for the second load cell etc Up to four load cells can be programmed for automatic peak data logging User input Available on request only the status of all sensors is recorded on demand A custom hardware modification to the GS550 display is required and a normally open push button must be installed on a digital input to the GS550 through a pre determined wire of the power supply and lockout cable All data All communications between a display and its sensors are recorded Date and Time Adjust the data logger date and time as requ
45. des and where the back of the surface is accessible in order to tighten the nuts 61 813 gt w 2 438 m O A 120 00 Figure Display mounting bracket footprint 2 Drill Y inch boltholes through the mounting surface with a inch bit following either the three or the four hole configuration 3 Install the display with the supplied bolts Add the washers and the lock nut behind the mount ing surface and tighten sufficiently 20 The GS550 System Tip If the nuts are on the outside of the cab caulk with silicone between the washers and the cab to prevent water entry 4 Loosen the wing nut of the bracket arm to adjust display orientation to facilitate viewing by the operator and then tighten it back up A Figure The power ca le requires about 4 Y in behind the display to protect the connector Antenna Position Figure Dipole Half Wave Elbow Antenna part Ne TADOS For optimal performance the antenna should be positioned on its side such that it is parallel to the sensor antennas but not pointing directly to or directly away from them e Adjust antenna position with the articulating base e The antenna must have 5 inches of clear space all around it The antenna must have an unobstructed line of sight to all sensor antennas at all boom angles Installation 21 Power Supply and Lockout Connection Connect the black wire ground to the negative terminal of the crane battery or the
46. distance If still insufficient contact your service representative B Hook block stops rising two block prevented with A Anti two block safety margin switch triggers two block alarm Figure Anti two block weight chain length test at minimum boom angle e TOCrenase 34 The GS550 System 4 Chain length adjustment Ne 2 maximum boom angle a Raise the boom to the maximum angle b Hoist slowly until the red two block warning lights comes on and the buzzer sounds Note the hoisting distance remaining this distance must be great enough to allow the operator and the lockout system if installed to prevent a two block event If necessary add lightweight chain between the sensor and weight to increase warning distance Ver ify that the warning distance is equal to or greater than that determined at the minimum boom angle B Hook block stops rising two block prevented with A Anti two block E safety margin switch triggers two block alarm Figure Anti two block weight chain length test at maximum boom angle Tip Have a second person stand off to the side of the crane to closely monitor the hoisting distance from the hook block to the head sheave block 5 Chain length adjustment Ne 3 speed test Lower the boom until the weight height becomes visually clear to the operator Repeatedly create two block progressively hoisting faster to en sure that the warning and lockout work within acceptable amo
47. ds on system sensor and capacity chart configuration Systems with more than one load sen sor typically display main hoist load information on the first page and auxiliary hoist load information on the second page This applies only if the GS550 has been correctly installed to control crane lockout function Operation 9 Info When the orange Info light flashes press Info to see critical sys tem alerts Press Next to advance from one page to the next Standard info menu pages include e BIOS Binary Input Output System number and version e Firmware number and version e Chart number and version if available e SPKG Software Package number Table Information Menu Alerts Alert Load id G15000 Sensor maximum limit id G15000 Sensor minimum limit Load Load id G15000 Sensor low battery Load id G15000 No communication Verify white wire unexpected voltage Verify white wire shorted to ground Main Out of chart Main angle above chart maximum Description The sensor indicates a value greater than the operator adjusted limit WARNING Do not operate the crane beyond the limits specified by the manufacturer e Verify operator adjusted limits in the limit menu The sensor indicates a value less than the operator adjusted limit WARNING Do not operate the crane beyond the limits specified by the manufacturer e Verify operator adjusted limits in the limit menu Less than 10 of batte
48. e operation display Installation 39 Radius Radius Verification and Adjustment 1 Verify the boom and luffing jib angles and the boom length are indicated correctly 2 Verify the correct rated capacity chart is selected 3 Test Ne 1 measure the actual radius and compare to the radius indicated Repeat with the boom at minimum angle at 45 degrees and at maximum angle repeat at minimum and maxi mum boom length If radius indication is not accurate then go to step 4 4 Measure the basic radius parameters on the crane see pages 42 and 43 Program the basic radius parameters in the radius settings menu see page 41 6 Test Ne 2 measure the actual radius and compare to the radius indicated Repeat with the boom at minimum angle at 45 degrees and at maximum boom angle repeat at minimum and maximum boom length If radius indication is not accurate then go to the next step g Tip If the difference between the displayed radius and actual radius remains constant at all boom lengths and angles then correct by adjusting the slew offset For example if the radius displayed Is always 2 3 feet longer than the actual radius then subtract 2 3 from the slew offset 7 If the crane is rigged with the main boom only then go directly to step 11 8 If the crane is rigged with a rooster jib or other extension then the advanced radius parame ters must be measured on the crane see page 44 and then programmed in th
49. e radius settings menu of the display see page 41 9 Test Ne 3 measure the actual radius and compare to the radius indicated Repeat with the boom at minimum angle at 45 degrees and at maximum boom angle repeat at minimum and maximum boom length If radius indication is not accurate then go to the next step 10 Test for boom deflection is the radius indicated equal to the actual radius with the boom at 0 degrees and at 90 degrees but greater than the actual radius with the boom at 45 degrees If yes then adjust the boom deflection value to compensate a Raise the boom to 45 degrees with a known load b Compare the indicated radius with the actual radius Change the boom deflection value and again compare the radius displayed with the actual radius Repeat until the radius displayed equals the actual radius Tip with the boom at 45 and the maximum load on the hoist the boom deflection value should egual the difference between the actual and the displayed radius With the boom at 45 and half the maximum load on the hoist the boom deflection value should equal twice the difference between the actual and the displayed radius 11 Test No 4 measure the actual radius and compare to the radius indicated Repeat with the boom at minimum angle at 45 degrees and at maximum boom angle repeat at minimum and maximum boom length If radius indication is not accurate then go to the next step When the hoist is rigged off a luffing
50. e the load pin in place with a cotter pin or other suitable keeper device Figure Load pin LPO11 LPO15 or LP026 installation on a single part block co Cotter pin Wedge socket Figure Load pin LP011 LP015 or LP026 installation at boom tip Pigtail Load Pin Transmitter GS001 1 Determine the transmitter mounting position a The load pin and transmitter pigtails must connect easily without stretching or kinking at all boom angles and working conditions The jumper cable may be used between the load pin and transmitter to increase transmitter placement options 47 Installation b There must be direct unobstructed line of sight from the transmitter to the display this may not be required on cranes with a maximum boom length less than 100 feet 33 me tres c The transmitter antenna must not be in contact with any metal object WARNING Do not weld in proximity to LSI sensor transmitters 2 Weld the mounting blocks where required 3 Mount the load pin transmitter on the mounting blocks Operation Display Jeers Peper eee Load Pins Line Riders and Compression Cells Calibration AAD Sensor Cal orator Load pins line riders and compression cells must be cali brated at installation and every time thereafter the installa tion the load sensor or the load transmitter is changed Enter user password aaa Important Do not recalibrate flat bar load links part 481 Automatic value numbers
51. eave head length perpendicular D1 e Sheave head length parallel O typical Extensions two possibilities 1 Manual length the offset is always zero degrees Special top sheaves 2 Lattice extension length the example rooster offset angle must be adjusted S e Sheave head length Be perpendicular D2 q Lattice extension length k dci parallel D3 N N N N N Lattice extension offset angle Boom top length Luffing jib length center sheave to center sheave Boom top offset angle bS Lattice extension length amp offset angle Luffing jib angle sensor Boom top length amp offset angle NX bS lt Boom length includes boom top lt gt aN Boom heel pin Slew offset e Boom length includes boom top Figure Advanced radius parameters 44 The GS550 System Wireless Wind Speed Sensor GS020 WARNING Do not weld in proximity to LST sen sor transmitters Figure GS020 wireless wind speed sensor Figure Do not weld on sensors 1 Remove the mounting rod from the wind speed sensor 2 Select the welding point for the mounting rod a Install the mounting rod on the same side of the boom as the cabin mounted display perpendicular to the boom and at the highest point possible b The wind speed sensor must pivot freely on the mounting rod at all boom angles Figure Swivel orientation c The wind cups must be fully e
52. een advised of the possibility of such damages In any event the total lability of LSI arising from any cause of action or claim whatsoever whether 1 in contract 2 in tort including negligence whether sole joint contributory concurrent or otherwise but not including intentional reckless or wanton tort 3 under strict lability 4 under any environmental or antipollu tion law or regulation 5 connected with any toxic or hazardous substance or constituent 6 arising out of any representation or instruction or under any warranty 7 or otherwise arising out of connected with or resulting from the design manufacture sale resale delivery repair replacement or use of Products or the furnishing of any service shall in no event exceed the price allocable to and paid to LSI for the individual unit of Products or service or part thereof which gives rise to the cause of action or claim REC OMMENDED PRACTICE LSI recommends careful consideration of the following factors when specifying and installing the Products Before installing a Product the Installation Operation and Maintenance instructions provided with the unit must be read and understood 84 The GS550 System LSI Contact Information USA Corporate Office Dubai Corporate Office Canadian Corporate Office Technical Support 9223 Solon Suite A Houston TX 77064 Toll Free Phone 888 819 4355 Direct Phone 281 664 1330 Toll Free Fax 888 238 4099
53. em Display Programming In order to indicate WLL the GS550 must be programmed with a valid rated capacity chart specific to the crane The capacity chart programmed can be verified on the chart number page of the Information menu press Info Next Next press Exit to return to the operation display If the chart number information screen says Chart not loaded the GS550 has not been programmed to function as a rated capacity indicator If rated capacity indication is required contact the person responsible for the GS550 system installation and maintenance If in doubt contact LSI Crane Rigging Under no circumstances is the GS550 a substitute for safe operating practices The operator must fully understand the crane rigging and the crane rated capacity chart to be able to correctly pro gram the GS550 for rated capacity indication The GS550 will not take into account critical vari ables such as weather ground and crane conditions that will reduce the safe working capacity of the crane Chart Wizard Rated capacity indication is based on interpretation of a selected capacity chart using boom angle and load radius The chart must be selected by rigging the working hoist in the GS550 this is done by following the chart wizard in menu 2 Crane Rigging Important It is possible to leave the chart wizard at any time by pressing Bypass the GS550 will display the message Rigging ABORTED Current capacity chart selection
54. emainder of the original term or sixty 60 days whichever is longer LSI will pay transportation costs of replacement or repaired parts to the destination in Canada and the continen tal United States of America LSI will not pay any transportation costs of replacement or repaired parts to destination outside of Canada and the continental United States of America which costs shall be for the pur chaser s account Parts with a Return Authorization Number can be sent to the following location From the USA and Mexico Receiving Department Tel 281 664 1330F ax 281 664 1390 LSI U S Warehouse 9223 Solon Rd Ste A Houston TX 77064 1238 United States From Canada Warranty amp Repair Tel 418 650 2330 Fax 418 650 3340 Load Systems International Inc 4495 boul Wilfrid Hamel Bureau 110 Qu bec QC G1P 2J7 Canada LSI PRODUCT WARRANTY 83 EXCLUSION OF OTHER WARRANTIES The above warranty is the sole warranty applicable and there are no express legal or implied warranties or conditions in relation to any Products including any implied warranty or condition of merchantability non infringement or fitness for a particular purpose and those otherwise arising by statute or otherwise in law or from a course of dealing or usage of trade which are expressly disclaimed No oral or written information or advice given by LSI or its employees or representatives shall create a warranty or condition or in any way increase
55. enus level one Press Enter to drill down one level and enter a selected menu Press Exit to leave a menu and return up one level Press Next to move to the next page within a menu press Back to move to the previous page within a menu Use Up and Down to modify numeric values and to move through a list of choices Tip most menus are circular press Next on the last page of a menu to return to the first page Tip most lists are circular press Down on the last entry of a list to return to the first entry 12 The GS550 System Menu Level One Move between menu levels with Enter and Exit Menu Level Two Move between pages of a menu with Next and Back Menu Level Three Select from a list or adjust values with Up and Down Figure Menu Navigation Password Protection The submenus of menu 4 Installation are protected by a password by default Password settings can be adjusted in menu 4H Password Settings The factory set administrator and user passwords are AZA If the user password is forgotten it can be changed as long as the administrator pass word is known Forgotten password Call LSI technical support Houston TX at 888 819 4355 or contact your local LSI representative Menu Layout The figure below shows the menus accessible to the operator without password protection under the default factory settings Operation 1 3 Operation Display 1 Parts of 2 Crane 3 Display 4 Installation
56. er plates must be configured to the pin size required by the specific dead end or hook to which it is to be attached In all cases the bush ings must be used where possible to adapt the holes in the load cell to the pins Bushings must be secured with the hex screws provided one on each side of the load cell 2 Place at least one washer between adapter plate and pin head or nut on each end of the pin that links the adapter plates to the load cell Additional washers should be added equally to each end of the pin as required to inhibit excessive lateral movement of load cell and adapter plates along the pin 3 If the dead end or hook to be connected to the adapter plates requires a larger opening washers may be placed between the load cell and the adapter plates equally on both sides of the load cell Crane dead end Plate kit for Loadilink Loadcell pa pa A r Important On the smaller of the two pins the space between the link and the plates should not exceed 14 inch either side of the centred link regardless of washer placement 4 In all cases the washers must be placed symmet rically such that the load cell is centred on the pins 5 Secure the pins with the nuts and cotter pins provided 6 A qualified person must verify every lift assembly Figure Typical load cell and adapter before first use and periodically thereafter includ plate assembly installed ing before any new difficult or otherwise different
57. est load would be 60 000 Ib or more Care Battery Lithium batteries over than 18 months old alkaline batteries over 6 months old should be changed at the first available planned inspection even if there is not yet a low battery warning This will avoid costly delays in the field Corrosion Verify that no corrosion is visible on the battery holder inside the load cell transmitter lf some trace of corrosion is visible rub it off gently and put a small amount of dielectric grease on each battery holder post to protect the contact Mechanical stresses Verify the load cell sides for dents or heavy scratches The side of the load cell under the transmitter box is the most sensitive region Engraving a number in this area will affect load cell accuracy and reliability If the transmitter box has been hit and the box does not fit perfectly to the underlying link please call LSI to have it repaired En graving on the transmitter box sides will not affect reading Seal If the transmitter box has been removed it must be correctly resealed with RTV non corrosive silicone Antenna Small scratches on the antenna will not affect radio communications A heavy bending of the antenna or bare sections on the wire may reduce the radio efficiency Hex bolts The hex head bolts on the transmitter box are there to protect the antenna and to hold the transmitter box on the load cell link If one or both hex nuts are scratched it will not affect the loa
58. flection 4C5 Boom top length 4C6 Boom top offset 4C7 No load deflection 4C8 Jib offset 4C9 Lattice extension offset 4C10 Jib mounting point perpendicular 4C11 Jib mounting point parallel 4C12 Select sheave 4C13 Jib length 4C14 Luffing jib length 4C15 Lattice extension length 4C16 Manual length 4C17 Sheave head length perpendicular 4C18 Sheave head length parallel 4C19 Sheave radius 4C20 Deduct 4D Chart Settings 4D1 Operation mode 4D2 Crane capacity chart interpolation 4D3 Out of charts default working load limit 4D4 Enable start section 4D5 Enable stop section 4D6 Retracted boom length tolerance 4D7 Intermediate boom length tolerance 4D8 Extended boom length tolerance 4D9 Radius tolerance 4D10 Boom angle tolerance 4E Memory Banks 4E1 Copy configuration to memory bank A 4E2 Copy configuration to memory bank B 4E3 Copy configuration to memory bank C 4E4 Copy memory bank A to current configuration 4E5 Copy memory bank B to current configuration 4E6 Copy memory bank C to current configuration 4E7 Restore factory configuration 4E8 Clear configuration 4F Data Logger 4F1 Data logger mode 4F2 Adjust date 4F3 Adjust time 4G Lockout Settings 461 Warning level 4G2 Alarm level 4G3 Lockout level 4G4 White wire lockout trigger 4G5 Green wire lockout trigger 4G6 Orange wire lockout trigger 4G7 Blue wire lockout trigger 4G8 Lockout relay inverted a a N aaa a
59. h for sensors 5B3 Select sheave 4C12 Sensor Calibration 4B Sensor Calibration password protection 4H11 Sensor List 4A Sensor List password protection 4H10 Sensor type and radio identification number 4A1 Set administrator password 4H1 Set user password 4H2 Set up sensor repeater 412 Sheave head length parallel 4018 Sheave head length perpendicular 4C17 Sheave radius 4C19 Slew offset 4C2 System Diagnostic 5 System Diagnostic password protection 4H18 System selected configuration number 4A2 System Sensors Diagnostic 5A System start up password protection 4H6 T Tare menu password protection 4H3 Time and date 5D1 Time clock battery test 5D2 Warning level 4G1 Weight units 3A White wire status and self test 501 White wire lockout trigger 4G4 82 The GS550 System LSI PRO DUCT WARRANTY 2006 05 26 LIMITED WARRANTY LOAD SYSTEMS INTERNATIONAL INC LSI warrants that its products the Products for a period of two 2 years after delivery of such Products the Warranty Period when installed and used in accordance with specifications described in user manuals technical materials and any related writings published by LSI with respect with such Products will be free from defects in materials and workmanship During the Warranty Period LSI or its designated service representative shall repair or at its option replace any Product that is confirmed to be defective by LSI
60. he cabin mounted display f The angle sensor antenna must not contact a metal object 2 Install the welding pads keep the angle sensor well removed from the weld site and any connecting metal objects while welding 3 Mount the angle sensor to the weld pads with the screws and washers provided 4 Verify angle indication on the GS550 LCD 8 WF 150001 R L Figure Typical operation page with boom angle indication 5 If the angle displayed by a GS010 01 boom angle sensor is a high negative value then tilt the angle sensor up over 45 degrees and then tilt back down to horizontal The GS010 01 boom angle sensor will automatically detect on which side of the boom it is installed and correct angle indication accordingly Tip To enable crane functions when alarm conditions are present press Bypass for 10 seconds to enter the Rig Mode Press Bypass once to exit Angle Calibration Procedure N2 1 Mechanical Set Up 1 Level the boom such that it is perfectly horizontal use a high quality bubble or digital angle sensor If the GS550 display indicates 0 0 degrees then angle calibration is complete if not then continue to step 2 2 For GS011 angle length sensors only Carefully remove the cover of the LS101 cable reel 3 Loosen the mounting screw in the slotted hole of the angle sensor mounting plate 4 Pivot the angle sensor slightly until angle indication is correct Tip When the angle sensor is moved very slowly it may ta
61. he second heavier known load save calib in sensor and then press Next 13 Use Up and Down to adjust the load value displayed to equal the actual known load lifted and then press Next 14 Note the new trim value and then press Next Figure The automatic load calibration wizard 48 The GS550 System 15 Note the new scale value and then press Next 16 Press Enter to send the new calibration to the load sensor 17 Press Exit three times to return to the operation display Four Point Lift The following functions are available for applications such as container cranes and gantry cranes that require load indication from four load sensors simultaneously e Sum load indication e Imbalance e Slack Rope These functions can be used to generate an alarm condition on the lockout wires of the GS550 Sum Load Indication When sum load indication is programmed the sum of the loads on the pre determined load sensors is indicated by the operation display To activate sum load indication program a Sum load sensor in the sensor list The id number is used to identify the load sensors to be summed Sum maximum limit The maximum limit for the sum load can be adjusted in the limit menu the default maximum limit for sum load indication is 10000 Ib or kg depending on load display units Program sum load indication 1 Press Menu gt Next Next Next Enter gt Enter to go to the sensor list menu page 4A1
62. ilable on the internet at Palm s web site http www Palmone com us support downloads win_desktop html The software should be installed in the default directory C Program Files Palm Follow the installation wizard step by step When asked to create a new account click Yes but leave the name field blank The installation wizard will automatically create a folder with the name of the PDA When prompted to reboot the PC click Yes In Windows Explorer go to C Program Files PalmOne and start HotSync exe A small icon will appear in the Windows tray bar to indicate that HotSync is installed on your PC this software is used to establish communication and synchronize data between the PDA and the PC Transferring Files Transfer Firmware Files from a Personal Computer to the PDA Two types of files can be sent to the PDA e LSI files identified by the filename extension pdb including firmware rated capacity charts and system configuration updates for the GS550 e LSI files identified by the filename extension prc including firmware and data logger software for the PDA 1 Connect the PDA to a USB port on the personal computer PC using the supplied cable Lacal 2 In Windows Explorer double click or right click on required file names with the pdb or prc ex G tensions Windows will automatically start a PalmOne list of files that will be sent to the PDA the next time the PDA is synchronized 3 On the PDA press the st
63. ind speed sensor id number Wind mph Average wind speed during the period Nb Gust Number of gusts exceeding the wind speed maximum limit during the period Max Gust mph Maximum wind speed gust during the period Wind charts The data from the Wind or Max Gust columns can be easily charted 1 Press Control and select the time column and either the Wind or the Max Gust column 2 Click Insert Chart 3 Select X Y Scatter Max Gust mph 17 16 48 17 19 41 17 22 34 17 25 26 17 28 19 17 31 12 17 34 05 Figure Max Gust Chart Portable Download Tool 69 Maintenance Replacing Sensor Batteries This procedure does not apply to the GS050 anti two block switch To change the batteries of the GS050 please refer to the Replacing Anti Two Block Switch Batteries section of this manual The following items are required e Ahex key 5 32 in approximately 3 97 mm e A flat bladed screwdriver e One 1 new high quality D cell battery 3 6 V lithium or alkaline e RTV non corrosive silicone Tip A 3 6 volt lithium D cell battery will provide about two years of battery life for a load cell while an alkaline D cell battery will provide less than one year of battery life Important Protect the interior of the anti two block switch from dirt and humidity at all times 1 Unscrew the two hex screws about a quarter of an inch 2 Insert the flat bladed screwdriver in the batte
64. ired 1 SOO 1 9 Press Menu Next Next Next Enter Next Next Next Next Next Enter Next to go to menu 4F2 Adjust date The last two digits of the year should be flashing use Up and Down to adjust the year Press Next to adjust the month The month should be flashing use Up and Down to adjust the month Press Next to adjust the day The day should be flashing use Up and Down to adjust the day Press Next to adjust the time The hour should be flashing use Up and Down to adjust the hour from 00 midnight to 23 11 pm Press Next to adjust the minute 10 The minute should be flashing use Up and Down to adjust the minute 11 Press Next to adjust the second 12 The second should be flashing use Up and Down to adjust the second 13 Press Enter to save any changes 14 Press Exit three times to return to the operation display Installation 57 The Sensor List All sensors in the GS550 system are programmed in the sensor list The GS550 uses information from all sensors in the sensor list Conversely the GS550 will not use or display information from sensors that are not programmed to the sensor list If a sensor is removed from the crane then it must be removed from the sensor list lf a sensor is replaced the sensor list must be updated with the new id number WARNING Information display from load angle and boom length sensors that are not correctly installed will not be
65. it Installation 61 Portable Download Tool The portable download tool consists of a compatible personal digital assistant PDA and LSI software kit Update firmware install rated capacity charts or export data logger files using the portable download tool without removing the display from the crane The PDA and the GS550 display connect wirelessly through the IrDA infrared ports and the PDA and a personal computer PC can be connected with a USB cable Internet J Figure Transfer firmware updates and rated capacity charts to the GS550 Load Systems International Load Systems International gt gt gt Infrared USB Internet MX Figure Transfer data logger files from the GS550 Important The PDA must be charged to function The purpose of this section is to explain e How to install PDA software on a PC e How to update a GS550 firmware o Transfer files from a PC to the PDA o Transfer files from the PDA to a GS550 o Conserve GS550 configuration when updating firmware e How to extract a data logger file from the GS550 o Transfer files from a GS550 to the PDA o Transfer files from the PDA to a PC Figure Transferring files from a Palm to a GS550 62 The GS550 System Installing PDA Software Insert the CD ROM identified Desktop Software amp manual in the personal computer PC CD ROM drive installation will begin automatically This software is also ava
66. jib only t Telescopic boom cranes only Systems with rated capacity charts programmed in the GS550 only 40 The GS550 System Radius Settings 1 Press Menu Next Next Next to go to menu 4 Installation 2 Press Enter Next Next to go to menu 4C Radius Settings 3 Press Enter use Up and Down Back and Next to enter the user password and then press Enter to go to the first radius settings page 4C1 Boom length 4 Use Back and Next to navigate between the radius settings pages and use Up and Down to adjust the settings 5 Press Enter to save any changes and press Exit three times to return to the operation display Important Radius settings 4C13 to 4C20 are specific to the hoist line or sheave number selected on page 4C12 Operation Display 13 pl 4 Installation Basic radius parameters ns ee a AA 4A iQ l mG 4C10 Jib mount point perpendicular 0 0 Enter user password 4C11 Jib mounting point parallel 0 0 4C1 Boom length 60 0 4012 Select hoist main 4C2 Slew offset E Jib length 0 0 4C3 Height offset on 4014 Luffing jib length 0 0 4C4 Boom deflection oh 4C15 Lattice extension length 0 0 4C5 Boom top length rA 4C16 Manual length 0 0 4C6 Boom top offset pes 4C17 Sheave head len perpendicular 0 0 4C7 No load Der LEELA ah 4C18 Sheave head len parallel 0 0 Y 4C8 Jib offset 0 0 O E 09 4C19 Sheave radius 0 0 Lattice extension t 4C
67. ke several seconds to see an update at the GS550 display Instead move the sensor up a couple of degrees and then bring it back down to where it should be The small light on the angle sensor flashes when it transmits a new value to the display Angle Calibration Procedure N 2 Correct with the GS550 Calibrate angle indication by adjusting the trim offset value in the GS550 display the GS550 will then communicate the updated trim value to the sensor 1 Position the boom at a precisely known angle Press Menu Next Next Next to go to 4 Installation Press Enter Next to go to 4B Sensor Calibration Press Enter to go to the password page Use Back Next Up and Down to enter the user password and then press Enter Next to go to 4B2 Manual parameter calibration Press Enter to go to page 4B2A 7 Use Back and Next to select the angle sensor to be calibrated e a gt 30 The GS550 System 8 Press Enter Next to go to the trim adjustment page 9 Use Up and Down to adjust the trim value Example If angle indicated is 0 3 over the actual angle adjust the trim value to 0 3 Example If angle indicated is 0 9 below the actual angle adjust the trim value to 0 9 10 Press Enter to save changes 11 Press Exit four times to return to the operation display 12 Verify accurate angle indication at both very high and very low angles Operation Display _ AA O MMMM I ISA 1 4B Senso
68. known to be non hazardous In all sensors except the GSO50 CSA use 3 6V lithium batteries model Tadiran TL 5930 In GS050 CSA anti two block switches use only alkaline C batteries model Duracell 1 5 volts PC1400 WARNING SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY WARNING SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I DIVISION 2 WARNING DO NOT remove power cable from display when on For sensors use T4 temperature code Certification Notes 77 Manufacturer s Name Manufacturer s Address 4495 boul Wilfrid Hamel bur 110 9223 Solon Rd Suite A Qu bec QC GIP 2J7 Model GC005 CE GC012 CE GCc018 CE C035 CE GCO060 CE GCO65 CE GC100 CE GC170 CE SS001 CE SS002 CE SS005 CE 65010 01 CE 65010 02 CE 65010 03 CE 65011 CE GS020 CE GSD50 CE GS550 CE 6 550 07 CE G5550 08 CE G5550 09 CE GS5550 10 CE CE Declaration of Conformity LSI LOAD SYSTEMS INTERNATIONAL INC Declaration of Conformity According to EN 45014 Load Systems International Inc United Arab Emirates YO Saif Zone P O Box T976 Houston TX 77064 Sharjah United States of America declare under our own responsibility that the products Description 5 000 Ib capacity load cell for Europe 12 000 Ib capacity load cell for Europe 18 000 Ib capacity load cell for Europe 35 000 Ib capacity load cell for Europe 50 000 Ib capacity load cell for Europe 65 000 Ib capacity load cell for Europe 1
69. l The primary functions are described below WLL is indicated by rated capacity indicators only 8 The GS550 System Bypass Press Bypass to override lockout for emergency purposes The alarm will remain silent until the next alarm lockout will re engage as soon as the button is released Tare Zero the hook and rigging weight 1 Press Tare to enter the tare menu 2 Use Next to select the load sensor 3 If no tare value then press Tare to create a tare value equal to the weight on the load sensor Example with hook block and rigging only Load display is net weight gross weight minus tare value 4 Toremove tare value press Tare 5 Press Exit to return to the operation display Tare and Load Indication LCD Indicator Tare Light_LCD Load Value Bar Graph No tare value T Off Gross weight Gross weight Tare value T On Net weight Gross weight Tare Zero rope payout length Sensor No 2ropePayou Enter gt set zero e Press Tare to enter the tare menu e Use Next to advance to the rope payout sensor i Communi i ER e Press Enter to zero rope payout length The new zero will o o be saved by the rope payout sensor iNew rope payout zero e Press Exit to return to the operation display pee Td Seley La e ee ee ee Sensor No 2ropePayou Enter gt set zero Hoist Press Hoist to change the operating display page The exact or der and content of operation display pages depen
70. lastic sheathing and pull it straight out of the hole in which it is seated Place the old antenna aside 7 Slide the white nylon hex bolt to the middle of the length of the new antenna 8 Coat the exposed metal foot of the new antenna with an electrical insulating compound by carefully inserting it in the mouth of the compound tube 72 The GS550 System Picture Coating the antenna foot 9 Hold the new antenna by the black plastic sheathing and guide it through the hole in the sensor box Carefully seat the antenna in its mating connector When the antenna is correctly seated pulling on it will be met with light resistance KK White nylon hex bolt SA TAO11 Antenna Antenna ntenna receptacle Figure Seating the antenna 10 Carefully re thread screw in and tighten the white nylon hex bolt to secure the antenna in place 11 Reinstall the sensor if necessary if removed from the boom or jib an angle sensor will require re calibration during the installation procedure see the angle sensor installation section of the user manual 12 Verify that the sensor functions properly Load Cells WARNING Heavy shock may affect load indication accuracy Inspect the load cell regu larly for clearly visible dents or scratches Test the load indication if collision damage is visible Reading Accuracy LSI flat bar load links are pre calibrated at the factory No zeroing or other calibration is required on installa
71. lay is waking up programmed sensors and creating a radio communication link with each Once a reliable radio communication network is established all green lights will remain lit without flashing This process may take up to one minute The delay is created by the battery management function and does not affect system security If an anti two block switch detects a pending two block event if a load cell detects a change in load or if an angle sensor detects a change in angle the appro priate radio link will be established in less than 0 1 seconds To immediately wake up a load cell lift the hook with a load to immediately wake up an angle sensor change the boom angle In special conditions of lockout created by a missing sensor you may bypass that sensor until the next display power up by pressing bypass for 10 seconds That sensor green light should stop flashing and then turn off Introduction 5 GS050 Anti Two Block Switch GS101 Angle and Length Sensor GS550 Display GC Series Load Figure Key components in a typical system 6 The GS550 System Operation Display GS550 The GS550 displays detailed information on the backlit two lines liquid crystal display LCD Additional information including warnings alarms and radio status is communicated by the display lights and the display buzzer Liquid Crystal Display LCD Sensor status lights ELSI iT A sae 10 15000 R 2 910000Ik MAINBOOM 0
72. lights flash green when communication is intermittent or absent The M refers to the first sensor programmed in the sensor list except anti two block The A refers to all other sen sors programmed in the sensor list except anti two block Low Battery The amber light of the battery icon comes on when battery life for a sensor programmed in the sensor list drops below 10 Normally several weeks of battery life re mains from the moment the low battery light first comes on Bar Graph The bar graph displays the gross load lifted by a load sensor as a proportion of the maximum load allowed expressed in 10 increments Maximum load is the lowest of the operator set maximum load limit and the working load limit WLL as calculated from the rated capacity charts When there are two or more load sensors programmed in the sensor list the bar graph will indicate the load for the sensor closest to its maximum allowable Infrared Port The infrared port is used to download data from the data logger or to upload firmware updates and capacity charts using a GT103 portable download tool or other compatible device Keypad The keypad consists of six buttons used to control consult program and troubleshoot the GS550 display and system Each button has two functions a primary function for the operation display and a secondary function for menu navigation and programming The secondary functions are described in the Menu Navigation sub section of this manua
73. may have changed possibly changing the rated capacity indicated by the GS550 Always complete the chart wizard all the way to the Rigging ok message before operating the crane 1 Press Menu Next Enter to start the chart wizard 2 The first page of the chart wizard is generally select hoist Use Up and Down to select the hoist If the there is only one load sensor in the system select main With two or more load sensors in the system the main hoist is associated with the first load sensor in the sensor list the auxiliary hoist is associated with the second sensor in the sensor list etc 3 Press Next to advance to the next step of the chart wizard 4 The steps that follow will depend on the size and complexity of the rated capacity chart itself Typical steps include chart selection outrigger on rubber selection and boom length selection lattice cranes only Use Up and Down to select from the list of choices and then press Next to advance to the next step For accurate rated capacity indication the rigging configuration se lected in the chart wizard must reflect the actual rigging of the working sheave 5 After the last step has been completed the GS550 will display Rigging ok and then it will return to the operation display If a sensor required by the selected capacity chart is not a part of the system or has not established communication with the GS550 then the GS550 will dis play sensor invalid
74. n a GS550 display When this option is selected the PDA retrieves the configuration from the GS550 and saves it before sending the new firmware If a problem occurs during the firmware update then the saved configuration file will be displayed in the LSI Firmware Charts Config list on the PDA The configuration can then be re turned to the GS550 by following the instructions Transfer Firmware Files from the PDA to a GS550 1 On the PDA start the LSI Firmware software a Press the house icon to go to the Home menu b Select All from the drop down menu in the upper right hand corner c Select LSI Firmware 2 Correctly align the infrared ports of the PDA and the GS550 3 On the PDA press GetCfg The GS550 will display Transferring When the transfer is complete the PDA generates a short musical alarm and a file with the name CONFIG is added to the Charts Config list Transfer Data Logger Files from the GS550 to the PDA 1 On the PDA start the LSI Datalogger software a Press the house icon to go to the Home menu b Select All from the drop down menu in the upper right hand corner c Select LSI Datalogger 64 The GS550 System 2 Align the infrared ports of the PDA and the GS550 about 6 inches 10 centimetres apart 3 On the PDA receive the file a Press Receive b Select Complete to transfer the entire data logger memory or select From Last to trans fer only data logged since the last download The GS550 will di
75. n at the time of the event Sensor type the sensor number corresponds to the sensor list programmed in the GS550 Sensor was active or inactive at the time of the event Sensor battery level Sensor value Examples Crane start up sensor alarm The beginning and end of sensor alarms are indicated as in and out examples overload in Wind Report 19 overload out Important The wind report ts only available when the data has been recorded with the data logger in the automatic recording mode To create a wind report in Excel click on the Wind Report button in the tool bar _ Eora Ecoma 2006 12 28 47 19 43 10033 0 0 ___0_ 2006 12 28 17 20 44 10033 5 o ___8_ 2006 12 28 17 21 45 10033 6 o i 2006 12 28 17 22 46 10033 8 0 4 2006 12 28 17 23 47 10033 12 0 16 2006 12 28 17 24 49 10033 22 1 30 2006 12 28 17 25 50 10033 13 0 15 2006 12 28 17 26 51 10033 9 o 42 2006 12 28 47 27 52 10033 9 0 ___16 2006 12 28 17 29 03 10033 8 0o 1 2006 12 28 17 29 54 10033 8 0 42 2006 12 28 47 30 55 10033 7 0o i 2006 12 28 17 31 56 10033 7 0 Mm Figure Excerpt of a Wind Report 68 The GS550 System Table Wind report column headings Column Description Date Date of event recorded Time Time of event recorded Sensor ID W
76. ng the reset but ton on the back All applications will then restart data should not be lost 66 The GS550 System Data Logger Viewer The Data logger viewer is a software application used to display on a personal computer PC a log file generated by the GS550 data logger To transfer data logger files from a GS550 to a PC see the section Transferring Files The Data logger viewer opens the log file converts it from a PDA database file to a text binary file and then displays the contents Two reports can be produced and transferred to Excel the full report and the wind speed report 151 12 29 2006 08 53_13 PDB Datalogger Viewer GS V1 0 0 1 P N B0028 File Edition OpenFilter ied x W Event Date Time System Units Battery Voltage Sensor Status Sensor Be Crane Startup 06 12 29 08 52 44 US Lbs 1r rY 100 F 1000 Wind Inactive N Automatic Recording 06 12 29 06 53 46 US Lbs 17 50 100 F 1000 wind Active 11 Wind Gust Limit ln 06 12 29 08 53 59 US Lbs 17 50 100 F 1000 Wind Active 11 Automatic Recording 06 12 29 06 54 48 LIS Lbs 17 40 100F 1000 wind Active 11 Tools View Help Figure Excerpt of a full report in Data Logger Viewer Installation on a Personal Computer Install the CD in a CD ROM drive The interactive installation process should start automatically within 30 seconds if not then 1 Click Start Click My Computer Double click on the CD ROM drive Double click on se
77. ngle sensor to the weld pads with the screws and washers provided 4 Verify list and trim angle indication by the GS550 in operation display use Next to advance to the list and trim indication page Trim angle List angle Figure Trim and list angle indication List and Trim Angle Calibration Procedure Calibrate angle indication by adjusting the offset values for list and trim in the GS550 display the GS550 will then communicate the updated offset values to the sensor 1 Install the sensor at a precisely known list and trim angle Press Menu Next Next gt Next to go to 4 Installation Press Enter Next to go to 4B Sensor Calibration Press Enter to go to the password page Use Back Next Up and Down to enter the user password and then press Enter to go to 4B1 Automatic value calibration wizard 6 Press Enter to go to page 4B1A oe SS 52 The GS550 System 7 Use Back and Next to select the trim or list sensor 8 Press Enter Next to go to the first step of the calibration wizard note the uncorrected angle indicated 9 Press Next to go to the second step angle correction Use Up and Down to adjust the angle value indicated until it is equal to the known angle 10 Press Next to go to the third step note the offset value 11 Press Enter to communicate changes to the sensor 12 Repeat steps 6 through 11 for the list angle 13 Press Exit four times to return to the operation display
78. nu 5D7 Radio FCC IC indicates Federal Communications Commis sion U S A and Industry Canada certification CE indicates European Community certifica tion The frequency used by the system network is indicated on the second line Press Exit three times to return to the operation display Digital Input Diagnostic Press Menu gt Back Enter Back Enter to go to menu 5E4 Blue Wire The page shows the blue wire digital input status Press Exit three times to return to the operation display Operation 19 Installation Display GS550 Important Do not crack or puncture the membrane fascia The GS550 display is splash and rain proof Waterproofing depends in part on the integrity of the membrane Important Do not power wash the display The GS550 display is not designed to withstand high pressure washing devices that can erode the membrane fascia seal or create fissures in the membrane fascia Power washing the display voids warranty coverage Mounting Bracket 1 Determine the mounting location The display may be installed either inside or outside the cab It can be mounted on the dash on a sidewall or on the ceiling of the cab To ensure reliable radio communication between sensors and the GS550 the antenna must not be in contact with metal and must have a direct and clear line of sight to the antennas of all sensors The mount ing bracket requires a flat surface of at least 2 inches in diameter on both si
79. old over 16 000 records this is equiva lent to several days or several years of operation depending on the recording mode selected and machine use The data can be extracted using a portable download tool and then transferred to a personal computer for analysis Recording Modes Adjust the data logger recording mode as required 1 Press Menu Next Next Next Enter Next Next Next Next Next Enter to go to menu 4F1 Data logger mode 2 Use Up and Down to select the data logger recording mode 3 Automatic modes only press Next to advance to the adjustment page for the interval auto matic recording mode variation automatic variation recording mode or threshold automatic peak recording mode 4 Press Enter to save any changes 5 Press Exit three times to return to the operation display or press Next to adjust the data logger date and time see below Tip all alerts are recorded by the data logger regardless of the mode selected Alarm only Record alarms only All the other data logger modes also record alarms 56 The GS550 System Automatic recording A record is added at a specified interval When the automatic re cording data logger mode is selected on menu page 4F1 see step 3 above press Next to go to page 4F11 and then use Up and Down to adjust the record interval in minutes Important Wind speed the data logger recording mode must be set to automatic recording to log the
80. r Calibration Enter user password ace l B1 482 Manual parameter ca calibration L _ AA gt gt 3 I ABRA 14B2A No x id Gxxxxx Angle sensor L T MM Figure Angle Calibration Procedure N 2 Anti Two Block Switch GS050 WARNING Keep the anti two block switch away from the boom and any connecting metal structures when welding mounting brackets to the boom Proximity to welding may cause permanent damage to the anti two block switch and render the anti two block system unsafe Important To ensure reliable radio communication between the anti two block switch and the GS550 display the following conditions must be respected e The antenna of the anti two block switch must not be in contact with metal e The anti two block switch antenna must point to the left or to the right of the boom it must not point directly to or away from the GS550 display e The anti two block switch antenna must have a clear line of sight to the GS550 display in most cases this means mounting the sensor on the same side of the boom as the operator s cab Installation 3 1 1 Verify the GS050 anti two block switch is programmed to the GS550 display Switches shipped with displays are pre programmed in the factory Test if the switch has been programmed to the display then the display will go in to two block alarm when the wire rope of the switch is re leased Press Bypass to silence
81. rge cranes Figure List and trim axes Installation 5 1 Programming the GS550 for List and Trim Indication For list indication add the GS010 03 id number to the sensor list menu 4A1 and select the sensor type List sensor For trim indication add the GS010 03 id number to the sensor list menu 4A1 and select the sensor type Trim sensor The maximum and minimum angles for list and trim indication can be adjusted in the limit menu The default limits are 10 0 maximum and 10 0 minimum Mounting Instructions WARNING Remove the angle sensor from any connecting metal structures or surfaces when welding the metal lugs to the mounting surface Proximity to welding may cause permanent damage to the angle sensor and prevent accurate angle indication 1 Determine the angle sensor position a The mounting surface must be flat and known to be level 0 in both the list and trim axes b The angle sensor must have a clear line of sight to the cabin mounted display c The angle sensor must be installed horizontally with the antenna pointing up d The list and trim axes are indicated on the angle sensor follow these indications to ori ent the sensor correctly for accurate list and trim indication e The angle sensor antenna must not contact a metal object 2 Install the welding pads keep the angle sensor well removed from the weld site and any connecting metal objects while welding 3 Mount the a
82. routed through a different programmed sensor repeater This can be done either to extend the range of the network or to assist communication around a large radio obstacle The battery life of the sensor repeated source will be reduced by about a year The battery life of the sensor repeater will be reduced to 35 days This function should not be used where it is not required Program a sensor repeater 1 Press Menu gt Next Next Next Enter Next Next Next Next gt Next Next Next Next Enter gt Next to go to menu 412 Set up sensor re peater 2 Press Enter to go to menu 4121 Select repeater 3 Use Up and Down to program the radio id number of the sensor that will be the re peater 4 Press Next to go to menu 4122 Select source 5 Use Up and Down to program the radio id number of the sensor that will be repeated 6 Press Next to go to menu 4123 Enter to save The new network path 7 Press Enter to save the new network path The following messages will be displayed briefly 8 Parameters saved correctly 9 Communicating with remote sensor 10 Configuration saved successfully 11 Press Exit three times to return to the operation display Repeated source battery life estimated for standard product using new factory specified batteries correctly installed operating 32 hours per week Individual results may vary with intensity of use environmental conditions
83. ry default maximum limit for load sensors is 10 000 Ib per part of line Tip When the weight units are tons the minimum load limit increment Is 0 1 ton per part of line Menu Press Menu to access the five basic system menus 1 Parts of Lines 2 Crane Rigging 4 5 System Diagnostic 3 Display Settings Installation Menu System There are five basic menus level one used to program consult and control the GS550 system 1 Parts of Lines 2 Crane Rigging 3 Display Settings 4 Installation 5 System Diagnostic The basic menus include nested sub menus level two three and four designed to address specific tasks including adjusting values choosing from lists and following wizards through step by step processes Operation 11 Menu Numbers Menus are identified by a number in the upper left corner The basic menus level one are num bered one through five Level two menus are lettered alphabetically Level three menus are num bered Level four menus are alphabetized Operation Level Menu Level One Menu Level Two Menu Level Three Menu Level Four Menu Navigation From the operation display press Menu to see the five basic m
84. ry cover notch to pry the box away from the mounting plate The silicone seal may cause some resistance 3 The link wires of a load cell may be disconnected to facilitate battery replacement 4 Remove the battery by hand 5 Remove the remaining silicone from both the box and the mounting plate 6 Install the new battery insert the positive end and then push in the direction of the positive pole 7 Reconnect the link wires if disconnected 8 Apply the non corrosive RTV silicone all around the edge of the mounting plate to create a new seal with out bubbles or breaks 9 Reposition the box over the mounting plate and screw in the hex screws Do not over tighten Figures Removing the battery Actual battery life will vary greatly depending on the application the frequency of use the age and quality of the battery etc 70 The GS550 System Replacing Anti Two Block Switch Batteries This procedure does not apply to the GS005 mechanical anti two block transmitter To change the batteries of the GS005 please refer to the Replacing Sensor Batteries section of this manual The following items are required e An adjustable wrench e Four 4 new high quality C cell batteries 3 6 V lithium or alkaline e RTV non corrosive silicone Tip Four 3 6 volt lithium C cell batteries will provide over four years of battery life while four alkaline C cell batteries will provide about one year of battery life
85. ry life remains in the sensor e Schedule battery replacement for the next available opportunity Typically several weeks of operation remain from the moment the sensor low battery warning is first triggered The display isn t receiving communication from the sensor e Verify that the sensor id number programmed matches the id number of the sensor installed on the crane Go to menu 5A1 Voltage is detected on the lockout wire when in alarm With the standard relay configuration voltage should not be present on a lockout wire in alarm condition e Verify the wire connection Refer to the Power Supply and Lockout Connec tion sub section of this manual Voltage is not detected on the lockout wire when safe With the standard relay configuration voltage should be present on a lockout wire in safe condition e Verify the wire is not shorted to ground e Verify the wire is not connected directly to the valve coils a relay should be installed between the wire and the valve coils Refer to the Power Supply and Lockout Connection sub section of this manual One or more primary conditions of the chart selected for the hoist is not met example telescopic boom length e Verify the conditions of the selected rated capacity chart The boom or jib angle is above the maximum angle permitted by the selected chart For charts determined by radius only this message will occur when the radius is less than the minimum radius permitted by the chart
86. sors received see step 2 a 4 Press Next to go to menu 5B4 Bit error rate communication test This test should only be conducted by LSI technical service personnel 5 Press Exit three times to return to the operation display 18 The GS550 System a oh eS gt Lockout Diagnostic Press Menu gt Back Enter Next Next Enter to go to menu 5C1 White wire The page shows the lockout condition of the output alarm or safe and the self test pass or fail To temporarily invert the lockout relay press Up or Down Press Next to go to menu 5C2 Green wire diagnostic Press Next to go to menu 5C3 Orange wire diagnostic Press Exit three times to return to the operation display Display Diagnostic Press Menu gt Back Enter Next Next gt Next gt Enter to go to menu 5D1 Time and Date The page shows the current time and date according to the GS550 internal clock Press Next to go to menu 5D2 Time clock battery Self test pass or fail Press Next to go to menu 5D3 External power voltage Press Next to go to menu 5D4 Display internal temperature Press Next to go to menu 5D5 GS550 base station id The base station id should be the same as the GS550 display serial number printed on the left side of the box GS550 03 portable displays only press Next to go to menu 5D6 Battery level The battery level of the onboard rechargeable battery pack is indicated Press Next to go to me
87. speed and pending two block can be detected and indicated to the operator in real time Working load radius can be calculated and compared to a rated capacity chart if programmed Furthermore the GS550 can be programmed to generate warnings alarms and lockout commands all triggered by adjustable thresholds and limits All these events can be recorded by the data logger with a time and date stamp The exact operational function of the GS550 system depends on the sensor configuration used and the rated capacity charts programmed where applicable The GS550 includes an infrared port to facilitate software and chart updates and data logger downloads using a compatible personal digital assistant PDA or cell phone Compatible sensors include the GS050 anti two block the GC series load cells and GS001 series line rider and load pin transmitters the GS010 angle sensors the GS011 angle sensor and length transmitter and the GS020 wind speed sensor The GS550 system is designed as an operator aide and is in no way a substitute for safe operating practice Version Compatibility GS series product with version 2 firmware is not compatible with GS series product with version 1 firmware For information on upgrading GS series product from version 1 to version 2 firmwares please contact LSI Start Up The GS550 must be correctly programmed for the system sensors installed The GS550 powers up with several green lights flashing this indicates that the disp
88. splay Transferring When the transfer is complete the PDA generates a short musical alarm and displays the uploaded file name in the LSI Datalogger file list ar EII A Ger Download Figure The Palm LSI Datalogger file list Figure The Palm LSI Datalogger options Transfer Data Logger Files from the PDA to a Personal Computer 1 Connect the PDA to a personal computer PC using the PDA USB cable 2 On the PDA press the star icon to start HotSync HotSync will connect the PDA with the PC and update files from each Data logger files will be transferred to the following directory of the personal computer C Program Files Palm PALM _NAME Backup Note PALM NAME is the actual name of the PDA device Portable Download Tool 65 Trouble Shooting PDA Communication Issues Copy to a PDA when using several PDAs with the same PC 1 Transfer a firmware toa PDA Size Type Da a Click on the mouse A Fa Firm4202067D000 00 pdb Open 158 K6 Palm Database File an rig ht button over the Scan For Viruses file in an Explorer epee i E mail with Yahoo window Then select Send To e and PDA EJ Compressed zipped Folder Quick Install See the Cut j Desktop create shortcut picture below ail pings Create Shortcut B My Documents b Or double click on Delete a the firmware received ae 3 3 Floppy a2 in an email Properties 2 Usually a window will pop up to confirm the addition of this file to
89. th an empty container or with rigging only The default imbalance minimum limit is 1000 pounds or kilograms depending on load display units Program the imbalance sensor 1 Press Menu gt Next Next Next Enter gt Enter to go to the sensor list 4A1 2 Press Next repeatedly to advance to the next available sensor position usually follow ing the four load sensors and the sum load sensor 3 The id can be left at 0 press Next 4 The sensor type should flash use Up and Down to select the sensor type Imbalance sensor Only one imbalance sensor is required to calculate imbalance for all four load sensors 5 Press Enter to save any changes Press Exit three times to return to the operation display 7 Confirm the imbalance factor limit and the imbalance minimum limit in the limit menu p Examples Imbalance factor calculation for load sensor N9 1 Average Load 2 3 and 4 Load 1 Load Ne 1 Imbalance Factor Average Load 2 3 and 4 8100 7500 Load Ne 1 A Imbalance Factor 100 X 8100 If the imbalance factor limit is 15 then an imbalance alarm is generated 8100 6800 Load Ne 1 A Imbalance Factor 100 8100 Slack Rope Systems programmed for four load sensors and four load sum indication can be programmed with a slack rope sensor to warn against unwanted rope payout when the load touches down 50 The GS550 System Slack rope minimum limit The sla
90. th and then press Next l 11 Hoist down payout the wire rope and then press Next a n e ee 12 Use Up and Down to program the actual wire rope LA payout length and then press Next Al SAO al 13 Note the new trim value and then press Next 14 Note the new scale value and then press Next een say ane a 15 Press Enter to send the new calibration to the rope payout sensor 2 8 HoistUp Pay In 16 Press Exit four times to return to the operation display SA 3 8 Adjust actual rope length oO aw Rope Payout Limits rope lengthn xXx The minimum and maximum rope payout length limits and 5 8 Adjust actual the maximum rope speed limit can be adjusted in the rope length xx x display in the limit menu The maximum rope payout limit can be programmed to trigger lockout when exceeded see a O menu 4G Lockout Settings The minimum rope payout limit l and the maximum rope speed limit will trigger an alarm 7 8 Calib result when exceeded The default limit for maximum rope payout Scale X XXXX is 300 feet the default minimum limit is 300 feet The default limit for maximum rope speed is 15 0 feet per second 8 8 Press Enter to Save calib in sensor Figure Rope payout Calibration Installation 59 Figure An alternative installation Data Logger The GS550 includes a data logger that records all significant events including actual sensor values and a date and time stamp The data logger memory can h
91. that if a second display is programmed for a sensor it will take control of it the sensor will no longer acknowledge communication from the first display Occasionally it may be useful to monitor an installed system from a remote display without disrupting the existing network The GS550 can be programmed to operate in listening mode In this mode the GS550 will display information from programmed sensors without becoming the network controller Important Sensors can only have one network controller at a time To receive com munication from a sensor without taking control of that sensor a display must first be programmed in listening mode Installation 59 Program the listen only mode 1 Press Menu Next Next Next Enter Next Next Next Next Next Next Next Next Enter to go to menu 411 2 Use Up and Down to switch between network controller and listen only modes 3 Press Enter to save any change 4 Press Exit three times to return to the operation display When a display is adjusted to listen only mode the following message flashes three times during the start up routine The display is in listen only mode Tip To regain network control of programmed sensors adjust the GS550 to network controller menu 411 see the procedure above shut the display off and then start it again Repeater Communication between a GS550 and a programmed sensor can be
92. the GS011 angle length sensor antenna coming out the top side of the cable reel cover 4 Install the first cable guide PA111 about 10 feet 3 metres from the cable reel Correct alignment of the first guide is critical to ensure orderly winding of the cable on the reel Install the other guides at the end of each of the intermediate sections and the anchor PA113 at the end of the last section All guides must be aligned so as to permit unobstructed movement of the cable 5 Pull out at least 5 feet 1 Y metres of cable but not more than half the excess extension D Feed through the cable guides and attach to the cable anchor on the tip of the last boom sec tion If additional cable length is required to reach the cable anchor point remove winds from the reel without putting additional tension on the cable reel spring There should be minimal tension on the cable reel spring when the boom is fully retracted 6 Verify the boom length indicated on the GS550 LCD Boom length is indicated following the length abbreviation L typically on the first or second operation page Boom length indicated should equal the actual total boom length The actual boom length is the distance from the boom base pin to the head sheave centre as measured along the boom centreline Depending on the exact placement of the cable reel and the cable anchor the displayed length may differ from the actual length 8 150001 R Figure GS550 LCD typical opera
93. the list of files to be transferred to a PDA Verify the User in this Nl lee ise ate window Two or more users may be configured to the PC User ls Verify PDA memory 1 Power up the PDA With the plastic pen press on the Home icon on the lower left side of the screen to see the time of day on the upper left 2 Press on the time of day a menu should pop up press on lt Info gt Example of having two usernames on the same PC One is LSI and the other one is Isi This can be confusing and must be verified when there is difficulty copying to the Palm in this menu A page will show How to free up memory how much free memory is available on the PDA 1 Power up the Palm With the plastic pen press on the Home icon on the lower left side of the screen until an icon called LS420 Download is visible Example 1 1M means 1 1 megabytes equates to 1100 kb kilobytes Each GS550 firmware uses more than 140 kb of MED If there is not enough meno 2 Press on the LS420 Download icon A left verify if some applications or data list of available files will be displayed logger files could be removed Note A firmware with crane capacity charts may 3 Press on the file to be deleted require more memory 4 Press on the delete button The PDA doesn t respond If the PDA doesn t appear to respond to commands or if prob lems occur during a transfer operation then the PDA can be reset by pressi
94. tion Each link is heat treated to age the steel and ensure stable readings for many years the load cells are individually temperature compensated to guarantee accuracy LSI flat bar load links are calibrated to indicate between 100 and 104 of their Safe Working Load SWL LSI load pins line riders and compression cells must be calibrated at installation and every time thereafter the installation the load sensor or the transmitter is changed Maintenance 73 SAE J 159 4 2 1 recommends load indicating devices should show not less than 100 of the actual load and not more than 110 of the actual load Load Testing LSI recommends testing the load cell every year for accuracy The simplest way of testing a load cell is to lift at least two known weights A test weight should be known with an accuracy of 1 If the load cell is installed at the boom tip dead end all additional equipment such as blocks slings sensors etc should also be known to an accuracy of 1 Determine the accuracy of the tested system with the following formula Indicated Load 49 9 of Load Actual Load Reference SAE J 159 7 3 The test loads must be significant relative to the load cell capacity The minimum test weight is about 20 of the safe working load a good test weight is greater than 50 of the SWL For example a 30 000 Ib load cell on four parts of line has a SWL of 120 000 Ib the minimum test load in this case would be 24 000 Ib a good t
95. tion page two with boom length indication Installation 37 Cable anchor Cable reel Boom length a Figure The actual boom length Boom Length Calibration Procedure N 1 Mechanical Set Up Important Monitor length sensor cable length remaining as the boom is extended for the first time with the installed cable reel This generally requires a second person in addition to the operator 1 2 3 Fully retract the boom Adjust the loose wire rope at the boom tip so that the displayed boom length matches the actual boom length Fully extend the boom Verify the boom length indicated at full boom extension matches the actual fully extended boom length If not then follow Boom Length Calibration Procedure Ne 2 Correct with the GS550 Boom Length Calibration Procedure N 2 Correct with the GS550 If the displayed boom length does not match the actual length of the boom retracted or extended and if it is not possible to easily correct by following Boom Length Calibration Procedure Ne 1 previous page then follow this procedure This procedure is completed in the operators cab it requires fully retracting and then fully extending the boom as prompted by the on screen instruc tions 38 The GS550 System Operation Display Enter user password ada 4B1 Automatic value calibration wizard 4B1A No x id GXXXXX Length sensor La e ie m Length calibration wizard Press Next
96. tup exe Complete the installation as instructed on screen 912 9 10 Quick Start 1 Select the Data logger viewer application from the Start menu of the personal computer 0 Fie Edition OpenFilter Tools View Help coo gt E lx WF Full Report button Wind Report button Figure Data Logger Viewer tool bar 2 Click on the file folder icon to open a log file or click on File Open 3 Enter the file location Example A typical PDA file folder C Program Files PDA PDA_NAME Backup The wind report is only available when the data logger has recorded in the automatic recording mode Portable Download Tool 67 Note PDA_NAME is the actual name given to the PDA 4 Select the log file to open Only pdb files generated by the LSI software in the Portable Download Tool are supported Example A typical file name for a log file generated by a GS550 data logger LSI_08_13 2004 15 31 _48 PDB Full Report To export the full report to Excel click on the Full Report button in the tool bar Table Full report column headings Column Description Event Record trigger Date Time System Units Battery Voltage Temperature Firm Version Sensor 1 Sensor Status Sensor Battery Value Event date stamp Event time stamp Length units metric or US and weight units at the time of the event Display power supply voltage at the time of the event Internal temperature of the display Display firmware versio
97. unt of time and distance In crease the length of the small chain if needed Length Sensor Cable Reel WARNING Arc welding will damage LSI sensors causing immediate failure or greatly reducing functional life Arc welding on or near LSI equipment will void warranty Keep LSI equipment well clear of any arc welding The GS101 includes the LS101 cable reel and the GS011 angle length sensor The GS011 is concealed under the cover of the LS101 though the antenna is visible Following cable reel installation and boom length indication calibration boom angle indication will have to be verified and possibly calibrated Refer to Angle Calibration Procedure Ne 1 Mechanical Set Up and Angle Calibration Procedure Ne 2 Correct with the GS550 in this manual Installation 35 GS011 angle length sensor antenna LS011 length sensor cable reel Figure GS101 angle amp length sensor Maximum Boom Extension Confirm the extension of the LS101 cable reel is compatible with the boom Step 1 Note the cable reel maximum extension 100 feet TS 30 5 metres unless specified otherwise Step 2 Note the retracted boom length A Step 3 Note the maximum extended boom length not B including jib Step 4 Calculate maximum boom extension C B A Step 5 Compare cable reel maximum extension T to D T C maximum boom extension C Maximum cable reel extension must be greater than maximum boom extension Mounting the Cable Reel
98. with sheaves greater than 16 inches 41 centimetres in diameter consult your service representative a bracket 2 4 in 5 10 cm a sheave centre Boom base gt Figure Jib rooster or other extension anti two block switch placement for single part of line operation only For fast line weight installation place the anti two block switch mounting bracket directly below the sheave center as low and as close to the edge of the sheave as possible Place the fast line weight mounting bracket on the opposite side of the sheave with the chain hole pointing down and lined up opposite the pivot of the anti two block switch mounting bracket 33 Installation Anti two block switch mounting bracket B b Front view oom base Mount bracket directly below sheave centre as low as possible Figure Fast line weight installation Fast line weight 3 Chain length adjustment Ne 1 minimum boom angle a At minimum boom angle with no additional weight on the hook block and one part of line only lift the boom just enough to have the hook block suspend and clear the sensor chain and weight b Hoist slowly until the red two block warning lights comes on and the buzzer sounds Note the hoisting distance remaining this distance must be great enough to allow the operator and the lockout system if installed to prevent a two block event If necessary add lightweight chain between the sensor and weight to increase warning
99. xposed to the wind and spin freely at all boom angles Installation 45 f a e a E a AA O Figure Wind clearance d There must be a clear and unobstructed line of sight between the wind speed sensor antenna and the cabin mounted display unit Fi satin ET ADOS LAL T TATATATA FIT Ti aTi TETT L i i ry ARANA DADA A Y AE T A a Te EA Le EXA a a m w i RE R tit N A rl SDE AZ HAN Figure Radio line of sight e The transmitter antenna must not contact any metal object Tip Angle iron can be used to extend the mounting position clear of the boom top 3 Weld the mounting rod to the boom at the selected point 4 Re position the wind speed sensor on the mounting rod add the washer and secure with the cotter pin 46 The GS550 System Wireless Load Pins WARNING Do not pull on a load pin by the pigtall LPO11 LPO15 and LP026 1 Mount the load pin to the boom tip or block by replacing the pin of the wedge socket The load pin is directional and must be oriented correctly to indicate load accurately Install the pin so that the bracket embraces the wedge socket and prevents pin rotation Load pi Tip When installed at the boom tip the lot number can be read right side up and the line pull arrow points down towards the block When installed at a single part block the lot number can be read upside down and the line pull arrow points up towards the boom tip 2 Secur
100. xt letter Press Enter to save any changes Installation 25 3 4H2 Set user password Press Next three times to advance to the tare menu protection page or to change the user password use Up and Down to adjust the flashing letter and then use Next to advance to the next letter Press Enter to save any changes 4 Menu 4H3 Tare protected use Up and Down to switch between yes and no and press Next to advance to the next menu page 5 Repeat step 4 to adjust password protection for each menu as required Press Enter at any time to save changes made Press Exit at any time to return to menu 4 Installation If there are any unsaved changes the display will request confirmation press Enter to save before quitting or press Exit to quit without saving 26 The GS550 System 72085 1aquunu pod JusLlus oo da y Datasheet Ap ds E JH Hl Oa ih NOldld 0530 IS lt q gt Nano gegzsy ADS yunoy OUOYIPPD sun mgp Si ramog opos uodo UD SID ZHI 999 SALUNWLUOTS UbSdaung PIOPUPIs ZHI O06 pubg Asuenbay OpY 40 91 CHE L DaSL Of ST oy S QUSIA DT do 91 OLET DoS CH OE sunpouedwiay Guyousda UIDS Y SADS JSSOLU JOSU Sou sus As PSdLuoOls Sul 0009 UOUL sop AOA 425607 Heg fig Fe YEYPAIOG uosa pyu PUD SOMUOD JODIDO UM 5 3193 90 04 OF 53ul Z y Gua 49 ADM 9 29008 42quNU Lod pepnyaul joy agos jdidns 13440 y pa osauuo gt s ADA Inox50 Jed Y sd Y 30A OF 9401 paluinbs Adans Jano
101. y and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interfer ence to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is con nected Consult the dealer or an experienced radio TV technician for help In order to maintain compliance with FCC regulations shielded cables must be used with this equipment Operation with non approved equipment or unshielded cables is likely to result in interference to radio and TV reception The user is cautioned that changes and modifications made to the equipment without the approval of manufacturer could void the user s authority to operate this equipment FCC ID QVBGS550 IC 7076A 1CGS550 RF Exposure Warning This product complies with FCC IC radiation exposure limits set forth for an uncontrolled environment To comply with RF exposure requirements the unit must be installed and op erated with 20 cm 8 in or more between the product and your body This product may not

GS550 Palm User Manual - Load Systems International

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