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GS550 Display GS550 Display - Load Systems International

1. A B C D E F 1 Date Time Sensor ID Wind mph Nb Gust Max Gust mph 2 2006 12 28 17 17 41 0 0 0 3 2006 12 28 17 18 42 0 0 0 4 2006 12 28 17 19 43 0 0 0 5 2006 12 28 17 20 44 5 0 8 6 2006 12 28 17 21 45 6 0 10 7 2006 12 28 17 22 46 8 0 14 8 2006 12 28 17 23 47 12 0 16 9 2006 12 28 17 24 49 22 1 30 10 2006 12 28 17 25 50 13 0 15 11 2006 12 28 17 26 51 9 0 12 12 2006 12 28 17 27 52 9 0 16 13 2006 12 28 17 29 03 8 0 18 14 2006 12 28 17 29 54 8 0 12 15 2006 12 28 17 30 55 10033 7 0 10 46 2006 12 28 17 31 56 10033 7 0 11 Table Column Sensor ID Figure Excerpt of a Wind Report Description period period Wind report column headings Date of event recorded Time of event recorded Wind 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 Max Gust mph Maximum wind speed gust during the 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 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 48 ees GS550 System 5 MAIN
2. 32 Minimum angle 2 Default green wire trigger 34 Table Example No 2 Maximum wind speed 1 Maximum angle 4 Overload 8 Maximum length 64 Two block 128 Slew Limit Left 1024 Slew Limit Right 2048 Maximum tip height 4096 Default white wire trigger 7373 Lockout relay inversion By default the lockout wires carry crane power supply voltage as long as the display is in safe condition N WARNING Inverting lockout relays will allow crane operation in the event the GS550 display fails Operating crane without functioning anti two block system and load and angle indication is 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 Go to 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 2 1e Password Settings Two levels of access are available administrator and user The administrator password is required to change the user password In the event both the
3. 40 3 5a Menu Numbers 40 3 5b Menu Navigation 40 3 5c Password Protection 40 3 5d MenubLayoul 40 3 5 Parts of Line 41 3 6 RATED CAPACITY INDICATORS 41 3 6a Display Programming 41 3 6b Crane Rigging 41 3 6c Chart Wizard 41 3 7 DISPLAY SETTINGS 42 3 a Weight Units 42 3 7b Wind Units 42 7 Language 42 3 d Lightlntensity 42 3 e Contirast u U UU Ta 42 3 f Backlight Mode 42 3 8 SYSTEM DIAGNOSTIC 42 3 8a System Sensors Diagnostic 42 3 80 Radio Network Diagnostic 43 8 Lockout Diagnostic 43 3 8d Display Diagnostic 43 3 8e Digital Input Diagnostic 43 3 9 WORK AREA MANAGEMENT 44 3 9a Set Fixed Limits 44 3 96 Set Dynamic Limits 44 3 9c Clear all work area limits
4. Figure Chain length test at maximum angle 3 Chain length adjustment No 3 speed test Lower the boom until the weight height becomes visually clear to the operator Repeatedly create two block progressively hoisting faster to ensure that the warning and lockout work within acceptable amount of time and distance Increase the length of the chain if needed IMPORTANT To increase chain length only use lightweight chain Y lt SA yes T Figure Chain length adjustment 2 6 Length Sensor Cable Reel K WARNING Arc welding may 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 85101 includes the 15101 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 No 1 Mechanical Set Up and Angle Calibration Procedure No 2 Correct with the GS550 sections of this manual GS011 angle length sensor antenna LS011 length sensor cable reel Figure GS101 angle amp length sensor 2 6a Maximum Boom Extension Confirm the maximum ex
5. 54 7 2 Specifications 54 7 26 Ensuring Safe Operation in Hazardous 55 7 2 Product Repair And Servicing 55 7 3 EQUIPMENT MARKINGS 55 7 4 15550 DISPLAY LABELS 56 7 5 CLASS 1 DIVISION 1 AND DIVISION 2 CERTIFICATIONS 56 7 6 ATEX CERTIFICATIONS 56 7 FCC AND IC INSTRUCTIONS TO THE USER c 57 7 8 EMI7 u u uu u aQ 58 7 9 ENVIRONMENTAL CONDITIONS 58 7 10 CLEANING AND DECONTAMINATION 59 rare c 59 7 11 Declaration of Conformity 59 CE GAE eee ee 59 GS550 MENU OUTLINE 60 LSI PRODUCT LIMITED WARRANTY APRIL 1ST 20183 62 9 1 LIMITED WARRANT Y 62 9 2 WARRANTY SERVICES PROCEDURES 62 9 3 EXCLUSION OF OTHER WARRANITIES 62 9 4 EXCLUSION 63 9 5 LIMITATION OF LIABILITY 63 9 6 RECOMMENDED PRACTICES 63 9 7 CHOICE OF LAW 63 9 8 ENTIRE AGREEMENT 63 9 9 VIENNA CONVENTION EXCLUDED 63 1 INTRODUCTION 1 1 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
6. 45 3 9d Warning alarm and lockout 45 3 9e Slew and work area display 45 POOL inna x C NUR ROGER 46 4 1 DATA LOGGER TRANSFER FROM DISPLAY u SG 46 4 1a Transfer from display to USB device 46 4 1b Transfer from USB device to 46 4 1C Troubleshooting 46 4 2 UPLOAD CAPACITY CHARTS 47 4 3 DATA LOGGER VIEWER 47 4 3a Installation on a PC 47 4 36 QUICK Start u Z u sassa 47 4 3c Full Report 47 4 3d Wind Report 48 MAINTENANCE 49 5 1 SENSORS 49 5 1a Replacing Sensor Battery 49 5 2 ANTI TWO BLOCK SWITCH 50 5 2a Replacing the GS050 Batteries 50 5 26 Replacing the GS075B Battery 50 5 3 REPLACING A SENSOR ANTENNA 51 5 4 LOAD CELLS 52 o 4a Reading 52 5 46 Load Testing 52 ES 52 6 TROUBLESHOOTING 53 7 CERTIFICATION NOTES 54 7 1 MODEL NUMBERS 54 7 2 IMPORTANT NOTES FOR HAZARDOUS AREA CERTIFIED COMPONENTS
7. u u uu uu s Sas 17 2 a Radius Verification and Adjustment 17 2 b Radius Settings 18 2 c Basic Radius Parameters for a Lattice cii qM 19 2 d Basic Radius Parameters for a Telescopic Boom Crane 19 2 e Advanced Radius Parameters 20 2 8 WIRELESS WIND SPEED SENSOR S020 m 21 2 9 WIRELESS LOAD PINS 22 2 9 011 015 and 026 22 2 96 Load Pin Transmitter GSO01 22 2 10 LINE RIDING TENSIOMETER 23 2 10a Line Riding Tensiometer Installation 23 2 10b Line Riding Tensiometer Installation on a Swing Arm 24 2 11 LOAD PINS LINE RIDING TENSIOMETERS AND COMPRESSION CELLS 25 2 12 FOUR POINT LIFT 26 2 12a Sum Load Indication 26 2 126 Imbalance 26 22126 RODG u uu uu 27 2 13 LIST AND TRIM ANGLE SENSOR 28 2 13a Programming the GS550 for List and Trim Indication 28 2 136 Mounting Instructions 28 2 13c List and Trim Angle Calibration Procedure 29 2 14 ROPE 30 2 1
8. Compression Cells Calibration Load pins line riding tensiometers and compression cells must be calibrated at installation and every time thereafter the installation the load sensor or the load transmitter is changed ensor Calibration nter user password aaa 451 wizard This procedure requires two known weights The first light weight should be about 10 of load sensor capacity and not less than 5 The second heavy weight should be over 50 of capacity and L 1 Go to menu 4B SENSOR CALIBRATION and press Enter nter actua rts of li 1 2 Enter the user password and press Enter twice _ to go to menu 4B1A 2 9 onfirm current unit Ib kg T t 3 Use Back and Next to select the load sensor and then press Enter to confirm communication ift known with the sensor is possible load No 1 xxxx 4 Press Next to start the wizard 1 9 Ndjust actua 5 Use Up and Down to adjust the actual parts of load No 1 xxxx line on the load sensor and then press Next ift Known 6 Note the units that will be used during the calibration wizard and then press Next 5 Adjust actua 7 Lift the first lighter known load and then press load No 2 Next 7 9 alib Result 8 Use Up and Down to adjust the load value Trim xxx displayed to equal the actual known load lifted 8 9 alib Result and then press Next Scale x xxxx 9 Lower the first load lift the second heavier 576 Dress Enter
9. LSI WIRELESS TECHNOLOGY amp CRANE INSTRUMENTATION DIVISIONS GS550 Display amp GS Series Sensors INSTALLER AND USER S MANUAL N WARNING The GS550 system is designed as an operator aid and is in no way a substitute for safe operating practice WARNING Carefully read and understand this manual before proceeding _REV2 209 www loaqsystems com LSI BEFORE PROCEEDING Read and understand the following For your safety and that of the people that come into contact with LSI products understand the significance of the instructions included in this guide respect all laws and regulations and comply with applicable standards Pay particular attention to items bearing the alert symbol A and the following words Warning this denotes an instruction that if not complied with may lead to serious injury or death CAUTION Caution this denotes an instruction that if not complied with may lead to product failure or property damage IMPORTANT Important this denotes an instruction that if not complied with may lead to product performance issues N WARNING Installation must be made in compliance with LSI instructions and using LSI supplied components only Failure to install all parts or replacing parts or components with parts or components not supplied by LS may lead to system failure serious injury or death TABLE OF CONTENTS
10. 1 INTRODUCTION 5 1 1 OVERVIEW 5 1 2 START UP 5 INSTALLATION 6 2 1 DISPLAY GS550 6 2 1a Mounting 6 2 1b Antenna Position 7 2 1c Power Supply and Lockout Connection 7 2 1d Lockout Settings 8 2 2 POWER SUPPLY VERIFICATION 9 29 LOAD CEL u uuu uuu 10 2 4 ANGLE SENSORS FOR THE BOOM OR 11 2 4a Mounting 11 2 40 Angle Calibration Procedure 1 Mechanical Set Up 11 2 4c Angle Calibration Procedure No 2 Correct with the GS550 12 2 5 ANTI TWO BLOCK SWITCH 12 2 5a Switch Bracket Installation LB011 12 2 56 5050 Installation 13 2 5 QGS075B Installation 14 2 5d Chain length adjustment 14 2 6 LENGTH SENSOR CABLE REEL 15 2 6a Maximum Boom Extension 15 2 66 Mounting the Cable Reel 15 2 606 Length Calibration Procedure 1 Mechanical Set Up 16 2 6d Boom Length Calibration Procedure No 2 Correct with the GS550 16 24 RADIUS
11. 35 days This function should not be used where it is not required Program a sensor repeater 1 Go to menu 4 21 Select repeater 2 Use Up and Down to program the radio ID number of the sensor that will be the repeater 3 Press Next to go to menu 4 22 Select source 4 Use Up and Down to program the radio ID number of the sensor that will be the source 5 Press Next to go to menu 4 23 Enter to save The new network path 6 Press Enter to save the new network path The following messages will be displayed briefly PARAMETERS SAVED CORRECTLY COMMUNICATING WITH REMOTE SENSOR CONFIGURATION SAVED SUCCESSFULLY 7 Press Exit three times to return to the operation display Clear a sensor repeater 1 Go to menu 4 3 Menu 4 3 details the last repeater programmed When no repeater has been programmed the menu 4 3 displays the message No REPEATER REGISTERED 2 To shut down the last repeater programmed press Enter The following messages will be displayed briefly REMOVING NETWORK PATH INITIALIZING NETWORK 3 Toshut down additional repeaters repeat step 2 4 Press Exit three times to return to the operation display CAUTION Test all system functions after setting up or removing a repeater Shut off and then restart the GS550 2 19c Wireless Sensor Update It is possible to send a firmware update to a sensor using the GS550 menu 4 4 For more information on i
12. Go to menu 4 7 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 Note To regain network control of programme sensors adjust the GS550 to NETWORK CONTROLLER menu 411 see the procedure above shut the display off and then start it again 2 19b Repeater Communication between a GS550 and a programmed sensor can be routed through a different programmed 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 and other factors 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 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
13. 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 SOME STATES OR JURISDICTIONS DO NOT ALLOW THE LIMITATION OR EXCLUSION OF LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU 9 6 Recommended Practices 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 and complied with 9 7 Choice of Law This Limited Warranty shall be governed by and construed in accordance with the laws of the Province of Quebec Canada for products sold by LSI in Quebec the laws of the Province of Ontario Canada for products sold by LSI in Ontario and anywhere else in Canada and the laws of the State of New York for products sold by LSI anywhere in the United States of America or anywhere else excluding Canada 9 8 Entire Agreement This document contains the enti
14. 502 TIME CLOCK BATTERY TEST 5D3 EXTERNAL POWER SUPPLY VOLTAGE 5D4 INTERNAL TEMPERATURE 5D5 GS550 BASE STATION IDENTIFICATION NUMBER 5D6 GS550 PORTABLE BATTERY LEVEL 507 RADIO CERTIFICATION AND FREQUENCY DIGITAL INPUT DIAGNOSTIC 5E4 BLUE WIRE STATUS 3 5e 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 Go to 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 auxiliary 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 3 6 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 received from the boom mounted sensors 3 6a 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 and Next twice press Exit to return to the operation display NMPORTANTI If the chart number inform
15. 6 HoistUp Pay length xx x E Adjust actual rope length xx x 4 HoistDown Payout rope length xx x E Adjust actua rope length xx x 2 8 Trim xx x 7 6 aliD result Scale 9 8 Press Enter to save callib sensor Figure Rope payout calibration 2 14c Rope Payout Limits The minimum and maximum rope payout length limits and the maximum rope speed limit can be adjusted in the display in the limit menu The maximum rope payout limit can be programmed to trigger lockout when exceeded see menu 4G Lockour SETTINGS The minimum rope payout limit and the maximum rope speed limit will trigger an alarm when exceeded The default limit for maximum rope payout is 300 feet the default minimum limit is 300 feet The default limit for maximum rope speed is 15 0 feet per second INSTALLATION PLSI 2 15 Slew Sensor Installation 2 15a Encoder Gear Verification Verify that the slew swing sensor was supplied with the correct gear for your application This spring needs to be in tension and keeps the slew encoder gear in strong contact with the slew gear Encoder gear rolls on the tooth edges Figure Encoder gear verification a Roll the encoder gear on the crane slew gear it should roll without skipping b The distance between the leading edges X of the slew gear teeth should correspond to the gear model shipped with your order Ex
16. Figure Example of a typical installation on a telescopic boom crane not to scale Line Riding Tensiometer mounting DN ounting Bracket for swing arm Bracket and Landing Pad wooden cushion Figure Example of a typical installation on a lattice boom crane allows for lower clearance not to scale LSI 2 106 Line Riding Tensiometer Installation on a Swing Arm 1 Verify that the line riding tensiometer size fits with the wire rope diameter Table Cable Line riding tensiometer part number and rope diameter size Inches GS series P N line rider with swing arm and transmitter P N mm Smal 259 Smal 259 Frame Sheave Size Medium 63 6 LD018 GD006 1125 11 8 Medium 6 10020 GD006 1250 127 32mm 8 LD022 GD008 1375 he a Large 8 10024 0008 1500 1 1 2 Large 8 10026 0008 1625 1 5 8 X Large 10 10028 0010 1750 X Large 10 10031 GD010 1890 48mm 10 Large 0036 0010 2250 2 1 4 2 Identify the hoist rope and choose a proper place normally as far up the butt section as practical to install the swing arm X Large 10 3 Install the swing arm by welding bolting or strapping it to the boom It should be located to be as centered as possible with the boom end sheave and positioned such that neither the swing arm nor the line riding tensiometer interfere with the hoist rope or other objects 4 Remov
17. Product that is not listed in the above chart for further details The Warranty Period commences after delivery of such Products to the user as evidenced on a LSI document subject to installation and use in accordance with specifications described in the LSI Installer and User s Manual as amended from time to time LSI technical materials and any related writings published by LSI with respect with such Products and any applicable industry standards 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 in its sole discretion in accordance with the Limited Warranty Services Procedures described in this section 9 2 Warranty Services Procedures In order to benefit from this Limited Warranty the purchaser must notify LSI s customer service or LSI s authorized distributor or representative originally responsible for the sale of the Products within 10 days of the occurrence of a suspected defect in materials or workmanship and in any case prior to the expiry of the Warranty Period Timely notification will permit the purchaser to obtain a Return Authorization Number which will indicate return procedures and terms and conditions of such returns A proof of purchase of the Product such as an invoice or a receipt certifying the validity of the Warranty must be presented in order to obtain Limited Warranty coverage In any
18. Remove the sheath to about 2 in remove the shield and remove the individual sheaths on the 6 wires to about 1 4 in Connect the 6 wires in the terminal block respecting the color codes and tighten the terminal block SCrews 5 Replace the transmitter cover and screw it in place 6 Test the sensor for proper function start up the display and move the encoder wheel 2 16 Slew sensor calibration Figure Cable length adjustment The slew sensor need to be calibrated on the crane where it is installed on before utilization 1 Go to Menu 4B1A select the slew sensor and press Enter Press Next to start the slew calibration wizard 2 Menu 1 5 CRANE GEAR TEETH Enter the teeth count of crane s slew gear 3 Menu 2 5 SENSOR GEAR TEETH Enter the teeth count of the gear of the slew sensor installed 4 Menu 3 5 ADJUST CONFIRM SLEW VALUE Enter the current position of the slew Swing 5 Menu 4 5 REVERSED ROTATION Depending on how the slew sensor is installed the rotation direction may be reversed The slew value should go up when you swing to right clockwise 6 Menu 5 5 PRESS ENTER TO SAVE CALIB IN SENSOR the settings will be saved in the sensor LSI 2 17 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 hold over 16 000 records this is equivalent to several days or several year
19. a Sensor Antenna Heavily damaged antennas ripped out sheared off wire exposed and fraying etc should be replaced to ensure effective communication between the sensor and the cabin mounted display unit 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 s manual IMPORTANT The interior of the sensor must be protected from dust grime and water at all times 1 Place the crane boom jib or ball hook such that the sensor is safely accessible 2 Clean dust grime and water from the sensor 3 Identify the short black whip antenna and the white hex bolt securing it 4 Inspect the antenna for signs of obvious physical damage 5 Carefully unscrew the white nylon hex bolt completely and slide it up the antenna way C9 7 9 7 7 16 in wrench Figure Unscrew the white nylon hex 6 Grip the antenna by the base of the black plastic sheathing and pull it straight out of the hole in which it is seated Place the old antenna aside Figure Pull out the antenna 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 carefull
20. a substitute for safe operating practices Read and understand the operator s manual Test before every use FCC ID QVBGS550 IC 7076A ICGS550 This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation ID 40450 5 LSI Load Systems International International 1 281 664 1330 Web www loadsystems com Email sales loadsystems com WARNING This device is intended as an operator aid only and is not a substitute for safe operating practices Read and understand the operator s manual Test before every use Model GS550 ATEX CE Built in 2008 4495 Hamel Blvd suite 110 Qu bec QC Canada D ID 50000 GS550 display Certificate CSA 41332949 on master contract 215780 is available on request Applicable requirements certified by CSA include CSA Standard C22 2 No 0 4 M2004 Bonding and grounding of electrical equipment protective grounding CSA Standard C22 2 No 0 M1991 General requirements Canadian electrical code part Il CSA Standard C22 2 No 0142 M1987 Process control equipment CSA Standard C22 2 No 157 M1992 Intrinsically safe and non incendive equipment for use in hazardous locations CSA Standard C22 2 No 213 M1987 Non incendive electric
21. administrator and the user passwords are lost please call LS technical support Menus accessible from the operation display can be individually protected by the user password 1 Go to menu 4H SET ADMINISTRATOR PASSWORD 2 Menu 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 next letter Press Enter to save any changes 3 Menu 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 ves and 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 2 2 Power Supply Verification The power from the crane needs to be checked in the DC and AC modes under the following conditions e Engine start up Engine idling e Engine revving up during complete process not just w
22. and if it is not possible to easily correct by following Rope Payout Calibration Procedure No 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 Go to menu 4B SENSOR CALIBRATION and press Enter 2 Enter the user password and press Enter twice to go to menu 4B1A 3 Use Back and Next to select the rope payout sensor and then press Enter to confirm communication with the sensor is established 4 Press Next to start the wizard o Note the units that will be used during the calibration wizard and then press Next 6 Hoist up pay in the wire rope and then press Next Use Up and Down to adjust the actual wire rope payout length and then press Next 8 Hoist down payout the wire rope and then press Next 9 Use Up and Down to adjust the actual wire rope payout length and then press Next 10 Note the new trim value and then press Next 11 Note the new scale value and then press Next 12 Press Enter to save and send the new calibration to the rope payout sensor 13 Press Exit four times to return to the operation display _ b ensor Calibration nter user passworq aaa Automatic value calibration Hope payout calibration wizard Press Next B ontirm current units feet metres 2
23. be done before proceeding with installation See the section How to Add a Sensor to the GS550 2 5a Switch Bracket Installation LBO11 20 38 30 Pivot Center Anchor shaft Figure Bracket footprint and orientation All dimensions are in inches Not to scale 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 positioned 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 Up to 8 in 20 cm diameter Mount bracket below and behind sheave center Figure Anti two block switch placement on a telescopic boom If the head sheave diameter is between 8 and 16 inches 20 41 centimeters then two mounting brackets will be required to permit both live and dead end mounting 8 16 in 20 41 cm diameter Mount bracket 4 in 10 cm below sheave center Figure Anti two block switch placement for live end mounting on a lattice boom 8 16 in 20 41 cm diameter Mount bracket 4 in 10 cm in front of the 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 with sheaves greater than 16 inches 41 centimeters in diameter consult your service representative Mo
24. c of rotation s Figure Basic radius parameters for a telescopic boom crane Typical installation Not to scale INSTALLATION 19 LSI 2 7 Advanced Radius Parameters Typical sheave heads SHEAVE HEAD LENGTH PERPENDICULAR D1 SHEAVE HEAD LENGTH PARALLEL 0 typical Special top sheaves example rooster SHEAVE HEAD LENGTH PERPENDICULAR D2 SHEAVE HEAD LENGTH PARALLEL D3 Extensions two possibilities 1 LENGTH the offset is always zero degrees 2 LATTICE EXTENSION LENGTH the offset angle must be adjusted 1 1 EXTENSION OFFSET Ld Boom TOP LENGTH TiP HEIGHT TOLERANCE ina ii Boom OFFSET Luffing jib pie angle sensor LUFFING JIB LENGTH CENTRE SHEAVE TO CENTRE SHEAVE FIXED JIB LENGTH EXTENSION amp OFFSET ANGLE LENGTH OFFSET ANGLE JIB MOUNTING POINT TOP LENGTH OFFSET ANGLE PARALLEL amp PERPENDICULAR Boom SLEW OFFSET Boom LENGTH includes boom top Boom P d angle sensor Boom HEIGHT OFFSET Boom heel pin Crane center of rotation Figure Advanced radius parameters Typical installation Not to scale 20 GS550 System 2 8 Wireless Wind Speed c The wind cups must be fully exposed to the wind and spin freely at all boom Sensor GS020 de i dd aaa Mount
25. encoder with a 6 ft cable but it can be installed beside the transmitter if convenient the cable can be cut to the length required 2 15f Slew Transmitter Installation MPORTANT The transmitter must be installed such that it does not interfere with the crane through all normal movements It may be installed at any angle as long as the cover can be removed when required to change the battery Figure Slew transmitter Dimensions are in inches Not to scale 1 Screw the slew transmitter to a flat surface with 1 4 in screws 2 needed weld pads can be used to facilitate transmitter installation NMPORTANTI Do not weld in proximity to LSI sensor transmitters 3 Tie wraps can be used to secure the cable between the encoder and transmitter 2 15g Cable Length Adjustment If the cable between the encoder and transmitter is too long it can be cut to the desired length 1 Remove the cover from the transmitter using either a flat or a Phillips No 2 screwdriver 2 Using a small flat screwdriver loosen the 6 screws of the terminal block and remove the wires from it Lay down the transmitter cover on a clean surface 3 Loosen the cable gland with a 3 4 in wrench and pull the cable from the inside of the transmitter box until you reach the desired length Tighten the gland back with the wrench Do not overtighten 4 Cut the cable excess leaving about 4 in in the transmitter box
26. is created by the battery management function Press Bypass Exit to temporarily bypass crane function lockout caused by a missing sensor If rigging requires a crane configuration outside of the limits defined by the rated capacity chart selected out of chart alarms can be avoided by placing the display in rig mode If the rig mode is enabled in the display press Bypass Exit for 10 seconds to activate it If the rig mode is not available contact your LSI representative or LSI technical support representative 55101 Angle Length Sensor LSI 2 INSTALLATION Note Refer to the Operation section for detailed menu navigation instructions for all calibration orocedures N WARNING Installation must be made or on the ceiling of the cab To ensure reliable in compliance with LS instructions and radio communication between sensors using LS supplied components only Failure and the GS550 the antenna should not be to install all parts or replacing parts or in contact with metal and should have a components with parts or components not direct and clear line of sight to the sensor antenna The mounting bracket requires a flat surface of at least 2 5 inches in diameter on both sides and where the back of the surface Is accessible in order to tighten the nuts 2 Drill 1 4 inch boltholes through the mounting supplied by LS may lead to system failure serious injury or death 2 1 Disp
27. new seal without bubbles or breaks RTV non corrosive Figure Apply non corrosive RTV silicone 9 Reposition the box over the mounting plate and screw in the hex screws Do not overtighten Actual battery life will vary greatly depending on the application the frequency of use the age and quality of the battery etc 49 PLSI 5 2 Anti Two Block switch IMPORTANT Replace all the 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 IMPORTANT Both lithium or alkaline batteries can be used however lithium battery will last about 2 5 times longer 5 2a Replacing the GS050 Batteries IMPORTANT Class Div sensors certified by CSA or ATEX should use alkaline batteries only NMPORTANTI Do not unscrew the white nylon hex bolt of the antenna IMPORTANTI Do not unscrew the small screw to the left of the antenna This procedure does not apply to the GS005 mechanical anti two block transmitter please refer to the Replacing Sensor Battery section 1 Remove the anti two block from the crane and clean off dust and grime 2 Place the anti two block on the edge of flat surface Use an adjustable wrench to unscrew the large white nylon hex bolt of the wire rope about one half inch 3 Carefully remove
28. or Connect the U transmitter pigtail Mounting other suitable keeper device to the Load pin block pigtal Figure Install the load pin transmitter GSOO1 Figure Load pin LPO11 LPO15 or LPO26 Installation at boom tip 2 10 Line Riding Tensiometer Tensiometer Figure Line riding tensiometer 2 10a Line Riding Tensiometer Installation CAUTION The Line Riding tensiometer must be held by the swing arm and the tension of the wire rope do not fix the line riding tensiometer to the boom The Ratio of the distance between the line riding tensiometer and the hoist drum must be 18 1 as minimum to allow a normal winding on the drum The angle between the swing arm and the measured rope shouldn t exceed 30 degrees Two Landing Pads Wooden cushion must be added to allow line riding tensiometer sitting when the boom is down Nothing should limit free displacement of the swing arm amp line riding tensiometer assembly at any boom angle or configuration Swing arm mounted Application Most applications mounted as far up the boom base as practical with the swing arm base attached near the tip of the butt section This mounting allows the line riding tensiometer to follow the movement of the wire rope path Commentary Make sure that the swing arm is long enough to allow free movement at any boom angle lt gt Line Riding 7 Tensiometer Line Riding Tensiometer
29. order to among others ensure that the written instructions and applicable standards including safety margins were respected and not exceeded during Product use Failure by the owner or user of the Product to supply such information shall be deemed a material default of the terms and conditions of this Limited Warranty and shall be irrevocably construed as evidence that the Product was misused or abused Consequently LSI shall irrevocably be relieved of any obligations to compensate the user or owner of the Product for any and all damages resulting from Product failures when data logging equipment and access to its content cannot be freely and readily provided unhampered to LSI LSI will pay ground freight transportation costs of replacement or repaired parts or Products to the destination in the countries in which it maintains a service center currently Canada continental United States of America United Kingdom Australia and the United Arab Emirates the Territory LSI will not pay any transportation costs of replacement or repaired parts to a destination outside of the Territory Shipping and handling costs to locations outside the Territory shall be the responsibility of and borne by Purchaser or Owner of the Product prior to any shipment by LSI Contact LSI to obtain a Return Authorization Number and the address to ship parts 9 3 Exclusion of Other Warranties THE ABOVE WARRANTY IS THE SOLE WARRANTY APPLICABLE AND T
30. prevent accurate angle indication 2 4a Mounting Procedure 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 Cabin Boom Angle Sensor Figure Angle sensor level with the boom typical installation Side View Figure Angle sensor top bottom axis within 15 of vertical typical installation Front View Figure Wedge used to mount the angle sensor with its top bottom axis within 15 of vertical typical installation Front View 1 Determine the angle sensor position WARNING The angle reading may be affected by vibration and may fluctuate the angle sensor should not be installed in close proximity to high RPM electric motor other source of high frequency vibration 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 port side of the jib c The angle sensor must be level with the boom or jib centerline d The top bottom axis of the angle sensor must be within 15 degrees of vertical e The angle sensor should have a clear line of sight to the cabin mounted display f The angle sensor antenna should not contact a metal object 2 Installthe welding pads keep the angle sensor at least three feet from
31. serviceable parts except the antenna and the batteries Suggested load cell maintenance instructions are described in the Maintenance section of this manual For any other suspected problems damage or required servicing please contact your closest LSI office 7 3 Equipment Markings ATEX Part number end with CSA CE Model Ne GS050 ATEXCE S Anti Two Block Switch WARNING Read the operator s manual Test before every use Batteries replace with size alkaline Duracell model 1400 TEST the light on the bottom must flicker red and green when the cable is cycled in and out 1281 664 1330 G Ex ia T150 O8ATEX0068 X Issuer 0344 Exia T150 WARNING DO NOT International Built in 2008 4495 Hamel Blvd suite 110 Qu bec QC Canada Serial number is on the front O REPLACE BATTERY WHEN AN EXPLOSIVE GAS ATMOSPHERE MAY BE PRESENT GS050 Model Ne GC012 ATEX CE Load Cell 5 4 t 12 000 Ib Single part line pull capacity Please read reference manual for details 6 11 G Ex ia IIC 4 O8ATEX0068 Issuer 0344 IIC 4 LSI Load Systems International Inc Built in 2008 4495 Hamel Blvd suite 110 QU bec QC Canada Serial number is on the WARNING DO NOT REPLACE BATTERY WHEN AN EXPLOSIVE GAS ATMOSPHERE GCxxx 65001 65002 5005 5010 GS020 GS020 Ignition hazard WARNING POTENT
32. than one ampere on the white wire Carefully disconnect the yellow cable from the display unit and reconnect it LSI 7 CERTIFICATION NOTES 7 1 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 CE Certified Certified CEs GC005 CE GC012 CE GC018 CE GC035 CE GCO60 CE GC065 CE GC100 CE GC170 CE GS001 CE GS002 CE GS005 CE GCO005 ATEX CE GC012 ATEX CE GC018 ATEX CE GC035 ATEX CE GC060 ATEX CE GC065 ATEX CE GC100 ATEX CE GC170 ATEX CE GS001 ATEX CE GS002 ATEX CE GS005 ATEX CE GS010 01 ATEX CE GS010 02 ATEX CE GS010 03 ATEX CE GS010 01 CE GS010 02 CE GS010 03 CE GS011 CE GS020 CE GS050 CE GS550 CE GS011 ATEX CE GS020 ATEX CE GS050 ATEX CE GS550 ATEX CE GS550 07 ATEX CE GS550 08 ATEX CE GS550 09 ATEX CE GS550 10 ATEX CE GS550 07 CE GS550 08 CE GS550 09 CE GS550 10 CE CSA and ATEX CSA Class I Division 1 and 2 Rated Equipment part numbers end with CSA Example GC012 CSA ATEX Zone 0 1 amp 2 the letters ATEX are included in the part numbers Example GCO12 ATEX CE 7 2 Important Notes for Hazardous Area Certified Components 7 2a Specifications WARNING e Understand manual before operation Replace batteries only in a non hazardou
33. the Sensor Limits menu The Sensor Limits 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 Note Press Up and Down simultaneously to return a limit to the factory default setting The factory default maximum limit for load sensors is 10 000 Ib per part of line Note When the weight units are tons the minimum load limit increment is O 1 ton per part of line Note The limits set in the limit menu are different than those set in the work area limits the limits set in Limit menu will stay active even if no work area has been defined Note to deactivate the permanent slew limits the limit menu the right and left limit should be set to O Set Work Area Limits The Work Area Limits menu is only available if a slew radius or tip height is configured in the system Press Limit Next and then Enter to access the Work Area Limits menu To prog
34. the crane enters a warning zone Work area limit warnings can also be used to trigger orange wire lockout The size of the warning zones and the orange wire lockout function can be adjusted in menu 4J 2 Alarm The buzzer the Limit and Info lights a limit alarm message and lockout all alert the operator when a work area limit is exceeded 3 Lockout The white and green wire lockout triggers can be adjusted to include work area limits in menu 4G 3 9e Slew and work area display When a slew sensor is installed current slew angle and left and right slew limits are displayed ew angle 100 22 lt gt 200 7 When defined work area 1 displayed e The first line left and right slew limits e The second line tip height and radius limits if defined When dynamic work area has been defined the tip height and radius limits for the current slew position are displayed LSI 4 USB TOOL Download data or upload capacity charts using 4 Press Enter once again to confirm the data logger a USB mass storage device USB key without download DATA LOGGER ENTER TO TRANSFER removing the display from the crane 5 Transfer progress is indicated on screen CAUTION Before transferring downloading data logger or firmware updates make sure the crane is stopped and is in a safe state The crane cannot be monitored during the download process 6 When the transfer is done TRANSFER
35. the plunger assembly without separating it from the cover and place it ona clean and dry surface Adjustable wrench CI Figure Remove the plunger assembly of the GSO50 4 Slide out the four old batteries 5 Insert the four new batteries following the positive negative schematic 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 New high quality C cell battery 3 6 V lithium or alkaline Figure Install the new batteries and the plunger 8 Reinstall the anti two block switch 9 Test the anti two block system for alarm and lockout before operating the machine 5 2b Replacing the GSO75B Battery 1 Remove the GS075B anti two block from the crane and clean off dust and grime 2 Unscrew the two screws of the battery cover and remove the battery cover 3 Remove the battery by hand 4 Insert the new battery following the positive negative schematic 5 Reposition the battery cover and screw in both SCrews New high quality D cell battery 3 6 V lithium or alkaline Battery cover Figure Replacing GSO75B battery 6 Reinstall the anti two block switch 7 Test the anti two block system for alarm and lockout before use 5 3 Replacing
36. the sensors to bring required lift data to the operator Hoist load boom and jib angles boom length wind speed and pending two block can be detected and then 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 a USB port to facilitate software and chart updates and data logger downloads using a USB mass storage device USB key The GS550 system is designed as operator aid and is in substitute for safe operating practice GS075B All In One 5050 Anti Two Anti Two Block Block Switch Switch and weight GC Series Load Cell 46 gt _ L U GS550 Display Figure Key components typical system Your product may vary Not scale 1 2 Start Up The GS550 must be correctly programmed for the system sensors installed If a sensor is missing or has a problem the Info button light will flash Press the Info button to get more details on the problem This process may take up to one minute The delay
37. 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 Figure Typical operation page with boom angle indication 5 If the angle displayed by 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 2 46 Angle Calibration Procedure No 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 WARNING Failure to ensure the boom is levelled will result in false reading of the radius hence the risk of structural failure of the crane or crane tipping over Note When the angle sensor is moved very slowly it may take 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 To assist at the calibration the angle sensor could be set to transmit continuously for 5 minutes by entering the automati
38. to easily correct by following 2 6c Boom Length Calibration Procedure No 1 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 instructions 1 Go to menu 4B SENSOR CALIBRATION 2 Press Enter to go to the password page 3 Enter the user password and press Enter twice to go to menu 4B1A 4 Use Back and Next to select the length sensor and then press Enter to confirm communication with the sensor is possible 5 Press Next to start the wizard 6 Note the units that will be used during the calibration wizard and then press Next 7 Fully retract the boom and then press Next 8 Use Up and Down to adjust the length value displayed to equal the actual fully retracted boom length and then press Next 9 Fully extend the boom and then press Next 10 Use Up and Down to adjust the length value displayed to equal the actual fully extended boom length and then press Next 11 Note the new trim value and then press Next 12 Note the new scale value and then press Next 13 Press Enter to send the new calibration to the length sensor 14 Press Exit three times to return to the operation display 2 Radius ensor Calibration 2 a Radius Verification and Adjustment 1 Verify the boom and luffing jib angles and the boom length are indicated correctly 2 Verify the correct rate
39. units are associated with weight units by default see the table below 1 Go to MENU 3A WEIGHT UNrrs 2 Use Up and Down to select the weight units for load display 3 Press Menu to save changes then press Next to advance to the language adjustment page or press Exit twice to return to the operation display Table Weight Units Unit Equivalent Weight Length Unit Notes Pound Ib 1 Ib 0 4536 kg Foot ft Kilogram kg 2 205 Ib 1 kg Metre m Short ton T 2000 Ib 907 2 kg Foot ft United States Long ton T 2240 Ib 1016 kg Foot ft United Kingdom Tonne t 2205 Ib 1000 kg Metre m International System SI 3 b Wind Units The wind units for wind display may be selected according to operator preference 1 Go to Menu WIND UNITs 2 Use Up and Down to select the wind units for wind display 3 Press Menu to save changes then Next to advance to the language adjustment page or press Exit twice to return to the operation display 3 c Language Future versions of the GS550 will include different display language options 1 Go to menu 3C DisPLAY LANGUAGE 2 Press Up and Down to change the display language 3 d Light Intensity Adjust the intensity off the LEDs light emitting diodes to facilitate viewing in bright sunlight or in reduced visibility 1 Go to menu 3D LIGHT INTENSITY ADJUSTMENT 2 Use Up and Down to adjust the intensity of the lights 3 Press Menu to save cha
40. with a slack rope sensor to warn against unwanted rope payout when the load touches down Slack rope minimum limit The slack rope sensor compares the sum load to an adjustable 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 Go to the sensor list menu 4 7 2 Press Next repeatedly to advance to the next available sensor position usually following the four load sensors the sum load sensor and the imbalance sensor 3 he ID can be left at O press Next 4 The sensor type should flash use Up and Down to select the sensor type S ack 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 6 Press Exit three times to return to the operation display 7 Adjust the slack rope minimum limit in the limit menu INSTALLATION 27 LSI 2 13 List and Trim Angle Sensor 2 136 Mounting Instructions The GS010 03 is a two axis angle sensor designed IMPORTANT Remove the angle sensor from to detect both list and trim angle Minimum any connecting metal structures or surfaces and maximum limits for list and trim angle are when welding the
41. 12 V or 24 V Figure Connection without lockout 3 Lockout number 1 if required connect the white wire to a Bosch relay coil terminal Connect the other coil terminal of the relay to the ground When operating properly the white wire will energize at the battery positive level Figure GS550 power supply connector Troubleshooting if no voltage is present on the white wire remove the load connected to the lockout Current over 1 ampere 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 3 and 4 these wires function in the same way as the white wire To valve coil if normally open is required Bosch relay be al MA Mn Power Supply or Battery 12 V 24 V To valve coil if normally closed is required Figure Connection with white wire lockout and recommended Bosch relay described in step 3 above Each lockout wire can be triggered by a different set of alarm conditions see the Lockout Settings sub section of this manual 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 con
42. 4a Rope Payout Calibration Procedure No 1 Mechanical Set Up 30 2 14b Rope Payout Calibration Procedure No 2 Correct with the GS550 30 2 14c Rope Payout Limits 31 2 15 SLEW SENSOR INSTALLATION 32 2 15a Encoder Gear Verification 32 2 156 Slew Encoder Location 32 2 15c Slew Encoder Orientation 32 2 15 Slew Encoder Installation 32 2 15e Slew Transmitter Location 33 2 15f Slew Transmitter Installation 33 2 159 Cable Length Adjustment 33 2 16 SLEW SENSOR CALIBRATION 33 2 17 DATA LOGGER 34 2 17a Recording Modes 34 2 176 Date and 34 2 18 SENSOR LIST 35 2 18a How to Add a Sensor to the GS550 35 2 186 How to Remove a Sensor from the 2 19 NETWORK OPTIONS 2 19a Listen Only Mode 2 19b Repeater 2 19c Wireless Sensor Update 9 1 DISPLAY GS550 MAU CN IN dus ERROR LSI 3 4 DISPLAY ABBREVIATIONS 39 3 5 SYSTEM MENU
43. AGNOSTIC 5B1 RADIO NETWORK BACKGROUND NOISE 5B2 LIST LAST 32 SENSORS RECEIVED 5B3 SEARCH FOR SENSORS Lockout DIAGNOSTIC 5C1 WHITE WIRE STATUS AND SELF TEST 5C2 GREEN WIRE STATUS AND SELF TEST 5C3 ORANGE WIRE STATUS AND SELF TEST 5D DisPLAY DIAGNOSTIC 5D1 TIME AND DATE 502 TIME CLOCK BATTERY TEST 5D3 EXTERNAL POWER SUPPLY VOLTAGE 5D4 INTERNAL TEMPERATURE 5D5 GS550 BASE STATION IDENTIFICATION NUMBER 5D6 GS550 PORTABLE BATTERY LEVEL 507 RADIO CERTIFICATION AND FREQUENCY DIGITAL INPUT DIAGNOSTIC 5E4 BLUE WIRE STATUS 5550 MENU OUTLINE 61 LSI 9 LSIPRODUCT LIMITED WARRANTY APRIL 1ST 2013 9 1 Limited Warranty LOAD SYSTEMS INTERNATIONAL INC hereafter LSI warrants its products the Products will be free from defects in materials and workmanship for a period as determined by the product family as indicated below the Warranty Period Warranty Length Product Family GC Series Load Cells GD Series Line Riders GP Series Load Pins GS001 GS002 GS003 GS004 GS005 GS007 GS010 25011 GS012 65020 65030 GS031 GS035 GS050 GS075 GS101 GS106 GS110 GS112 GS220 GS221 GS222 GS224 25550 GS820 LP Series Load Pins LS051 LS055 PT00100 GS025 65085 55320 GS375 24 months 12 months Unless otherwise specified the default Warranty Period for the Products is 12 months after delivery of such product Please consult LSI for any
44. ATION NUMBER 4A2 SYSTEM SELECTED CONFIGURATION NUMBER 4A3 CONFIGURATION NUMBER SELECTION MODE 4B SENSOR CALIBRATION 4B1 AUTOMATIC VALUE CALIBRATION WIZARD 4B2 MANUAL PARAMETER CALIBRATION 4B3 RESET SENSOR PARAMETERS 4C RADIUS SETTINGS 4C1 BOOM LENGTH 4C2 SLEW OFFSET 4C3 BOOM FOOT HEIGHT 4C4 BOOM DEFLECTION 4C5 TOP LENGTH 4C6 BOOM TOP OFFSET 4 7 NO LOAD DEFLECTION 4C8 JIB OFFSET 4C9 LATTICE EXTENSION OFFSET 4C10 JIB MOUNTING POINT PERPENDICULAR 4C11 JIB MOUNTING POINT PARALLEL 4 12 HEIGHT TOLERANCE 4C13 SELECT SHEAVE 4C 14 JIB LENGTH 4C15 LUFFING JIB LENGTH 4C16 LATTICE EXTENSION LENGTH 4 17 MANUAL LENGTH 4C 18 SHEAVE HEAD LENGTH PERPENDICULAR 4C 19 SHEAVE HEAD LENGTH PARALLEL 4C20 SHEAVE RADIUS 4C21 DEDuCT 4D1 4D2 4D3 ADA 405 406 407 408 409 OPERATION MODE CRANE CAPACITY CHART INTERPOLATION OUT OF CHARTS DEFAULT WORKING LOAD LIMIT ENABLE START SECTION ENABLE STOP SECTION RETRACTED BOOM LENGTH TOLERANCE INTERMEDIATE BOOM LENGTH TOLERANCE EXTENDED BOOM LENGTH TOLERANCE RADIUS TOLERANCE 4010 BOOM ANGLE TOLERANCE 4E Memory BANKS 4E1 4E2 4E3 4E4 4E5 4 6 4 COPY CONFIGURATION TO MEMORY BANK COPY CONFIGURATION TO MEMORY BANK B COPY CONFIGURATION TO MEMORY BANK C MEMORY BANK TO CURRENT CONFIGURATION COPY MEMORY BANK TO CURRENT CONFIGURATION COPY MEMORY BANK C TO CURRENT CONFIGURATION RESTORE FACTORY CONFIG
45. Bushings must be secured with the two allen screws provided one on each side of the load cell 2 As required place a 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 maximum 1 8 total movement 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 In all cases the washers must be placed symmetrically such that the load cell is centered on the pins to avoid uneven loading Secure the pins with the nuts and cotter pins provided A qualified lift supervisor or crane inspector person must verify every lift assembly before first use and periodically thereafter one to twelve months including before any new difficult or otherwise different lift Crane dead end Plate kit for loadlink Loadcell C C to loaded cable Figure Typical load cell and adapter plate assembly installed 2 4 Angle Sensors for the Boom or Jib IMPORTANT Keep the angle sensor away from the boom and any connecting metal structures when welding the metal lugs to the boom Proximity to welding may cause permanent damage to the angle sensor and
46. D should flash press Next the sensor type should flash this means it 1 adjustable Use Up and Down to select No SENSOR This will remove the sensor from the sensor list but retain the sensor ID Note Press Next and Back simultaneously to remove the sensor from the sensor list The 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 AL NO L U Load cell 4A1 No 1 D C No sensor Figure Menu 1A the sensor list LSI 2 19 Network Options 2 19a Listen Only Mode When the GS550 is started it normally wakes up the sensors in the sensor list and takes control of them The last display powered on that is programmed for a sensor becomes that sensor s network controller This means 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 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 communication from a sensor without taking control of that sensor a display must first be programmed in listening mode Program the listen only mode 1
47. E Wind speed sensors GS5020 CE GS020 ATEX CE Pressure sensors PTOO120 XXX 0130 Gateways GS2XX XX CE Displays GS320 CE 55375 GS550 CE GS550 ATEX CE GS550 03 CE GSo50 Xx G5820 CE GS820 XX CE to which this declaration refers conform to the relevant standards or other standardising documents Safety 61010 1 274 ed 2001 EN 61010 1 2 ed 2001 Wireless 300 220 3 V1 1 1 2000 09 EMC 301 489 3 V1 4 1 2002 08 Qu bec September 9 2011 ric Beaulieu Technologies Manager 7 11b CE Safety N WARNING When captors are used the ambiant temperature should be higher than 84 C and the display should not be used when the ambiant temperature is higher than 59 C otherwise there can be a burn possibility IMPORTANT The IP of equipment corresponds to 65 N WARNING For the operator s safety take only the ambiant temperature range into consideration The device should used within WARNING The protection will be impaired if the material and equipment are used in a manner not specified the manufacturer this range specified above LSI 8 GS550 MENU OUTLINE 4D CHART SETTINGS 1 PARTS OF LINE 2 CRANE RIGGING 3 DISPLAY SETTINGS 3A WEIGHT UNITS 3B WIND UNITS 3C DISPLAY LANGUAGE 3D LIGHT INTENSITY 3E LCD CONTRAST 3F BACKLIGHT MODE 4 INSTALLATION 4A SENSOR LIST 4A1 SENSOR TYPE AND RADIO IDENTIFIC
48. GS550 LCD Boom length is indicated following the length abbreviation L typically on the first or second display 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 centerline Depending on the exact placement of the cable reel and the cable anchor the displayed length may differ from the actual length 6 Figure GS550 LCD Typical operation page two with boom length indication 2 6 Boom Length Calibration Procedure No 1 Mechanical Set Up 1 Fully retract the boom CAUTION Visually monitor remaining length on the cable reel as the boom is extended for the first time following installation This generally requires a second person in addition to the operator 2 Adjust the loose wire rope at the boom tip so that the displayed boom length matches the actual boom length Cable guide Figure The actual boom length typical installation 3 Fully extend the boom 4 Verify the boom length indicated at full boom extension matches the actual fully extended boom length If not then follow Boom Length Calibration Procedure No 2 Correct with the GS550 2 6d Boom Length Calibration Procedure No 2 Correct with the GS550 the displayed boom length does not match the actual length of the boom retracted or extended and if it is not possible
49. HERE 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 THE SCOPE OF LSI S OBLIGATIONS LSI DOES NOT WARRANT THAT THE BUSINESS RESULTS OBTAINED FROM THE USE OF THE PRODUCTS WILL BE APPROPRIATE OR ADEQUATE FOR THE PURCHASER 9 4 Exclusion This Limited Warranty does not cover and shall not apply to Any Product that is misused or abused including being altered modified or repaired not in accordance with LSI written instructions or authorizations or used not in compliance with LSI s instructions and or industry standards and practices Any incidental costs or expense such as 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 damages caused during the transport or the moving of the Product Damages caused by accidents abuse misuse a force majeure described as events outside a LSI s or any Product user s control including war riot strikes embargoes or external
50. IAL ELECTROSTATIC CHARGING HAZARD FCC WARNING Read the operator s manual Test before every use Model Ne GS050 Anti Two Block Switch Batteries size lithium 3 6V or alkaline TEST the light on the bottom must flicker red and green when the cable is cycled in and out USA 888 819 4355 International 1 281 664 1330 1 7076 1 050 FCC ID QVBGS050 This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation GS050 LSI Load Systems International Inc IC 7076 55000 FCC ID QVBGSOO0 This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation GCxxx GS001 GS002 GS005 GS010 GS020 See manual for details ub219 Replace with Tadiran TL5930 lithium 3 6V battery Use non corrosive RTV sensor safe silicone only The use of other silicones void the International Sales amp Service Houston USA 281 664 1330 Inside Battery Boxes GCxxx GS001 5002 GS005 GSO10 GSO20 ATEX and FCC Model GC012 Load Cell 12 000 Ib Single pa
51. Next to advance to the next sensor B 50 50 of battery life remains typically several months IN TIMEOUT Communication not yet established Verify the radio ID corresponds to the installed sensor Battery status is usually known within 2 minutes When 10 or less battery life remains for any sensor a message will be generated the Info alert light will flash Follow the battery diagnostic procedure to identify the sensor Batteries do not need to be replaced before the Low BATTERY message is generated Usually several days or weeks of operation remain from the moment the Low BATTERY message comes A new high quality alkaline or lithium cell battery may be used Radio communication 1 Verify that the antennas have a direct clear line of sight to each other Verify that the antennas do not point directly towards or directly away from each other Verify that the antennas are not in contact with metal other than the sensor itself Verify the antenna for damage Go to menu 5A SYSTEM SENsons DIAGNOSTIC and press Enter Select a sensor and press Enter to verify the sensor status Press Exit and then Next to advance to the next sensor R 85 means radio reception is at 85 Lockout Malfunction 1 Verify the connections of the lockout wire s white green orange blue Verify lockout coil connections Verify correct relay installation for lockout systems drawing more
52. SUCCESSFUL will appear for 2 seconds Unplug the USB device The GS550 will restart by itself 7 crane is now ready for operation 4 1b Transfer from USB device to PC 1 Connect the USB device to a computer lt gt 2 data logger file is located in the root directory of the USB device Figure Transfer charts or data logger files LSI_MM_dd_yyyy_hh_mm_ss dtl where the double letters represent the time and date of the USB transfer The size of the file should be 4096 kb 4 1 Data logger transfer from Display 4 1c Troubleshooting Problem 4 1 Transfer from display to USB The file does not appear on the USB key device Solution 1 Did the transfer complete successfully Try again Ue 2 is Solution 2 Look in the root directory of the USB a password IS required contac key The root directory is the folder that appears LSI to get the download password The when you open the USB key Display ID will be asked by LSI Problem 1 Make sure there is at least 4 MB of available The file appears on the key but its size is 0 kb space on the USB key Connect the USB key Solution Did the transfer complete successfully in the USB port on the left side of the display fry again Problem The following message appears on screen during the transfer UNABLE TO CREATE FiLE REPLACE USB Solution 1 The USB device may not work correct
53. TENANCE 5 1 Sensors 5 1a Replacing Sensor Battery IMPORTANT Protect the interior of the sensor from dirt and humidity at all times IMPORTANT Both lithium or alkaline batteries can be used however lithium battery will last about 2 5 times longer 1 Unscrew the two allen screws about a quarter of an inch 2 Insert a flat bladed screwdriver in the battery cover notch to pry the box away from the mounting plate The silicone seal may cause some resistance Hex key 5 32 Ns Flat bladed screwdriver Figure Remove the sensor box from the mounting plate 3 The data wires of a load cell may be disconnected to facilitate battery replacement Figure Disconnect the data wires MAINTENANCE 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 data wires if disconnected Note 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 New high quality D cell battery 3 6 V lithium or alkaline Figure Install the new battery and reconnect the data wires 8 Apply a non corrosive RTV silicone all around the edge of the mounting plate to create a
54. URATION CLEAR CONFIGURATION 4F DATA LOGGER 4F1 4F2 4F3 DATA LOGGER MODE ADJUST DATE ADJUST TIME 4G Lockour SETTINGS 4G1 4G2 4G3 4G4 4G5 496 497 498 WARNING LEVEL ALARM LEVEL LOCKOUT LEVEL WHITE WIRE LOCKOUT TRIGGER GREEN WIRE LOCKOUT TRIGGER ORANGE WIRE LOCKOUT TRIGGER BLUE WIRE LOCKOUT TRIGGER LOCKOUT RELAY INVERTED 4H PASSWORD SETTINGS 4H1 4H2 4H3 SET ADMINISTRATOR PASSWORD SET USER PASSWORD TARE MENU PASSWORD PROTECTION LIMIT MENU PASSWORD PROTECTION INFO MENU PASSWORD PROTECTION 4H6 SYSTEM START UP PASSWORD PROTECTION 4 7 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 Lockour SETTINGS PASSWORD PROTECTION 4H17 NETWORK OPTIONS PASSWORD PROTECTION 4H18 SYSTEM DIAGNOSTIC PASSWORD PROTECTION 4H19 ALARM BYPASSED PROTECTION 4l NETWORK OPTIONS 411 DISPLAY MODE 4 2 SET UP SENSOR REPEATER 413 LAST REPEATER PROGRAMMED 414 INSTALL UPDATE 4J WORK AREA MANAGEMENT 4J1 SLEW APPROACH 4J2 HEIGHT APPROACH 4J3 RADIUS APPROACH 4J4 UsE ORANGE WIRE FOR APPROACH 5 SYSTEM DIAGNOSTIC 5A SYSTEM SENSORS DIAGNOSTIC 5B RApio NETWORK DI
55. al equipment for use in class division 2 hazardous locations UL Standard 508 seventeenth edition industrial control equipment UL Standard 913 sixth edition intrinsically safe apparatus and associated apparatus for use in class I Il Ill division 1 hazardous classified locations LS Series UL Standard 913 seventh edition intrinsically safe apparatus and associated apparatus for use in class Il Ill division 1 hazardous classified locations GS Series UL Standard 1604 third edition electrical equipment for use in class and Il division 2 and class Ill hazardous classified locations 7 6 ATEX certifications e EN 60079 0 2004 Electrical apparatus for explosive atmospheres General requirements e EN 60079 11 2007 Explosive atmospheres Part 11 Equipment protection by intrinsic safety e EN 60079 26 Explosive atmospheres Part 26 Equipment with equipment protection level EPL Ga Test Report KEMA No 211369200 7 7 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 energy and if not installed and used in accordance with the instructions may cause harmful interference to radio com
56. ample P N PA133 01 corresponds to a slewgear with teeth leading edges 2 in apart Note The slew sensor can be installed on either internal or external tooth slew gears N WARNING Missing or damaged teeth on the crane slew gear will prevent proper operation of the slew sensor and render the system unsafe 2 15b Slew Encoder Location 1 Install the slew encoder near the crane slew gear where it will roll freely on the slew gear when the crane slews Slew Sensor Transmitter GS030 Crane Upper This side up in wet locations Slew Sensor Encoder GS031 Figure Slew encoder location Typical installation 2 Make sure that the slew encoder does not come into contact with any other parts of the crane through the full motion of the crane upper body N WARNING Keep the slew encoder away from 2 15c Slew Encoder Orientation The slew encoder bracket is designed so that the encoder can be installed on either bottom top or side surfaces If the surface on which the sensor is to be installed is not at a square angle to the slew gear the mounting plate can be bent and or cut Slew Encoder Bracket 5 5 Fp 7 Slew Sensor Encoder Figure Slew encoder bracket orientation 2 15d Slew Encoder Installation 1 Find a rigid level space near the slew gear to install the slew encoder mounting bracket 2 Weld the mounting bracket in place or install with 1 4 in screws The screws can be
57. ar Press Next to adjust the month Use Up and Down to adjust the month Press Next to adjust the day Use Up and Down to adjust the day Press Next to adjust the time EE UL The hour should be flashing use Up and Down to adjust the hour from 00 midnight to 23 11 9 Press Next to adjust the minute 10 Use Up and Down to adjust the minute 11 Press Next to adjust the second 12 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 2 18 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 If a sensor is replaced the sensor list must be updated with the new ID number NMPORTANTI Information displayed from load angle and boom length sensors that are not correctly installed will not be accurate IMPORTANT Rated capacity radius and tip height based on information from angle and boom length sensors that are not correctly installed will not be accurate Note To ensure communication sensors must be at least six feet from the GS550 display 2 18a How to Add a Sensor to the GS550 1 Determine the radio identification number ID o
58. ated to indicate between 100 and 104 of their Safe Working Load SWL LSI load pins line riding tensiometers and compression cells must be calibrated at installation and every time thereafter the installation the load sensor or the transmitter is changed 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 5 46 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 Actual Load X 100 of Load Reference SAE J 159 7 3 The test loads must be significantly 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 SWL of 120 000 the minimum test load in this case would be 24 000 Ib a good test load would be 60 000 Ib or more 5 4c Care Battery Lithium batteries older than 18 months old alkaline batteries over 6 months old should be changed at the first avai
59. ation 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 3 6b 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 set the GS550 for rated capacity indication The GS550 will not take into account critical variables such as weather ground and crane conditions that will reduce the safe working capacity of the crane 3 6c 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 NMPORTANTI 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 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 Go to menu 2 CRANE RIGGING and press Enter to start the chart wizard 2 he first page of the chart wizar
60. ave changes 9 Press Exit four times to return to the operation display 10 Verify accurate angle indication at both very high and very low angles N WARNING Keep the anti two block switch 2 5 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 ommunication 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 should not be in contact with metal e The anti two block switch antenna should point to the left or to the right of the boom it should not point directly to or away from the GS550 display e The anti two block switch antenna should 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 Verify the 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 into two block alarm when the switch is released Press Bypass to silence the alarm until the next two block event or simulation If the switch has not been programmed to the display this should
61. by LSI and press Enter Transfer progress is indicated on screen 8 When the transfer is done TRANSFER SUCCESSFUL will appear Unplug the USB device The GS550 will restart by itself 4 3 Data Logger Viewer The data logger viewer is a software application used to display the data logger log file on a personal computer PC The data logger viewer converts the log 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 Datalogger Viewer GS 1 0 0 1 P N B0028 File Edition OpenFilter Tools View Help US Lbs US Lbs US Lbs US Lbs 06 12 29 06 12 29 06 12 29 06 12 29 Figure Excerpt of a full report in Data Logger Viewer 08 52 44 08 53 46 08 53 59 08 54 48 Crane Startup Automatic Recording Wind Gust Limit In Automatic Recording 17 40 V 4 3a Installation on a PC Install the CD in a CD ROM drive The interactive installation process should start automatically within 30 seconds if not then 1 Click Start 2 Click My Computer 3 Double click on the CD ROM drive EEE USB TOOL M 47 Double click on setup exe 5 Complete the installation as instructed on screen File Edition OpenFilter xw Wind Report button Full Report button Tools View Help Figure Data Logger Viewer tool bar 4 3b Quick Start 1 Start the data lo
62. c calibration menu 4B1 and by selecting the angle sensor LSI For GS011 angle length sensors only Carefully remove the cover of the GS101 cable reel Loosen the mounting screw in the slotted hole of the angle sensor mounting plate Pivot the angle sensor slightly until angle indication is correct Repeat the angle validation step 1 as required 2 4c Angle Calibration Procedure No 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 2 Goto 4B SENSOR CALIBRATION and press Enter 3 Enter the user password using Back Next Up and Down as described in Password settings section and press Enter 4 Go to 4B2A 5 Use Back and Next to select the angle sensor to be calibrated 6 Press Enter and then Next to go to the trim adjustment page 7 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 O 9 4 Installation alibration ensor nter user password Vianual parameter gt calibration 4B2A No x ID Angle sensor XXXXX nm 0 0 Up Down Enter gt Save Figure Angle Calibration Procedure No 2 8 Press Enter to s
63. cause Any cost damage or expenses for field labor or any other expenses related to or arising from the replacement of defective parts Products used for pile driving wire rope activated clamshell or dragline applications If purchaser uses the Products for pile driving wire rope activated clamshell or dragline application the Limited Warranty will be deemed to have been violated for abuse Any costs associated with providing LSI with data logging equipment 9 5 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 of revenue or profit lost or damaged data business interruption or any other pecuniary loss whether based on contract tort or other causes of action even if LSI has been advised of the possibility of such damages In any event the total liability 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 OUGMNBNQ not including intentional reckless or wanton tort 3 under strict liability 4 under any environmental or antipollution law or regulation 5 connected with
64. d capacity chart is selected 1 No x ID Gxxxxx 3 Test No 1 measure the actual radius and eng compare to the radius indicated Repeat with Communicating with remote sensor the boom at minimum angle at 45 degrees and at maximum angle repeat at minimum and ength calibration wizard maximum boom length If radius indication is 4 Measure the basic radius parameters on the 1 8 onfirm current units feet metres crane 2 8 Retract boom to min length o Program the basic radius parameters in the XX X RADIUS SETTINGS menu Adjust actual boom length 6 Test No 2 measure the actual radius and ARS compare to the radius indicated Repeat with the 1 8 xtend boom to max length boom at minimum angle at 45 degrees and at XXX X maximum boom angle repeat at minimum and maximum boom length If radius indication is 9 6 Adjust actual boom length XXX X not accurate then go to the next step 5 8 alib Result Note If the difference between the displaye Trim XX X radius and actual radius remains constant at all UE boom lengths and angles then correct by adjusting Scaler S DX the slew offset For example if the radius displayed is always 2 3 feet longer than the actual radius a cee CPV nter tO cen then subtract 2 3 from the slew offset 7 Ifthe 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 o
65. d is generally select hoist Use Up and Down to select the hoist If 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 selected in the chart wizard must reflect the actual rigging of the working sheave 5 After the last step has been completed the GS550 displays RIGGING and then returns to menu 2 Press Exit to return to the operation display or press Enter to rig another hoist 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 display SENSOR INVALID LSI 3 7 Display Settings Program the display for operator preferences in menu 3 DISPLAY SETTINGS 3 a Weight Units The weight units for load display may be selected according to operator preference Length
66. dard 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 Alert Main Out of chart Description 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 Alert Main above chart maximum angle Description 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 e Verify the boom and jib angles permitted by the rated capacity chart selected Alert Main below chart minimum angle Description The boom or jib angle is under the minimum angle permitted by the selected chart For charts determined by radius only this message will occur when the 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 If the lockout relay is inverted this alert will occur when voltage is not detected on the wire in alarm 3 3c Limit m 4 Set Hoist Limits Press Limit and then Enter to access
67. ditions will trigger lockout on the white wire 3 Add the lockout codes for the selected alarms together to find the lockout trigger number 4 Use Up and Down to adjust the white wire lockout trigger number o 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 WS od gie re Fe ew ee 7373 Geer umasa 34 uen a a rar dora 32767 sj 0 Table Lockout Codes Condition Code Maximum wind speed 1 Minimum angle 2 Maximum angle 4 Overload u CARE 8 Not used 16 Maximum radius 32 Maximum length 64 Two block 128 Maximum wind gust 206 Maximum rope payout 512 Slew Limit Left 1024 Slew Limit Right 2048 Maximum tip height 4096 Maximum imbalance factor 8192 Minimum slack 16384 Minimum list angle 32 68 Maximum list angle 65536 Minimum trim angle 131072 Maximum trim 262144 Table Example No 1 Maximum radius
68. e 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 1 is not more than that permitted for successful communication Antenna List LSI P N 011 Description 1 4 wave monopole MFG Load Systems International LSI 7 8 EMI EMC EMI EMC Electro Magnetic Immunity amp Electro Magnetic Compatibility EN 301 489 3 V1 4 1 2002 08 Clause 8 2 Limits for radiated emissions from ancillary equipment measured on a standalone basis measuring distance of 10m Pass Clause 8 3 Limits for conducted emissions DC power input ouput ports Pass Test method used CISPR 22 EN 61000 3 2 2000 and EN 61000 3 3 1995 A1 2001 All tests were performed using measurement apparatus defined in CISPR 16 1 Radiated emissions measurements conformed to requirements of CISPR 16 1 Clause 8 immunity tests Enclosure radio frequency electromagnetic field EN 61000 4 3 Pass Signal RF common mode EN 61000 4 6 Pass DC Power input ports RF common mode EN 61000 4 6 Pass Clause 9 2 radio frequency electromagnetic field Pass Clause 9 5 radio frequency common mode Pass ESD Electro Static Discharges LSI products are tested against norm EN 61000 4 Other Compliances e SAE J159 and SAE J987 e ASME B30 5 2000 e Franklin laboratory LSI products are safe to us
69. e in proximity to blasting caps e New York City MEA 110 05 E in compliance with 19 1 1 a 1 requirements of Reference Standard RS 19 2 of the Building Code e ABS American Bureau of Shipping API Spec 2C compliant 7 9 Environmental conditions Ambient temperature 84 C maximum for the sensors and 59 C maximum for the display 35 C to 85 a temperature 31 F to 185 F Humidity 0 to 100 range 7 10 Cleaning and decontamination Exposure to pressure washing will void all factory warranties Use a clean towel water and soft soap for all cleaning and decontamination Operating 7 11 CE 7 11a Declaration of Conformity Manufacturer s Name Load Systems International Inc Manufacturer s Address Canada United States of America United Arab Emirates 4495 Blvd Wilfrid Hamel Suite 110 9633 Zaka Road Q3 171 SAIF Zone 7976 Qu bec QC Canada 27 Houston TX 77064 Sharjah UAE Declare under our own responsibility that the products Load sensors 005 GC005 ATEX CE GC012 CE GC012 ATEX CE GCO018 CE GCO18 ATEX CE GC035 CE GC035 ATEX CE GC060 CE GC060 ATEX CE GC100 CE GC100 ATEX CE GC170 CE GC170 ATEX CE GS001 CE GS001 ATEX CE GS002 CE GS002 ATEX CE GS007 CE GS009 CE Anti Two Block GS005 CE 6 005 GS075 CE GS050 CE GS050 ATEA CE Angle sensors GS010 XX CE GS010 XX ATEX CE GS011 XX CE GS011 XX ATEX CE GS012 CE GS030 C
70. e top sheaves and top bolts amp spacers from the line riding tensiometer Place the line riding tensiometer on the unloaded hoist rope oriented such that the transmitter antenna is on the cab side and the swing arm holes are The hoist rope can also be installed by passing the wire rope around the pulleys when the hook does not interfere directed to the boom top Re install bolts and sheaves 5 Attach the swing arm end to the line riding tensiometer 6 Verify that the angle the swing arm forms with the boom is not too large and that nothing limits free displacement of the swing arm and line riding tensiometer assembly at any boom angle or configuration Extend the swing arm as needed 7 Ifthe line riding tensiometer has been supplied with rope payout ensure that both proximity switches led operate as the appropriate sheave turns 8 Verify that the sensor antenna is not curved 9 Verify that all bolts are tight 10 Operate the hoist to verify correct line riding tensiometer function 11 Proceed to load pin Line riding tensiometer calibration of the display receiver see Line Riding Tensiometer Calibration section Figure Removing top sheaves bolts and spacers on Line Riding tensiometer type 1 10008 shown MA Pulley 697 CN 2 272 Figure Removing top sheaves bolts spacers on Line Riding tensiometer type 2 10024 shown 2 11 Load Pins Line Riding Tensiometers
71. ert Angle Sensor minimum limit G15000 Description The sensor indicates a value less than the operator adjusted limit e Verify operator adjusted limits in the limit menu N WARNING operate the crane beyond the limits specified by the manufacturer Alert Load Sensor low battery G15000 Description Less than 10 of battery 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 Alert Load No communication G15000 Description 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 SAT Alert Verify white wire unexpected voltage Description 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 Connection sub section of this manual If the lockout relay is inverted this alert will occur when voltage is detected on the wire when safe 38 The 25550 System II Information Menu Alerts Continued Alert Verify white wire shorted to ground Description Voltage is not detected on the lockout wire when safe With the stan
72. etween the load pin and transmitter to increase transmitter placement options b There must be direct unobstructed line of sight from the transmitter to the display IMPORTANT Do not pull on a load pin this may not be required on cranes with by the pigtail pull on the handle wire a maximum boom length less than 100 feet 33 metres LP011 LPO15 and LP026 c The transmitter antenna must not be in 1 Mount the load pin to the boom tip or block contact with any metal object by replacing the pin of the wedge socket The 2 Weld the mounting blocks where required load pin is directional and must be oriented correctly to indicate load accurately Install the IMPORTANT Do not weld in proximity to LSI pin so that the bracket embraces the wedge sensor transmitters socket and prevents pin rotation Note When installed at the boom tip the lot Mount the load pin transmitter on the mounting number can be read right side up and the line blocks pull arrow points down towards the block When installed at the hook ball or block the lot number can be read upside down and the line pull arrow points up towards the boom tip Wedge socket Z Load pin Figure Load pin 1 i TINd INIT N LLMOLVV Hook ball or block Figure Load pin LPO11 LP015 or LP026 Installation on a single part block 2 Secure the load pin in place with a cotter pin
73. event even if a Return Authorization Number is provided to purchaser LSI reserves the right to inspect the damaged Product or part before its final decision to repair or replace the defective Product or part The Product or part shall be returned to LSI or its designated service representative accompanied by the Return Authorization Number with prepaid shipping charges 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 the 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 or Products replaced repaired or removed from a repaired Product If LSI repairs a Product the Product Warranty coverage Period is not extended and the Limited Warranty shall expire as if uninterrupted at the end of the last month of the original Warranty Period from shipping from LSI If LSI replaces a Product the replaced Product is warranted for the remainder of the original term or sixty consecutive 60 days whichever is longer LSI reserves the right to require from the user or owner of the Products prior to determining if the Limited Warranty coverage is applicable that LSI receive the data logging equipment used with the Products and that LSI be authorized to retrieve all information from such data logging equipment in
74. f the sensor to be added This number between 10000 and 99999 is engraved on the sensor 2 Go to menu page 4A 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 5 Press Next Note Press Up and Down simultaneously to make the sensor id number jump directly to 20000 Press Up and Down simultaneously again to make the sensor id number jump directly to 15000 Press Up and Down simultaneously a third time to make the sensor id number jump directly to 0 6 The sensor type 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 2186 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 sensor 2 Go to menu page 4A7 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 I
75. gger viewer application 2 Open the log file see section 4 1b Only dtl files generated by the GS550 data logger can be displayed 4 3c 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 Event date stamp Time Event time stamp System Units Length units metric or US and weight units at the time of the event Battery Voltage Display power supply voltage at the time of the event Temperature Internal temperature of the display Firm Version Display firmware version at the time of the event Sensor 1 Sensor type the sensor number corresponds to the sensor list programmed in the GS550 Sensor Status Sensor was active or inactive at the time of the event Sensor Battery Sensor battery level Value Sensor value Examples Crane start up sensor alarm The beginning FEL and end of sensor alarms are indicated as in and out 7 examples overload in overload out 4 3d Wind Report IMPORTANT The wind report is 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
76. hen it is revved up Engine revving down same process as above e Engine shut down The DC power should not exceed 30 VDC and the AC should be negligible lt 1VAC Power supply rating 5A 10 30Vdc LSI 2 3 Load Cell N WARNING Capacity and safety factor for load cells and adapter plate assemblies are calculated for loads along the intended axis of load vertical with the assembly hanging free side loading cause load cell 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 CAUTION The load cell must be centered on the pins to avoid uneven loading on the plate kit assembly IMPORTANT The load cell antenna should not be in contact with metal IMPORTANT For optimal performance and signal reception the load cell antenna should have a clear line of sight to the GS550 display IMPORTANT The load cell antenna should point to the left or to the right of the boom it should not point directly to or away from the GS550 display 1 Install load cell bushings as supplied by LSI Assembly of the load cell and adapter 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 bushings supplied by LS must be used where possible to adapt the holes in the load cell to the pins
77. ice Crane Jib mounting point Sheave head length parallel Menu 4 2 SLEW OFFSET The distance from the boom base pin to the crane centre of rotation If the boom base is behind the centre Head of rotation this value will be negative sheave Your measurement L Menu 4C19 SHEAVE RADIUS Your measurement Menu 4C17 SHEAVE HEAD LENGTH PERPENDICULAR The distance from the head sheave centre to the boom centerline Your measurement Menu 4C1 Boom LENGTH The distance from the boom base pin to the head sheave centre Boom base pin Your measurement Crane center of rotation Figure Basic radius parameters for a lattice crane Typical installation Not to scale 2 d Basic Radius Parameters fora Telescopic Boom Crane Menu 4C1 Boom LENGTH Menu 4 2 SLEW OFFSET The distance from the boom base The distance from the boom base pin to pin to the head sheave centre the crane centre of rotation If the boom base pin is behind the centre n TP 1AO s p of rotation this value will be negative Your measurement Your measurement 3 Menu 4 19 5 RADpIUS base pin Your measurement Menu 4C17 SHEAVE HEAD LENGTH PERPENDICULAR The distance from the head sheave centre to the boom centerline l l Your measurement
78. igging only The default imbalance minimum limit is 1000 pounds or kilograms depending on load display units Examples Imbalance factor calculation for load sensor Ne 1 Average B C D A Load Ne 1 A Imbalance Factor 00 x Average B G D Load 1 Load 3 Load 2 D Load 4 If the imbalance factor limit is 15 then the system is safe 8100 7500 Load Ne 1 Imbalance Factor 100 x 3100 7 5 If the imbalance factor limit is 15 then an imbalance alarm is generated Load 1 A Imbalance Factor 100 x B1 6000 16 6800 8 8100 C 8000 D 8200 Program the imbalance sensor 1 Go to the sensor list menu 4A7 2 Press Next repeatedly to advance to the next available sensor position usually following the four load sensors and the sum load sensor The ID can be left at press Next 4 The sensor type should flash use Up and Down to select the sensor type mbalance sensor Only one imbalance sensor is required to calculate imbalance for all four load sensors 5 Press Enter to save any changes 6 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 2 12c Slack Rope oystems programmed for four load sensors and four load sum indication can be programmed
79. ing rod Figure 65020 wireless wind speed sensor 1 Remove the mounting rod from the wind speed sensor Figure Wind clearance IMPORTANT Do not weld in proximity to LSI d There should be a clear and unobstructed sensor transmitters line of sight between the wind speed sensor antenna and the cabin mounted 2 Determine the mounting rod position display unit 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 Radio line of sight Crane top view e The transmitter antenna should not contact any metal object Note Angle iron can be used to extend the mounting position to be clear of the boom top 3 Weld or screw the mounting rod to the boom at the selected position Figure Swivel orientation 4 Re position the wind speed sensor on the mounting rod add the washer and secure with the cotter pin EEE INSTALLATION M 21 LSI 2 9 Wireless Load Pins 2 9b 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 b
80. installed directly on the crane plate or a custom weld pad can be built and welded on the crane any connecting metal structures when welding mounting bracket to the boom Proximity to welding may cause permanent damage to the slew encoder and render the system unsafe Slew Encoder Bracket Figure Mounting bracket footprint Dimensions are in inches 3 Once the mounting bracket is installed screw on the encoder with the nuts and bolts provided Put tension on the spring by inserting the cotter pin in the middle hole in front of the hinge Slew Encoder Bracket Slew Encoder Spring Figure Slew encoder installation Typical installation Note The tension applied by the slew encoder spring is required to keep the encoder gear in contact with the slew gear 2 15e Slew Transmitter Location IMPORTANT To ensure reliable radio communication between the slew sensor and the GS550 display the following conditions must be respected e The antenna of the slew transmitter should not be in contact with metal e The antenna should point to the left or to the right of the boom it should not point directly to or away from the GS550 display e The antenna should have a clear line of sight to the GS550 display in most cases this means mounting the transmitter outside of the crane structure on the same side of the boom as the operator s cab The slew transmitter is connected to the slew
81. kout for emergency purposes The alarm will remain silent until the next alarm lockout will re engage as soon as the button is released Exit menu Tare Back Zero the hook and rigging weight zero rope payout Move to the previous page Hoist Next Change the operating display page The exact order and content of operation display pages depends on system sensor and capacity chart configuration Systems with more than one load sensor typically display main hoist load information on the first page and auxiliary hoist load information on the second page Move to next page Info Down When the orange Info light flashes press Info to see critical system alert messages Modify numeric values and move down through a list of choices Limit Up Set hoist limits and work area limits Modify numeric values and move up through a list of choices Menu Enter Access the system menus refer to System Menu section Enter menu confirm changes to system settings This applies only if the GS550 has been correctly installed to control crane lockout function The Work Area Limit menu 1 only available if a slew radius or tip height is configured in the system 37 LSI 3 3a Tare Zero the hook and rigging weight e Press Tare to enter the tare menu e Use Next to select the load sensor e no tare value is displayed then press Tare to create a tare value equal to the weight on the l
82. l Inc GM550 ENG 20130909 www loadsystems com
83. lable 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 If 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 contacts 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 LS to have it repaired Engraving on the transmitter box sides will not affect reading Seal 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 load cell readings or operation If the bolt head is bent or sheared verify that the transmitter box fits tightly to the load cell link before contacting LSI for re
84. lay GS550 IMPORTANT Do not crack or puncture the surface with a 1 4 inch bit following either the membrane fascia The GS550 display is two three or the four holes configuration splash and rain proof Waterproofing depends in part on the integrity of the membrane 0 308 Z flat surface IMPORTANT Do not power wash the display j 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 AN ON 2 Figure Display mounting bracket footprint Not to scale Field replaceable antenna 3 Install the display with bolts Add washers and Two way radio system lock nut behind the mounting surface and tighten sufficiently bolts nuts and washers not included Note If the nuts are on the outside of the cab caulk with silicone between the washers and the Adjustable cab to prevent water entry Ram Bracket with dual ball joints Part number 4 Loosen the wing nut of the bracket arm to design V LB002B i M adjust display orientation to facilitate viewing Figure Display GS550 by the operator and then tighten it back up Rugged aluminium enclosure 5 84 4 3 8 55010203040 50 607080 90 100110 7 56 10 13 Figure Display dimensions inches N
85. ly Heplace the USB device A USB Port Solution 2 The USB device may be in read only AP D 249 mode Allow read write permissions Problem NS An error message appears on screen during the J transfer ERROR where is the error number Figure USB port location Solution restart the GS550 and try again to transfer the file If the trouble persists contact LSI 2 After a short delay about 2 seconds Copy Problem DATALOG TO USB will appear on the LCD Nothing happens when the USB key is inserted into press Enter the USB port of the display Solution Insert the USB key in the USB port 3 In most case you will be prompted to enter a power down and then power up the display password enter the download password given by LSI and press Enter 4 2 Upload Capacity Charts IMPORTANT Contact LSI to get the upload password this password changes according to the random number indicated on the LCD Please provide the random number to LSI 1 Connect the USB key to a computer and copy the updated chart on the USB key 2 Connect the USB key in the USB port 3 After a short delay about 2 seconds Copy DATALOG TO USB appears on the LCD press Next 4 GET FILE FROM USB Press Enter 5 Choose the file to upload and press Enter Example typical file name 5 XXXX pab 6 A password could be asked enter the upload password given
86. metal lugs to the mounting adjustable in the display The display will generate surface Proximity to welding may cause an alarm if the limits are exceeded and can be permanent damage to the angle sensor and programmed to generate lockout Furthermore prevent accurate angle indication list and trim angle can be used to control rated capacity chart selection where required example 1 Determine the angle sensor position barge cranes a The mounting surface should be flat and Known to be level 0 in both the list and trim axes b The angle sensor should have a clear line of sight to the cabin mounted display ie P angle sensor should be installed 27 horizontally with the antenna pointing up Ea 92 d The list and trim axes are indicated on the angle sensor follow these indications lt g E to orient the sensor correctly for accurate p list and trim indication p List roll gt e The angle sensor antenna should not Trim pitch contact a metal object Figure List and Trim axes 2 Install the welding pads keep the angle sensor well removed from the weld site and any connecting metal objects while welding 2 13a Programming the GS550 for 3 Mount the angle sensor to the weld pads with List and Trim Indication the screws and washers provided For list indication add the 25010 03 ID number to 4 Verify list and trim angle indication by the the senso
87. ms 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 Go to menu 4G2 ALARM LEVEL 2 Use Up and Down to adjust the alarm level 3 Press Next to 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 4G8 When a lockout level is reached voltage is cut on all lockout wires linked to the lockout condition see menu 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 Go to 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 Go to menu 4G4 WHITE WIRE LOCKOUT TRIGGER 2 Select which alarm con
88. munications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference 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 e ncrease the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected 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 IMPORTANT Changes or modifications to this equipment not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment IC 7076A ICGS550 FCC ID QVBGS550 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 operated 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 tra
89. nd chain assembly can either be supplied by LSI as an option or the original assembly supplied with the crane If the original assembly is to be used its total weight must not be more than 13lb 2 5d Chain length adjustment 1 Chain length adjustment No 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 I Z x 7 Ss p Ng Hook block stops rising two block prevented with safety margin A Anti two block t switch triggers two block alarm Figure Chain length test at minimum angle b Hoist slowly until 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 chain between the sensor and weight to increase warning distance If still insufficient contact your service representative 2 Chain length adjustment No 2 maximum boom angle a Raise the boom to the maximum angle b Hoist slowly as described in Step 1 b Verify that the warning distance is equal to or greater than that determined at the minimum boom angle Hook block stops rising two block prevented with safety margin 4 Anti two block switch triggers two block alarm
90. nections where the cable meets the connector The power cable requires about 4 1 2 in behind the display to protect the connector White wire Lockout 1 Blue wire Lockout 4 Black wire Negative ground Red wire Positive 12 or 24 volts Yellow cable LSI 2 1d Lockout Settings Warning alarm and lockout control is programmed in this menu The GS550 can be programmed to generate alarms and lockouts for almost all programmed limits and two block Furthermore warnings are generated when approaching programmed load limits and rated capacity when applicable Warning level When gross load regardless of tare value approaches the maximum limit for a load sensor an intermittent warning message is generated on the LCD The maximum limit for a load sensor is the lower of a the operator set limit Limit Menu and b the working load limit WLL if rated capacity charts are 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 Go to menu 4G1 WARNING LEVEL 2 Use Up and Down to adjust the warning level 3 Press Next to advance to the alarm level adjustment page or press Menu to confirm any changes and then press Exit three times to return to the operation display Alarm level All programmed and rated capacity limits and two block will generate an audible alarm when the alarm level is reached Alar
91. nges then press Next to advance to the contrast adjustment page or press Exit twice to return to the operation display 3 e Contrast Adjust the LCD contrast to optimize visibility 1 Go to menu 3E LCD CONTRAST 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 3 f Backlight Mode Adjust the LCD backlight control mode to conform to viewing and power supply conditions 1 Go to menu 3F 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 Menu to save changes then press Next to advance to the backlight adjustment page or press Exit twice to return to the operation display 3 8 System Diagnostic Diagnose system issues with the sub menus of menu 5 SYSTEM DIAGNOSTIC 3 8a System Sensors Diagnostic 1 Go to menu 5Af 2 Use Back and Next to select the sensor 3 Press Enter to see sensor data Sensor value Battery level Radio power received by the display Radio power emitted Internal temperature 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 Version numbe
92. nsmitter 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 1 is not more than that permitted for successful communication Antenna List LSI P N 001 Description 1 4 wave monopole MFG Linx Technologies P N ANT 916 CW QW LSI P N TA008 Description 1 2 wave dipole MFG Nearson P N S467AH 915S FCC ID QVBGSOOO0 7076A ICGS000 FCC ID QVBGSOO01 7076A 1CGS001 FCC ID QVBGS050 7076A ICGS050 FCC ID QVBGSO75 IC 7076A ICGS075 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 operated 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 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 devic
93. nstalling a sensor update refer to the field service guide How to Update the Firmware of a GS Series System document part number GM550 01 1 provided with the firmware update kit Ga OPERATION 3 OPERATION 3 1 Display GS550 The GS550 displays detailed information on the backlit two line liquid crystal display LCD warnings alarms and radio status is also communicated by the display buzzer Parts of line Hoist indicator Tare indicator Load 3 2 USB Port The USB port is used to download data from the data logger or to upload capacity charts using a USB mass storage device USB key Radius Chart name Working load limit USB Port 100 58 js 910000 LCD 0 10 20 304050607080 100 110 Bar graph P GS550 indicates the load on the hoist as a percent of the working load limit Tare warning light The total load is not displayed when tare light is on 3 3 Keypad WWW LOADSYSTEMS COM Keypad Info alert light Press Info when the info light flashes to see critical alert messages 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 manual Bypass Exit Override loc
94. o go to the third step note the sensor offset value Figure Trim angle calibration 9 Press Enterto save and communicate changes M to the sensor 10 Repeat steps 4 through 9 for the list angle 11 Press Exit four times to return to the operation display 12 Verify accurate list and trim angle indication EE INSTALLATION M 29 LSI 2 14 Rope payout Rope payout sensor Figure Rope payout on a line riding tensiometer Typically the rope payout sensor is factory installed on the line riding tensiometer load sensor figure above Alternatively the rope payout sensor may be installed on an appropriate sheave figure below A GS550 display can then be programmed to communicate with the sensor and to indicate rope payout length and rope speed Figure Alternative installation of a rope payout Zero the rope payout using the Tare menu before calibration 2 14a Rope Payout Calibration Procedure No 1 Mechanical Set Up Hoist up to reel in the wire rope fully Install the rope payout system Zero the rope payout length in the Tare menu Pr 9 ut Hoist down to pay out a known length of wire rope for example 20 feet o Verify the rope payout indicated matches the actual length of wire rope paid out If not then follow Rope Payout Calibration Procedure No 2 2 14b Rope Payout Calibration Procedure No 2 Correct with the GS550 If rope payout indicated does not match actual rope payout
95. o menu 5E4 BLuE Wire The page shows the blue wire digital input status 2 Press Exit three times to return to the operation display PLSI 3 9 Work Area Management IMPORTANT Follow the left and right orientation indicated by the display to set limits correctly 3 9a Set Fixed Limits Record crane position at the limit to set a fixed slew radius or tip height limit 1 Left and right slew limits Approaching or exceeding a slew limit will trigger a warning or alarm state a Press Limit select Work Area Limits and then A DEFINE WORK AREA SLEW b Menu A1 Move the crane to the left limit and press Enter c Menu A2 Move the crane to the right limit and press Enter d Menu A3 Move the crane to the safe area within the left and right slew limits and then press Enter e To adjust the slew warning zone go to menu 4J1 use Up and Down to change and press Enter to confirm eae gt x 25 25 Ay x 2752 gt I it 525 222 m E x x fe El A b 5 SOx 4X gt lt z NZ SS Z lt ew approach warning x z 22 2229 Left OS elt 2 K Bi 2 x Limit Ra I 5 54 SR Figure Slew limits Maximum tip height Approaching or exceeding the maximum tip height will trigger a warning or alarm state a Pre
96. oad sensor Example with hook block and rigging only Load display is net weight gross weight minus tare value e To remove a tare value press Tare Press Exit to return to the operation display LCD Tare LCD Indicator Load Pl No Tare Gross Gross Value weight weight Tare On Net Gross Value weight weight Zero rope payout length e Press Tare to enter the tare menu e Use Next to select the rope payout sensor e Press Enter to zero rope payout length The new zero will be saved by the rope payout sensor e Press Exit to return to the operation display Sensor No 2 rope Payout Enter gt set zero I Communicatin with j remote sensor New payoukzero saved in sensor Sensor No 2 rope Payout Enter gt set zero Figure Zero rope payout 3 36 Info When the orange Info light flashes press Info to see critical system alerts Press Next to advance from one page to the next Standard info menu pages include e BIOS Bootloader number and version e Firmware number and version e Chart number and version if available SPKG Software Package number Table Alert Load Sensor maximum limit Information Menu Alerts G15000 Description The sensor indicates a value greater than the operator adjusted limit e Verify operator adjusted limits in the limit menu N WARNING operate the crane beyond the limits specified by the manufacturer Al
97. ot to scale Cab mounting surface 2 1a 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 Figure Install the display and adjust orientation 2 16 Antenna Position For optimal performance the antenna should be 1 2 3 positioned on its side such that it is parallel to the sensor antennas but not pointing directly to or directly away from them Adjust the antenna position with the articulating base The antenna should have 5 inches of clear space all around it The antenna should have an unobstructed line of sight to all sensor antennas at all boom angles 2 1 Power Supply and Lockout Connection 1 2 CAUTION Overvoltage will void warranty Refer to section 2 2 on p 9 for power supply verification procedure Connect the black wire ground to the negative terminal of the battery or the panel connection alternatively bolt the black wire to the body of the machine with a 1 4 inch or 5 16 inch bolt The ground connection must be strong enough to sustain 3 amperes Connect the red wire to a fused accessory source rated at least 3 amperes that supplies 12 or 24 volts when the machine is in use GS550 will automatically detect the voltage level and adjust itself To GS550 power supply connector Step 5 Power Supply or Battery
98. placement bolts Dow Corning dielectric grease No 4 6 TROUBLESHOOTING Display Not On 1 Verify the connection between the yellow cable wires and the crane power supply Verify the crane battery the fuse and the accessory switch Carefully disconnect the yellow cable from the display unit and reconnect it Display In Alarm 1 Identify the sensor in alarm Place the sensor in safe condition press Bypass if necessary Verify that the limits the parts of line and the tare are correctly adjusted Verify all sensor batteries see Battery Diagnostic troubleshooting section Verify the red light on the sensor box flashes release the wire rope of an anti two block change the load on a load sensor change the angle of an angle sensor change the boom length of a length sensor Verify radio communication see Radio communication troubleshooting section Sensor Malfunction 1 Verify the sensor batteries see Battery Diagnostic troubleshooting section Verify the red light on the sensor box flashes release the wire rope of an anti two block change the load on a load sensor change the angle of an angle sensor change the boom length of a length sensor Verify radio communication see Radio communication troubleshooting section Battery Diagnostic Go to menu 5 SYSTEM SENSORS DIAGNOSTIC and press Enter Select a sensor and press Enter to verify the sensor status Press Exit and then
99. r Product number Figure Sensor firmware product and version numbers 5 Press Exit five times to return to the operation display 3 86 Radio Network Diagnostic 1 Go to menu 5B1 RADIO NETWORK BACKGROUND NOISE CAUTION The list of last 32 sensors received includes all functioning GS series sensors 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 Lisr LAST 32 SENSORS RECEIVED a Press Enter to access 5 21 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 sensors received see step 2 a 4 Press Next to go to menu 5B4 ERROR RATE COMMUNICATION TEST This test should only be conducted by LSI technical service personnel o Press Exit three times to return to the operation display 3 8 Lockout Diagnostic Menu 5C Lockour DIAGNOSTIC shows the lockout condition of the output alarm or safe and the self test pass or fail it is recommended to manually test the lockout condition 1 Go to menu 5C WHITE winE To tempora
100. r alarm state a Press Limit select Work Area Limits and then D DEFINE WORK AREA SLEW AND HEIGHT b Menu D1 Move the crane to the left slew limit at the maximum tip height for that slew position and then press Enter c Menu D2 Slew the boom to the right slew limit while maintaining the maximum tip height to trace the maximum tip height boundary at all slew positions When the crane is at the right slew limit and at the maximum tip height for that slew position press Enter d Menu D3 Move the crane into the safe area within the slew limits and below the maximum tip height and then press Enter adjust the warning zone go to menu 4J WORK AREA 2 Slew and maximum radius Record the left and right slew limits and the maximum radius at every degree of crane rotation in between the slew limits Approaching or exceeding a slew or radius limit will trigger a warning or alarm state a Press Limit select Work Area Limits and then E DEFINE WORK AREA SLEW AND RADIUS b Menu E1 Move the crane to the left slew limit at the maximum tip height for that slew position and then press Enter c Menu E2 Slew the boom to the right slew limit while maintaining the maximum radius to trace the maximum radius boundary at all slew positions When the crane is at the right slew limit and at the maximum radius for that slew position press Enter d Menu E3 Move the crane into the safe area within the slew limits and
101. r list menu 4A1 and select the sensor GS550 in operation display use Next to 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 Figure Trim and list angle indication 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 2 13c List and Trim Angle Operation Display Calibration Procedure E _ 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 2 Goto menu 4B SENSOR CALIBRATION 3 Press Enter to go to the password page eee 4 Enter the user password and press Enter twice Communicating with to go to 4B1A iremote sensor 5 Use Back and Next to select the trim or list rim calibration wizard 6 Press Enter Next to go to the first step of the Known trim calibration wizard note the uncorrected angle angle 0 6 indicated 2 4 n just actua 7 Press Next to go to the second step angle trim angle 0 17 correction Use Up and Down to adjust the alib Result angle value indicated until it is equal to the trim 0 5 Known angle fort amp Press Enter to save In 8 Press Next t
102. ram fixes and dynamics limits refer to section 3 9 Work Area Management Programmation 3 4 Display abbreviations Angle Auxiliary hoist Length Luffing angle Main hoist Maximum Maximum or minimum angle Communication not established Radius Tare net weight Gross weight Wind speed Whip hoist PLSI 3 5 System Menu N System limits are not monitored when the display is menu mode DO the crane in menu mode DO NOT navigate system menus when operating the crane There are five basic menus level one used to program consult and controlthe 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 3 5a Menu Numbers Menus are identified by a number in the upper left corner The basic menus level one are numbered one through six Level two menus are lettered alphabetically Level three menus are numbered Level four menus are alphabetized Menu Level Four Menu Level Three Menu Level Two Menu Level One Figure Menu Numbers 3 56 Menu Navigation From the operation display press Menu to see the basic menus level one Press Enter to drill down one level and enter a selected menu Press Exit to leave a menu and re
103. re agreement of the parties regarding the subject matter of the Product and supersedes all previous communications representations understandings and agreements either oral or written between you and LSI 9 9 Vienna Convention Excluded The United Nations Convention on Contracts for the International Sale of Goods does not apply to this Limited Warranty LSI LSI technical support is available 24 hours a day 7 days a week techsupport loadsystems com USA Load Systems International Corp 9633 Zaka Road Houston 77064 Toll Free Tel 1 888 819 4355 Toll Free Fax 1 888 238 4099 Tel 1 281 664 1330 Fax 1 281 664 1390 sales loadsystems com AUSTRALIA LSI Robway Pty Ltd 32 West Thebarton Road Thebarton South Australia 5031 Tel 61 08 8238 3500 Fax 61 08 8352 1684 sales lsirobway com au UK Load Systems UK Ltd Unit 5 Silverfield House Claymore Drive Aberdeen Energy Park Bridge of Don Aberdeen AB23 8GD Scotland UK Tel 44 0 1224 392900 Fax 44 0 1224 392920 uksales loadsystems com DUBAI UAE Load Systems International FZE Q3 171 SAIF Zone PO Box 7976 Sharjah UAE Tel 971 6 557 8314 Fax 971 6 557 8315 lsifzc emirates net ae CANADA PRODUCTION AND R amp D Load Systems International Inc 4495 Wilfrid Hamel Blvd Suite 110 Quebec City QC Canada G1P 2J7 Tel 1 418 650 2330 Fax 1 418 650 3340 sales loadsystems com 2013 Load Systems Internationa
104. rily activate or deactivate the lockout relay press Up or Down 9C1 WhiteWire alarm Self test pass Figure Menu 5C1 White Wire lockout condition example 2 Press Next to go to menu 5C2 GREEN WIRE DIAGNOSTIC Repeat lockout diagnostic test 3 Press Next to go to menu 5C3 ORANGE WIRE DIAGNOSTIC Repeat lockout diagnostic test 4 Press Exit three times to return to the operation display 3 8d Display Diagnostic 1 Go to menu 501 AND DATE The page shows the current time and date according to the GS550 internal clock 2 Press Next to go to menu 502 TIME cLock BATTERY Self test pass or fail 3 Press Next to go to menu 5D3 EXTERNAL POWER VOLTAGE 4 Press Next to go to menu 5D4 DISPLAY INTERNAL TEMPERATURE 5 Press Next to go to menu 505 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 6 GS550 03 portable displays only press Next to go to menu 506 BATTERY LEVEL The battery level of the onboard rechargeable battery pack is indicated 7 Press Next to go to menu 507 Rano IC indicates Federal Communications Commission U S A and Industry Canada certification CE indicates European Community certification The frequency used by the system network is indicated on the second line 8 Press Exit three times to return to the operation display 3 8e Digital Input Diagnostic 1 Go t
105. rt line pull capacity LSI INC Battery Operated D Type Lithium 3 6 VDC Class 1 Gr amp D Exia O INTRISICALLY SAFE Temperature Code T4 Model US Intrinsically safe sensors have the following stainless steel plate p n UB223 LSI 7 4 GS550 Display Labels 7 5 Class 1 Division 1 and Division 2 certifications Class 1 Division 1 certification intrinsically safe is available for most LSI sensors Class 1 Division 2 certification non incendive is available for the 0 9 25 lt P dl NS E Figure GS550 Display labels position CSA Class 1 Div 2 and ATEX 1 Label UB217 CAUTION CAUTION Dogs UO DO NOT connect NOR PRESSURE WASHING WILL disconnect unless VOID ALL the area is known to d be non hazardous WARRANTIES 3 Label UB226 4 Label UB296 WARNING Substitution of components may impair suitability for Class 1 Division 2 or ATEX 2 Label UB227 WARNING POTENTIAL ELECTROSTATIC CHARGING HAZARD SEE INSTRUCTIONS 4 Label UB228 CSA specific LSI In GS550 CSA 12 VDC 1 0A Class 1 Division 2 Groups A B C D 5 CSA Class Div 2 TAA 2 LSI Load Systems International USA 888 819 4355 International 1 281 664 1330 Web www loadsystems com Email sales loadsystems com WARNING This device is intended as an operator aid only and is not
106. s area Substitution of components may impair intrinsic safety Substitution of components may impair suitability for Class I Division 2 Do not remove power cable from display when on Battery type and specification GCOO5 ATEX CE D Type GCO12 ATEX CE 3 6 V lithium batteries GC018 ATEX CE Tadiran TL 5930 model GCOS5 ATEX CE Temperature code T4 GCO60 ATEX CE GC100 ATEX CE GC170 ATEX CE GS001 ATEX CE GS002 ATEX CE GS005 ATEX CE GS010 01 ATEX CE GS010 02 ATEX CE GS010 03 ATEX CE GS 011 ATEX CE GS020 ATEX CE GS050 ATEX CE C Type 1 5 V alkaline Duracell PC1400 model Temperature code T 150 C Table Battery type Sensors GCxxx ATEX CE series sensors GS001 ATEX CE GS002 ATEX CE GSO10 ATEX CE GSO11 ATEX CE 15020 GS005 ATEX CE GS050 ATEX CE all intrinsically safe II 1G Ex ia IIC T4 GS550 ATEX CE display M 3 G ExnA II T4 7 26 Ensuring Safe Operation Hazardous Areas WARNING e Equipment must be correctly installed according to the instructions desbribed in this manual and need to be installed in locations providing adequate protection from impact and external damage e Always make sure the system works properly Test all before using the crane A description of display status and warning lights is available in the Operation section of this manual 7 2 Product Repair And Servicing LSI products have no replaceable or user
107. s of operation depending on the recording mode selected and machine use The data can be extracted using a USB mass storage device USB key and then transferred to a personal computer for analysis 2 17a Recording Modes Adjust the data logger recording mode as required 1 Go to menu 4F1 DATA LOGGER MODE 2 Use Up and Down to select the data logger recording mode Automatic modes only press to advance to the adjustment page for the interval automatic 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 Note all alerts are recorded by the data logger regardless of the mode selected Recording Modes description Alarm only Record alarms only All the other data logger modes also record alarms Automatic recording A record is added at a specified interval When the automatic recording data logger mode is selected on menu 4F1 see step 3 above press Next to go to menu 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 data required by the wind speed report feature of the Data Logger Viewer software Automatic variation A record is added when load increa
108. ses by more than the operator adjusted percentage When the automatic variation data logger mode is selected on menu 4F1 see step 3 above press Next to go to menu 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 4F1 see step 3 above press Next to go to menu 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 2 17b Date and Time Adjust the data logger date and time as required 1 Go to menu 4F2 ADJUST DATE 2 he last two digits of the year should be flashing use Up and Down to adjust the ye
109. sor zeroed If the cable reel is installed perfectly level on the boom at O degrees the angle sensor of the GS011 will also be zeroed Minor adjustments to the angle sensor within plus or minus two degrees are possible after cable reel installation 2 Mount the welding tabs They must be placed parallel to each other with 16 1 8 inches between the holes centres Install the tabs such that they create a level mounting position in line with the boom at O degrees 3 Attach the reel to the welding tabs with the bolts provided 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 1 2 metres of cable but not more than half the excess extension of measurement D Feed through the cable LSI guides and attach to the cable anchor on the tip of the last boom section 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 Verify the boom length indicated on the
110. ss Limit select Work Area Limits and then B DEFINE WORK AREA MAX TIP HEIGHT b Menu B1 Move the crane to the maximum tip height and press Enter c Menu B2 Move the crane into the safe area below the maximum tip height and then press Enter d Io adjust the tip height warning zone go to menu 4J2 use Up and Down to change and press Enter to confirm 25255 5 gt DEE T PEGE ss KY 5 gt gt lt abc 100 00 a a s d ax mm c EE ee 2 5 ee 22 25 224 7 Figure Maximum tip height Maximum radius Approaching or exceeding the maximum radius will trigger a warning or alarm state a Press Limit select Work Area Limits and then C DEFINE WORK AREA MAX RADIUS b Menu C1 Move the crane to the maximum radius and press Enter c Menu C2 Move the crane into the safe area within the maximum radius and then press Enter d To adjust the radius warning zone go to menu 4J3 use Up and Down to change and press Enter to confirm Radius approach warning Figure Maximum radius 3 96 Set Dynamic Limits 1 Slew and maximum tip height Record the left and right slew limits and the maximum tip height at every degree of crane rotation in between the slew limits Approaching or exceeding a slew or tip height limit will trigger a warning o
111. tension of the LS101 cable reel is compatible with the maximum boom length otep 1 Note the cable reel maximum extension 100 feet 30 5 metres unless specified otherwise Tz otep 2 Note the retracted boom length Az otep 3 Note the maximum extended boom length not including jib B Step 4 Calculate maximum boom extension C B A Step 5 Compare cable reel maximum extension T to maximum boom extension C D T C Maximum cable reel extension must be greater than maximum boom extension 2 66 Mounting the Cable Reel 1 Determine placement Find a clear mounting position on the left side of the first main 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 Swing 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 Welding pad holes tapped 3 8 16 Welding pads level and in line with the boom at 0 degrees from horizontal base Welding pad holes 2 1 4 in apart centre to centre Welding pads holes pads 16 1 8 in apart centre to centre Figure Cable reel mounting position Note When factory installed the GS011 angle length sensor transmitter is integrated to the 15101 cable reel with the angle sen
112. th the boom at 45 and half the maximum load on the hoist the boom deflection value should equal twice the difference between a SSS UON the actual and the displayed radius 4G8 o PUES 11 Test No 4 measure the actual radius and compare to the radius indicated Repeat with the 409 poder extension offset boom at minimum angle at 45 degrees and at maximum boom angle repeat at minimum 4C10 Jib mounting point maximum boom length If radius indication is pida not accurate then refer to Radius Settings ni diii n 1 Go to menu 4C Rapius SETTINGS id 2 Enter the user password and press Enter to go to elect hoist main the first radius settings page 4C 1 BOOM LENGTH 3 Use Back and Next to navigate between the radius settings pages and use Up and Down to adjust the settings hin 4614 ib lengt 0 0 3 15 uffing jib lengt 60 9 9 4 Press Enter to save any changes and press Exit three times to return to the operation display B attice extension lengt Vlanual lengt o o IMPORTANT Radius settings 4C 14 to 4C21 are specific to the hoist line or sheave number selected in Select hoist main 4C 16 engi perpendicular 0 4619 eave head length paralle gt pos radius o c e kk i Telescopic boom cranes only Figure Radius settings Basic radius parameters 2 c Basic Radius Parameters for a Latt
113. the maximum radius and then press Enter e o adjust the warning zone go to menu 4J WORK AREA 3 Slew maximum tip height and maximum radius Record the left and right slew limits and both the maximum tip height and the maximum radius at every degree of crane rotation in between the slew limits Approaching or exceeding a slew tip height or radius limit will trigger a warning or alarm state a Press Limit select Work Area Limits and then F DEFINE WORK AREA SLEW HEIGHT RADIUS b Menu F1 Move the crane to the left slew limit at the maximum tip height and radius for that slew position and then press Enter c Menu F2 Slew the boom to the right slew limit while maintaining the maximum tip height and radius to trace the maximum tip height and radius boundary at all slew positions When the crane is at the right slew limit and at both the maximum tip height and maximum radius for that slew position press Enter d Menu Move the crane into the safe area within the slew tip height and radius limits and then press Enter e o adjust the warning zone go to menu 4J WORK AREA 3 9c Clear all work area limits Press Limit and select Work Area Limits Press Enter Select G ERASE WoRK AREA LIMIT menu and press Enter 3 9d Warning alarm and lockout 1 Warning An intermittent beep the Limit and Info lights and a limit warning message all warn the operator of an approaching work area limit when
114. ther extension then the advanced radius parameters must be measured on the crane and then programmed in the RADIUS SETTINGS menu of the display 9 Test No 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 Figure The boom length calibration wizard When the hoist is rigged off of a luffing jib only Telescopic boom cranes only Systems with rated capacity charts programmed in the GS550 only M 17 LSI 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 nter r worq a Raise the boom to 45 degrees with a Radius Settings known load 60 9 engt b Compare the indicated radius with kG the actual radius Change the boom 0 0 deflection value and again compare the 1 Soom foot height radius displayed with the actual radius 0 0 Repeat until the radius displayed equals the actual radius Note with the boom at 45 and the maximum loa Boom top lengt on the hoist the boom deflection value should 0 0 equal the difference between the actual and the j Soom top offset displayed radius Wi
115. to save calib in sensor known load and then press Next 10 Use Up and Down to adjust the load value displayed to equal the actual known load lifted and then press Next Figure The automatic load calibration wizard 11 Note the new trim value and then press Next 12 Note the new scale value and then press Next 13 Press Enter to save and send the new calibration to the load sensor 14 Press Exit three times to return to the operation display INSTALLATION Www h i l 5 l 25 PLSI 2 12 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 2 12a 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 Go to menu 4 7 SENSOR LIST 2 Press Next repeatedly to advance
116. to the next available sensor position usually following the four load sensors 3 Determine the sum load cell ID number For example ID 1234 to indicate the sum of load sensors No 1 No 2 No 3 and No 4 or ID 34 to indicate the sum of load sensors No 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 2 12b Imbalance oystems 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 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 calculated for each of the four load sensors and then compared to an adjustable limit The default imbalance factor limit is 1596 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 with an empty container or with r
117. turn 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 Note most menus are circular press Next the last page of a menu to return to the first page Note most lists are circular press Down on the last entry of a list to return to the first entry 3 bc 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 lf the user password is forgotten it can be changed as long as the administrator password is known orgotten password Call LSI technical support Houston TX at 888 819 4355 3 54 Menu Layout The menus accessible to the operator without password protection under the default factory settings are listed below 1 PARTS OF LINE 2 CRANE RIGGING 3 DISPLAY SETTINGS 3A WEIGHT UNITS 3B WIND UNITS 3C DISPLAY LANGUAGE 3D LIGHT INTENSITY 3E LCD CONTRAST BACKLIGHT MODE 4 INSTALLATION 5 SYSTEM DIAGNOSTIC 5A SvsrEM SENSORS DIAGNOSTIC 5B RApio NETWORK DIAGNOSTIC 5B1 RADIO NETWORK BACKGROUND NOISE 5B2 LIST LAST 32 SENSORS RECEIVED 5B3 SEARCH FOR SENSORS 5C Lockour DIAGNOSTIC 5C1 WHITE WIRE STATUS AND SELF TEST 5C2 GREEN WIRE STATUS AND SELF TEST 5C3 ORANGE WIRE STATUS AND SELF TEST 5D DisPLAY DIAGNOSTIC 5D1 TIME AND DATE
118. unt bracket 4 in 10 cm below sheave center 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 Mount bracket directly below sheave center as low as Fast line possible mounting bracket Front View Figure Fast line weight installation 2 56 GS050 Installation 1 Mount the GS050 on the bracket and verify that the GS050 can rotate freely through all possible boom movements without being able to come off the bracket 2 Install the weight and chain assembly around the cable and attach the other end of the chain to the GS050 Tighten all the chain links of the chain assembly 3 Adjust chain length as required see sub section Chain length adjustment 4 Test system function LSI 2 5 QGSO75B Installation 1 Install the GS075B on the LBO11 switch bracket already installed on the crane boom step 2 5a with the antenna pointing away from the boom 2 Install a weight and chain assembly to the eye nut The weight a
119. y inserting it in the mouth of the Compound tube Electrical insulating compound Figure Coat the exposed metal foot of the antenna 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 White nylon hex bolt TA011 Antenna Sensor box Antenna receptacle Figure Install the new antenna 10 Carefully re thread screw in and tighten the white nylon hex bolt to secure the antenna in place Do not overtighten 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 s manual 12 Verify that the sensor functions properly PLSI 5 4 Load Cells N WARNING Heavy shock may affect load indication accuracy Inspect load regularly for clearly visible dents or scratches Test the load indication if collision damage is visible 5 4a Reading Accuracy LSI flat bar load links are pre calibrated at the factory No zeroing or other calibration is required on installation 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 calibr

GS550 Display GS550 Display - Load Systems International

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