LSI GS550 Installer And User Manual
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LSI GS550 Installer And User Manual

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INSTALLER AND USER'S MANUAL
INSTALLER AND USER'S MANUAL
WARNING! The GS550 system is designed as an operator aid and is in no way a
!
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WARNING! Carefully read and understand this manual before proceeding.
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!
GM550
.20101219
REV
GS550 Display
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substitute for safe operating practice.
WIRELESS TECHNOLOGY & CRANE INSTRUMENTATION
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DIVISIONS
www.loadsystems.com

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Summary of Contents for LSI GS550

  • Page 1 5 5 0 L I M L I M 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. GM550 .20101219...
  • Page 2 Failure to install all parts, or replacing parts or components with parts or components not supplied by , may lead to system failure, serious injury or death. The GS550 System The GS550 System...

  • Page 3: Table Of Contents

    2.6c Basic Radius Parameters for a Lattice 2.17 SENSOR LIST ........35 Crane ............19 2.17a How to Add a Sensor to the GS550 ..35 2.6d Basic Radius Parameters for a Telescopic 2.17b How to Remove a Sensor from the GS550..35 Boom Crane..........19 2.18 NETWORK OPTIONS ....35...
  • Page 4 7.2c Product Repair And Servicing ....55 3.7e Contrast ............42 7.3 EQUIPMENT MARKINGS ....55 3.7f Backlight Mode ........42 7.4 GS550 DISPLAY LABELS ....56 3.8 SYSTEM DIAGNOSTIC ....42 3.8a System Sensors Diagnostic ......42 7.5 CLASS 1 DIVISION 1 AND DIVISION 3.8b Radio Network Diagnostic ......43 2 CERTIFICATIONS ......56...

  • Page 5: Introduction

    Start-Up Overview Start-Up The GS550 system includes the cabin mounted The GS550 must be correctly programmed for the GS550 radio display and compatible crane system sensors installed. Once a reliable radio mounted sensors. The GS550 creates a two-way communication network is established, the display radio network with the sensors to bring required lift lights will remain lit without flashing.

  • Page 6: Installation

    ø2.5 in. min. 0.906 flat surface IMPORTANT! Do not power wash the display. The GS550 display is not designed to 0.594 withstand high-pressure washing devices that can erode the membrane fascia seal or create 0.594 fissures in the membrane fascia.

  • Page 7: Antenna Position

    To GS550 power supply connector (Step 5) Figure: Connection with white wire lockout and recommended Bosch relay. Yellow cable 5. Connect the yellow cable to the GS550. The connector is waterproof and well rated for Blue wire Lockout #4 - Optional Orange wire Lockout #3 external environments.

  • Page 8: Lockout Settings

    3. Press Next to advance to the white wire lockout Warning, alarm and lockout control is programmed trigger adjustment page or press Exit three in this menu. The GS550 can be programmed to times to return to the operation display generate alarms and lockouts for almost all programmed limits and two-block.

  • Page 9: Password Settings

    Next to advance to the next menu page. WARNING! Inverting lockout relays will 5. Repeat step 4 to adjust password protection for allow crane operation in the event the GS550 each menu as required. Press Enter at any time display fails. Operating a crane without a to save changes made.

  • Page 10: Load Cell

    Plate kit for signal reception, the GS550 load cell antenna loadlink 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...

  • Page 11: Angle Sensors For The Boom Or Jib

    The GS010 series angle sensors can be turned on at least three feet from the weld site and any by starting up the GS550 display to which they are connecting metal objects while welding. programmed. The angle sensor can then assist in levelling itself with the red and green LED.

  • Page 12: Angle Calibration Procedure № 2: Correct With The Gs550

    Calibrate angle indication by adjusting the trim (offset) switch and the GS550 display the following value in the GS550 display; the GS550 will then conditions must be respected: communicate the updated trim value to the sensor.

  • Page 13: Gs050 Installation

    Position the sensor mounting bracket. To ensure that For fast line weight installation place the anti-two- the sensor can pivot securely on the mounting block switch mounting bracket directly below the bracket throughout the full range of boom angle, the sheave center as low and as close to the edge of mounting bracket must be positioned at a 30°...

  • Page 14: Gs075B Installation

    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. The GS550 System The GS550 System...

  • Page 15: Length Sensor Cable Reel

    3/8-16 0 degrees from horizontal Procedure № 1: Mechanical Set-Up and Angle Boom Boom Calibration Procedure № 2: Correct with the base GS550, sections of this manual. Welding Welding Welding pads holes pad holes pads 16 1/8 in. apart, 2 1/4 in.

  • Page 16: Boom Length Calibration Procedure № 1: Mechanical Set-Up

    3 3. 0 A: 69.2° 2. Press Enter to go to the password page. Figure: GS550 LCD - Typical operation page two with boom 3. Enter the user password and press Enter twice length indication to go to menu 4B1A).

  • Page 17: Radius

    * 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 OPERATION INSTALLATION OPERATION INSTALLATION...

  • Page 18: Radius Settings

    4C21) are specific to the hoist line (or sheave number) selected in Select hoist main. 4C19) Sheave head length parallel 4C20) Sheave radius 4C21) Deduct ** Telescopic boom cranes only Figure: Radius settings * Basic radius parameters The GS550 System The GS550 System...

  • Page 19: Basic Radius Parameters For A Lattice Crane

    2.6c Basic Radius Parameters for a Lattice Crane Jib offset Jib mounting point angle Sheave head Menu 4C2) S LEW OFFSET length parallel The distance from the boom base pin to the crane centre of rotation. If the boom base pin is behind the centre of rotation this value will be negative.

  • Page 20: Advanced Radius Parameters

    OFFSET ANGLE AIN BOOM OOM LENGTH LEW OFFSET includes boom top Boom angle sensor OOM FOOT HEIGHT OFFSET Boom heel pin Crane center of rotation Figure: Advanced radius parameters. Typical installation. Not to scale. The GS550 System The GS550 System...

  • Page 21: Wireless Wind Speed Sensor Gs020

    Wireless Wind Speed c. The wind cups must be fully exposed to Wireless Wind Speed the wind and spin freely at all boom Sensor GS020 Sensor GS020 angles. Mounting rod Figure: GS020 wireless wind speed sensor 1. Remove the mounting rod from the wind speed Figure: Wind clearance sensor.

  • Page 22: Wireless Load Pins

    Load pin block pigtail Boom tip Figure: Install the load pin transmitter GS001 Load pin AA10K11 LINE PULL Pigtail Cotter pin Wedge socket Figure: Load pin LP011, LP015 or LP026 - Installation at boom tip The GS550 System The GS550 System...

  • Page 23: Line Riding Tensiometer

    Line Riding Tensiometer Line Riding Tensiometer Line Riding Swing Arm Tensiometer Swing Arm Hoist drum Line Riding Landing Tensiometer Pads Figure: Line riding tensiometer Figure: Typical installation (not to scale) 2.9a Line Riding Tensiometer Installation Swing Arm CAUTION! The Line Riding tensiometer must be held by the Line Riding Tensiometer swing arm and the tension of the wire rope;...

  • Page 24: Line Riding Tensiometer Installation On A Swing Arm

    * The hoist rope can also be installed by passing Figure: Removing top sheaves, bolts and spacers on Line the wire rope around the pulleys when the hook Riding tensiometer type 2 (LD024 shown). does not interfere. The GS550 System The GS550 System...

  • Page 25: Load Pins, Line Riding Tensiometers And Compression Cells: Calibration

    2.10 Load Pins, Line Riding 2.10 Load Pins, Line Riding Operation Display Tensiometers and Tensiometers and Installation Sensor Calibration Compression Cells: Compression Cells: Calibration Calibration Enter user password: Load pins, line riding tensiometers and compression cells must be calibrated at installation and every time 4B1) Automatic value thereafter the installation, the load sensor or the load...

  • Page 26: Four Point Lift

    These functions can be used to generate an alarm other three. The imbalance factor is calculated condition on the lockout wires of the GS550. for each of the four load sensors and then compared to an adjustable limit. The default imbalance factor limit is 15%.

  • Page 27: Slack Rope

    4. The sensor type should flash; use Up and Down to select the sensor type “Imbalance sensor”. Only one imbalance sensor is required to calculate imbalance for all four load sensors. 5. Press Enter to save any changes. 6. Press Exit three times to return to the operation display.

  • Page 28: List And Trim Angle Sensor

    List and Trim Indication 4. Verify list and trim angle indication by the GS550; in operation display, use Next to For list indication, add the GS010-03 ID number to advance to the list and trim indication page.

  • Page 29: List And Trim Angle Calibration Procedure

    Calibration Procedure Installation Calibrate angle indication by adjusting the offset Sensor Calibration values for list and trim in the GS550 display; the GS550 will then communicate the updated offset Enter user password: values to the sensor. 1. Install the sensor at a precisely known list...

  • Page 30: Rope Payout

    3. Use Back and Next to select the rope payout below). Power supply must be provided to the rope sensor, and then press Enter to confirm payout sensor. A GS550 display can then be communication with the sensor is established. programmed to communicate with the sensor and 4.

  • Page 31: Rope Payout Limits

    Two types of connections are recommended; 4B1) Automatic value 1) Always powered up calibration wizard 2) Powered-up at the same source as the 4B1A) No. x ID:GXXXXX GS550 display unit Rope payout Communicating with remote sensor Rope payout calibration wizard. Press Next. 1/8) Confirm current...

  • Page 32: Slew Sensor Installation

    2. Make sure that the slew encoder does not come Slew Encoder Bracket into contact with any other parts of the crane Slew Encoder Spring through the full motion of the crane upper body. Slew Sensor Encoder Figure: Slew encoder installation. Typical installation. The GS550 System The GS550 System...

  • Page 33: Slew Transmitter Location

    • The antenna should have a clear line of sight remove the shield and remove the individual to the GS550 display; in most cases this sheaths on the 6 wires to about 1/4 in. Connect means mounting the transmitter outside of...

  • Page 34: Data Logger

    4F11) and then use Up and Down to 2.16 Data Logger adjust the variation threshold. The GS550 includes a data logger that records all Automatic peak. In the automatic peak mode significant events including actual sensor values and the data logger analyzes the measured weight a date and time stamp.

  • Page 35: Sensor List

    20000. Press Up and Down simultaneously again to make When the GS550 is started it normally wakes up the the sensor id number jump directly to 15000. Press sensors in the sensor list and takes control of them.

  • Page 36: Repeater

    35 days**. This function should not be used where It is possible to send a firmware update to a sensor it is not required. using the GS550 (menu 4I4). For more information Program a sensor repeater on installing a sensor update refer to the field service 1.

  • Page 37: Operation 3.1 Display Gs550

    Keypad Keypad The keypad consists of six buttons used to control, consult, program, and troubleshoot the GS550 display and system. Each button has two functions; a primary function for the operation display, and a secondary function for menu navigation and programming. The secondary functions are described in the Menu Navigation sub-section of this manual.

  • Page 38: Tare

    • Chart number and version (if available) * If the lockout relay is inverted this alert will occur • SPKG (Software Package) number when voltage is detected on the wire when safe. The GS550 System The GS550 System...

  • Page 39: Limit

    Information Menu Alerts (Continued) Use Up and Down to adjust a limit. Alert: When using the GS550 as a load indicator without programmed crane specific rated capacity charts the Verify white wire load limit is typically set to the lesser of the rope limit,...

  • Page 40: System Menu

    (Houston, TX) at 888 819 4355. operating the crane. 3.5d Menu Layout There are six basic menus (level one) used to program, consult and control the GS550 system; 1) P ARTS OF INES The menus accessible to the operator without 2) C ;...

  • Page 41: Parts Of Line

    GS550 must be programmed for the number of load radius. The chart must be selected by “rigging” parts of line. the working hoist in the GS550; this is done by following the chart wizard in menu 2) C RANE 1.

  • Page 42: Display Settings

    1. Go to menu 5A1). 2. Use Back and Next to select the sensor. 3.7c Language 3. Press Enter to see sensor data. Future versions of the GS550 will include different Sensor value display language options. Battery level 1. Go to menu 3C) D...

  • Page 43: Radio Network Diagnostic

    THE LIST OF TEMPERATURE . Sensors are THE LAST SENSORS RECEIVED 5. Press Next to go to menu 5D5) GS550 shown with their radio ID number and the BASE ID. The base station ID should be the sensor type. STATION same as the GS550 display serial number b.

  • Page 44: Work Area Management

    To adjust the tip height warning zone, go limit at the maximum tip height for that to menu 4J2); use Up and Down to slew position, and then press Enter. change and press Enter to confirm. The GS550 System The GS550 System...

  • Page 45: Clear All Work Area Limits

    c. Menu D2) Slew the boom to the right positions. When the crane is at the right slew limit while maintaining slew limit and at both the maximum tip maximum tip height to trace the height and maximum radius for that slew maximum tip height boundary at all slew position, press Enter.

  • Page 46: Usb Tool

    ” will appear for 2 seconds. Unplug downloading) data logger or firmware SUCCESSFUL the USB device. The GS550 will restart by itself. updates, make sure the crane is stopped and is in a safe state. The crane cannot be 7. The crane is now ready for operation.

  • Page 47: Upload Capacity Charts

    2. Open the log file (see section 4.1b). Only .dtl 4. “G USB”; Press Enter. ET FILE FROM files generated by the GS550 data logger can be 5. Choose the file to upload and press Enter. displayed. Example typical file name: “ SPKG3_XXXX.pdb ”...

  • Page 48: Wind Report

    Sensor ID ..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 period. Max. Gust (mph) Maximum wind speed (gust) during the period. The GS550 System The GS550 System...

  • Page 49: Maintenance

    MAINTENANCE MAINTENANCE Sensors 4. Remove the battery by hand. Sensors 5. Remove the remaining silicone from both the 5.1a Replacing Sensor Battery box and the mounting plate. 6. Install the new battery: insert the positive end and IMPORTANT! Protect the interior of the then push in the direction of the positive pole.

  • Page 50: Anti-Two-Block Switch

    Figure: Remove the plunger assembly of the GS050 6. Reinstall the anti-two-block switch. 4. Slide out the four old batteries. 7. Test the anti-two-block system for alarm and 5. Insert the four new batteries following the lockout before use. The GS550 System The GS550 System...

  • Page 51: Replacing A Sensor Antenna

    Replacing a Sensor 7. Slide the white nylon hex bolt to the middle of Replacing a Sensor the length of the new antenna. Antenna Antenna 8. Coat the exposed metal foot of the new antenna Heavily damaged antennas (ripped out, sheared off, with an electrical insulating compound by wire exposed and fraying etc.) should be replaced carefully inserting it in the mouth of the...

  • Page 52: Load Cells

    SWL of 120 000 lb; the minimum test load in this case would be 24 000 lb, a good test load would be 60 000 lb or more. * Dow Corning dielectric grease №4 The GS550 System The GS550 System...

  • Page 53: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING Display Not On • Battery status is usually known within 2 minutes. When 10% or less battery life remains, 1. Verify the connection between the yellow cable for any sensor, a message will be generated wires and the crane power supply (the Info alert light will flash).

  • Page 54: Certification Notes 7.1 Model Numbers

    ATEX Zone 0 & 2: the letters “ATEX” are included GS011-ATEX-CE, GS020-ATEX-CE, GS005-ATEX- in the part numbers CE, GS050-ATEX-CE (all intrinsically safe): Example: GC012-ATEX-CE II 1 G Ex ia IIC T4 GS550-ATEX-CE display: II 3 G ExnA II T4 The GS550 System The GS550 System...

  • Page 55: Ensuring Safe Operation In Hazardous Areas

    7.2b Ensuring Safe Operation in GCxxx, GS001, GS002, GS005, GS010, GS020; Hazardous Areas GS020; Ignition hazard: "WARNING - POTENTIAL WARNING! ELECTROSTATIC CHARGING HAZARD” • Equipment must be correctly installed according to the instructions desbribed in this manual and need to be installed in Model : GS050 locations providing adequate protection...

  • Page 56: Gs550 Display Labels

    Certificate CSA #1332949 on master contract 5 5 0 . M I 215780 is available on request Applicable requirements certified by CSA include: Figure: GS550 Display labels position • CSA Standard C22.2 No.0.4-M2004: Bonding CSA Class 1 Div 2 and ATEX grounding...

  • Page 57: Fcc And Ic - Instructions To The User

    Antenna List interference to radio communications. However, LSI P/N: TA001 there is no guarantee that interference will not occur Description: 1/4 wave monopole in a particular installation.

  • Page 58: Emi / Emc

    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 • SAE J159 and SAE J987 • ASME B30.5-2000 •...

  • Page 59: Declaration Of Conformity

    7.10 7.10 7.10a Declaration of conformity 7.10b CE Safety WARNING! When captors are used, the WARNING! The protection will be impared if ambiant temperature should not be higher the material and equipment are used in a than 84°C and the display should not be used manner not specified by the manufacturer.

  • Page 60: Gs550 Menu Outline

    GS550 MENU OUTLINE GS550 MENU OUTLINE 1) P 4D) C HART ETTINGS ARTS OF 4D1) O 2) C PERATION MODE RANE IGGING 4D2) C RANE CAPACITY CHART INTERPOLATION 3) D ISPLAY ETTINGS 4D3) O UT OF CHARTS DEFAULT WORKING LOAD LIMIT...
  • Page 61 IME AND DATE 5D2) T IME CLOCK BATTERY TEST 5D3) E XTERNAL POWER SUPPLY VOLTAGE 5D4) I NTERNAL TEMPERATURE 5D5) GS550 BASE STATION IDENTIFICATION NUMBER 5D6) GS550 ( PORTABLE BATTERY LEVEL 5D7) R ADIO CERTIFICATION AND FREQUENCY 5E) D IGITAL NPUT...

  • Page 62: Lsi Product Limited Warranty - 2009/02/16 9.1 Limited Warranty

    (24) consecutive months after sixty consecutive (60) days, whichever is longer. delivery of such Products to the user (as evidenced LSI reserves the right to require from you the user or on a LSI document) (the “Warranty Period”), when...

  • Page 63: Exclusion

    In any event, the INFORMATION OR ADVICE GIVEN BY LSI OR ITS total liability of LSI arising from any cause of action or EMPLOYEES REPRESENTATIVES SHALL claim whatsoever, whether (1) in contract, (2) in tort...
  • Page 64 LSI Contact Information Technical Support: Technical Support: LSI Technical Support is available 24 hours a day, 7 days a week from our Houston and Dubai locations. Please direct all technical support questions to either of these locations or contact us via email: techsupport@loadsystems.com...

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