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Summary of Contents for Sole Digital Liftlog XL
- Page 1 Liftlog™XL Advanced Crane Data Logger Model LL300, Version 2.0 Installation and User Manual V1.8: 07/10/2013 © CASWA Pty Ltd – 2013...
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Page 2: Table Of Contents
CONTENTS OVERVIEW .......................... 4 1.1 Liftlog™XL Versions ..........................4 SPECIFICATIONS ........................5 2.1 Operational Specifications ........................5 2.2 Physical Specifications ........................... 5 2.3 Electrical Specifications ......................... 6 2.4 Communication Specifications ......................6 INSTALLATION DETAILS ......................7 3.1 Prior to Installation ..........................7 3.2 Inserting/Changing Your SIM Card ...................... - Page 3 4.6.6 Resetting the Calibration ....................25 4.7 Comms Tab ............................25 4.7.1 3G configuration ......................... 25 4.7.2 Link Status ........................... 25 4.8 Inputs and Limits ..........................26 4.8.1 Using XL devices with a HVDC IO Expander ................ 26 4.8.2 Tuning Sensitivity and Noise Immunity................27 4.9 Overloads ............................
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Page 4: Overview
1 OVERVIEW Liftlog™XL is an advanced remaining life and load limiting data-logger for cranes. It can simultaneously monitor two hoists and in addition to logging vertical lifting motions, also supervises long and cross travel. Overloads and dangerous usage will trigger immediate email or SMS alerts. Data is automatically downloaded in real time using GSM/3G/GPRS or WIFI connectivity. -
Page 5: Specifications
2 SPECIFICATIONS 2.1 Operational Specifications Parameter Description Units Maximum number of logged events 10,000,000 count Frequency of logged events Duration of a logged event 30000 2.2 Physical Specifications Overall length (mm): Overall width (mm): Overall height (mm): Weight (kg): Mounting: Screwed or 30mm DIN rail Electrical connections: 56 x screwed terminals... -
Page 6: Electrical Specifications
2.3 Electrical Specifications Parameter Description Units Supply voltage Supply current Overload relay voltage limit Overload relay current limit Limit Switch input voltage limit mv load sensor sensitivity mV/V sense Input impedance of 0-10V input 1500 Ohms 24V output current Note 2 Operating temperature °C Notes:... -
Page 7: Installation Details
3 INSTALLATION DETAILS 3.1 Prior to Installation Before installing your Liftlog™XL device visually inspect the unit and check that: (a) the case is not damaged and fits together securely; (b) terminals are secure; (c) terminal numbering is as per section 3.3.1 (i.e. stickers have been correctly placed). If you have chosen to install your own SIM card, then this should be inserted now. -
Page 8: Terminals
3.3.1 Terminals Please note that the terminals of Liftlog™XL have changed slightly for different versions of the product. Label descriptions have also been altered slightly. Sticker orientations showing terminals, for Liftlog™XL devices with serial numbers that start with a ‘2-’ (i.e. numbers greater than 199) are as follows: 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Figure 2: Version 2 Sticker Orientations... - Page 9 The following table describes each terminal on Liftlog™XL units that have serial numbers starting with a ‘2-’ (i.e. greater than 199). Terminal Description Label Number Negative reference for mV, mA and V sensors (black wire on RC-3 or RC-5 rope clamps) -ve sense input for MAIN Hook strain gauge (mV) load cell/pin (white wire on RC-3 or RC-5 rope clamps) +ve sense input for MAIN Hook strain gauge (mV) load cell/pin...
- Page 10 0-10V input for AUX hook from loadcell/pin amplifier or Konecranes Control- 0-10V Return connection for AUX hook 4-20mA strain gauge (mA) load cell/pin, or 4-20mA output from load display Excitation voltage (3.3V) for AUX hook strain gauge (mv) load cell/pin (red XCite wire on RC-3 or RC-5 rope clamps) +ve sense input for AUX Hook strain gauge (mV) load cell/pin (green wire on...
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Page 11: Connecting The Power Supply
3.3.2 Connecting the Power Supply Series 2 Liftlog™XL is designed to operate from 24-240VAC grounded neutral. (Note: Series 1 units could only operate from 48-240VAC.) It can also operate from 12-48VDC, however this is not preferred as load limits cannot be used in this configuration. - Page 12 3.3.2.2 Using a DC Power Source To connect a DC source from 12-24VDC wire active and neutral as follows. LiftlogXL 12-24VDC 9,36: 24V 12-24V DC Power Supply 0V (Neutral) 25,27: 0VAC Notes: All pins marked as ‘GND’ are connected internally to pin 25, 0VAC. Figure 4: Connecting a DC Power Source It is important to remember that when powering the Liftlog™XL from a DC source, that it may not be possible to use the load limiting functions of the Liftlog™XL as the outputs only switch AC.
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Page 13: Connecting Motion Inputs
3.3.3 Connecting Motion Inputs Motion input pins (Aux1, Aux2, Aux3, E-W Fast, West, East, N-S Fast, South and North) must be connected to GND or 0VAC (pins 1, 25, 27, 33) by a set of voltage independent contacts. Where spare or auxiliary contacts are not available on the MAIN contactors, small relays must be employed. For example, the DOWN and UP inputs on the Auxiliary hoist would be connected as follows: To existing control circuitry... -
Page 14: Connecting Limit Inputs
3.3.4 Connecting Limit Inputs There are two input pins for each limit input (e.g. Pins 45 and 46 for the Main hoist SidePull limit). Each input pair should be connected across the limit switch, or chain of limit switches, to be monitored. -
Page 15: Connecting Load Sensor Inputs
3.3.5 Connecting Load Sensor Inputs The Liftlog™XL supports two load sensor inputs (marked MAIN and AUX) of various types: a) Strain gauge input (e.g. CASWA rope clamp load cell); b) 4-20mA input; c) 0-10V input; d) ABUS LIS Q, F1 or F2 inputs. The load sensor for the MAIN hoist is connected to pins 1-7, the load sensor for the auxiliary hoist connects to pins 28-34. - Page 16 3.3.5.2 4-20mA load sensor input When using a 4-20mA signal to monitor the load, connect the load sensor between pins 5 and 9 for the MAIN hoist and pins 29 and 36 for the AUX hoist. LiftlogXL 9: 24V 4-20mA Load Sensor on MAIN hook 5: 4-20mA...
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Page 17: Connecting The Fault Output
3.3.5.4 ABUS LIS Q or Frequency Input Liftlog™XL will also accept a load signal from either the Q, F1 or F2 terminals of an ABUS LIS. This has the advantage of not requiring a separate calibration of the load signal. In this scenario the load signal from the ABUS LIS (marked as Q, F1 or F2) is connected into the ‘Q- Link +’... -
Page 18: Commissioning Details
4 COMMISSIONING DETAILS Liftlog™XL is designed to be commissioned using a laptop computer. You will need a CASWA LINK-2 Bluetooth Modem and the Field Service Utility (FSU) software application loaded on a laptop. 4.1 Installing and Launching the FSU Application 4.1.1 FSU Program Installation Ensure that your computer is switched on, connected to the internet and that the minimum required software versions are installed (see Appendix B: for minimum system requirements). -
Page 19: Connecting To The Device
4.2 Connecting to the Device The FSU will scan for Bluetooth enabled devices. This process takes approximately 10 seconds; when complete a list of all CASWA devices within range will be displayed. If a particular Liftlog™XL unit is not found, ensure it is powered up and press <Look again> to repeat the search. -
Page 20: Checking The Date/Time
Press <Update> to update the Liftlog™XL to the latest available firmware version (recommended). The new firmware will be installed on the device. DO NOT switch off the computer or remove the LINK2 modem until this is complete – doing so may leave the Liftlog™XL in an unrecoverable state. Alternatively, press <Not now>... -
Page 21: General Tab
General Tab 4.5.1 Setting Equipment Name The only configurable item on the General page is the Equipment ID. This text can be up to 18 characters long and it is used to identify the crane in the reporting system. Whilst any name may be used, it is highly recommended that the XL be named according to the registration details provided at the time of purchase. -
Page 22: Input Selection
4.6.1 Input Selection Select the button that corresponds to the input you have connected to the Liftlog™XL . For connection details see section 3.3.5. Hint: If the Auxiliary input is not used, it is strongly recommended that its input selection be set to 4- 20mA as this input is relatively insensitive to electrical noise. -
Page 23: Using The Liftlogxl With A Controlpro
The name of the bound HoistNet device will be shown on the Main/Aux screen. The connection status will also be shown: NB: You will need to ensure that the originating HoistNet device's load signal has been calibrated correctly. To unbind a Liftlog™XL from a HoistNet device, or to change the bound device, press the <Bind> button on the Load screen and then select <Unbind>... -
Page 24: Checking The Gain
Enter the capacity of the hoist in tonnes and press <OK>. Your device is now calibrated and you will not need to zero or calibrate this hoist in order to use this Liftlog. NB: You need to have selected the <0-10V> input type on the LiftlogXL and also check that the ControlPRO is set to output load on its analog output pins. -
Page 25: Resetting The Calibration
4.6.6 Resetting the Calibration Under some circumstances, it may be necessary to erase the calibration of a hoist. Warning: IF YOU ERASE THE CALIBRATION THEN YOU WILL NEED A TEST WEIGHT TO SET IT AGAIN! To reset the calibration for a hoist, tap the <!> button. NB: Resetting the calibration of one hoist (MAIN or aux) does not affect the calibration of the other. -
Page 26: Inputs And Limits
When a signal is detected, the respective box will be checked. 4.8.1 Using XL devices with a HVDC IO Expander If you have been supplied a Sole Digital HVDC10 module for installing a LiftlogXL on your 80-270VDC crane, check the <Use HVDC IO Expander> box. -
Page 27: Tuning Sensitivity And Noise Immunity
4.8.2 Tuning Sensitivity and Noise Immunity Very short duration events are often caused by noise; these may appear as very short duration input events. To remove these from the logged data set, adjust the value in the <Ignore inputs shorter than>... -
Page 28: Sd Card Management
If the Lockout control is set to a non-zero value, when the indicated load exceeds <Overload>+Lockout% a special alert will be sent and the fault output will not close. This effectively disables the crane until it can be inspected and put back into service. NB: The locked state can only be cleared by unchecking the “Locked”... -
Page 29: Reformat Sd Card
4.10.2 Reformat SD Card If necessary, it is possible to delete all loading history from the LiftlogXL device by formatting the SD card. A typical example of where this is useful is when the test process has not been successful, or if the data logger is moved from one crane to another and prior data on the device is no longer applicable. -
Page 30: Recording A Service
4.12 Recording a Service Liftlog™XL data logs can now incorporate a history of maintenance performed on the crane. To record that a service has been conducted, select the Service tab on the FSU Application. (Hint: You may need to scroll through the tabs to see it.) Enter the relevant reference number for the work (e.g. -
Page 31: Routine Maintenance
5 ROUTINE MAINTENANCE There is no routine maintenance required for this device. 31 | Page © CASWA Pty Ltd – 2013... -
Page 32: Operating Liftlog™Xl
6 OPERATING LIFTLOG™XL 6.1 Operating Status The Liftlog™XL is fitted with 3 LEDs labelled Power, Connected and Overload. These are visible from the front of the unit. Power LED : Illuminates whenever power is applied to the unit. Connected LED: Flashes quickly while a GPRS/3G connection is being established. -
Page 33: Downloading Data
Select the name of the crane/hook you wish to interrogate. A variety of information is available via this screen to extract data, present data via charts/graphs and further configure the device’s reporting features. Events data: This shows the date/time (mm/dd/yyyy format), type of event and if an AccessPack is also installed on the equipment, the name of the responsible person using the crane at the time of the event. -
Page 34: Troubleshooting
8 TROUBLESHOOTING Fault Cause Intermittent connection Intermittent power supply Ensure power has not been supplied after the K1 or between XL and Link2 during E-Stop relay. If so, rewire to supply constant commissioning power. Failure to do so will cause the electronics to fail very quickly. -
Page 35: Appendix A: Communication Protocol
Appendix A: COMMUNICATION PROTOCOL The host sends single character commands to the device to write or query parameters. Each command must be followed by a carriage return <CR>(ASCII 13). Where the command is a query command, no arguments are sent and the device will respond with a single line (except for the “u”... - Page 36 Communication commands: Command Description Example Read Query the firmware version number. Send:v<CR> Rcv:1.02b<CR> Read Display a summary of all settings Read Query the input mode: Send:h<CR> 0=Analog Rcv:2<CR> 1=Q-Link 2=Frequency Write Set the input mode Send:H0<CR> Read Query the raw loadpin reading. The lifted load Send:r<CR>...
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Page 37: Appendix B: Communication Options
When purchasing a SIM card for use with the Liftlog™XL system please ensure: 1. The pre or postpaid plan includes data access. Voice only SIM cards will not work with the Liftlog XL. 2. That you obtain the network name, User ID, and Password required for connection to the carriers network. -
Page 38: Appendix C: Fsu System Requirements
Appendix C: FSU SYSTEM REQUIREMENTS The minimum requirements for operating CASWA’s Field Service Utility (FSU) and Link-2 Bluetooth modem are: Laptop computer running Windows XP SP3 or later; One Spare USB port; Microsoft .NET framework 3.5. 38 | Page ©... -
Page 39: Appendix D: Data File Format
Appendix D: DATA FILE FORMAT Data is recorded each time a motion is detected (a contactor closes). Each datum set contains: 1. Date/Time (based on the logger’s internal clock – when a user connects to the logger via Bluetooth using the FSU software, the time is compared to the time on the laptop and can be reset) 2.
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