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WIRELESS TECHNOLOGY & CRANE INSTRUMENTATION
DIVISIONS
GS820 Display
& GS Series Sensors
INSTALLER AND USER'S MANUAL
WARNING! The GS820 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.
!
GM820_ENG_rev20130808
www.loadsystems.com
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Troubleshooting
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Summary of Contents for LSI GS Series
- Page 1 WIRELESS TECHNOLOGY & CRANE INSTRUMENTATION DIVISIONS GS820 Display & GS Series Sensors INSTALLER AND USER’S MANUAL WARNING! The GS820 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.
- Page 2 BEFORE PROCEEDING Read and understand the following: d th t f ll For your safety and that of the people that come into contact with products, understand the significance of the instructions included in this guide, respect all laws and regulations and comply with applicable standards.
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Page 3: Table Of Contents
TABLE OF CONTENTS 1. INTRODUCTION ........5 1 INTRODUCTION 2.9a Line Riding Tensiometer Installation ..24 Ridi I t ll ti 2.9b Line Riding Tensiometer Installation on a 1.1 OVERVIEW ........5 Swing Arm ..........25 1.2 START-UP ......... 5 2.10 LOAD PINS, LINE RIDING TENSIOMETERS AND 2. - Page 4 7.8b CE Safety ..........61 3.13f How to Delete Work Area Limits ....48 8. GS820 MENU OUTLINE ....62 4. USB TOOL ........49 9. LSI PRODUCT LIMITED WARRANTY - 4.1 DATA LOGGER TRANSFER FROM APRIL 1ST, 2013 ......64 DISPLAY .......... 49 4.1a Transfer From Display to USB ....49 4.1b Transfer From USB Device to PC ....
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Page 5: Introduction
1. INTRODUCTION 1.1 Overview 1 1 O 1.2 Start-Up 1 2 St t U The GS820 system includes the cabin mounted The GS820 must be correctly programmed for the GS820 radio display and compatible crane system sensors installed. Once a reliable radio mounted sensors. -
Page 6: Installation
2. INSTALLATION Note: Refer to the Operation section for detailed menu navigation instructions for all calibration procedures. or on the ceiling of the cab. To ensure reliable WARNING! Installation must be made radio communication between sensors in compliance with instructions and and the GS820, the antenna should not be using supplied components only. -
Page 7: Antenna Position
2.1b Antenna Position To GS820 power supply For optimal performance the antenna should be connector (Step 5) positioned on its side such that it is parallel to the sensor antennas (but not pointing directly to Yellow cable or directly away from them). Blue wire Lockout #4 1. -
Page 8: Lockout Settings
5. Connect the yellow cable to the GS820. The Alarm level. All programmed and rated capacity connector is waterproof and well rated for limits and two-block will generate an audible external environments. Simply connect the alarm when the alarm level is reached. Alarms will cable to the display and gently tighten the nut. -
Page 9: Password Settings
Table: Default Triggers WARNING! A hard stop to crane rotation may Lockout Wire Default Trigger cause loss of stability, structural damage to the White ......4301 machine, property damage, personal injury or Green . -
Page 10: Load Cell
5. In menu 4H), select 2) U SER PASSWORD and press supplied by must be used where possible Enter to modify. to adapt the holes in the load cell to the pins. Bushings must be secured with the two allen 6. -
Page 11: Angle Sensors
2.3 Angle Sensors e. The angle sensor should have a clear line of sight to the cabin mounted display. IMPORTANT! Keep the angle sensor away f. The angle sensor antenna should not contact a metal object. from the boom and any connecting metal structures when welding the metal lugs to WARNING! The angle reading may be the boom. -
Page 12: Angle Calibration Procedure No. 2: Correct With The Gs820
2. For GS011 angle/length sensors only: Carefully 8. Press Enter to save changes. remove the cover of the GS101 cable reel. 9. Press Exit to return to the operation display. 3. Loosen the mounting screw in the slotted hole 10. Verify accurate angle indication at both very of the angle sensor mounting plate. -
Page 13: Switch Bracket Installation Lb011
2.4a Switch Bracket Installation LB011 For live end mounting on multiple sheave blocks with sheaves greater than 16 inches (41 centimeters) in diameter consult your service representative. Mount bracket 4 in. Boom (10 cm) below sheave base ø0.38 center. Figure: Jib, rooster or other extension; anti-two-block switch 30°... -
Page 14: Gs075B Installation
2.4c GS075B Installation 1. Install the GS075B on the LB011 (switch bracket) already installed on the crane boom (step 2.4a), with the antenna pointing away from the boom. 2. Install a weight and chain assembly to the eye nut. The weight and chain assembly can either be supplied by (as an option) or the B) Hook block stops... -
Page 15: Length Sensor Cable Reel
2.5 Length Sensor Cable Reel 2.5b Mounting the Cable Reel 1. Determine placement. Find a clear mounting WARNING! Arc welding may damage position on the left side of the first (main) sensors, causing immediate failure or greatly section of the boom. The mounting position reducing functional life. -
Page 16: Boom Length Calibration Procedure No. 1: Mechanical Set-Up
length is required to reach the cable anchor Cable guide point remove winds from the reel without putting additional tension on the cable reel spring. There should be minimal tension on Cable reel the cable reel spring when the boom is fully Cable retracted. -
Page 17: Radius
6. Fully retract the boom, and use Up and Down 2.6 Radius to adjust the length value displayed to equal the actual fully retracted boom length, and 2.6a Radius Verification and then press Enter to confirm. Adjustment 7. Fully extend the boom, and use Up and Down 1. -
Page 18: Radius Settings
10. Test for boom deflection (telescopic crane only): is the radius indicated equal to the actual radius with the boom at 0 degrees and at 90 degrees but smaller than the actual radius with the boom at 45 degrees? If yes then adjust the boom deflection value to compensate: a. -
Page 19: Basic Radius Parameters For A Lattice Crane
2.6c Basic Radius Parameters for a Lattice Crane Jib mounting Jib offset point angle Sheave head Menu 4C) 2) 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 And Height Parameters
2.6e Advanced Radius and Height Parameters Typical sheave heads: • S = D1 HEAVE HEAD LENGTH PERPENDICULAR • S = 0 (typical) HEAVE HEAD LENGTH PARALLEL Special top sheaves (example: rooster): • S Extensions, two possibilities: HEAVE HEAD LENGTH = D2 1) M : the offset is PERPENDICULAR... -
Page 21: Radius Parameters For A Lattice Crane With Mast
2.6f Radius Parameters for a Lattice Crane with Mast Menu 4E) 9) M Jib mounting point SHEAVE RADIUS (Your measurement) Mast sheave head length parallel Menu 4E) 7) M AST SHEAVE Mast Head sheave HEAD LENGTH PERPENDICULAR (Your measurement) Jib offset angle length Menu 4E) 5) M... -
Page 22: Wireless Wind Speed Sensor Gs020
2.7 Wireless Wind Speed c. The wind cups must be fully exposed to the wind and spin freely at all boom 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 23: Wireless Load Pins
2.8 Wireless Load Pins 2.8b Load Pin Transmitter GS001 1. Determine the transmitter mounting position. a. The load pin and transmitter pigtails must connect easily without stretching Handle wire or kinking at all boom angles and working conditions. The jumper cable Pigtail may be used between the load pin and transmitter to increase transmitter... -
Page 24: Line Riding Tensiometer
2.9 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! Line Riding The Line Riding tensiometer must be held by the Tensiometer swing arm and the tension of the wire rope;... -
Page 25: Line Riding Tensiometer Installation On A Swing Arm
6. Verify that the angle the swing arm forms with Table: Line riding tensiometer part number and rope diameter. the boom is not too large and that nothing limits free displacement of the swing arm and GS series Cable Frame line-rider with... -
Page 26: Load Pins, Line Riding Tensiometers And Compression Cells: Calibration
2.10 Load Pins, Line Riding 7. Lower the first load, lift the second (heavier) known load, use Up and Down to adjust the Tensiometers and load value displayed to equal the actual known Compression Cells: load lifted, and then press Enter. Calibration Load pins, line riding tensiometers and compression cells must be calibrated at installation and every... -
Page 27: Four Point Lift
2.11 Four Point Lift 2.11b Imbalance Systems programmed for four load sensors and The following functions are available for applications four load sum indication can be programmed with such as container cranes and gantry cranes that an imbalance sensor to warn against uneven load require load indication from four load sensors distribution or against unwanted rope payout if one simultaneously. -
Page 28: Slack Rope
4. Use Up and Down to select the sensor type “Imbalance sensor” and press Enter. Only one imbalance sensor is required to calculate imbalance for all four load sensors. 5. The ID can be left at 0, press Enter. 6. Press Enter to save any changes. 7. -
Page 29: List And Trim Angle Sensor
2.12 List and Trim Angle Sensor 2.12b 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 metal lugs to the mounting adjustable in the display. -
Page 30: List And Trim Angle Calibration Procedure
2.12c List and Trim Angle 8. Press Enter to save and communicate changes to the sensor. Calibration Procedure 9. Repeat steps 4 through 8 for the list angle. Calibrate angle indication by adjusting the offset 10. Press Exit to return to the operation display. values for list and trim in the GS820 display;... -
Page 31: Rope Payout
2.13 Rope Payout 2.13b Rope Payout Calibration Procedure No. 2: Correct with the GS820 If rope payout indicated does not match actual rope payout, and if it is not possible to easily correct by following Rope Payout Calibration Procedure No. 1, then follow this procedure. This procedure requires hoisting up to fully reel in the wire rope, Rope payout sensor... -
Page 32: Rope Payout Limits
Figure: Rope payout calibration, adjust the actual rope length 8. Note the new trim and scale values. Figure: Rope payout calibration, trim and scale values 9. Press Enter to save and send the new calibration to the rope payout sensor. 10. -
Page 33: Slew Sensor Installation
2.14 Slew Sensor Installation 2.14c Slew Encoder Orientation The slew encoder bracket is designed so that the WARNING! Missing or damaged teeth on the encoder can be installed on either bottom, top or crane slew gear will prevent proper operation of side surfaces. -
Page 34: Slew Transmitter Location
2.14g Cable Length Adjustment Note: The tension applied by the slew encoder spring is required to keep the encoder gear in contact If the cable between the encoder and transmitter is with the slew gear. too long, it can be cut to the desired length; 1. -
Page 35: Data Logger
data logger mode is selected on menu 4K) 1) 2.16 Data Logger (see step 3 above) select 1A) T HRESHOLD The GS820 includes a data logger that records all 1, press Enter and then use Up and Down to significant events including actual sensor values adjust the peak threshold for the first load cell. -
Page 36: Sensor List
2. Go to menu 4A). 2.17 Sensor List 3. Enter the user password and press Enter. All sensors in the GS820 system are programmed in the sensor list. The GS820 uses information 4. Select the sensor to be removed and press from all sensors in the sensor list. -
Page 37: Remote Monitoring
Operation IMPORTANT! Sensors can only have one The supervisor display is not synchronized network controller at a time. To receive when the operator display is in the menu communication from a sensor without taking mode. When the operator display is returned control of that sensor a display must first be from menu to operating mode it synchronizes programmed in “listening mode”. -
Page 38: Wireless Sensor Update
Program a sensor repeater 4. Press Exit to return to the operation display. 1. In menu 4I), select 4I) 3) S ENSOR EPEATER 2.18d Wireless Sensor Update 2. Select 1) S , press Enter to ELECT REPEATER It is possible to send a firmware update to a sensor modify and use Up and Down to program the using the GS820 (menu 4I) 4) I NSTALL... -
Page 39: Operation
3. OPERATION 3.1 Display GS820 3 1 Di GS820 GS820 3.2 USB Port 3 2 USB P USB P The GS820 displays detailed information on the liquid The USB port is used to download data from the crystal display (LCD); warnings, alarms, and radio data logger or to upload capacity charts using a status is also communicated by the display buzzer. -
Page 40: Menu System
DO NOT navigate system menus when be changed as long as the administrator password operating the crane. is known. Forgotten password? Call LSI technical support (Houston, TX) at 888 819 4355. 3.5d Menu Layout The menus accessible to the operator without password protection under the default factory settings are listed below. -
Page 41: Parts Of Line
3.5e Parts of Line 3.6c Chart Wizard The load sensor often shares the weight with multiple Rated capacity indication is based on interpretation parts of line. For accurate load indication the GS820 of a selected capacity chart using boom angle and must be programmed for the number of parts of line. -
Page 42: Display Settings
4. After the last step has been completed, the 3.7b Backlight Mode GS820 displays “R IGGING OK ” and then returns Adjust the LCD backlight control mode to conform to menu 2). Press Exit to return to the operation to viewing and power supply conditions. The LCD display or press Enter to rig another hoist. -
Page 43: Radio Network Diagnostic
GS820 internal clock. CAUTION! The list of “last sensors received” 2) D : current date according to the includes all functioning GS series sensors GS820 internal clock. within range. Programming a GS820 display 3) T for sensors from a different system will disable IME CLOCK BATTERY : self-test pass or fail. -
Page 44: System Limits
3.9 System Limits Critical system alerts or information messages are also displayed on the top part of the LCD. See Set hoist limits examples below: The limit menu displays the limits for each sensor in the sensor list. 1. Go to menu 6) S YSTEM IMITS 2. - Page 45 Table: Information Alerts Table: Information Alerts (Continued) Alert: Alert: “L ID: G15000 M ” “V )” AXIMUM LIMIT ERIFY WHITE WIRE SHORTED TO GROUND Description: Description: The sensor indicates a value greater than the Voltage is not detected on the lockout wire when operator adjusted limit.
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Page 46: Mast Settings
3.12 Mast Settings To indicate rated mast capacity, the GS820 must be programmed with rated mast capacity charts. Set the mast capacity chart selection mode in menu 4E) 4. The options are: None: Rated mast capacity is not indicated. The mast load limit is determined by the load cell limit (menu 6) and the number of parts of line. -
Page 47: Dynamic Limits
Maximum Right Slew limit Radius Limit warning zone Safe Area Radius limit warning zone Safe Area Slew limit Left Limit warning zone Figure: Maximum radius Figure: Slew free area 3.13b Dynamic Limits 2. Maximum tip height: Define the maximum tip height limit and warning zone. The display 1. -
Page 48: Virtual Wall
3. Slew, maximum tip height and maximum 3.13d Limit Warning, Alarm and radius: Define the maximum tip height and the Lockout maximum radius limits for every degree of rotation 1. Limit warning: When the boom tip reaches enters within the slew limits of the safe area. The display a warning zone the display will alert the operator will alert the operator when a slew, maximum tip with an intermittent beep, the yellow warning light,... -
Page 49: Usb Tool
4. USB TOOL Download data or upload capacity charts using d d t given by and press Enter. Press Enter once a USB mass storage device (USB key) without again to confirm the data logger download. removing the display from the crane. 4. -
Page 50: Upload Capacity Charts
setup.exe 4.2 Upload Capacity Charts 4. Double-click on 5. Complete the installation as instructed on IMPORTANT! Contact to get the upload screen. password; this password changes according to the random number indicated on the LCD. Please 4.3b Quick Start provide the random number to 1. -
Page 51: Wind Report
4.3d Wind Report Wind charts. The data from the Wind or Max Gust columns can be easily charted. IMPORTANT! The wind report is only 1. Press Control and select the time column and available when the data has been recorded either the Wind or the Max Gust column. -
Page 52: Maintenance
5. MAINTENANCE 5.1 Sensors 5 1 S 3. The data wires of a load cell may be disconnected 3 Th d t f l d b di to facilitate battery replacement. 5.1a Replacing Sensor Battery 4. Remove the battery by hand. 5. -
Page 53: Anti-Two-Block Switch
5.2 Anti-Two-Block switch 6. Replace the plunger assembly. Correctly align the bottom cover before screwing in the white nylon hex bolt of the wire rope. Tighten well. IMPORTANT! Replace all the batteries of 7. Pull and release the wire rope, the light emitting the anti-two-block switch at the same time. -
Page 54: Replacing A Sensor Antenna
5.3 Replacing a Sensor Antenna 8. Coat the exposed metal foot of the new antenna with an electrical insulating compound Heavily damaged antennas (ripped out, sheared off, by carefully inserting it in the mouth of the wire exposed and fraying etc.) should be replaced compound tube. -
Page 55: Load Cells
5.4 Load Cells 5.4c Care Battery. Lithium batteries older than 18 months WARNING! Heavy shock may affect load old (alkaline batteries over 6 months old) should be indication accuracy. Inspect the load cell changed at the first available planned inspection regularly for clearly visible dents or scratches. -
Page 56: Troubleshooting
6. TROUBLESHOOTING Display Not On N t O • Battery status is usually known within 2 B tt ithi 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 57: Certification Notes
7. CERTIFICATION NOTES 7.1 Important Notes for 7 1 I t N t WARNING! Hazardous Area Certified • Equipment must be correctly installed according to the instructions described Components in this manual and need to be installed in locations providing adequate protection 7.1a Specifications from impact and external damage. -
Page 58: Class 1 Division 1 And Division 2 Certifications
I, II, III, division 1, hazardous GCxxx, GS001, GS002, GS005, GS010, GS020; (classified) locations (GS Series) • UL Standard 1604, third edition: electrical equipment for use in class I and II, division 2, (ub219) See manual for details. -
Page 59: Atex Certifications
7.4 ATEX Certifications in a particular installation. If this equipment does cause harmful interference to radio or television • EN 60079-0: 2004 - Electrical apparatus for reception, which can be determined by turning the explosive atmospheres - General requirements equipment off and on, the user is encouraged to try •... -
Page 60: Emi / Emc
ESD (Electrostatic Discharges) than 2.0 dB are strictly prohibited for use with LSI products are tested against norm EN 61000-4. this device. The required antenna impedance is 50 ohms. Other Compliances To reduce potential radio interference to other •... -
Page 61: Declaration Of Conformity
7.8 CE 7.8a Declaration of Conformity 7.8b CE Safety WARNING! When captors are used, the WARNING! The protection will be impaired ambient temperature should not be higher if 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 62: Gs820 Menu Outline
8. GS820 MENU OUTLINE 1) P 1) P ARTS OF 16C) Lattice extension length 16C) L tti 16D) Sheave head length perpendicular 2) C RANE IGGING 16E) Sheave head length parallel 3) D ISPLAY ETTINGS 16F) Sheave radius 16G) Deduct 1) Unit 17) Auxiliary hoist 2 2) Language... - Page 63 4E) M 4K) D ETTINGS OGGER 4F) W 4L) L OCKOUT ETTINGS 4F1) W 4M) B IMIT IZARD EFLECTION 4F2) W ARNING ETTINGS 5) D IAGNOSTIC 4F3) E RASE 5A) S YSTEM ENSORS 4G) L OMENT NDICATOR 5B) R ADIO ETWORK 4H) P ASSWORD...
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Page 64: Lsi Product Limited Warranty - April 1St, 2013
9.1 Limited Warranty repair or replace the defective Product or part. LOAD SYSTEMS INTERNATIONAL INC. (hereafter The Product or part shall be returned to LSI or its “LSI”) warrants its products (the “Products”) will be designated service representative, accompanied free from defects in materials and workmanship for... - Page 65 To the maximum extent permitted by applicable law, The United Nations Convention on Contracts for the in no event will LSI be liable to the purchaser or any International Sale of Goods does not apply to this third party for any indirect, special, consequential, Limited Warranty.
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