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GS820 Install and User - Bode Technical Services

1. ccccceccccsssseeeeeeeeeeeeseeeees 50 9 3 EXCLUSION OF OTHER 4 3d Wind Report cccccccccsccssesssssessecsecsecseeseesseee 51 WARRANTIES ccceeeeseenseeenseeees 64 5 MAINTENANCE 9 4 EXCLUSION siisisceccsctctcasssncsacccsatatetns 65 2 Py ee bo 5 Co eee ee ee ee eee 52 9 5 LIMITATION OF LIABILITY 65 5 1a Replacing Sensor Battery 00 c 52 9 6 RECOMMENDED PRACTICES 65 9 2 ANTI TWO BLOCK SWITCH 93 9 7 CHOICE OF LAW ssie 65 9 fa Entire Agreement ccccccseeeseeeeeeees 65 eee The GS820 System yy ga INTRODUCTION 1 INTRODUCTION 1 1 Overview The GS820 system includes the cabin mounted GS820 radio display and compatible crane mounted sensors The GS820 creates a two way radio network with the sensors to bring required lift data to the operator Hoist load boom and jib angles boom length wind 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 GS820 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 GS820 system depends on the sensor configuration used and the rated capacity charts programmed where applicable The GS820 in
2. 29 2 12c List and Trim Angle Calibration Procedure Calibrate angle indication by adjusting the offset values for list and trim in the GS820 display the GS 820 will then communicate the updated offset values to the sensor 1 Install the sensor at a precisely known list and trim angle 2 Go to menu 4 INSTALLATION and select 4B SENSOR CALIBRATION 3 Enter the user password and press Enter 4 Select 4B1 AUTOMATIC CALIBRATION WIZARD 5 Use Up and Down to select the trim or list Sensor 6 Press Enter to go to the first step of the calibration wizard note the uncorrected angle indicated 7 Use Up and Down to adjust the angle value indicated until it is equal to the known angle ABl Automatic Calibration Wizard ae Adjust actual trim angle 000005 0 Baw data go0005 4 FF A modify F confirm Figure Trim Angle calibration adjust the angle 481 Automatic Calibration Wizard an j Trim Scale F gave calib in sensor to quit Figure Trim Angle calibration trim and scale values LS a 7 Note the trim and scale values 8 Press Enter to save and communicate changes to the sensor 9 Repeat steps 4 through 8 for the list angle 10 Press Exit to return to the operation display 12 Verify accurate list and trim angle indication 30 nn The GS820 System my 2 13Rope payout Figure Rope payout on a line riding tensiometer Typically the rope p
3. Carefully disconnect the yellow cable from the display unit and reconnect it 7 CERTIFICATION NOTES 7 1Model Numbers CSA and ATEX CSA Class l Division 1 and 2 Rated Equipment part numbers end with CSA Example GC012 CSA ATEX Zone 0 amp 2 the letters ATEX are included in the part numbers Example GC012 ATEX CE 7 2 Important Notes for Hazardous Area Certified Components 7 2a Specifications WARNING Understand manual before operation Replace batteries only in a non hazardous 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 Table Battery type Battery type and specification GC005 ATEX CE GC012 ATEX CE GC018 ATEX CE GC035 ATEX CE GC060 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 D Type 3 6 V lithium batteries Tadiran TL 5930 model Temperature code T4 C Type 1 5 V alkaline Duracell PC 1400 model Temperature code T 150 C ga CERTIFICATION NOTES Sensors GCxxx ATEX CE series sensors GS007 ATEX CE GS002 ATEX CE GS010 ATEX CE GS011 ATEX CE GSO20 ATEX CE GS005 ATEX CE GS050 ATEX CE all intrinsically safe 114 G Ex ia IIC T4 7 2b Ensuring Safe Operation
4. Figure Rope payout calibration trim and scale values 9 Press Enter to save and send the new calibration to the rope payout sensor 10 Press Exit to return to the operation display 2 13c 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 4L LockouT 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 32 nn The GS820 System my 2 14Slew Sensor Installation 2 14c 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 IN WARNING Missing or damaged teeth on the crane slew gear will prevent proper operation of the slew sensor and render the system unsafe 2 14a Encoder Gear Verification Verify that the slew swing sensor was supplied with the correct gear for your application Slew Encoder Bracket This spring needs to be in tension and keeps the slew encoder gear in strong co
5. LSI WIRELESS TECHNOLOGY amp CRANE INSTRUMENTATION DIVISIONS GS820 Display amp GS Series Sensors INSTALLER AND USER S MANUAL IN WARNING The GS820 system is designed as an operator aid and is in no way a substitute for safe operating practice IN WARNING Carefully read and understand this manual before proceeding GM820 REv 20101219 www loadsystems com LS a 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 ZX 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 LSJ may lead to system failure eee The GS820 System yy TABL
6. 1 Boom LENGTH Menu 4C 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 ee of rotation this value will be negative Your measurement Your measurement Boom base pin Menu 4C 12E SHEAVE HEAD LENGTH PERPENDICULAR The distance from the head sheave centre to the boom centerline l l Your measurement ir Se of rotation all Figure Basic radius parameters for a telescopic boom crane Typical installation Not to scale ga INSTALLATION 19 LSI 2 6e Advanced Radius and Height Parameters Typical sheave heads e SHEAVE HEAD LENGTH PERPENDICULAR D1 e SHEAVE HEAD LENGTH PARALLEL Q typical Special top sheaves example rooster e SHEAVE HEAD LENGTH PERPENDICULAR D2 e SHEAVE HEAD LENGTH PARALLEL D3 Extensions two possibilities 1 MANUAL LENGTH the offset is always zero degrees 2 LATTICE EXTENSION LENGTH the offset angle must be adjusted 1 I IS EXTENSION OFFSET 4 ae a Boom TOP LENGTH TIP HEIGHT TOLERANCE iung iib BR nag angle sensor LUFFING JIB LENGTH CENTRE SHEAVE TO CENTRE SHEAVE FIXED JIB LENGTH EA EXTENSION amp OFFSET ANGLE LENGTH EA OFFSET ANGLE JIB MOUNTING POINT a TOP LENGTH a OFFSET ANGLE PARALLEL amp PERPENDICULAR MAIN Boom Boom LENGTH includes boom top SLEW OFF
7. 9 Repeat steps 7 and 8 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 f there are any unsaved changes the display will request confirmation press Enter to save before quitting or press Exit to quit without saving 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 Ga INSTALLATION Si 2 2Load Cell JN WARNING Capacity and safety factor for load cells and adapter plate assemblies are calculated for load along the intended axis of load vertical with the assembly hanging free side loading may cause load cell and adapter plate assembly to fail causing load to drop Lifts must be rigged such that the load cell and adapter plate assembly hang free and not be subjected to side loading CAUTION The load cell must be centered on the pins to avoid uneven loading on the plate kit assembly N IMPORTANT The load cell antenna should not be in contact with metal IMPORTANT For optimal performance and signal reception the GS820 load cell antenna should have a clear line of sight to the GS820 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 GS820 display 1 Install load cell bushin
8. Operation The supervisor display is not synchronized when the operator display is in the menu mode When the operator display is returned from menu to operating mode it synchronizes the supervisor display with any changes that have been made to the system configuration The supervisor display records all normal data logger events in parallel with the operator display except during synchronization or when it is turned off When remote monitoring is turned off the entire system configuration is cleared from the supervisor display and all parameters revert to their default values Restrictions Both the supervisor and operator displays must have exactly the same firmware and capacity chart if applicable Remote monitoring uses the standard LSJ radio protocol it is subject to the same limitations A clear and direct line of sight may be required between the remote monitor and both the operator display and the system sensors Supervisor display system parameters cannot be adjusted when in remote monitor mode An operator display can only be monitored by one supervisor display at a time 2 18c Repeater Communication between a GS820 and a programmed sensor can be routed through a different programmed sensor repeater This can be done either to extend the range of the network or to assist communication around a large radio obstacle The battery life of the sensor repeated source will be reduced by about a year The batter
9. e ASME B30 5 2000 e Franklin laboratory LSI products are safe to use 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 ABS American Bureau of Shipping API Spec 2C compliant 7 8 Environmental conditions Ambient 84 C maximum for the temperature sensors and 59 C maximum for the display Operating 35 C to 85 C temperature 31 F to 185 F Humidity 0 to 100 range 6O nn The GS820 System i 7 9 CE 7 9a Declaration of conformity Declaration of Conformity According to EN 45014 Manufacturer s Name Load Systems International Inc Manufacturers Address Canada United States of America United Arab Emirates 4495 Blvd Wiltid Hamel Suite 110 9223 Solon Suite A Q3 171 SAIF Zone P O Box 7976 Quebec OC Canada G1P 27 Houston TA 77064 onharjah UAE declare under our own responsibility that the products Model Description p GC005 CE GC005 ATEX CE 5000 Ib Capacity Load Cell GC012 CE GC012 ATEX CE 12 000 tb Capacity Load Cell GC018 CE GCO1B ATEX CE 18 000 Ib Capacity Load Cell GC035 CE GC035 ATEX CE 35 000 Ib Capacity Load Cell GCO60 CE GCO60 ATEX CE 60 000 Ib Capacity Load Cell E 400 000 Ib Capacity Load Cell GC170 CE GC170 ATEX CE __ 4170 000 lb Capacity Load Cell GS001 CE GS001 ATEX CE Load Transmitter With Pigtail 6 in GS002 CE GS002 ATEX CE Load Tra
10. 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 LD008 shown Figure Removing top sheaves bolts and spacers on Line Riding tensiometer type 2 LD024 shown 25 LSI 2 10Load Pins line riding tensiometers and 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 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 absolutely not less than 25 1 Go to menu 4 INSTALLATION and select 4B SENSOR CALIBRATION 2 Enter the user password press Enter and select 4B1 AUTOMATIC CALIBRATION WIZARD 3 Use Up and Down to select the load sensor and then press Enter to confirm communication with the sensor is possible and to start the wizard 4 Use Up and Down to adjust the actual parts of
11. 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 16a Recording Modes Adjust the data logger recording mode as required 1 Go to menu 4 and select 4K DATA LOGGER 2 Enter the user password and press Enter 3 Use Up and Down to select the data logger recording mode and press Enter Automatic modes only select the record added below the recording mode interval variation or threshold press Enter and adjust the value using Up and Down then press Enter 4 Press Enter to save any changes 5 Press Exit to return to the operation display or press Down to adjust the data logger date and time see Date and Time sub section 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 4K 1 see step 3 above select 1A MINUTES press Enter 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 increases by more t
12. pigtail Figure Install the load pin transmitter GS001 LSI 2 9Line Riding Tensiometer Tensiometer Figure Line riding tensiometer 2 9a Line Riding Tensiometer Installation 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 Line Riding Tensiometer Hoist Line Riding Tensiometer Figure Example of a typical installation on a telescopic boom crane not to scale Swing Arm Line Riding Tensiometer 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 24 as The GS820 System ma ga INSTALLATION 2 96 Line riding tensiometer installation on a swing arm 1 Verify that the line riding tensiometer size fits with the wire rope diameter Table Line riding tensiometer part number and rope diamater GS series rame line rider with Sheave P N l Size swign arm and transmitter P N Small 4 25 LDOO6 GD004 0375 Small 4 25 LDOO6 GD004 0500 Small 4 25 LDOO9 GD004 0563 9 16 Small 4 25 LDO10 GD004 0625 Small 4 25 LD012 GD004 0750 Me
13. representative as well as the technician out of pocket expenses including traveling lodging and meal expenses if any e The damages caused during the transport or the moving of the Products e Damages caused by accidents abuse misuse a force majeure described as events outside a LST s or any Product user s control including war riot strikes embargoes or external cause e Any cost damage or expenses for field labor or any other expenses related to or arising from the replacement of defective parts e 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 e Any costs associated with providing LSJ with data logging equipment 9 5 Limitation of Liability To the maximum extent permitted by applicable law in no event will LST be liable to the purchaser or any third party for any indirect special consequential incidental or exemplary damages whatsoever including but not limited to loss or revenue or profit lost or damaged data business interruption or any other pecuniary loss whether based in contract tort or gag LSI PRODUCT LIMITED WARRANTY S 5S other causes of action even if LSI has been advised of the possibility of such damages In any event the total liability of LST arising from any cause of action or
14. the cable can be cut to the length required 2 14f Slew Transmitter Installation IMPORTANT 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 If needed weld pads can be used to facilitate transmitter installation IX IMPORTANT Do not weld in proximity to LST sensor transmitters 3 Tie wraps can be used to secure the cable between the encoder and transmitter 34 nn he GS820 System yy 2 14g 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 Ne 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 to overtighten 4 Cut the cable excess leaving about 4 in in the transmitter box Remove the sheath to about 2 in remove the shield and remove th
15. the load cell link before contacting LSJ for replacement bolts Dow Corning dielectric grease Ne 4 I 6 TROUBLESHOOTING Display Not On 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 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 5A SYSTEM SENSORS DIAGNOSTIC Select a sensor and press Enter to verify the senso
16. 12 28 17 18 42 10033 0 0 0 4 2006 12 28 17 19 43 10033 0 0 0 5 2006 12 28 17 20 44 10033 5 0 8 6 2006 12 28 17 21 45 10033 6 0 10 7 2006 12 28 17 22 46 10033 8 0 14 8 2006 12 28 17 23 47 10033 12 0 16 9 2006 12 28 17 24 49 10033 22 1 30 2006 12 28 17 25 50 10033 13 0 15 44 2006 12 28 17 26 51 10033 9 0 12 12 2006 12 28 17 27 52 10033 9 0 16 13 2006 12 28 17 29 03 10033 8 0 18 14 2006 12 28 17 29 54 10033 8 0 12 15 2006 12 28 17 30 55 10033 7 0 10 16 2006 12 28 17 31 56 10033 7 0 11 Figure Excerpt of a Wind Report Table Wind report column headings Column Description Dat cccceeeeeee Date of event recorded TIME Time of event recorded 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 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 LS a 5 MAINTENANCE 5 1 Sensors 5 1a Replacing Sensor Battery IMPOR
17. 2 ALARM LEVEL and press Enter to modify 2 Use Up and Down to adjust the alarm level and press Enter to confirm any change 3 Press Down to select 3 LOCKOUT LEVEL or press Exit 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 4L 8 LOCKOUT RELAY INVERTED When a lockout level is reached voltage S nn The GS820 System my LS a is cut on all lockout wires linked to the lockout condition see menu 4L 4 through 4L 7 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 In menu 4L select 3 LOCKOUT LEVEL and press Enter to modify 2 Use Up and Down to adjust the lockout level and press Enter to confirm any change 3 Press Down to select 4 WHITE WIRE LOCKOUT TRIGGER Or press Exit 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 In menu 4L select 4 WHITE WIRE LOCKOUT TRIGGER and press Enter to modify 2 Select which alarm conditions will trigger lockout on the white
18. 6 SYSTEM LIMITS Ga INSTALLATION p 2 2 11b Imbalance Systems programmed for four load sensors and four load sum indication can be programmed with an imbalance sensor to warn against uneven load distribution or against unwanted rope payout if one corner of the load touches down before the others 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 15 Imbalance minimum limit Imbalance is not calculated when the four load sum is below the imbalance minimum limit Adjust this limit to avoid generating an imbalance alarm under minimum load conditions for example with an empty container or with rigging only The default imbalance minimum limit is 1000 pounds or kilograms depending on load display units Examples F Imbalance factor calculation for load sensor Ne 1 Average B C D A Load Ne 1 A Imbalance Factor 100 x Average B C D n_a A Load Ne 1 C Load Ne 3 B Load Ne 2 D Load Ne 4 7 If the imbalance factor limit is 15 then the system is safe 8100 7500 _ o 8100 ee Load Ne 1 A Imbalance Factor 100 x If the imbalance factor limit is 15 then an imbalance alarm is generated Load Ne 1 A Imbalance
19. 6 months old should be changed at the first available planned inspection even if there is not yet a low battery warning This will avoid costly delays in the field Corrosion Verify that no corrosion is visible on the battery holder inside the load cell transmitter 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 LSJ to have it repaired Engraving on the transmitter box sides will not affect reading Seal If the transmitter box has been removed it must be correctly resealed with RTV non corrosive silicone Antenna Small scratches on the antenna will not affect radio communications A heavy bending of the antenna or bare sections on the wire may reduce the radio efficiency Hex bolts The hex head bolts on the transmitter box are there to protect the antenna and to hold the transmitter box on the load cell link If one or both hex nuts are scratched it will not affect the load cell readings or operation If the bolt head is bent or sheared verify that the transmitter box fits tightly to
20. ABl Automatic Calibration Wizard ter actual parts of line Figure The automatic load calibration wizard adjust the actual parts of line line on the load sensor and then press Enter to confirm 5 Note the units that will be used during the calibration wizard and then press Enter 6 Lift the first lighter known load use Up and Down to adjust the load value displayed to equal the actual known load lifted and then press Enter 7 Lower the first load lift the second heavier known load use Up and Down to adjust the load value displayed to equal the actual known load lifted and then press Enter ABl Automatic Calibration Wizard cage ees j A Litt known load N 1 B Adjust actual load N 1 1b 4000 lb 4507 1b v A modify F confirm Figure The automatic load calibration wizard adjust the load Baw datari 8 Note the new trim and scale values 4B1 Automatic Calibration Wizard a Step 5 of 5 iv Trim Scale F save calib in sensor to guit Figure The automatic load calibration wizard trim and scale values 9 Press Enter to send the new calibration to the load sensor 10 Press Exit to return to the operation display 26 nn The GS820 System my 2 11 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 Im
21. 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 Ga OPERATION p 4 Table Information Alerts Continued Alert VERIFY WHITE WIRE SHORTED TO GROUND Description Voltage is not detected on the lockout wire when safe With the standard relay configuration voltage should be present on a lockout wire in safe condition e Verify the wire is not shorted to ground e Verify the wire is not connected directly to the valve coils a relay should be installed between the wire and the valve coils Refer to the Power Supply and Lockout Connection sub section of this manual 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 ANGLE ABOVE CHART MAXIMUM 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 capa
22. Down to adjust the year and press Next 5 Use Up and Down to adjust the month and press Next 6 Use Up and Down to adjust the day and press Enter to confirm 7 Select 3 Time and press Enter to adjust the time 8 The hour should be flashing use Up and Down to adjust the hour from 00 midnight to 23 11 pm 9 Press Next to adjust the minute 10 Use Up and Down to adjust the minute and press Next 11 Use Up and Down to adjust the second and press Enter to save any changes 12 Press Exit to return to the operation display 2 17Sensor List All sensors in the GS820 system are programmed in the sensor list The GS820 uses information from all sensors in the sensor list Conversely the GS 820 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 A IMPORTANT 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 GS820 display 2 17a How to Add a Sensor to the GS820 1 Determine the radio id
23. Factor 100 x 8100 6800 o m S O B 8100 D 8200 Program the imbalance sensor 1 Go to menu 4 INSTALLATION and select 4A7 SENSOR LIST 2 Enter the user password and press Enter 3 Use Up and Down to advance to the next available sensor position usually following the LS a four load sensors and press Enter to modify 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 The ID can be left at 0 press Enter Press Enter to save any changes Press Exit to return to the operation display oe ee Confirm the imbalance factor limit and the imbalance minimum limit in menu 6 SYSTEM LIMITS 2 11c Slack Rope Systems programmed for four load sensors and four load sum indication can be programmed with a slack rope sensor to warn against unwanted rope payout when the load touches down 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 menu 4
24. GS002 GS005 GS010 GS020 s LSI ub219 ee manual for details Replace with Tadiran T5930 lithium 3 6V battery Use non corrosive RTV sensor safe silicone only The use of other Model Ne GC012 Load Cell 12 000 Ib Single part line pull capacity silicones may void the warran pe International Sales amp Service Houston USA 281 664 1330 Inside Battery Boxes GCxxx GS001 GS002 GS005 GS010 GS020 ATEX and FCC LSI INC Battery Operated D Type Lithium 3 6 VDC Class l Gr A B C amp D Exia O INTRISICALLY SAFE Temperature Code T4 Model A US Intrinsically safe sensors have the following stainless steel plate p n UB223 7 4Class 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 GS820 display Certificate CSA 1332949 on master contract 215780 is available on request Applicable requirements certified by CSA include e CSA Standard C22 2 No 0 4 M2004 Bonding and grounding of electrical equipment protective grounding e CSA Standard C22 2 No 0 M1991 General requirements Canadian electrical code part Il e CSA Standard C22 2 No 0142 M1987 Process control equipment e CSA Standard C22 2 No 157 M1992 Intrinsically safe and non incendive equipment for use in hazardous locations e CSA Standard C22 2 No 213 M1987 Non inc
25. 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 LS _12_29 2006 08 53_13 PDB Datalogger Viewer GS V1 0 0 1 P N B0028 File Edition OpenFilter Tools View Help whi ki Ww Date Time System Units _ Battery Voltage lt gt Crane Startup 06 12 29 08 52 44 US Lbs Automatic Recording 06 12 29 06 12 29 06 12 29 08 53 46 US Lbs 08 53 59 US Lbs 08 54 48 US Lbs Wind Gust Limit In Automatic Recording Figure Excerpt of a full report in Data Logger Viewer 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 4 Double click on setup exe SO nn The GS820 System im I 5 Complete the installation as instructed on screen 4 3b Quick Start 1 Start the data logger viewer application 2 Open the log file see section 4 1b Only dt files generated by the GS820 data logger can be displayed File Editon OpenFilter Tools View Help e a zw Wind Report button Full Report button Figure Data Logger Viewer tool bar 4
26. Tip Height eee POR TN ees Dn 4 PROVO N A LOY OC Na SD CORE A KEK Ce CRTC OEIC Mc Coun en Wis SORES NONE NC SON IOS SON NO OSE NCE EN OOS EN Oo A Aa A ee KA Ah Rt Oh lAN _ so N warning e el ae zone Figure Maximum tip height 3 Maximum radius Define the maximum radius limit and warning zone The display will alert the operator when the maximum radius limit is approached or exceeded a Select Radius in the menu 4F 1 b Position the boom tip at the maximum radius limit of the work area and press Enter c Position the boom tip safely inside the limits of the new work area d The radius limit warning zone is adjusted to 5 ft by default To adjust the size of the radius limit warning zone go to menu 4F 2 mE OPERATION rr a Oe COS X al i lt x x Vs 4 A ER x a xq xx x A Coal ae J A i limit gt x lt x x os o gt warning s 4 MOO IE Safe Area Loose oceaaeee Figure Maximum radius 3 14b Dynamic limits 1 Slew and maximum tip height Define the maximum tip height limit for every degree of rotation within the slew limits of the safe area The display will alert the operator when a slew or tip height limit is approached or exceeded a Select Slew and Height in the menu 4F 7 b Position the boom tip at the left slew and height limit of the work area then press Enter to start work area definition c Swing right to define the
27. WITH REMOTE SENSOR CONFIGURATION SAVED SUCCESSFULLY Press Exit to return to the operation display 413 Set Up Sensor Repeater 1 Select repeater Id Goo0o000 i 2 Select source Id Gooooo0 Set up repeater Figure Program a sensor repeater Clear a sensor repeater 1 In menu 41 select 4I 2 REPEATOR List Menu 4I 2 details the last repeater programmed When no repeater has been programmed No REPEATER SET UP message is displayed Select a repeater in the list and press REMOVE REPEATER to shut down the repeater programmed The following messages will be displayed briefly REMOVING NETWORK PATH INITIALIZING NETWORK To shut down additional repeaters repeat step 1 and 2 38 nn The GS820 System my aa lt 6 LSI 3 OPERATION 3 1 Display GS820 The GS820 displays detailed information on the liquid crystal display LCD warnings alarms and radio status is also communicated by the display buzzer Status light Percent of limit Info alert or warning message USB Port Bar graph indicates load on hoist as percent of limit 3 3 Keypad Warning light 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 Alarm light Working load limit Selection buttons Press the selection button to access line or menu shown on LCD Liquid Crysta
28. also displayed on the top part of the LCD See 12 mph use Load id G16484 maximum limit 1 2 Luffing jib Cwt 50000 lb 50 0 9600 1b 5 0 60 Et y 138 5 ft y Chart Name Datrigger Luft fing Len Extended Cwt 50000 lb Figure the GS820 displays an information alert 44 nn The GS820 System yy ae lt 6 LSI Table Information Alerts Alert Loap ID G15000 MAXIMUM LIMIT Description The sensor indicates a value greater than the operator adjusted limit JN WARNING Do not operate the crane beyond the limits specified by the manufacturer e Verify operator adjusted limits in the limit menu Alert ANGLE ID G15000 Minimum LIMIT Description The sensor indicates a value less than the operator adjusted limit JN WARNING Do not operate the crane beyond the limits specified by the manufacturer e Verify operator adjusted limits in the limit menu Alert Loap ID G15000 Low BATTERY 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 Loap ID G15000 NOT RECEIVED 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 5AT
29. associated with sheave two the auxiliary hoist etc Press Enter to modify 3 Use Up and Down to adjust the number of parts of line 4 Press Enter to save any changes and then press Exit to return to the operation display 3 6 Rated Capacity Indicators The GS820 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 GS820 must be programmed with a valid rated capacity chart specific to the crane The capacity chart programmed can be verified in the Information menu press Menu and select 8 INFORMATION press Exit to return to the operation display A IMPORTANT If the chart number information screen says CHART NOT AVAILABLE no chart is loaded in the GS820 and CHART NOT USED the GS820 has not been programmed to function as a rated capacity indicator If rated capacity indication is required contact the person responsible for the GS820 system installation and maintenance If in doubt contact LSI 3 66 Crane Rigging Under no circumstances is the GS820 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 GS820 for rated capacity indication The GS820 will not take in
30. claim whatsoever whether 1 in contract 2 in tort including negligence whether sole joint contributory concurrent or otherwise but not including intentional reckless or wanton tort 3 under strict liability 4 under any environmental or antipollution law or regulation 5 connected with any toxic or hazardous substance or constituent 6 arising out of any representation or instruction or under any warranty 7 or otherwise arising out of connected with or resulting from the design manufacture sale resale delivery repair replacement or use of Products or the furnishing of any service shall in no event exceed the price allocable to and paid to LSI for the individual unit of Products or service or part thereof which gives rise to the cause of action or claim 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 1 For Products sold in Canada the Province of Quebec or For Products sold i
31. eZ Ce y Za Ye Q Ze Figure USB port location 2 After a short delay about 2 seconds the USB Menu shows up on the LCD 3 Select Copy DATALOG TO USB and press Enter In most case you will be prompted to enter a password enter the download password ga USB TOOL 1 Make sure there is at least 8 MB of available given by LST and press Enter Press Enter once again to confirm the data logger download 4 Transfer progress is indicated on screen 5 When the transfer is done TRANSFER SUCCESSFUL will appear Press Enter then unplug the USB key 6 The crane is now ready for operation 4 1b Transfer from USB device to PC 1 Connect the USB key to a computer 2 The data logger file is located in the root directory of the USB device LSI_MM_dd_yyyy_hh_mm_ss dtP where the double letters represent the time and date of the USB transfer The size of the file should be 8192 kB 4 1c Troubleshooting Problem The file does not appear on the USB key Solution 1 Did the transfer complete successfully Try again Solution 2 Look in the root directory of the USB key The root directory is the folder that appears when you open the USB key Problem The file appears on the key but its size is O kB Solution Did the transfer complete successfully Try again Problem The following message appears on screen during the transfer UNABLE TO CREA
32. each sensor in the sensor list 1 Go to menu 6 SYSTEM Limits 2 Use Up and Down to select a sensor and press Enter to modify 3 Use Up and Down to adjust the limit and press Enter 4 Press Exit to return to the operation display When using the GS820 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 GS820 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 Left and Right 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 0 1 ton per part of line 3 10 Tare Zero the hook 1 Go to menu 7 TARE 2 Select the load sensor 3 Press Enter to set or clear tare weight 4 Press Exit to return to the operation display 3 11 Information Go to Menu 8 INFORMATION Standard info menu pages include Software package Firmware Language pack Graphic library Capacity chart Sensor update pkg BIOS Bootloader number and version USB driver oS oe eS YS Critical system alerts or information messages are
33. epeeeceeedecreeeter 25 3 12 MAST SETTINGS ccssscesssssesssssssesee jo AO ATER CERTE RION a aa 7 6 FCC AND IC INSTRUCTIONS TO SAORA ARER MANAGEMENT aie ii THE USER coe cccegwseennanesasestwevce neeneseoes 59 3 14a Fixed limits ccccccecccseeceeeeceeeseeeseeeeees 46 3 14b Dynamic limits oncdcshacenasocnscsusceosusussssesennsien 47 7 7 EMI EMC 2 ccccccccccccccecccccccuccccueces 60 3 14c Virtual wall ioc ccedesoehdcvievnnnmecdeciewdenndinsaetacenee 48 3 14d Limit warning alarm and lockout 48 7 8 ENVIRONMENTAL CONDITIONS 60 3 14e Chart area management 0cccseeees 48 3 14f How to delete work area limits 48 7 9 CE PTETUTTTITITILI LTTE LeeLee 61 7 9a Declaration of conformity ceee 61 4 USB TOOL 7 9b CE Safety reren 61 4 1 DATA LOGGER TRANSFER FROM 8 GS820 MENU OUTLINE 62 DISPLAY ence veeeteetansdetsacdecseaceaneepecaseens 49 4 1a Transfer from display to USB 49 9 LSI PRODUCT LIMITED 4 1b Transfer from USB device to PC 49 WARRANTY 2009 02 16 AAC Troubleshooting accesnssiesecsieeonnrvesnsncinewsesnes 49 4 2 UPLOAD CAPACITY CHARTS 50 9 1 LIMITED WARRANTY 64 4 3 DATA LOGGER VIEWER 50 9 2 WARRANTY SERVICES 4 38 Installation on a PC scccccussiicccersiercenneneen 50 PROCEDURES cceseseeeeeee 64 AOD QUICK Stari see sata ancicasticossessaaseceattcsieeaieence 50 4 3C Full Report
34. in 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 Always make sure the system works properly Test all componenents before using the crane A description of display status and warning lights is available in the Operation section of this manual 7 2c Product Repair And Servicing LSI products have no replaceable or user 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 LSTI office 7 3 Equipment Markings ATEX Part number end with CSA CE Model Ne GS050 CSA CE rs LSI Anti Two Block Switch WARNING Read the operator s manual Test before every use Batteries replace with C size alkaline Duracell model PC 1400 TEST the light on the bottom must flicker red and green when the cable is cycled in and out 1 281 664 1330 Ex I1 G Ex ia IIC T150 O8ATEX0068 X Issuer 0344 International Built in 2008 A dadic T10 suite 110 Qu bec WARNING DO NOT QC Canada REPLACE BATTERY WHEN AN Serial number is on EXPLOSIVE GAS the front ATMOSPHERE MAY BE PRESENT Model Ne GC012 CSA CE Load Cell 5 4 t 12 00
35. kg Metre m Short ton T 2000 Ib 907 2 kg Foot ft United States Long ton T 2240 lb 1016 kg Foot ft United Kingdom Metric tonne t 2205 Ib 1000 kg Metre m International System SI 42 en The GS820 System yy 3 7b Backlight Mode Adjust the LCD backlight control mode to conform to viewing and power supply conditions 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 7c Wind speed units The wind speed units can be set to km h mph m s or knot 3 d Rounding By default indicated load is rounded off to the nearest 50 Ib or 50 kg For display in pounds or kilograms the rounding value can be adjusted to 1 10 50 100 200 500 or 1000 For display in US short tons British long tons or metric tonnes the rounding value can be adjusted to 0 01 0 02 0 05 0 1 0 2 0 5 or 1 3 8 System Diagnostic Diagnose system issues with the sub menus of menu 5 DIAGNOSTIC 3 8a System Sensors Diagnostic 1 Go to menu 5A SYSTEM SENSORS DIAGNOSTIC 2 Select the sensor and press Enter to see the sensor data in menu 5A1 SENSOR INFORMATION 3 Press Exit to return to menu 5A and select an other sensor or press Exit again to return to the operation display 541 Sensor information Sensor Id Sensor type Raw value 1b Battery VF Temp
36. line Telescopic boom cranes only 15A Jib length 15B Luffing jib length 15C Lattice extension length 15D Sheave head length perpendicular 15E Sheave head length parallel 15F Sheave radius 15G Deduct 16 Auxiliary hoist 16A to 16G same as 15A to 15G 17 Auxiliary hoist 2 17A to 17H same as 15A to 15G 18 Auxiliary hoist 3 18A to 18H same as 15A to 15G 19 Auxiliary hoist 4 19A to 19H same as 15A to 15G 20 Auxiliary hoist 5 20A to 20H same as 15A to 15G Basic radius parameters 18 ee The GS820 System my 2 6c Basic Radius Parameters for a Lattice Crane Jib mounting a point Sheave head length parallel Menu 4C 2 SLEW OFFSET The distance from the boom base pin to the crane centre of rotation l If the boom base pin is behind the centre Head of rotation this value will be negative sheave Your measurement om Menu 4C 12G SHEAVE RADIUS Your measurement Menu 4C 12E SHEAVE HEAD LENGTH PERPENDICULAR The distance from the head sheave centre to the boom centerline Your measurement Menu 4C 1 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 6d Basic Radius Parameters for a Telescopic Boom Crane Menu 4C
37. or operated in conjunction with any other antenna or transmitter This device has been designed to operate with Ga CERTIFICATION NOTES p 5O the antennas listed below and having a maximum gain of 2 0 dB Antennas not included in this list or having a gain greater than 2 0 dB are strictly prohibited for use with this device The required antenna impedance is 50 ohms To reduce potential radio interference to other users the antenna type and its gain should be so chosen that the equivalent isotropically radiated power e i r p is not more than that permitted for successful communication Antenna List LSI P N TAOO1 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 QVBGS000 IC 7076A ICGS000 FCC ID QVBGS001 IC 7076A ICGS001 FCC ID QVBGS050 IC 7076A ICGS050 FCC ID QVBGS075 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 gai
38. orientation indicated by the display left or right must be followed to ensure limits are correctly programmed 2 For mast load indication set the mast load cell ID in menu 4E 2 for mast angle and radius indication set the mast angle sensor id in menu 4E 3 Mast radius indication can be calibrated IMPORTANT Work area can not be defined by adjusting the mast radius parameters in 4E 6 for a mast to 4E 9 Note When a load or an angle sensor is JN WARNING Radius and tip height indication associated to the mast the word mast is added must be accurately calibrated for work area to the sensor type in the sensor list management Use of the work area management feature with incorrect radius or tip height Note When the mast is deactivated the system ignores the sensors associated to the mast however the mast sensor ID numbers are retained to facilitate future re activation 3 14a Fixed limits Adjust fixed limits in the learning mode by positioning the crane at the limit and then recording installed r the position indication may result in an accident causing loss of property serious injury or death AE Mast Settings Mast load cell ID 1 Slew safe area Define safe area slew limits and Mast angle sensor ID warning zone The display will alert the operator Mast chart selection when a slew limit is approached or exceeded Boom length ft a Select Slew in menu 4F 1 Slew offset ft b Ste
39. sensor list menu 4A and select the sensor type Trim sensor The maximum and minimum angles for list and trim indication can be adjusted in the limit menu The default limits are 10 0 maximum and 10 0 minimum 2 12b Mounting Instructions A IMPORTANT Remove the angle sensor from any connecting metal structures or surfaces when welding the metal lugs to the mounting surface Proximity to welding may cause permanent damage to the angle sensor and prevent accurate angle indication 1 Determine the angle sensor position a The mounting surface 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 c The angle sensor should be installed horizontally with the antenna pointing up d The list and trim axes are indicated on the angle sensor follow these indications to orient the sensor correctly for accurate list and trim indication e The angle sensor antenna should not contact a metal object 2 Install the welding pads keep the angle sensor well removed from the weld site and any connecting metal objects while welding 3 Mount the angle sensor to the weld pads with the screws and washers provided 4 Verify list and trim angle indication in the operation display System OK Lf ee 25 20000 1b i moh Gust Hax 15 moh 5000 1 Figure Trim and list angle indication
40. the trim value to 0 3 Example If angle indicated is 0 9 below the actual angle adjust the trim value to 0 9 8 Press Enter to save changes 9 Press Exit to return to the operation display 10 Verify accurate angle indication at both very high and very low angles 12 AX WARNING Keep the anti two block switch 2 4 Anti Two Block Switch away from the boom and any connecting metal structures when welding mounting brackets to the boom Proximity to welding may cause permanent damage to the anti two block switch and render the anti two block system unsafe IMPORTANT To ensure reliable radio communication between the anti two block switch and the GS820 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 display e The anti two block switch antenna should have a clear line of sight to the 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 GS820 display Switches shipped with displays are pre programmed in the factory Jest 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 th
41. tip height limit through all slew positions When the right slew and height limit of the work area is reached press Enter d Position the boom tip safely inside the limits of the new work area e To adjust the size of the height and slew limit warning zones go to menu 4F 2 2 Slew and maximum radius Define the maximum radius limit for every degree of rotation within the slew limits of the safe area The display will alert the operator when a slew or radius limit is approached or exceeded a Select Slew and Radius in the menu 4F 1 b Position the boom tip at the left slew and radius limit of the work area then press Enter to start work area definition c Swing right to define the radius limit through all slew positions When the right slew and radius limit of the work area is reached press Enter d Position the boom tip safely inside the limits of the new work area e To adjust the size of the radius and slew limit warning zones go to menu 4F 2 3 Slew maximum tip height and maximum radius Define the maximum tip height and the maximum radius limits for every degree of rotation within the slew limits of the safe area The display will alert the operator when a slew maximum tip LS a 2 Limit alarm When a work area limit is reached the display will alert the operator with the buzzer the red alarm light and an intermittent alarm message on the LCD Lockout triggers The display can be c
42. to Remove a Sensor from the GS820 36 COAG coasts aa aN 19 2 6d Basic Radius Parameters for a Telescopic 2 18 NETWORK OPTIONS 065 36 B GM Crane a ck ianummlncsh aah 19 Z JOM LISIEN O SENSOr ODIY aa a oe 36 2 6e Advanced Radius and Height Parameters 20 2 18b Remote monitoring 37 2 6f Radius Parameters for a Lattice Crane with ZO Rep ater idan sivcutadae disiadacadeddade a 37 Masts naa tonentcese 21 2 18d Wireless Sensor Update 00 38 2 7 WIRELESS WIND SPEED SENSOR 3 OPERATION ES UP e nee eee eR 2 3 1 DISPLAY GS820 iaieiisiiviiavdieionduiecwedass 39 2 8 WIRELESS LOAD PING 23 2 8a LP011 LP015 and LPO26 ccc0c000e 23 92 USB PORT acreana aa 39 AS A A AS lk arai a Sa KEYPAD oana 39 2 9 LINE RIDING TENSIOMETER 24 2 9a Line Riding Tensiometer Installation 24 3 4 DISPLAY LIGHTS ceseseeeeeeseees 2 96 Line riding tensiometer installation on a 35 MENU SYSTEM SWING AN e 25 Rg re Te ee erat cba eennin se She bee teed epee Pee ee 3 5a Menu Numbers s cjcccceicdnelcaeanederienatueivaaend 40 5 2a Replacing the GS050 Batteries 53 3 5b Menu Navigation cccccscceseseeseeeeeeees 40 5 2b Replacing the GS075B Battery 53 3 5c Password Protection vcssistivelwweaciwmectcavindend 40 3 5d Menu Layout ooonnnnoennnenennnnnennnenennnennennne 40 5 3 REPLACING A SENSOR ANTENNA 54 3 56 Pans of LINE crnaccctsseatenctsenot
43. 0 Ib Single part line pull capacity Please read reference manual for details amp 11 G Ex ia IIC T4 O8ATEX0068 Issuer 0344 Exia lIC T4 WARNING DO NOT Canada REPLACE BATTERY WHEN A Serial number is on the EXPL ee a ATMOSPHERE front MAY BE P RESEN Load Systems International Inc Built in 2008 4495 Hamel Blvd suite 110 Qu bec QC GCxxx GS001 GS002 GS005 GS010 GS020 GS020 Ignition hazard WARNING POTENTIAL ELECTROSTATIC CHARGING HAZARD FCC Model Ne GS050 Anti Two Block Switch WARNING Read the operator s manual Test before every use Batteries C 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 IC 7076A ICGS050 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 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
44. 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 eee Record trigger Date o n Event date stamp THN vo ceccccceeeeeeee 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 GS820 Sensor Status Sensor was active or inactive at the time of the event Sensor Battery Sensor battery level Value 1 cccccceeee Sensor value Examples Crane start up sensor alarm The beginning and end of sensor alarms are indicated as in and out I3 hk examples overload in overload out ne lt 6 LSI 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 A B G D E F 1 Date Time __ Sensor ID Wind mph Nb Gust Max Gust mph 2 2006 12 28 17 17 41 10033 0 0 0 3 2006
45. ATION 2 Enter the user password and press Enter 3 Select 4B1 AUTOMATIC CALIBRATION WIZARD 4 Use Up and Down to select the rope payout sensor and then press Enter to confirm communication with the sensor is established 5 Note the units that will be used during the calibration wizard and then press Enter 6 Hoist up pay in the wire rope use Up and Down to adjust the actual wire rope payout length and then press Enter ABl Automatic Calibration Wizard tea J A HoistUp Pay in rope length B Adjust actual rope length ft 000060 0 6 1 Et v ry modify PI confirm Figure Rope payout calibration adjust the actual rope length Raw data 7 Hoist down payout the wire rope use Up and Down to adjust the actual wire rope payout length and then press Enter LS a 4B1 Automatic Calibration Wizard 2 13d Electrical connections m Voltage 9 to 30 Volts DC about 0 3 Amp Step 3 of 4 i a Red wire positive voltage ae Blue wire negative or ground A HoistDown Payout rope length B Adjust actual rope length ft l 3 pe 2 Two types of connections are recommended 000100 0 1 Always powered up 2 Powered up at the same source as the Rew data 102 5 ft GS820 display unit AA a modify F confirm Figure Rope payout calibration adjust the actual rope length 8 Note the new trim and scale values ABl Automatic Calibration Wizard all J F save calib in sensor to quit
46. E OF CONTENTS 1 INTRODUCTION 2 10 LOAD PINS LINE RIDING Ga TABLE OF CONTENTS p 3 TENSIOMETERS AND 1 14 OVERVIEW aoia a a iaaa 5 COMPRESSION CELLS eae nn ene 5 CALIBRATION sessesteseeteetesteteas 26 2 11 FOUR POINT LIFT 20e0000 27 2 INSTALLATION 2 11a Sum Load Indication a n 27 2 ID AMOAIAMNC S soss ines 27 a gowiatal nar Cpe tee Fe Page ty 2 ANAC SIACK RODE nnee iT EOS 28 1a Mounting Bracket eee eeeeeeeeeeeeeeeees 2 1b POE Postion EE E E EE T T 2 12 LIST AND TRIM ANGLE SENSOR 29 2 1c Power Supply and Lockout Connection T 2 12a Programming the GS820 for List and Trim 2 1d Lockout Settings ci tetet eke ces 8 NCIC ATION aeaa S 29 2 1e Password SCtingS ciicsasidcwesiotaiviecsmdevveciles 9 2 12b Mounting Instructions ccceeeeeeeeeeees 29 2 2 LOAD CELL oaen 10 2 12c List and Trim Angle Calibration Procedure30 2 13 ROPE PAY OU TL viciiisiciiivchinsetecarteasens 31 2 3 ANGLE SENSORS 2 0 ce0005 11 3 4 3a Rope Payout Calibration Procedure Ne 2 3a MOUNTING Procedure x ici iincesvecdivasthedinereshvins 11 Mechanical Set Up ceccecsesereeseeeerees 31 2 3b Angle Calibration Procedure Ne 1 2 13b Rope Payout Calibration Procedure Ne 2 Mechanical Set Up ccecececcceeeeeeeeees 11 Correct with the GS820 31 2 3c Angle Calibration Procedure Ne 2 2 13c Rope Payout Limits 0ccc cece eee 32 Correct With the GSO20 as
47. ENSOR 44 Sensor List d GOis4e4 FY 2 Angle sensor Radius sensor No sensor i Ho sensor No sensor Configuration Figure Menu 4A the sensor list 2 18Network Options 2 18a Listen to sensor only When the GS820 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 Occasionally it may be useful to monitor an installed system from a remote display without disrupting the existing network The GS820 can be programmed to operate in listening mode In this mode the GS 820 will display information from programmed sensors without becoming the network controller A 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 Go to menu 4 and select 4 NETWORK OPTIONS 2 Enter the user password and press Enter 3 Select 4I 1 NETWORK CONTROL 4 Press Enter to modify DISPLAY MODE and use Up and Down to switch between NETWORK CONTROLLER and LISTEN ONLY modes gi Press Enter to save any c
48. INSTALLATION and select 4A1 SENSOR LIST 2 Enter the user password and press Enter 3 Use Up and Down to advance to the next available sensor position usually following the four load sensors the sum load sensor and the imbalance sensor Press Enter to modify 4 Use Up and Down to select the sensor type Slack rope sensor Only one slack rope sensor is required to calculate slack rope for all four load sensors 5 The ID can be left at 0 press Enter 6 Press Exit to return to the operation display 7 Adjust the slack rope minimum limit in menu 6 SYSTEM LIMITS 28 nn The GS820 System my ga INSTALLATION 2 12List and Trim Angle Sensor The GS010 03 is a two axis angle sensor designed to detect both list and trim angle Minimum and maximum limits for list and trim angle are adjustable in the display The display will generate an alarm if the limits are exceeded and can be programmed to generate lockout Furthermore list and trim angle can be used to control rated capacity chart selection where required example barge cranes a x P Pg 7 gt P we ist Tiny y D ce S L P U ba v4 List roll Trim pitch Figure List and Trim axes 2 12a Programming the GS820 for List and Trim Indication For list indication add the GS010 03 ID number to the sensor list menu 4A and select the sensor type List sensor For trim indication add the GS010 03 ID number to the
49. Loosen the mounting screw in the slotted hole of the angle sensor mounting plate 4 Pivot the angle sensor slightly until angle indication is correct Repeat the angle validation step 1 as required Note When the angle sensor is moved very slowly it may take several seconds to see an update at the GS820 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 set the angle sensor to transmit continuously for 5 min go to menu 4B1 Automatic Calibration and select the angle sensor 2 3c Angle Calibration Procedure Ne 2 Correct with the GS8 amp 20 Calibrate angle indication by adjusting the trim offset value in the GS820 display the GS820 will then communicate the updated trim value to the sensor Position the boom at a precisely Known angle Go to menu 4 and select 4B SENSOR CALIBRATION Enter the user password and press Enter Select 4B2 MANUAL PARAMETER ADJUSTMENT Use Up and Down to select the angle sensor to be calibrated and press Enter 6 Select 2 TRM and press Enter to modify 4B2 Manual Parameter Adjustment 1 Heartbeat 180 2 Trim oS ah a ao Scale 4 Sensitivity 5 Dual mode Figure Angle Calibration Procedure Ne 2 7 Use Up and Down to modify the trim value Example If angle indicated is 0 3 over the actual angle adjust
50. Procedure Ne 1 Mechanical Set U 5 Press Enter to confirm the units that will be p used during the calibration wizard 4B1 Automatic Calibration Wizard KX CAUTION Visually monitor remaining or length on the cable reel as the boom is of steep aes iv extended for the first time following installation This generally requires a second A Retract boom to min length person in addition to the operator B Adjust actual boom length ft 1 Fully retract the boom 000100 0 2 Adjust the loose wire rope at the boom tip so that the displayed boom length matches the mee AOE TSS ee actual boom length 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 Ne 2 Correct with the GS820 Figure The boom length calibration wizard confirm minimum boom length 6 Fully retract the boom and use Up and Down to adjust the length value displayed to equal the 16 ee The GS820 System may actual fully retracted boom length and then 2 6 Radius press Enter to confirm 7 Fully extend the boom and use Up and Down 2 6a Radius Verification and to adjust the length value displayed to equal the A djustment actual fully extended boom length and then press Enter to confirm 1 Verify the boom and luffing jib angles and the boom length are indicated correctly IBI Automatic Calibratio
51. SET Boom a angle sensor Boom Foot HEIGHT OFFSET Boom heel pin Crane center of rotation Figure Advanced radius and height parameters Typical installation Not to scale 20 The GS820 System JE 2 6f Radius Parameters fora Lattice Crane with Mast i Wises a ee Menu 4E 9 Mast Jib mounting SHEAVE RADIUS D T l 1 Your measurement M Mast sheave head J l length parallel Menu 4E 7 MAST SHEAVE HEAD LENGTH PERPENDICULAR sheave pees aae x m lt ae a L D Y Q Your measurement Jib offset angle DA l Menu 4E 5 Mast Boom LENGTH Your measurement Boom base pin Menu 4E 6 MAST SLEw OFFSET Crane center of rotation Your measurement Figure Advanced radius parameters Lattice crane with Mast Typical installation Not to scale ga INSTALLATION 21 LSI 2 7 Wireless Wind Speed c The wind cups must be fully exposed to the wind and spin freely at all boom Mounting rod Figure GS020 wireless wind speed sensor 1 Remove the mounting rod from the wind speed Figure Wind clearance sensor d There should be a clear and unobstructed line of sight between the wind speed sensor antenna and the cabin mounted 2 Determine the mounting rod position display unit IMPORTANT Do not weld in proximity to LSI sensor transmitters a Install the mounting rod on the same side of the boom as the cabin mounted di
52. TANT 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 Hex key 5 32 in _ Flat bladed screwdriver Figure Remove the sensor box from the mounting plate 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 Figure Disconnect the data wires 52 3 The data wires of a load cell may be disconnected to facilitate battery replacement 4 Remove the battery by hand 5 Remove the remaining silicone from both the box and the mounting plate 6 Install the new battery insert the positive end and then push in the direction of the positive pole Note A 3 6 volt lithium D cell battery will provide about two years of battery life for a load cell while an alkaline D cell battery will provide less than one year of battery life New high quality D cell battery 3 6 V lithium or alkaline QO Figure Install the new battery and reconnect the data wires 7 Reconnect the data wires if disconnected 8 Apply a non corrosive RTV silicone all around the edge of the mounting plate to create a new seal without bubbles or breaks RTV non corrosive Figure Appl
53. TE FILE REPLACE USB Solution 1 The USB device may not work correctly Replace the USB device Solution 2 The USB device may be in read only mode Allow read write permissions Problem An error message appears on screen during the transfer ERROR where is the error number Solution restart the GS820 and try again to transfer the file If the trouble persists contact LSI Problem Nothing happens when the USB key is inserted into the USB port of the display Solution Insert the USB key in the USB port power down and then power up the display 49 4 2 Upload Capacity Charts IMPORTANT Contact LS 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 the USB Menu will show up on the LCD Select GET FILE FROM USB and press Enter 4 Choose the file to upload and press Enter Example typical file name SPKG3_XXXx 820 5 A password may be required enter the upload password given by LSI and press Enter 6 Transfer progress is indicated on screen 7 When the transfer is done TRANSFER SUCCESSFUL will appear Press Enter and then unplug the USB key The GS820 will restart by itself 4 3 Data
54. The GS820 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 4L LockouT SETTINGS 2 Enter the user password using Back Next Up and Down as described in Password settings section and press Enter 3 Select 1 WARNING LEVEL and press Enter to modify 4 Use Up and Down to adjust the warning level and press Enter to confirm any change 3 Press Down to select 2 ALARM LEVEL or press Exit 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 Alarms will generate an intermittent alarm message on the LCD The proportion of a limit that must be reached to trigger an alarm is the alarm level The default factory setting for the alarm level is 100 1 In menu 4L select
55. a 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 N CS l ee gt 7 1 6 In lt 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 54 7 Slide the white nylon hex bolt to the middle of the length of the new antenna 8 Coat the exposed metal foot of the new antenna with an electrical insulating compound by carefully insert
56. ad right side up and the line 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 Load pin nnana FESS LLMOLVV Hook ball or block Figure Load pin LP011 LP015 or LP026 Installation on a single part block 2 Secure the load pin in place with a cotter pin or other suitable keeper device Boom tip Load pin Figure Load pin LP011 LP015 or LP026 Installation at boom tip Ga INSTALLATION p 2 2 86 Load Pin Transmitter GS001 Determine the transmitter mounting position IMPORTANT Do not weld in proximity to The load pin and transmitter pigtails must connect easily without stretching or kinking at all boom angles and working conditions The jumper cable may be used between the load pin and transmitter to increase transmitter placement options There must be direct unobstructed line of sight from the transmitter to the display this may not be required on cranes with a maximum boom length less than 100 feet 33 metres The transmitter antenna must not be in contact with any metal object 2 Weld the mounting blocks where required LST sensor transmitters 3 Mount the load pin transmitter on the mounting blocks eG Connect the Pi transmitter pigtail Mounting to the Load pin block
57. al power supply voltage 5 Internal temperature 6 GS820 base station identification number 7 GS820 portable battery level 8 Radio certification 9 Radio frequency 5E DIGITAL INPUT 5F CURRENT ALARMS 6 SYSTEM LIMITS 7 TARE 8 INFORMATION 1 Software package Firmware Language pack graphic library capacity chart sensor update pkg bios usb driver TANDA AWN a 9 LSI PRODUCT LIMITED WARRANTY 2009 02 16 9 1 Limited Warranty LOAD SYSTEMS INTERNATIONAL INC hereafter LSI warrants its products the Products for a period of twenty four 24 consecutive months after delivery of such Products to the user as evidenced on a LSI document the Warranty Period when installed and used in accordance with specifications described in LSJ 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 industry standards will be free from defects in materials and workmanship During the Warranty Period LSI or its designated service representative shall repair or at its option replace any Product that is confirmed to be defective by LSI in its sole discretion in accordance with the Limited Warranty Services Procedures described below 9 2 Warranty Services Procedures In order to benefit of this mentioned Limited Warranty coverages and benefits the purchaser must notify LSIs customer se
58. angle length sensor transmitter is integrated to the LS101 cable reel with the angle sensor zeroed If the cable reel is installed perfectly level on the boom at 0 degrees the angle sensor of the 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 0 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 guides and attach to the cable anchor on the tip of the last boom section If additional cable length is LSI required to reach the cable anchor point F l Pa able guide remove winds from the reel without putting additional tension on the cable reel spring The
59. ant temperature range into consideration The device should be used within this range specified above ma CERTIFICATION NOTES p 6 LS a 1 PARTS OF LINE 2 CRANE RIGGING 3 DISPLAY SETTINGS 1 Unit 2 Language 3 Backlight mode 4 Wind speed units 5 Rounding 4 INSTALLATION 4A SENSOR LIST 4A1 SENSOR TYPE AND RADIO IDENTIFICATION NUMBER 1 Configuration select automatic manual 2 Configuration number 3 Start up page 4B SENSOR CALIBRATION 4B1 AUTOMATIC VALUE CALIBRATION WIZARD 4B2 MANUAL PARAMETER ADJUSTMENT 4B3 ESET SENSOR PARAMETERS 4C RADIUS AND HEIGHT SETTINGS 1 Boom length 2 Slew offset 3 Boom foot height offset 4 Tip height tolerance 5 Boom top length 6 Boom top offset Jib offset 8 Lattice extension offset 9 Jib mounting point perpendicular 10 Jib mounting point parallel 11 Reel includes manual 12 Manual boom section length 13 Fully retracted boom length 14 Fully extended boom length 15 Main hoist 4D 15A Jib length 15B Luffing jib length 15C Lattice extension length 15D Sheave head length perpendicular 15E Sheave head length parallel 15F Sheave radius 15G Deduct 16 Auxiliary hoist 16A Jib length 16B Luffing jib length 8 GS820 MENU OUTLINE 16C Lattice extension length 16D Sheave head length perpendicular 16E Sheave head length parallel 16F Sheave radius 16G Deduct 17 Auxiliary hoist 2 17A Jib length 17B Luffin
60. ar load links are calibrated 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 T A of L Actual Load A E O ERAR 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 a SWL of 120 000 Ib the minimum test load in this case would be 24 000 Ib a good test load would be 60 000 Ib or more EE MAINTENANCE p 55 5 4c Care Battery Lithium batteries older than 18 months old alkaline batteries over
61. ayout 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 Power supply must be provided to the rope payout sensor A GS820 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 13a Rope Payout Calibration Procedure Ne 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 ae o Hoist down to pay out a known length of wire rope for example 20 feet 5 Verify the rope payout indicated matches the actual length of wire rope paid out If not then follow Rope Payout Calibration Procedure Ne 2 Ga INSTALLATION p 2 13b Rope Payout Calibration Procedure Ne 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 Ne 7 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 4 INSTALLATION and select 4B SENSOR CALIBR
62. balance e Slack Rope These functions can be used to generate an alarm condition on the lockout wires of the GS820 2 11a 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 lb or kg depending on load display units Program sum load indication 1 Go to menu 4 INSTALLATION and select 4A7 SENSOR LIST 2 Enter the user password and press Enter 3 Use Up and Down to advance to the next available sensor position usually following the four load sensors and press Enter to modify 4 Determine the sum load cell ID number For example D 1234 to indicate the sum of load sensors Ne 1 Ne 2 Ne 3 and Ne 4 or ID 34 to indicate the sum of load sensors Ne 3 and Ne 4 5 Use Up and Down to select the sensor type Sum load cell and press Enter to confirm 6 Use Up and Down to adjust the ID number and press Enter 7 Press Enter 8 Use Up and Down to advance to the next available sensor position to program the imbalance sensor or press Exit to return to the operation display 9 Adjust the sum maximum limit in menu
63. city chart selected Alert MAIN ANGLE BELOW CHART MINIMUM 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 detected on the wire when safe If the lockout relay is inverted this alert will occur when voltage is not detected on the wire in alarm LSI 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 Operator mode The operator must manually select the appropriate mast capacity chart in the CRANE RIGGING menu G2 REZ 2 T 55 0 ft 93 7 ft y Automatic mode The mast capacity chart is TC12000 Conf VIII automatically determined by the crane load Main CHT 456 Kips Aux CHT 720 kips chart s selected Hinge CWT 398 kips l Figure The GS820 displays the mast information 3 14Work area management 1 Activate mast display in menu 4E 1 IMPORTANT The
64. cludes a USB port to facilitate software and chart updates and data logger downloads using a USB mass storage device USB key JN WARNING The GS820 system is designed as an operator aid and is in no way a substitute for safe operating practice GS075B All In One GS050 Anti Two Anti Two Block Block Switch Switch and weight GC Series peaa ven GS 820 Dis al Figure Key components in a typical system installation Your product may vary Not to scale a Oy 1 2 Start Up The GS820 must be correctly programmed for the system sensors installed Once a reliable radio communication network is established the display lights will remain lit without flashing If a sensor is missing or has a problem a message will be displayed on the LCD liquid crystal display This process may take up to one minute The delay 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 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 LST representative or LSI technical support representative 5 LS 2 INSTALLATION WARNING installation m
65. ctions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful 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 e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e 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 FCC ID QVBGS820 RF Exposure Warning IC 7076A ICGS820 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
66. d it 3 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 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 2 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 The GS820 will automatically detect the voltage level and adjust itself To GS820 power supply connector Step 5 Blue wire mums LOCKOUt 4 mam Orange wire Lockout 3 Green wire Lockout 2 White wire Lockout 1 Red wire aal OIN Power Supply or Battery 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 Troubleshooting if no voltage is present on the white wire remove the load connected to the lockout ga INSTALLATION 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 4 Lockout number 2 3 and 4
67. d place it ona clean and dry surface Adjustable wrench Figure Remove the plunger assembly of the GS050 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 ga MAINTENANCE 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 CS 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 26 Replacing the GS075B Battery 1 Remove the GSO75B 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 GS075B battery 6 Reinstall the anti two block switch 7 Test the anti two block system for alarm and lockout before use 53 LSI 5 3 Replacing a Sensor Antenn
68. dium 6 LD015 GD006 0875 Medium 6 LDO17 GD006 0945 24mm Medium 6 LD016 GD006 1000 Medium 6 LD018 GD006 1125 11 8 i 11 4 Medium 6 LD020 GD006 1250 32mm 1 3 8 Large 8 LDO22 GD008 1375 36mm X Large 10 2 Identify the hoist rope and choose a proper place normally as far up the butt section as practical to install the swing arm 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 Remove 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 lf the line riding tensiometer has been supplied with rope payout
69. e LS a B Hook block stops rising two block prevented with safety margin A Anti two block switch triggers two block alarm Figure Chain length test at maximum angle 3 Chain length adjustment Ne 3 speed test Lower the boom until the weight height becomes visually clear to the operator Repeatedly create two block progressively hoisting faster to ensure that the warning and lockout work within acceptable amount of time and distance Increase the length of the chain if needed Figure Chain length adjustment A IMPORTANT To increase chain length only use lightweight chain ee The GS820 System yy 2 5 Length Sensor Cable Reel Ay 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 The GS101 includes the LS101 cable reel and the GS011 angle length sensor The GS011 is concealed under the cover of the LS101 though the antenna is visible Following cable reel installation and boom length indication calibration boom angle indication will have to be verified and possibly calibrated Refer to Angle Calibration Procedure Ne 1 Mechanical Set Up and Angle Calibration Procedure Ne 2 Correct with the GS820 sections of this manual GS011 angle length sensor antenna LS011 length sensor cable reel Figure GS101 a
70. e alarm until the next two block event or simulation If the switch has not been programmed to the display this should be done before proceeding with installation See the section How to Add a Sensor to the GS820 2 4a Switch Bracket Installation LB011 20 38 Pivot Center Anchor shaft a wo Dy Oo Oo LN oo We Figure Bracket footprint and orientation All dimensions are in inches Not to scale The GS820 System Iam 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 centimetres 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 o
71. e angle sensor should not be installed in close proximity to a high RPM electric motor or other source of high frequency vibration 2 Install the welding pads keep the angle sensor at least three feet from the weld site and any connecting metal objects while welding 3 Mount the angle sensor to the weld pads with the screws and washers provided 4 Verify angle indication on the GS820 LCD System OF ae 12 mph 1 2 Max 20000 1b Wind gust 1 mph 5000 1b Figure Typical operation page with boom angle indication 5 Ifthe angle displayed by a GS010 01 boom angle sensor is a high negative value then tilt the angle sensor up over 45 degrees and then tilt back down to horizontal The GS010 01 boom angle sensor will automatically detect on which side of the boom it is installed and correct angle indication accordingly 2 36 Angle Calibration Procedure Ne 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 GS820 display indicates 0 0 degrees then angle calibration is complete if not then continue to step 2 IN WARNING Failure to ensure the boom is levelled will result in false reading of the crane s radius hence the risk of structural failure of the crane or crane tipping over 2 For GS011 angle length sensors only Carefully remove the cover of the GS101 cable reel Gag INSTALLATION p LSI 3
72. e 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 Figure Cable length adjustment 2 15Slew sensor calibration The slew sensor need to be calibrated on the crane where it is installed on before utilisation 1 Go to menu 4B1A select the slew sensor and press Enter 2 Menu 1 5 SET CRANE GEAR TEETH NUMBER enter the teeth count of crane s slew gear 3 Menu 2 5 SET SLEW SENSOR GEAR TEETH enter the teeth count of the gear of the slew sensor installed 4 Menu 3 5 SLEW ANGLE MUST INCREASE WHEN ROTATES TO THE RIGHT REVERSE 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 5 Menu 4 9 ADJUST CONFIRM SLEW VALUE enter the current position of the slew swing 6 Menu 5 5 PRESS ENTER TO SAVE CALIB IN SENSOR the settings will be saved in the sensor 2 16Data Logger The GS 820 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 32 000 records this is equivalent to several days or several years of operation depending on the recording mode selected and
73. e low battery message first appears A warning message is also generated on the LCD Alarm light red The alarm light flashes when a sensor limit is reached 100 and more An alarm message is also generated on the LCD LSI 3 5 Menu System WARNING System limits are not monitored when the display is in menu mode DO NOT operate the crane in menu mode DO NOT navigate system menus when operating the crane 1 Parts of Line 5 Diagnostic 6 System Limits 2 Crane Rigging 3 Display Settings nte Oo Information Z to exit Figure Basic menus level one 4 Installation There are eight basic menus level one used to program consult and control the GS820 system 1 PARTS OF LINES 2 CRANE RIGGING 3 DISPLAY SETTINGS 4 INSTALLATION 5 SYSTEM DIAGNOSTIC 6 SYSTEM LIMITS 7 TARE 8 INFORMATION The basic menus include nested sub menus level two and three designed to address specific tasks including adjusting values choosing from lists and following wizards through step by step processes 3 5a Menu Numbers The basic menus level one are numbered one through eight Level two menus are lettered alphabetically Level three menus are numbered Menus can also include numbered lists 3 56 Menu Navigation From the operation display press Menu Enter to see the eight basic menus level one Use the selection button to select a menu Press Exit to leave a menu and return up one lev
74. el 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 40 eee The GS820 System aa 3 5 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 f the user password is forgotten it can be changed as long as the administrator password 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 1 PARTS OF LINE 2 CRANE RIGGING 3 DISPLAY SETTINGS 4 INSTALLATION 5 SYSTEM DIAGNOSTIC 5A SYSTEM SENSORS DIAGNOSTIC 5B Rapio NETWORK DIAGNOSTIC 5B1 RADIO NETWORK 5B2 LAST SENSORS RECEIVED 5B3 SEARCH FOR SENSORS 5B4 B r ERROR RATE TEST 5C Lockout DIAGNOSTIC 5D DISPLAY DIAGNOSTIC 5E DIGITAL INPUT DIAGNOSTIC 6 SYSTEM LIMITS 7 TARE 8 INFORMATION nas LSI 3 5e Parts of Line The load sensor often shares the weight with multiple parts of line For accurate load indication the GS820 must be programmed for the number of parts of line 1 Go to menu 1 PARTS OF LINE 2 Use Up and Down to select the load sensor typically sensor number one is associated with sheave one the main hoist and sensor number two is
75. embly installed Fe The GS820 System yy 2 3 Angle Sensors 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 prevent accurate angle indication 2 3a Mounting Procedure Angle Sensor Figure Angle sensor level with the boom typical installation Side View Boom Figure Angle sensor top bottom axis within 15 of vertical typical installation Front View Boom Figure Wedge used to mount the angle sensor with its top bottom axis within 15 of vertical typical installation Front View The GS010 series angle sensors can be turned on by starting up the GS820 display to which they are programmed The angle sensor can then assist in levelling itself with the red and green LED 1 Determine the angle sensor position 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 AX WARNING The angle reading may be affected by vibration and may fluctuate th
76. endive electrical equipment for use in class division 2 hazardous locations e UL Standard 508 seventeenth edition industrial control equipment e 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 e UL Standard 913 seventh edition intrinsically safe apparatus and associated apparatus for use in class Il Ill division 1 hazardous classified locations GS Series e UL Standard 1604 third edition electrical equipment for use in class and Il division 2 and class II hazardous classified locations 7 5ATEX 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 i e EN 60079 26 Explosive atmospheres Part 26 Equipment with equipment protection level EPL Ga Test Report KEMA No 211369200 S6 nn The GS820 System i 7 6FCC 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 instru
77. entification number ID of the sensor to be added This number between 10000 and 99999 is engraved on the sensor 2 Go to menu 4A 3 Enter the user password and press Enter 4 Advance to the next empty sensor position in the sensor list No SENSOR Up to 32 sensors may be added to the sensor list Press Enter 5 Use Up and Down to select the sensor type and press Enter 6 Use Up and Down to program the sensor ID and press Enter 7 Press Enter to save any changes made to the sensor list 8 Press Exit to return to the operation display 2 176 How to Remove a Sensor from the GS820 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 36 nn The GS820 System my ee 10000 and 99999 is engraved on the sensor 2 Go to menu 4A 3 Enter the user password and press Enter 4 Select the sensor to be removed and press Enter to modify 5 Use Up and Down to select No sensor This will remove the sensor from the sensor list but retain the sensor ID 6 Press Enter to save any changes made to the sensor list 7 Press Exit to return to the operation display Note Press Next and Back simultaneously to remove the sensor from the sensor list The ID number will revert to 0 and the sensor type will revert to No S
78. erature F Emitted BRE power idb Received EF power Sensor version Figure Sensor information menu ae lt 6 LSI 3 86 Radio Network Diagnostic 1 Go to menu 5B2 LAST SENSORS RECEIVED sensors are shown with their radio ID number and the sensor type AX CAUTION The list of last sensors received includes all functioning GS series sensors within range Programming a GS820 display for sensors from a different system will disable that system and render indication by both systems inaccurate a Use Up and Down to scroll through the list b Press Exit to return to menu 5B 2 Go to menu 5B3 SEARCH FOR SENSORS a Press Enter to launch a sensor search 3 Go to menu 5B4 BIT ERROR RATE TEST This test should only be conducted by LSJ technical service personnel 4 Press Exit to return to the operation display 3 8 Lockout Diagnostic Menu 5C LockouT DIAGNostTc shows the lockout condition of the output a arm or safe and the self test pass or fail it is recommended to manually test the lockout condition 1 Go to menu 5C Lockout Select N 1 WHITE WIRE To temporarily activate or desactivate the lockout relay press Enter 5C Lockout He 1 White wire Selft test pasa Status alarm Selft test Fail H 2 Green wire F to toggle lockout Figure Menu 5C Lockout condition example 2 Press Down to go to N 2 GREEN WIRE Repeat lockout diagnostic test 3 Press Down t
79. esurcereertmcemeneeets 41 54 LOAD CELLS a 55 3 6 RATED CAPACITY INDICATORS 41 5 4a Reading Accuracy cccsccesseeeseeeeneees 55 3 6a Display Programming E E 41 5 4b Load Testing E E A en Te Tee ere AT 59 3 6b Crane Rigging E EEEE TEE 41 5 40 Care ee On ee 99 3 6c Chart Wizard coks cxsiveavcdetecnsnierdesebetacnbieenics 41 6 TROUBLESHOOTING 56 3 7 DISPLAY SETTINGS 0 42 i ANN EE E E EE EEE 42 3 7b Backlight Mode scsecscasscacacssusscicassindcensadneies 42 Aa CEES TAEA A aoe 3 7c Wind speed units a nn0nnnnnannnennennnnnnnnnnne 42 3 7d Roundi g eae eee enn en Pe 42 LE MODET KOMBERS oron cearececaees ee 3 8 SYSTEM DIAGNOSTIC 000 42 1 2 An OUE RE CERED 3 8a System Sensors Diagnostic 0008 42 3 8b Radio Network Diagnostic 06 43 COMPONENTS ecceceeteeeeteetees 57 3 80 LOCKOULDIGONOS UG ve cnscusicnnatccptnsvoncesdeenwnid 43 28 Specifications sssaaa 57 3 8d Display Diagnostic sicse costes toertetsasenenctcxaneesad 43 7 20 Ensuring Safe Operation in Hazardous 3 8e Digital Input Diagnostic eee 43 PVC AS N E A AE 57 3 8f Current Alarms ox cacinncainannicanndacat tuceeieatuwanionnes 43 7 2c Product Repair And Servicing 57 3 9 SYSTEM LIMITS 0 eee 4A 7 3 EQUIPMENT MARKINGS 57 3 10 ARE ea ee ld 7 4 CLASS 1 DIVISION 1 AND DIVISION 3 14 INFORMATION cccssssssssssseessesesesen 44 ern ee nea aot a
80. event the GS820 display fails Operating a crane without a functioning anti two block system and load and angle indication is dangerous and may be against the law triggered lockout condition In this case if the display fails crane functions will not lockout 1 In menu 4L select 8 LOCKOUT RELAY INVERTED and press Enter to modify 2 Use Up and Down to switch between YEs and NO and press Enter to confirm any change 3 Press Exit 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 administrator and the user passwords are lost please call LSI technical support Menus accessible from the operation display can be individually protected by the user password 1 Go to menu 4 INSTALLATION and select 4H PASSWORD SETTINGS 2 Enter the administrator password and press Enter 3 Select 1 ADMINISTRATOR PASSWORD and press Enter to modify 4 Use Up and Down to adjust the administrator password Press Enter to save any changes 5 In menu 4L select 2 USER PASSWORD and press Enter to modify 6 Use Up and Down to adjust the administrator password Press Enter to save any changes 7 In menu 4L select 3 TARE PROTECTED and press Enter to modify 8 Use Up and Down to switch between yes and NO and press Enter to save any changes
81. g jib length 17C Lattice extension length 17D Sheave head length perpendicular 17E Sheave head length parallel 17F Sheave radius 17G Deduct 18 Auxiliary hoist 3 18A Jib length 18B Luffing jib length 18C Lattice extension length 18D Sheave head length perpendicular 18E Sheave head length parallel 18F Sheave radius 18G Deduct 19 Auxiliary hoist 4 19A Jib length 19B Luffing jib length 19C Lattice extension length 19D Sheave head length perpendicular 19E Sheave head length parallel 19F Sheave radius 19G Deduct 20 Auxiliary hoist 5 20A Jib length 20B Luffing jib length 20C Lattice extension length 20D Sheave head length perpendicular 20E Sheave head length parallel 20F Sheave radius 20G Deduct CHART SETTINGS 1 2 3 4 9 6 8 9 Rated capacity indicator 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 10 Boom angle tolerance Cn The GS820 System i ne lt 6 LSI 4E MAST SETTINGS 4F W ORK AREA 4F1 Work AREA LimMIT WIZARD 4F2 WARNING SETTINGS 4F3 ERASE WORK AREA 4G LoADb MOMENT INDICATOR 4H PASSWORD SETTINGS 1 Administrator password 2 User password 3 Tare menu password protection 4 Limit menu password protection 5 Info menu password pro
82. gs 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 LSI must be used where possible to adapt the holes in the load cell to the pins 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 4 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 Figure Typical load cell and adapter plate ass
83. han the operator adjusted percentage When the automatic variation data logger mode is selected on menu 4K 1 see step 3 above select 7A VARIATION Ga INSTALLATION p 35 press Enter 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 4K 1 see step 3 above select 7A THRESHOLD N 1 press Enter and then use Up and Down to adjust the peak threshold for the first load cell Press Down to repeat for the second load cell etc Up to four load cells can be programmed for automatic peak data logging User input The status of all sensors is recorded on demand A normally open push button must be installed on a digital input to the GS 820 through a pre determined wire of the power supply and lockout cable All data All communications between a display and its sensors are recorded 2 166 Date and Time Adjust the data logger date and time as required 1 Go to menu 4 and select 4K DATA LOGGER 2 Enter the user password and press Enter 3 Select 2 DATE and press Enter 4 The digits of the year should be flashing use Up and
84. hange 6 Press Exit to return to the operation display When a display is adjusted to listen only mode the following message flashes three times during the start up routine THE DISPLAY IS IN LISTEN ONLY MODE Note To regain network control of programmed sensors adjust the GS820 to NETWORK CONTROLLER Shut the display off and then start it again 2 18b Remote monitoring The remote monitor mode enables one GS820 the supervisor display to monitor another GS820 the operator display from a remote location The supervisor display is synchronized with the operator display configuration and listens directly to the sensors in the sensor list Furthermore with the option sync operating page the supervisor display can be synchronized to the exact page shown by the operator display when not in menu mode IMPORTANT Do not set a dedicated system display to remote monitoring mode The entire system configuration will be lost including the sensor list and radius parameters Set up 1 Set the display mode to remote monitor on line 1 of menu 41 1 NETWORK CONTROL 2 Set the ID of the operator display to be monitored on line 2 3 Set the sync operating page option as required on line 3 When communication has been established and the supervisor display configuration has been synchronized the message Remote monitor of id Gxxxxx appears on the top line of the supervisor display
85. ical 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 Enter 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 LS a 4 After the last step has been completed the GS820 displays RIGGING oK 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 GS820 then the GS820 will display SENSOR INVALID Boom Length Rigging ok Figure the GS820 displays rigging ok 3 7 Display Settings Program the display for operator preferences in menu 3 DISPLAY SETTINGS 1 Go to Menu 3 DISPLAY SETTINGS 2 Use Up and Down to select the setting to modify and press Enter 3 Use Up and Down to modify the setting 4 Press Enter to confirm 5 Press Exit to return to the operation display 3 fa Units The weight units for load display may be selected according to operator preference Length units are associated with weight units by default see the table below Table Weight Units Unit Equivalent Weight Length Unit Notes Pound Ib 1 Ib 0 4536 kg Foot ft Kilogram kg 2 205 Ib 1
86. if required these wires function in the same way as the white wire 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 To valve coil if normally open is required Blue wire Lockout 4 Orange wire Lockout 3 Green wire Lockout 2 White wire Lockout 1 Red wire Bosch relay AAA Power Supply or Battery 12 Vor 24 V To valve coil if normally closed is required Figure Connection with white wire lockout and recommended Bosch relay 5 Connect the yellow cable to the GS820 The connector is waterproof and well rated for external environments Simply connect the cable to the display and gently tighten the nut Do not put a kink in the yellow cable where it enters the connector any bend in the cable at the base of the connector must not be so severe as to break the internal connections where the cable meets the connector The power cable requires about 4 1 2 in behind the display to protect the connector White wire Lockout 1 Sh Blue wire Lockout 4 Ws Black wire Negative ground a RY j y SF Orange wire Lockout 3 SQ INN Green wire Lockout 2 Red wire Positive 12 or 24 volts Yelow cable 2 Figure GS820 power supply connector 7 2 1d Lockout Settings Warning alarm and lockout control is programmed in this menu
87. ing it in the mouth of the compound tube Electrical insulating compound 4 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 The GS820 System JEE ae lt 6 LSI 5 4Load Cells IN WARNING Heavy shock may affect load indication accuracy Inspect the load cell 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 b
88. ipping from LSI f LST 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 you the user or owner of the Products prior to determining if the Limited Warranty coverage is applicable that LSJ receive the data logging equipment used with the Products and that LSI be authorized to retrieve all information from such data logging equipment in 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 you 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 you 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 LST LSI will pay ground freight transportation costs of replacement or repaired parts or Products to the destination in Canada and the continental United States of America the Territory LSI will not pay any transportation costs of replacement or repaired parts to destination outside
89. l Display LCD Keypad The main keypad consists of six buttons used to control consult program and troubleshoot the GS820 display and system The keypad also includes the selection buttons that allows the user to quickly access the menus and informations displayed on the LCD Bypass Exit lt x Override lockout for emergency purposes The alarm will remain silent until the next alarm lockout will re engage as soon as the button is released Exit menu Back Move to the previous page digit D Menu Enter lt l Access the system menus refer to Menu System section Enter menu confirm changes to system settings Next Move to next page digit Down Modify numeric values and move down through a list of choices Up A Modify numeric values and move up through a list of choices This applies only if the GS820 has been correctly installed to control crane lockout function Ga OPERATION p gt 3 4 Display lights Status light green The status light stays on when the GS820 has a reliable radio communication link to all programmed sensors Warning light yellow The warning light flashes when 1 the communication with a sensor is not established NoRx apears on LCD 2 a warning threshold has been reached typically 90 of the maximum limit 3 an alarm is bypassed 4 the sensor battery life drops below 10 Normally several weeks of battery life remains from the moment th
90. l radius Figure Radius settings menu Note with the boom at 45 and the maximum load on the hoist the boom deflection value should 4C RADIUS SETTINGS equal the difference between the actual and the 1 Boom length displayed radius With the boom at 45 and half the 2 Slew offset maximum load on the hoist the boom deflection 3 Boom foot height offset value should equal twice the difference between 4 Tip height tolerance the actual and the displayed radius 5 Boom top length 11 Test No 4 measure the actual radius and 6 Boom top orsel compare to the radius indicated Repeat with the 7 Jib offset boom at minimum angle at 45 degrees and at 8 Lattice extension offset maximum boom angle repeat at minimum and 9 Jib mounting point perpendicular maximum boom length If radius indication is 10 Jib mounting point parallel not accurate then refer to Radius Settings 11 Reel includes manual 12 Manual boom section length 2 66 Radius Settings 13 Fully retracted boom length Go to menu 4 INSTALLATION and select 4C 14 Fully extended boom length RAbIUS AND HEIGHT SETTINGS 15 Main hoist Enter the user password and press Enter Use Up and Down to navigate between the radius settings press Enter to modify and use Up and Down to adjust the settings Press Enter to save any changes and press Exit to return to the operation display IMPORTANT Radius settings 4C 12 to 4C 17 are specific to the hoist
91. n Wizard 2 Verify the correct rated capacity chart is a Step 3 of 4 H selected 3 Test Ne 1 measure the actual radius and A Extend boom to max length compare to the radius indicated Repeat with the boom at minimum angle at 45 degrees and at maximum angle repeat at minimum and 000200 0 maximum boom length If radius indication is not accurate then go to step 4 B Adjust actual boom length ft Raw date 215 1 ft 4 Measure the basic radius parameters on the crane Y f i modi ty el ien 5 Program the basic radius parameters in the Figure The boom length calibration wizard confirm maximum RADIUS SETTINGS MENU poom Engin 6 Test Ne 2 measure the actual radius and compare to the radius indicated Repeat with the 8 Note the new trim and scale values boom at minimum angle at 45 degrees and at maximum boom angle repeat at minimum and Simenewem i not accurate then go to the next step pence 7 j Cage Note If the difference between the displayed radius and actual radius remains constant at all boom lengths and angles then correct by adjusting the slew offset For example if the radius displayed is always 2 3 feet longer than the actual radius then subtract 2 3 from the slew offset 7 lf the crane is rigged with the main boom only then go directly to step 11 l save calib in sensor eae 8 Ifthe crane is rigged with a rooster jib or other Figure The boom length calibratio
92. n a lattice boom For live end mounting on multiple sheave blocks with sheaves greater than 16 inches 41 centimetres in diameter consult your service representative Mount bracket 4 in 10 cm below sheave center Figure Jib rooster or other extension anti two block switch placement for single part of line operation only Ge INSTALLATION p 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 Chain hole Front View Figure Fast line weight installation 2 46 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 GSO50 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 2 4 GS075B Installation 1 Install the GSO75B on the LBO11 switch bracke
93. n greater than 3 0 dB are strictly prohibited for use with this device The required antenna impedance is 50 ohms To reduce potential radio interference to other users the antenna type and its gain should be so chosen that the equivalent isotropically radiated power e i r p is not more than that permitted for successful communication Antenna List LSI P N TAO11 Description 1 4 wave monopole MFG Load Systems International LSI 7 7 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
94. n the USA the State of Florida without giving effect to principles of conflicts of law You agree that the exclusive venue for any disputes arising under this Agreement shall be the state and federal courts located in Orlando Florida 9 7a Entire Agreement This document contains the entire 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 LST LS a NOTES l 00 The GS820 System am LSI LSI Contact Information 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 North America Middle East amp Africa Phone 971 6 557 8314 Fax 971 6 557 8315 Toll Free Phone 888 819 4355 Toll Free Fax 888 238 4099 International 1 281 664 1330 r USA Corporate Office 9633 Zaka Road Houston TX 77064 Direct Phone 281 664 1330 Direct Fax 281 664 1390 GM820 REv 20101219 Email sales loadsystems com Canadian Corporate Office 4495 Blvd Hamel Suite 110 Quebec QC G1P 2J7 Direct Phone 418 650 2330 Direct Fax 418 650 3340 Email sales loadsystems com 2010 Load Systems International I
95. n wizard Trim and Scale extension then the advanced radius Par ameters values must be measured on the crane and then programmed in the RADIUS SETTINGS menu of the 9 Press Enter to send the new calibration to the display length sensor 9 Test No 3 measure the actual radius and 10 Press Exit to return to the operation display compare to the radius indicated Repeat with the boom at minimum angle at 45 degrees and at maximum boom angle repeat at minimum and maximum boom length If radius indication is not accurate then go to the next step When the hoist is rigged off of a luffing jib only Telescopic boom cranes only Systems with rated capacity charts programmed in the GS820 only Ga INSTALLATION p I a 10 Test for boom deflection telescopic crane only is the radius indicated equal to the actual radius AC Radius and Height Settings with the boom at O degrees and at 90 degrees Boom length ft but smaller than the actual radius with the boom Slew offset ft at 45 degrees If yes then adjust the boom Height offset ft deflection value to compensate iaceedneneeeies a Raise the boom to 45 degrees with a Boom top length ft known load Boom top offset b Compare the indicated radius with the No load deflection actual radius Change the boom deflection value and again compare the radius displayed with the actual radius Repeat until the radius displayed equals all moai ty exit the actua
96. na 12 2 13d Electrical connections cicc 32 2 4 ANTI TWO BLOCK SWITCH 12 2 14SLEW SENSOR INSTALLATION 33 2 4a Switch Bracket Installation LB011 12 2 14a Encoder Gear Verification 0 000cee 33 2 4b GS050 Installation EEE ware acon A TE 13 2 14b Slew Encoder Location ccccccccccccccccccceee 33 246 GS075B Installation OTe Pe eT ee Sr Trees 14 2 14c Slew Encoder Orientation PEH EEEE EE RERE 33 2 4d Chain length adjustment cc csee 14 2 14d Slew Encoder Installation cccccce00ee 33 2 5 LENGTH SENSOR CABLE REEL 15 2 14e Slew Transmitter Location 000 34 RBs Masini Boar Eueasian 45 2 14f Slew Transmitter Installation 0 0000 0 34 2 5b Mounting the Cable Reel aanne 15 2 14g Cable Length Adjustment 0c 34 2 5c Boom Length Calibration Procedure Ne 1 2 15 SLEW SENSOR CALIBRATION 34 Mechanical Set Up cccccceececeeeee ees 16 2 5d Boom Length Calibration Procedure No 2 2 16 DATA LOGGER PToUUOCTUCOLICOTICOTLOLOLT OTT 35 Correct with the GS820 ceeeseeeeees 16 2 16a Recording MOd S c csccesesersesssereceseress 35 2 6 RADIUS 17 2 16b Date and WMC ccsedssrtasceedieciercdeautecssaciaks 35 2 6a Radius Verification and Adjustment MN PETES 17 2 17 SENSOR LIST TETELE EEEETEEEEEEEEEEEEEETEET 36 2 00 Radius Settings sartsa ii 18 2 17a How to Add a Sensor to the GS820 36 2 6c Basic Radius Parameters for a Lattice 2 17b How
97. nc Dubai Corporate Office Q3 171 SAIF Zone PO Box 7976 Sharjah UAE Phone 971 6 557 8314 Fax 9716 557 6315 Email lsifzc emirates net ae www loadsystems com
98. ngle amp length sensor 2 5a Maximum Boom Extension Confirm the maximum extension of the LS101 cable reel is compatible with the maximum boom length Step 1 Note the cable reel maximum extension 100 feet 30 5 metres unless specified otherwise T Step 2 Note the retracted boom length AS e Step 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 Maximum cable reel extension must be greater than maximum boom extension Ga INSTALLATION p S 2 56 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 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 Welding pad holes 2 1 4 in apart centre to centre Welding pads pads holes 16 1 8 in apart centre to centre Figure Cable reel mounting position Note When factory installed the GS011
99. nsmitter With Pigtail 6 in for balanced cell GS005 CE GS005 ATEX CE Antt Two Block Transmitter GS010 XX CE GS010 XX ATEX CE Angle Sensor GS011 XX CE GS011 XX ATEX CE Angle Sensor With Length Input 65012 CE Angle Length Sensor O n GS020 CE GS020 ATEX CE Wind Speed Sensor GS035 CE Pressure Transducer GS5050 CE GS050 ATEX CE Anti Two Block Sensor All In One Anti Two Block Switch Wei LSI Wireless Gateway GS320 CE Stand Alone Wind 5 eed Disola 65375 CE stand Alone AZB Display GS550 CE GS550 ATEX CE Standard GS displa GS550 03 CE Hand Held GS display GS550 XX CE OEM GS displa GS820 CE a Graphical GS display to which this declaration refers conform to the relevant standards or other standardising documents Safety IEC 61010 1 2 ed 2001 EN 61010 1 2 ed 2001 Wireless EN 300 220 3 V1 1 1 2000 09 a EMC EN 301 489 3 V1 4 1 2002 08 x7 Qu bec April 1 2010 echnologies Manager 7 96 CE Safety WARNING When captors are used the JN 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 when the ambiant temperature is higher than 59 C otherwise there can be a burn possibility IMPORTANT The IP of equipment corresponds to 65 WARNING For the operator s safety take only the ambi
100. ntact with the slew gear Slew Sensor Encoder Figure Slew encoder bracket orientation Encoder gear rolls on the tooth edges 2 14d Slew Encoder installation Figure Encoder gear verification f K 3 1 Find a rigid level space near the slew gear to a Roll the encoder gear on the crane slew install the slew encoder mounting bracket gear it should roll without skipping 2 Weld the mounting bracket in place or install b The distance between the leading edges X with 1 4 in screws The screws can be installed of the slew gear teeth should correspond to directly on the crane plate or a custom weld pad the gear model shipped with your order can be built and welded on the crane Example P N PA133 01 corresponds to a AX WARNING Keep the slew encoder away from slewgear with teeth leading edges 2 in apart any connecting metal structures when welding Note The slew sensor can be installed on either mounting bracket to the boom Proximity to internal or external tooth slew gears welding may cause permanent damage to the slew encoder and render the system unsafe 2 14b 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 Crane Upper Slew Sensor lt lt Body Transmitter GS030 Slew Encoder Bracket Figure Mounting bracket footprint Dimensions are in inches 3 Once the mounting bracke
101. o go to N 3 ORANGE WIRE Repeat lockout diagnostic test 4 Press Exit to return to the operation display Gg OPERATION Si 43 3 8d Display Diagnostic 1 Go to menu 5D DispLay DiAGnostic The page shows different informations 1 Time current time according to the GS820 internal clock 2 DATE current date according to the GS 820 internal clock 3 TIME CLOCK BATTERY Self test pass or fail 4 EXTERNAL POWER external power supply voltage 5 Display Internal temperature 6 Base station ID The base station ID should be the same as the GS820 display serial number printed on the left side of the box 7 Power supply 8 Radio certification FCC IC indicates Federal Communications Commission U S A and Industry Canada certification CE indicates European Community certification 9 Radio frequency the frequency used by the system network 2 Press Exit to return to the operation display 3 8e Digital Input Diagnostic 1 Go to menu SE DiciTaL Input DiAGnostic The page shows the wires digital input status white green orange and blue wires 2 Press Exit to return to the operation display 3 8f Current Alarms Go to menu 5F CURRENT ALARMS to see the complete list of current alarms The same alarms are displayed in the messenger at the top of the main screen LSI 3 9 System Limits Set hoist limits The limit menu displays the limits for
102. of the Territory Shipping and handling costs to locations outside the Territory shall be the responsibility and borne by Purchaser or Owner of the Product prior to any shipment by LSI Contact LSI to get 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 THERE ARE NO EXPRESS LEGAL OR IMPLIED WARRANTIES OR CONDITIONS IN RELATION TO ANY PRODUCTS INCLUDING ANY IMPLIED WARRANTY OR CONDITION OF MERCHANTABILITY NON INFRINGEMENT OR FITNESS FOR A PARTICULAR PURPOSE AND THOSE OTHERWISE ARISING BY STATUTE OR OTHERWISE IN LAW OR FROM A COURSE OF ae lt 6 LSI DEALING OR USAGE OF TRADE WHICH ARE EXPRESSLY DISCLAIMED NO ORAL OR WRITTEN INFORMATION OR ADVICE GIVEN BY LST OR ITS EMPLOYEES OR REPRESENTATIVES SHALL CREATE A WARRANTY OR CONDITION OR IN ANY WAY INCREASE THE SCOPE OF LEST S OBLIGATION LST DOES NOT WARRANT THAT THE BUSINESS RESULTS OBTAINED FROM THE USE OF THE PRODUCTS WILL BE APPROPRIATE OR ADEQUATE FOR THE PURCHASER 9 4Exclusion This Limited Warranty does not cover and shall not apply to e Any Product that is misused or abused including being altered modified or repaired not in accordance to LSJ written instructions or authorizations and any use not in compliance with LSTs instructions and or industry standards and practices e Any incidental costs or expense such as shipping charges to LSI or an designated service
103. onfigured height or radius limit is approached or exceeded a Position the boom tip at the left slew and radius limit of the work area and then press Enter to start work area definition b Swing right to define the radius limit through all slew positions When the right slew and radius limit of the work area is reached press Enter c Position the boom tip within 2 of the left slew limit and at the height limit of the work area and then press Enter to start definition of the height limit for the work area d Swing right to define the height limit through all slew positions When the right slew and height limit of the work area is reached press Enter to trigger lockout on the following condition a Slew left and right limit b Slew left and right warning limit c Maximum radius d Maximum height Refer to section 2 1d for information on lockout triggers 3 14e Chart area management Chart area management enables the rated capacity indicator system to automatically select the correct Capacity chart based on working area as defined by the crane manufacturer on the rated capacity chart Chart area management will determine capacity by load position e Position the boom tip within the limits of the safe area f To adjust the size of the radius height and slew limit warning zones go to menu 4F 2 3 14c Virtual wall A virtual wall can be defined by two points During the slew and radius limit definition wiza
104. p 1 of 3 Position the boom tip at the sheave Meaden perp AEL left slew limit of the work area and then press Enter c Step 2 of 3 Swing right to the right slew limit of the work area and then press Enter d Step 3 of 3 Position the boom tip safely inside the limits of the new work area e The slew limit warning zone is adjusted to 5 by default To adjust the size of the slew 46 nn The GS820 System yay x x Se aces ae bo ad Se a Slew limit NN x SSX ES D4 7 MA sy warning zone MO 5 is LK aye ee ae Wee os AX lt SS Oe OS TEN A A OK peer A a Pe Se HK Oe Br a a os y xx Ay Sey x ae ie BS PS SS ee ee s AX OK ca lt Ls Ss Sx x lt US DR 8 OS RO Ne Se CC Ce oe oO SS SR a SS SZ Me dle a yO S Ge Limit warning zone Figure Slew free area 2 Maximum tip height Define the maximum tip height limit and warning zone The display will alert the operator when the maximum tip height limit is approached or exceeded a Select Height in menu 4F 7 b Position the boom tip at the maximum height limit and then press Enter c Lower the boom tip to a safe height d The height limit warning Zone is adjusted to 5 ft by default To adjust the size of the height limit warning zone go to menu 4F 2
105. r status BATTERY 50 50 of battery life remains typically several months UNABLE TO REACH REMOTE SENSOR communi cation not yet established Verify the radio ID corresponds to the installed sensor 0 nn The GS820 System im 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 Anew high quality alkaline or lithium D 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 SENSORS DIAGNOSTIC Select a sensor and press Enter to verify the sensor status RECEIVED RF POWER 85 reception is at 85 means radio 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 than one ampere on the white wire
106. rd a Position the boom tip at the left end of the virtual wall b Press the virtual wall button The radius limit drawing on the display will be temporarily disabled c Position the boom tip at the right end of the virtual wall 3 14f How to delete work area limits a Go to menu 4F 3 ERASE Work AREA b Press Enter to erase the work area d Press on the virtual wall button again to generate the wall straight line between the two positions defined 3 14d Limit warning alarm and lockout 1 Limit warning When the boom tip reaches enters a warning zone the display will alert the operator with an intermittent beep the yellow warning light and an intermittent warning message on the LCD The size of the work area limit warning zones can be adjusted in menu 4F 2 48 nn The GS820 System yy ae lt 6 LSI 4 USB TOOL i Download data or upload capacity charts using a USB mass storage device USB key without removing the display from the crane PLSI lt gt USBKey A GS820 N Figure Transfer charts or data logger files 4 1 Data logger transfer from Display 4 1a Transfer from display to USB A IMPORTANT To copy the data logger to the USB key a password is required contact LSI to get the download password The Display ID will be asked by LSI space on the USB key Connect the USB key in the USB port on the left side of the display USB Port K a SEI
107. re should be minimal tension on the cable reel spring when the boom is fully retracted 6 Verify the boom length indicated on the GS820 LCD Boom length indicated should equal the actual total boom length The actual boom length is the distance from the boom base pin to the head sheave centre as measured along the boom centreline Depending on the exact placement of the cable reel and the cable anchor the displayed length may differ fromthe 2 5d Boom Length Calibration Figure The actual boom length Typical installation actual length Procedure Ne 2 Correct with the GS820 System OK if2 MEE ax 20000 1b If the displayed boom length does not match the actual Sere ib length of the boom retracted or extended and if it is not eae SATER ui a ge possible to easily correct by following 2 6c Boom Length 5 O 0 0 1b Calibration Procedure Ne 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 4 INSTALLATION and select 4B SENSOR CALIBRATION 2 Enter the user password press Enter and go to menu 4B1 AUTOMATIC CALIBRATION WIZARD Figure Typical operation page with boom length indication 3 Use Up and Down to select the length sensor and then press Enter to confirm communication i with the sensor is possible 2 5 Boom Length Calibration j 4 Start the wizard
108. rvice or LST 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 prior to the expiry of the Limited Warranty Period in order to obtain a Return Authorization Number A proof of purchase of the Product such as an invoice or a receipt certifying the validity of the Warranty must be presented in order to obtain Limited Warranty coverage In any event even if a Return Authorization Number is provided to purchaser LSI reserves the right to inspect the damaged Product or part before the final decision of repairing or replacing the defective Product or part The 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 defective part or Product LSJ will at its option repair or replace the Product or part returned to LSI or to its designated service representative LSJ owns all parts or Products replaced repaired or removed from a repaired Product If LSI repairs a Product the Product 64 as The GS820 System Warranty coverage Period is not extended and the Limited Warranty shall expire as if uninterrupted upon the occurrence of the 24th month from sh
109. splay 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 bs A X A y N oR ans S lt J N i Oe aSa ao Z NOR ee Na WO NR x amp AN aR E IN y IS X aa EO KOT SEAN Nee Nes Noa Tis NEN SNT TAS ON Oe oe oF Se NZ x Nee SN iai ee Ne Sx _ ae ees 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 22 nn The GS820 System my 2 8 Wireless Load Pins Handle wire Figure Load pin IMPORTANT Do not pull on a load pin by the pigtail pull on the handle wire 2 8a LP011 LP015 and LP026 1 Mount the load pin to the boom tip or block by replacing the pin of the wedge socket The load pin is directional and must be oriented correctly to indicate load accurately Install the pin so that the bracket embraces the wedge socket and prevents pin rotation Note When installed at the boom tip the lot number can be re
110. t already installed on the crane boom step 2 4a with the antenna pointing away from the boom Install a weight and chain assembly to the eye nut The weight and chain assembly can either be supplied by LSJ 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 4d Chain length adjustment 1 Chain length adjustment Ne 1 minimum boom angle a At minimum boom angle with no additional weight on the hook block and one part of line only lift the boom just enough to have the hook block suspend and clear the sensor chain and weight Boom cs base gt lt i a N p Hook block stops rising two block prevented with safety margin f A Anti two block switch triggers i e 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 Ne 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 angl
111. t 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 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 Slew Encoder Bracket crane through the full motion of the crane upper Slew Encoder Spring body Slew Sensor Encoder Sy Figure Slew encoder installation Typical installation ga INSTALLATION 33 LS a Note The tension applied by the slew encoder spring is required to keep the encoder gear in contact with the slew gear 2 14e Slew Transmitter Location IMPORTANT To ensure reliable radio communication between the slew sensor and the GS820 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 GS820 display e The antenna should have a clear line of sight to the GS820 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 encoder with a 6 ft cable but it can be installed beside the transmitter if convenient
112. t radius 524288 Maximum mast radius 1048576 Minimum load limit 2097152 Slew Warning Left 4194304 SlewWarningRight 8388608 COAT QUNG oso arc i s iets ae eels Sig ote 16777216 ChartValueReversed 33554432 Table Example Ne 1 Maximum radius o24s bean bd we Pane 32 Minimum angle nanana anana ae Default green wire trigger 34 Table Example Ne 2 Maximum wind speed 1 Maximum angle 05 oo onthe aw eed a 4 Overload sisaan a a a a ee 8 Maximum length nananana aaa 64 HU ONO Ged lated a side ey Or omy Coste ane setae 128 Maximum tip height 4096 Default white wire trigger 4301 IN WARNING A hard stop to crane rotation may cause loss of stability structural damage to the machine property damage personal injury or death The slew warning triggers can be used to engage a damping system to safely slow down crane movement before slew limits are reached within machine tolerances at expected duty cycle speeds In all cases the crane manufacturer s recommendations should be followed Lockout relay inversion By default the lockout wires carry crane power supply voltage as long as the display is in safe condition When lockout is triggered voltage is cut on the lockout wires linked to the lockout condition J WARNING inverting lockout relays will allow crane operation in the
113. t 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 surface with a 1 4 inch bit following either the two three or the four holes configuration 2 5 in min ae flat surface hS A SAL t7 ANNI 20 120 TYE Figure Display mounting bracket footprint Not to scale 0 750 lt _ gt lt 10 750 3 Install the display with bolts Add washers and 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 cab to prevent water entry 4 Loosen the wing nut of the bracket arm to adjust display orientation to facilitate viewing by the operator and then tighten it back up WX S AN YK Cab mounting surface Aw A Figure Install the display and adjust orientation 2 16 Antenna Position For optimal performance the antenna should be positioned on its side such that it is parallel to the sensor antennas but not pointing directly to or directly away from them 1 Adjust the antenna position with the articulating base 2 The antenna should have 5 inches of clear Space all aroun
114. tection 6 System start up password protection 7 Parts of Line menu password protection 8 Chart Rigging password protection 9 Display Settings password protection 10 Sensor List password protection 11 Sensor Calibration password protection 12 Radius Settings password protection 13 Chart Settings password protection 14 Memory Banks password protection 15 Data logger password protection 16 Lockout Settings password protection 17 Network Options password protection 18 System Diagnostic password protection 19 Alarm Bypassed protection 41 NETWORK OPTIONS 411 NETWORK CONTROL 4 2 REPEATER LIST 413 SET UP SENSOR REPEATER 414 INSTALL SENSOR UPDATE 4J Memory BANKS 1 Save config A Copy configuration to memory bank A 2 Save config B Copy configuration to memory bank B 3 Save config C Copy configuration to memory bank C 4 Get config A Copy memory bank A to current configuration 5 Get config B Copy memory bank B to current configuration 6 Get config C Copy memory bank C to current configuration 7 Restore default Restore factory configuration 8 Clear configuration 4K DATA LOGGER EE GS3820 MENU OUTLINE Xr oS 4L LockouT SETTINGS 4M Boom DEFLECTION 5 DIAGNOSTIC 5A SYSTEM SENSORS 5B RADIO NETWORK 5B1 RADIO NETWORK 5B2 LAST SENSORS RECEIVED 5B3 SEARCH FOR SENSORS 5B4 B r ERROR RATE TEST 5C LockouT 5D DISPLAY 1 Time 2 date 3 Time clock battery test 4 Extern
115. to account critical variables such as weather ground and crane conditions that will reduce the safe working capacity of the crane mE OPERATION p 4 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 GS820 this is done by following the chart wizard in menu 2 CRANE RIGGING A IMPORTANT It is possible to leave the chart wizard at any time by pressing Bypass ExiT the GS820 will display the message RIGGING ABORTED Current capacity chart selection may have changed possibly changing the rated capacity indicated by the GS 820 Always complete the chart wizard all the way to the Rigging ok message before operating the crane 1 Goto menu 2 CRANE RIGGING and press Enter to start the chart wizard 2 The first page of the chart wizard is select hoist Use Up and Down to select the hoist and press Enter f there is only one load sensor in the system select man 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 2A Select hoist Main hoist Auxiliary hoist Figure Select hoist menu 3 The steps that follow will depend on the size and complexity of the rated capacity chart itself Typ
116. ust 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 LSJ may lead to system failure serious injury or death 2 1 Display GS820 A IMPORTANT Do not crack or puncture the membrane fascia The GS820 display is splash and rain proof Waterproofing depends in part on the integrity of the membrane IMPORTANT Do not power wash the display The GS820 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 Field replaceable antenna Part number TA008 Ram Bracket with dual ball joints Part number LB002B design Figure Display GS820 Figure Display dimensions inches Not to scale 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 G nnn The GS820 System ym Note Refer to the Operation section for detailed menu navigation instructions for all calibration procedures sidewall or on the ceiling of the cab To ensure reliable radio communication between sensors and the GS820 the antenna should not be in contact with metal and should have a direct and clear line of sigh
117. wire see tables below 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 and press Enter to confirm any change 5 Press Down to select the next wire trigger line and repeat steps 1 through 5 or press Exit to return to the operation display Table Default Triggers Lockout Wire Default Trigger White as scorns axa ions nananana aaa 4301 Green anana Jo See Bee Boas 34 Dange se pesos Ace weet eget ec 32767 Blue pote Hed Hoe aaa 0 Table Lockout Codes Condition Code Maximum wind speed 1 Minimum angle 00 00 eee 2 Maximum angle 0 0008 4 Overload ses senaia aa Wado a E ee ae a 8 Work area warning approach 16 Maximum radius 0005 32 Maximum length 64 Two bloCk nanana es en dee ee ee ee 128 Maximum wind gust 256 Maximum rope payout 512 Slew Left Limit 1024 Slew Right Limit 2048 Maximum tip height 4096 Maximum imbalance factor 8192 Table Lockout Codes Continued Condition Code Minimum slack rope 16384 Minimum list angle 32 768 Maximum list angle 65536 Minimum trim angle 131072 Maximum trim rope 262144 Minimum mas
118. y life of the sensor repeater will be reduced to 35 days This function should not be used where it is not required 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 Ge INSTALLATION p gt a LS a Program a sensor repeater 4 Press Exit to return to the operation display 1 In menu 4I select 4 3 SET UP SENSOR REPEATOR Yo 2 18d Wireless Sensor Update 2 Select 1 SELECT REPEATER press Enter to modify and use Up and Down to program the Itis possible to send a firmware update to a sensor radio ID number of the sensor that will be the Using the GS820 menu 4 4 INSTALL SENSOR repeater and press Enter to confirm UPDATE For more information on installing a Select 2 SELECT SOURCE press Enter and sensor update please contact LSZ program the radio ID number of the sensor that will be the source and press Enter Press SET UP REPEATER to save the new network path The following messages will be displayed briefly PARAMETERS SAVED CORRECTLY COMMUNICATING
119. y 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 The GS820 System JEE ne 6 LSI 5 2 Anti Two Block switch A 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 IMPORTANT Do not unscrew the white nylon hex bolt of the antenna IMPORTANT Do not unscrew the small screw to the left of the antenna 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 the plunger assembly without separating it from the cover an

GS820 Install and User - Bode Technical Services

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