Manufacturers of Wireless Weighing Systems GS820 Display & GS Series Sensors INSTALLER AND USER’S MANUAL ! WARNING! ! GM820 The GS820 system is designed as an operator aid and is in no way a substitute for safe operating practice. WARNING! Carefully read and understand this manual before proceeding. REV.20090409 www.loadsystems.
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 ! and the following words: WARNING! ! Warning: this denotes an instruction that if not complied with may lead to serious injury or death.
TABLE OF CONTENTS 1. INTRODUCTION 1.1 OVERVIEW ........................................5 1.2 START-UP..........................................5 2. INSTALLATION 2.1 DISPLAY GS820 ................................6 2.1a 2.1b 2.1c 2.1d 2.1e Mounting Bracket ........................................6 Antenna Position ........................................7 Power Supply and Lockout Connection ......7 Lockout Settings ........................................8 Password Settings ..................................
3.4 DISPLAY LIGHTS ............................35 3.5 MENU SYSTEM ..............................36 3.5a 3.5b 3.5c 3.5d 3.5e Menu Numbers ........................................36 Menu Navigation ......................................36 Password Protection ................................36 Menu Layout ............................................36 Parts of Line..............................................37 3.6 RATED CAPACITY INDICATORS ..37 3.6a Display Programming................................37 3.
1. INTRODUCTION 1.1 Overview 1.2 Start-Up 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 twoblock 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).
2. INSTALLATION Note: Refer to the Operation section for detailed menu navigation instructions for all calibration procedures ! 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 LSI , may lead to system failure, serious injury or death. 2.1 Display GS820 ! IMPORTANT! Do not crack or puncture the membrane fascia.
2.1b 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 around it. 3. The antenna should have an unobstructed line of sight to all sensor antennas at all boom angles. 2.1c Power Supply and Lockout Connection 1.
2.1d Lockout Settings Warning, alarm and lockout control is programmed in this menu. 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.
Table: Lockout Codes (Continued) Condition 2.1e Password Settings Code Minimum slack rope . . . . . . . . . . . . . . . . 16384 Minimum list angle . . . . . . . . . . . . . . . . . 32768 Maximum list angle . . . . . . . . . . . . . . . . 65536 Minimum trim angle . . . . . . . . . . . . . . . 131072 Maximum trim rope . . . . . . . . . . . . . . . 262144 Table: Example № 1 Maximum radius. . . . . . . . . . . . . . . . . . . . . . 32 Minimum angle . . . . . . . . . . . . . . . . . . . . . .
2.2 Load Cell ! 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. 4.
e. The angle sensor should have a clear line of sight to the cabin mounted display. f. The angle sensor antenna should not contact a metal object. 2.3 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.
2. For GS011 angle/length sensors only: Carefully remove the cover of the GS101 cable reel. 3. Loosen the mounting screw in the slotted hole of the angle sensor mounting plate. 2.4 Anti-Two-Block Switch ! WARNING! Keep the 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 antitwo-block switch and render the anti-twoblock system unsafe. 4.
2.5 2.1 0.3 Mount bracket 4 in. (10 cm) below sheave center. 0 25 0 .25 75 Figure: Jib, rooster or other extension; anti-two-block switch placement for single part of line operation only ø0.38 5 37 1.9 2.5 30° 0.7 Pivot Center (Anchor shaft) 5 For fast line weight installation place the anti-twoblock switch mounting bracket directly below the sheave center as low and as close to the edge of the sheave as possible.
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. 2.4b GS075 Installation 1. Optional Bracket: Position the optional mounting bracket on the boom. Bolt or weld securely. 2.
2.5 Length Sensor Cable Reel ! 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.
and attach to the cable anchor on the tip of the last boom section. If additional cable length is required to reach the cable anchor point remove winds from the reel without putting additional tension on the cable reel spring. There should be minimal tension on the cable reel spring when the boom is fully retracted. 6. Verify the boom length indicated on the GS820 LCD. Boom length indicated should equal the actual total boom length.
6. Fully retract the boom, and use Up and Down to adjust the length value displayed to equal the actual fully retracted boom length, and then press Enter to confirm. 7. Fully extend the boom, and use Up and Down to adjust the length value displayed to equal the 2.6 Radius 2.6a Radius Verification and Adjustment 1. Verify the boom and luffing jib* angles, and the boom length**, are indicated correctly. 2. Verify the correct rated capacity chart is selected***. 3.
10. Test for boom deflection (telescopic crane only): is the radius indicated equal to the actual radius with the boom at 0 degrees and at 90 degrees but smaller than the actual radius with the boom at 45 degrees? If yes then adjust the boom deflection value to compensate: a. Raise the boom to 45 degrees with a known load. b. Compare the indicated radius with the actual radius. Change the boom deflection value and again compare the radius displayed with the actual radius.
2.6c Basic Radius Parameters for a Lattice Crane Jib offset angle Jib mounting point Sheave head length parallel Menu 4C) 2) SLEW OFFSET The distance from the boom base pin to the crane centre of rotation. If the boom base pin is behind the centre of rotation this value will be negative. Jib length Head sheave (Your measurement) 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.
2.6e Advanced Radius Parameters Typical sheave heads: • SHEAVE HEAD LENGTH PERPENDICULAR = D1 • SHEAVE HEAD LENGTH PARALLEL = 0 (typical) Special top sheaves (example: rooster): • SHEAVE HEAD LENGTH PERPENDICULAR = D2 • SHEAVE HEAD LENGTH PARALLEL = D3 D2 Extensions, two possibilities: 1) MANUAL LENGTH: the offset is always zero degrees. 2) LATTICE EXTENSION LENGTH: the offset angle must be adjusted.
2.7 Wireless Wind Speed Sensor GS020 c. The wind cups must be fully exposed to the wind and spin freely at all boom angles. Mounting rod Figure: GS020 wireless wind speed sensor 1. Remove the mounting rod from the wind speed sensor. ! IMPORTANT! Do not weld in proximity to LSI sensor/transmitters. 2. Determine the mounting rod position. Figure: Wind clearance d. There should be a clear and unobstructed line of sight between the wind speed sensor antenna and the cabin mounted display unit. a.
2.8b Load Pin Transmitter GS001 2.8 Wireless Load Pins 1. Determine the transmitter mounting position. Handle wire Pigtail 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.
2.9 Line Riding Tensiometer Line Riding Tensiometer Swing Arm Swing Arm Line Riding Tensiometer Hoist drum Landing Pads Figure: Line riding tensiometer Figure: Typical installation (not to scale) 2.9a Line Riding Tensiometer Installation Swing Arm CAUTION! ! The Line Riding tensiometer must be held by the swing arm and the tension of the wire rope; do not fix the line riding tensiometer to the boom.
2.9b 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. P/N GS series line-rider with swign-arm and transmitter P/N Cable size Inches (mm) Small (4.25") LD006 GD004-0375 3/8" Small (4.25") LD006 GD004-0500 1/2" Small (4.25") LD009 GD004-0563 9/16" Small (4.25") LD010 GD004-0625 5/8" Small (4.
2.10 Load Pins, line riding tensiometers and Compression Cells: Calibration 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. 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.
2.11 Four Point Lift 2.11b Imbalance The following functions are available for applications such as container cranes and gantry cranes that require load indication from four load sensors simultaneously. 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.
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. 5. The ID can be left at 0, press Enter. 6. Press Enter to save any changes. 7. Press Exit to return to the operation display. 8. Confirm the imbalance factor limit and the imbalance minimum limit in menu 6) SYSTEM LIMITS. 2.
2.12 List 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). 2.
