LSI Load Systems International LS 420 – Two lines display – Universal User Manual GENERAL: The LS420 is a wireless capable display which shows the measurements taken by up to nine sensors linked in a local radio frequency network that can include any combination of load cells, angle sensors, anti-two-block switches and a wind sensor. This unit is compatible with the LSI network allowing full expansion.
Table of Contents System Description and Features .........................................................................................3 Important Note on System Operation and Start-up:........................................................4 Contact Information: ..................................................................................................................4 1.1 LS420 Indicator Lights......................................................................................................
System Description and Features The LS420 system detects and displays load and capacity related information and can warn the operator when a limit is exceeded or a two-block event is pending. This system is an operator aid and should not be solely relied upon for safe hoist operation.
Important Note on System Operation and Start-up: For proper operation of the LS420 display unit it must be calibrated for the configuration of installed sensors. The display unit powers up with several green lights flashing, this indicates that a radio communication link is being created with all load sensors, angle sensors, wind sensors and anti-two-block switches. Once a reliable radio communication link is established, all green lights will remain lit without flashing.
Chapter 1: LS420 Front Panel 1.1 LS420 Indicator Lights WARNING! “Two-Block” light indicates two-block condition “M” = main, “A” = auxiliary. Steady green indicates a2b sensor online and functioning Load indicated in pounds WARNING! “Load” light indicates that a load limit has been exceeded. “M” = main, “A” = auxiliary. Steady green indicates load cell online and functioning WARNING! “Low Batt” light indicates that one or more sensors need new batteries.
1.3 LS420 Buttons Bypass 1) The basic function of the bypass button is to bypass the anti-two block lockout for emergency purposes. The alarm will remain silent until the next two-block event; lockout will re-engage as soon as the button is released. 2) When one of the operating screens is displayed, pressing the bypass button automatically returns the display to the main hoist operating screen.
Tare 1) The tare function enables the operator to zero the hook and rigging weight. The operating screen will show the net weight. Pushing the tare button accesses the tare function. The tare can now be enabled, or disabled, by again pushing the tare button. The hoist button allows the operator to scroll between the main and the auxiliary hoists. When the tare function is not in use, the load displayed is preceded by the hook and ball symbol: .
1.4 LS420 Display Options 1.4.1 Weight units To change from pounds (lbs.) to kilograms (kg) or vice versa: Step 1) Press the bypass and tare buttons simultaneously to enter the calibration menu. Step 2) Press the hoist button to advance to the weight units selection screen. Step 3) Press either the limit+ or limit- button to change from pounds to kilograms. Step 4) Turn the display off, then on again. Adjust all load limits to conform to the new units. 1.4.
Chapter 2: Installation 2.1 Display Unit Installation To ensure reliable radio communication between the display unit and the installed sensors), the display unit antenna must not be in contact with metal and must have a direct, clear line of sight to the antennae of all sensors. 2.1.1 Mounting the display The display box may be installed either inside or outside the cab; though water can penetrate the display box, the interior is fully potted and will function properly in up to 1 ft (30 cm) of water.
the load connected on the lockout. An internal auto-re-settable fuse limits the current to 1 Amp. If a current higher than 1.5 Amp appears on the white wire, the fuse will trigger, cutting the current on this circuit. The fuse will permit the normal current flow to resume a few seconds after short-circuit removal. Fuse model #60R075 from www.littlefuse.com. • Green wire: normally not used. For optional second lockout, only when ordered. • Orange wire: do not connect.
Wiring example with lockout and recommended Bosch Relay Yellow cable Bosch relay White wire To valve coil if n.c. is required. n.c. Red wire Black wire n.o. co Battery +12V or +24V To valve coil if n.o. is required. Wiring example with lockout for valve requiring less than 0.75 Amp, without recommended Bosch Relay Yellow cable White wire Black wire Red wire Battery +12V or +24V 11 Valve coil Diode LS420 Universal User Manual V2.91 2003-01-21.
2.1.3 LS420 Display Unit Datasheet Dimensions : Weight: 1.5 pounds Hardware Electronics: 4) Antenna length: 3.25" 3) Height: 4.45" • Voltage: 10Vdc to 28Vdc • Radio Frequency: 925.43 MHz • Temperature: 0°F to 140°F (-20°C to +60°C) • Power requirement: 0.3 Amp • Output: 1 Amp mosfet relay (for lock out relay) • Antenna: 3.25" semi-rigid, replaceable Hardware Housing: • Rugged aluminum box. Electronic circuit com partment completely filled with neutral gel. 1) Thickness: 2.
2.2 Load Cell Installation V1.2 The load cell must be placed such that the antenna is not in contact with metal as this will interfere with radio communication between the load cell and the display unit. Step 1) The load cell has two different pin assembly sizes. Assembly of the load cell and adapter plates (fish-plates) must be configured to the pin size required by the specific dead end or hook to which it is to be attached.
2.3 Angle Sensor Installation Warning! The angle sensor must be installed such that the antenna is not in contact with a metal surface or object (boom, jib, wire, chain etc.). Such contact will interfere with radio communication between the angle sensor and the display unit. Warning! When welding the metal lugs to the boom the angle sensor must be kept well away from the weld site and any touching metal objects.
Manual zeroing: the easiest method for two people Mount the angle sensor with the indicator light pointing to the boom tip. Set the boom at a known angle such as forty-five degrees. Finely adjust the position of the bolt in the curved slot until the angle sensor displays the correct value; allow the sensor a few seconds to ensure it has the most accurate reading. The system should then show the correct angle from zero to ninety degrees.
2.4 Anti-two-block switch installation V2.0 To ensure reliable radio communication between the sensor (anti-two-block switch) and the display unit the sensor must be placed such that its antenna is not in contact with metal and has a direct, clear line of sight to the display unit antenna. Mount the sensor on the same side of the boom as the operator's cab. Before mounting any anti-two-block switch, verify that it is calibrated to the display unit.
b) A2B switch placement on a lattice crane. On sheaves between 8” and 16” in diameter two mounting brackets are necessary to permit both live end and dead end mounting. For live end mounting: For dead end mounting: 8” to 16” diameter 8” to 16” diameter Dead end pin Mount bracket 4” (10 cm) below sheave center (see shaded region of diagram). Mount bracket 4” (10cm) forwards of dead end pin.
Step 3) Test chain length. i) 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. ii) Hoist slowly until the red two-block warning lights up and the buzzer sounds. Note the hoisting distance remaining; this distance must be great enough to allow the operator or the lockout system, if installed, to prevent a two-block event.
2.5 Installation of a length sensor cable reel Step 1) Install the reel on its solder tab on the main boom. The cable reel is usually installed on the main boom’s lower section on a clear area. Guides should be placed along the boom sections and a cable anchor near the boom head. Step 2) Feed the cable through the cable guides and pull on it to attach it to the cable anchor. There should be minimal tension on the cable reel spring when the boom is fully retracted.
2.6 Installation of radius calculation V1.0 Before proceeding with radius calibration: • • • • • • Install the display unit (see section 2.1 of this manual). Install the angle sensor (see section 2.3 of this manual). If a pendulum type angle sensor is to be used it must be properly calibrated (see section 2.6.5 of this manual). Install the length sensor (hydraulic cranes only) (see section 2.5 of this manual) Enter the boom length on the boom length adjustment screen of the display (lattice cranes only).
2.6.2 Radius parameters for a lattice crane. The radius calculation parameters highlighted in green must be measured on the crane and set into the advanced menu of the LS420 display unit. Jib mounting point. Jib offset angle. Head sheave. Distance from head sheave center to jib mounting point. (Your measurement) Head sheave radius. Jib length. (Your measurement) Sheave head length: distance from head sheave center to boom centerline.
2.6.3 Radius parameters for a hydraulique crane. The radius calculation parameters in green must be measured on the crane and set into the advanced menu in the LS420 display. The radius equation is roughly: slew offset + boom length x cos(angle) + sheave length x sin(angle) + sheave radius = radius The sheave head length is the distance between the boom centerline and the center of the lower sheave.
2.6.4 Radius display troubleshooting For accurate radius calculation the actual boom length and angle, and the jib length and angle must be correctly displayed by the LS420 and the calibration parameters described in section 2.6.1 must be correctly measured and entered in the advanced options of the LS420 display. Before proceeding with troubleshooting confirm that the radius calibration procedure described in section 2.6.1 has been followed correctly.
Chapter 3: Changing Batteries 3.1 Changing Load Sensor Batteries V1.4 DO NOT change load sensor batteries without first reading these instructions. Many operators of LS401 and LS420 systems damage their load sensors with incorrect battery changing procedures. ALWAYS replace all three batteries of a load sensor at the same time. Replacing just one or two batteries will cause the unchanged batteries to reverse polarity, dramatically reducing the efficiency and life of the new batteries.
Do not unscrew the white nylon hex bolt of the antenna. Do not unscrew the four round topped hex bolts Do not cut any wires Step 3. Unscrew the two Phillips head screws about ¼ inch. Do not fully unscrew or remove these screws to avoid destroying the seal in which they are set. Step 4. Carefully cut the silicone seal all around the base of the box where it meets the link. Step 5.
Step 8. To install the three fresh, top quality, alkaline “C” cells the positive/negative alig nment of the batteries as indicated on the interior walls of the box must be respected. Insert the negative pole first. Once the negative pole is halfway in, gentle pressure in the direction of the negative pole will allow the positive end of the battery to be pushed in. Do not force more than is necessary.
3.2 Changing Angle Sensor Batteries V1.4 DO NOT change angle or wind sensor batteries without first reading these instructions. Many operators of LS401, 420, 425 and 2002 systems damage their angle and wind sensors with incorrect battery changing procedures. ALWAYS replace all three batteries of an angle or wind sensor at the same time. Replacing just one or two batteries will cause the unchanged batteries to reverse polarity.
Do not unscrew the white nylon hex bolt of the antenna. Do not unscrew the four round topped hex bolts Step 3. Unscrew the two Phillips head screws about ¼ inch. Do not fully unscrew or remove these screws to avoid destroying the seal in which they are set. Step 4. Carefully cut the silicone seal all around the base of the box where it meets the mounting plate. Step 5.
Step 7. Install the three fresh, top quality, alkaline “C” cells; the positive/negative alignment of the batteries must be respected as indicated on the interior walls of the box. Insert the negative pole first, keeping the battery as parallel to its final position as possible. Once the negative pole is halfway in, gentle pressure in the direction of the negative pole will allow the positive end of the battery to be pushed in. Do not force more than is necessary.
3.3 Changing Anti-two-block Batteries V1.5 ALWAYS replace all four batteries of a two-block sensor at the same time. Replacing just one, two or three batteries will cause the unchanged batteries to reverse polarity. This means that all batteries will need to be changed again within the next couple of days or even hours… • Batteries should be changed when reduced to 10 – 20 % of full charge. • The following items are necessary to successfully change the batteries of the anti-twoblock: a) A monkey wrench.
Chapter 4: Replacing Antennae 4.1 Replacing Load, Angle and Two-block Sensor Antennae V2.1 • • There are two types of sensor antennae: 1. Two-block sensor antennae: a blue tape identifies those made in the spring of 2002 and thereafter, they are replaceable. The antennae of two-block sensors made before February 16th, 2002 are not replaceable in the field: please contact your service representative. 2.
Step 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. Step 7. Slide the white nylon hex bolt to the middle of the length of the new antenna. Step 8. Coat the exposed metal foot of the new antenna with an electrical insulating compound by carefully inserting it in the mouth of the compound tube. White nylon hex bolt Antenna Step 9.
Chapter 5: Adding and Removing Sensors • • If in difficulty, disconnect and reconnect the yellow cable of the LS420, then press the test button to verify all calibrated sensors. If in serious difficulty, simply start over by erasing all sensors from the system (section 5.2), then re-entering them one by one (section 5.1). Correctly set the parts of line, tare and all applicable limits for any newly added sensor.
5.2 How to Remove A Sensor from the LS420 Step 1) To enter the manual calibration mode, hold the bypass button down continuously and press the tare button once. Release the bypass button when the screen displays "Calibration Mode". Step 2) Press the hoist button until the sensor to be removed is shown with the correct ID and sensor type (Load, Angle etc.). Press the tare button to remove the sensor. The display will show "ID = 0" on the first line and "No Sensor" on the second line.
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 0 0 0 0 0 0 0 0 0 0 1 0 1 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 1 0 1 1 1 0 1 1 1 0 1 1 1 l load, 2 angle, 1 wind For systems with only a2bs 1 load, 1 angle, 1 radius, 1 length LS2002 configuration 2 load with sum 2 load with sum, 1 angle 2 load, 2 angle, 1 wind, 1 radius LS425 5 load load and a2b with dual lock-out outputs 1 load, 1 angle, 1 wind, 1 radius 2 load, 1 angle, 1 wind, 1
Chapter 6: Troubleshooting 1.0 Troubleshooting Index 6.1 The Display Doesn't Light Up 6.2 The Lock-out Doesn't Engage 6.3 The Display Unit Is Always In 2 Block Alarm Mode 6.4 The Display Unit Is Always In Alarm Mode, the main hoist green light is flashing 6.5 The Display Unit Is Always In Overload Alarm Mode 6.6 The Display Unit Is Always In Limit Alarm Mode 6.7 The Display Unit Is Always In Wind Speed Alarm Mode 6.8 Radio Communication Problem 36 LS420 Universal User Manual V2.91 2003-01-21.
6.1 The Display Unit Does Not Light Up The display won't light up Press "Test" button Is there a change in the display? Please call your service representative Yes No Verify the connections of the black wire, the red wire and, if appropriate, the white wire of the yellow cable as described in section 2.1 of the Universal User Manual.
6.2 The Lock-out Doesn't Engage Carefully create a lock-out using an A2B switch. If there is no A2B switch in communication with the display lock-out may be created by temporarily adjusting a load or angle limit. The lock-out doesn't engage Verify the connection of the white wire of the yellow cable Is there a bad connection? Measure the voltage on the white wire of the yellow cable.
6.3 The Display Unit Is Always In Alarm Mode, The "2 Block" warning light is on 6.4 The Display Unit Is Always In Alarm Mode, the main hoist green light is flashing The display is always in alarm mode, the "2 Block" warning light is on? The display is always in alarm mode, the main hoist green light is on? Yes Yes The load cell failsafe warning is on.
6.5 The Display Unit Is Always In Alarm Mode, the Load warning light is on Remove weight from load cell. The display is always in alarm mode: the "Load" warning light is on. If "Hoist" button green light is on press the "Hoist" button until it goes off. Press the "Parts" button to verify that the parts of lines is consistent with actual cable configuration. Refer to the "Parts" button section in the user manual.
6.6 The Display Unit Is Always In Alarm Mode, the Limit+ or Limitwarning light is flashing The display is always in alarm mode: the "Limit + " warning light is flashing. The display is always in alarm mode: the "Limit -" warning light is flashing. Press the "Hoist" button until the boom angle is displayed. Press the "Hoist" button until the boom angle is displayed. Does the angle shown correspond to actual boom angle. No Yes Verify the angle sensor installation.
6.7 The Display Unit Is Always In Alarm Mode, the wind speed alarm message is flashing The wind speed alarm message is always flashing Does the wind speed shown correspond to actual wind speed? No Yes Is wind speed greater than set wind speed limit? No Visually inspect the wind speed sensor for physical damage. Verify proper installation, refer to wind speed sensor installation instructions.
6.8 Radio Communication Problem Radio communication between sensor(s) and cabin mounted display unit faulty. Press the "Test" button and verify the sensor ID #. The ID # for each sensor can be found on the sensor itself or on any invoice or shipping document for that sensor. Note that the ID # of older A2B switches is indicated on the A2B switch body in binary form. The binary to decimel conversion procedure is detailed in the A2B calibration mode section of the distributor manual.
Chapter 7: Purchasing and Customer Service Always call your service representative first, as he or she already knows the details of the sale and applications. They may also supply lockout and be able to provide the required service for that application. If not available please contact: LSI Corporate Offices: Dave Smith PO Box 820486 Vancouver, WA 98682 Phone (888) 819-4355 Fax (360) 256-3344 sales@loadsystems.
INSTRUCTION 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 instructions, may cause harmful interference to radio communications.
