Cranesmart Systems LAB110 User Manual
The LOAD & A-2-B Company Inc.
Cranesmart™
LMI System
Installation and Operating Manual
“Congratulations! You have invested in the industry’s
leading technology in crane safety equipment.
Thank you very much for your business”
The contents of this manual must be read
and thoroughly understood before operating the
crane with this equipment installed
For sales, service or assistance:
1-888-562-3222 / (780) 437-2986
www.cranesmart.com
Please have the serial number of your system handy before calling to purchase batteries or to ask for
technical assistance. You can find the serial number on either the receiver panel or the transmitters.
Please see page 54 for FCC Compliance
Revision March 18, 2003 – 1.09A
1
Table of Contents 1
Foreword – Installation guidelines, tools required 4
Section One Contents 5
– ANTI-2-BLOCK installation and explanation 9-13
– ANGLE SENSOR installation 14
– RECEIVER/DISPLAY PANEL installation 15
– SHUT OFF configuration 17
– ANTENNA installation 17
Section Two Contents 19
– PANEL BUTTON definitions and use 20
– FIRST TIME system start up, LOAD CHART information 21
– Correct CHART in use selection 21
– Correct PARTS-OF-LINE selection 22
– PRIMARY OPERATING DISPLAY explained 22
– LOAD CELL installation 6-8
– ALARM HUB installation and explanation 16
– Cranesmart™ Load Moment Indicator panel functions 20
– Correct WINCH in use selection 21
– SECONDARY OPERATING DISPLAY explained 23
Section Three Contents 25
– ANGLE SENSOR SIDE selection 30-32
– ANGLE ZERO calibration 33-35
– LOAD CELL calibration – KNOWN WEIGHTS explained 26-29
– ANGLE SENSOR SELECTION for use (main or jib) 36-38
2
Table of Contents 2
Section Four Contents 39
– Selecting WINCH LINE in use 40
– Setting LOAD MINIMUM alarms 41
– Setting LOAD MAXIMUM alarms 42
– To ENABLE TARE OUT function 43-44
– To DISABLE TARE OUT function 44
– Setting ANGLE MINIMUM alarms 45
– Setting ANGLE MAXIMUM alarms 46
– Setting RADIUS MINIMUM alarms 47
– Setting RADIUS MAXIMUM alarms 48
– Setting TIP HEIGHT MINIMUM alarms 49
– Setting TIP HEIGHT MAXIMUM alarms 50
Section Five Contents – Bypass key instructions 51
– Trouble-shooting for panel, battery and system lights 52
– No communication between transmitters and panel 53
– System technical component specifications 54
– Warranty 54
Warranty
The Load & A-2-B Company Inc. warrants to the purchaser of each new Cranesmart™ System that any part thereof
which proves to be defective in material or workmanship within two (2) years from date of delivery will be repaired or
replaced at no charge, if the system is returned to us in Edmonton, Alberta with all freight charges prepaid. If a
performance problem should occur, contact our office in Edmonton, Alberta at 1-888-562-3222.
This warranty does not cover defects resulting from accident, alteration, improper use, or failure of the purchaser to
follow normal operating procedures as outlined in this instruction manual. PLEASE NOTE: OPENING THE BLUE
RECEIVER PANEL VOIDS WARRANTY.
THIS WARRANTY IS IN LIEU OF ANY WARRANTY OR MERCHANTABILITY AND OF ALL OTHER WARRANTIES,
EXPRESSED OR IMPLIED, ALL OF WHICH ARE HEREBY EXCLUDED.
The Load & A-2-B Company Inc. shall in no event be liable for any special, indirect, or consequential damages
whatsoever and neither assumes nor authorizes any person to assume for it any other obligation or liability.
3
THIS LOAD MOMENT INDICATOR ***DOES NOT***
REQUIRE CALIBRATION.
IT IS
CALIBRATED AT THE FACTORY.
DO NOT CONSIDER THIS SYSTEM
A SUBSTITUTE FOR GOOD JUDGMENT, EXPERIENCE
AND ACCEPTED, SAFE CRANE OPERATING PRACTICES.
————————————————————
THE CONTENTS OF THIS
MANUAL MUST BE READ AND THOROUGHLY
UNDERSTOOD BEFORE OPERATING THE CRANE.
———————————————————
THIS SYSTEM UTILIZES A
SERIES OF ELECTRICAL AND MECHANICAL
COMPONENTS AND CANNOT BE 100% FAIL SAFE.
Installation guidelines
Read all of these instructions completely prior to beginning
D 12 volt application only. Check voltage as a step down converter will be required if
voltage is other than 12VDC
D Mount the load cells, anti-2-block switches and or angle transducers first
D Plan the installation
D Have the necessary tools available
D Mount the display panel second
D Test the system
Tools required
D Man basket – to reach the boom, rooster sheave and or jib tip
D Pliers for removing and bending cotter pins
D Electric drill with various drill bits
D Welder for attaching weld plated to boom/jib tips
D Wire crimping tools – for the display power and ground connections
D Screw drivers and or socket set
D Clear silicone
ATTENTION
4
Section One
This section provides
information for placement
and installation of the following components:
D Load cells
D Anti-2-block switches
D Angle sensors
D Receiver/display panel
D Alarm Hub panel
D Antennae
5
Load cell installation and placement guide for load cell links
Figure ‘A’ - Pin the BLUE load cell between the wire rope socket (becket) and the dead end on the main
boom of the crane. >MAIN<
Figure ‘B’- Pin the YELLOW load cell between the wire rope socket (becket) and the headache ball on the
auxiliary sheave (rooster) on the cranes boom tip. >AUX 1<
Figure ‘C’- Pin the ORANGE load cell between the wire rope socket (becket) and the headache ball on the
jib extension. >AUX 2< (Note: for three line load systems only)
JIB EXTENSION
DEAD END
Figure ‘C’
(Note: for two line load systems only)
Auxiliary 2
ORANGE Load cell
placement
Headache balls
Rooster sheave
whip/fast line
Becket or wire
rope socket
Figure ‘B’
Auxiliary 1
YELLOW Load cell
placement
Figure ‘A’
MAIN
BLUE Load cell
placement
Hook
block
Blue receiver panel
mounted in cab
External mount
antenna placed on
roof of
operator cab
6
15,000 - 25,000 lb. SLP load cell installation instructions
Male – Female - Load cell link
Placement on BOOM TIP DEAD END
Even part-of-line operation
For even parts-of-line, the load cell link is simply pinned
between the wire rope (wedge) socket and the dead end on the
boom tip as illustrated.
FRONT VIEW OF
SHEAVES AND
BOOM TIP
DEAD END/
TERMINATION
POINT
OR WIRE
PINS
BECKET
ROPE
SOCKET
LOAD
CELL
LINK
PINS
LOAD
CELL
LINK
BECKET
OR WIRE
ROPE
SOCKET
Male – Female - Load cell link
Placement on HEADACHE BALL
Single part-of-line
For single part-of-line, the load cell link is pinned
between the wire rope (wedge) socket and the
‘headache ball’ or traveling block.
DEAD END /
TOP OF SWIVEL BEARING
IMPORTANT SERVICE NOTE: THE COLORED BLOCKS ON THE LOAD
CELLS CONTAIN TRANSMITTERS, LITHIUM BATTERY PACKS, INTERNAL
STRAIN GAUGES IN ADDITION TO VARIOUS MODERN TECHNOLOGY
ELECTRONICS. VISUALLY INSPECT THE SEALS WHERE THE COLORED
BLOCKS ATTACH TO THE LOAD CELL. IF A SEAL IS BROKEN DUE TO
MIS-USE, AND EVEN IF IT CONTINUES TO WORK, SHIP THE SYSTEM IN
FOR SERVICE IMMEDIATELY. THIS WILL PREVENT MOISTURE FROM
TURNING A $100 REPAIR INTO A $700 REPAIR.
7
40,000 - 50,000 - 80,000 lb. SLP load cell installation instructions
Male – Male - Load Cell Link
Placement on BOOM TIP DEAD END
Even part-of-line
D For even parts-of-line, the load cell link is simply pinned between the wire rope socket (becket)
and the dead end on the boom tip. Please follow the diagram below which illustrates the correct
use of the 'sandwich link' rigging attachment for this load cell.
Front view of boom tip and sheaves
Sandwich
link
2 sides
This pin has three cotter pin holes which allow
for different dead end widths. Select the cotter
pin hole which provides the tightest fit, then
secure with washers and new cotter pins.
Threaded Locking Pin:
PINS
LOAD
CELL
MUST BE INSTALLED HERE.
Pin the becket to the bottom end of the load
cell. If becket pin diameter is too big, a
properly rated C-shackle can be used.
Sandwich Link Stabilization Pin
ATTENTION: THIS PIN PREVENTS DAMAGE TO THE LOAD CELL BY KEEPING THE SANDWICH LINK FROM
FOLDING AGAINST THE LOAD CELL IN A TWO BLOCK SITUATION. SUCH DAMAGE WILL NOT BE COVERED
UNDER WARRANTY. CHECK THIS PIN REGULARLY TO ENSURE THAT IT IS SECURE & IN PLACE.
Load Cell
8
Radio anti-2-block switch installation instructions
D Main Boom – Refer to Figures below to locate and install weld plate and A-2-B switch.
Please note that the weld plate & switch are shown larger than actual size for reference purposes.
Anchor loop
Figure ‘A’
Weld
plate
20° to 45°
TOP Ï
Front view of weld plate
These holes tapped
for 3/8th allen bolts
BACK of weld plate
WELD THIS SIDE
TO CRANE BOOM
Untapped holes
for anchor loop attachment
Figure ‘B’
Side view of weld plate
TOP Ï
FRONT of weld
plate with
anchor loop
Attached
FACE AWAY
FROM CRANE
D Ensure A-2-B switch and weld plate are attached. Place switch and weld plate at the desired location on
boom tip, at a 20 to 45 degree angle as illustrated in Figure ‘A’ above and mark with a scribe. A 20
degree angle is ideal for a mobile hydraulic machine, a 40-45 degree angle is ideal for a conventional
crane. Ensure that nothing will interfere with switch (such as a swing away jib extension, etc.) and that
the antenna is not touching any metal on the boom.
D Remove weld plate on A-2-B switch by unbolting the two 3/8th inch allen cap bolts. Weld the back of the
weld plate as per Figure ‘B‘ to the crane. Anchor loop should move freely once weld plate is welded.
Note that weld plate should be offset at a 20-45 degree angle from the boom as illustrated in Figure ‘A‘.
D After welding weld plate(s) to boom tip, allow weld plate to cool to the touch prior to mounting the A-2-B
switch onto weld plate with the two allen bolts. Installed switch should now look like Figure ‘C‘ below. It
should be positioned directly above the dead end or slowest speed line. Ensure that the location of the
switch is such that the line of sight is not blocked from the cab by any brackets or flanges.
D Install the chain onto the cable loop on the bottom of the A-2-B switch. Attach the counter weight to the
dead end line or the slowest speed line.
D Repeat this procedure for rooster sheave (Aux. winch 1) and or jib extension (Aux. winch 2) A-2-B switch
installations.
O
I
D
A
R
B
-
2
-
A
A-2-B switch
Figure ‘C’
20° to 45°
9
Radio Anti-2-Block installation and placement guide
RADIO
A-2-B
Figure A - Location of radio anti-2-block switch on main boom of crane.
Figure B - Location of radio anti-2-block switch on ‘rooster sheave‘ or Auxiliary winch 1.
Figure C - Location of radio anti-2-block switch on ‘jib extension’ or Auxiliary winch 2.
Figure D - Location of external magnetic mount antenna on operator cab of crane.
Figure C
Jib or Aux 2 switch
placement
If installing two switches, install the switch
with AUX after the serial number on the
auxiliary line, not the main line
JIB EXTENSION
RADIO
A-2-B
Figure B
Rooster or Aux 1
switch placement
RADIO
A-2-B
Please note:
Figure A
Main line switch
placement
Headache balls
Hook
block
Blue receiver panel
mounted in cab
Figure D
External magnetic
mount antenna
placed on roof of
operator cab
10
Optional Fast Line Counterweight – single part of line only
Installation – hanging procedure
Install weld plate for A2B switch as per instructions on page 4 of this manual. Weld second weld plate to
opposite side of boom close to the bottom of the boom tip with the quick link hanging away and down. Attach
counterweight cable to the bottom of A2B transmitter using the quick link supplied. Attach counterweight
chain to second weld plate on opposite side of the boom. Adjust the length with the chain links until
counterweight sits level on the wire rope as illustrated. Slide wire rope into donut by following the simple
illustration instruction below. Fast line counterweight installation is now complete.
Radio A2B
switch
Weld plate
bolts
Weld plate
Attach cable
with dual
bottom lines
here
Attach cable
with single
bottom line
Attach two short
cables to single
thimble here
here
Front view of boom tip
Second
weld plate
Attach chain to quick
link on weld plate here
To level counterweight on
wire rope – adjust length of
chain by shortening or
lengthening chain on quick
link at weld plate
Front view of
weld plate
Side view of
weld plate
TOP Ï
BACK of weld plate.
Weld this side to
crane boom
Important note:
If you need to remove
either of these bolts
ensure that you use
loctite when you
retighten them.
Operate with level counterweight
Remove this section, slip wire rope through
and replace allen head bolts using loctite.
11
Description of anti-2-block switch – red flagged transportation clip
D The Transportation Clip with the red tag is a device which keeps the switch
in a non-2-block state for transportation purposes. If you fold away your jib
or remove a counterweight from a switch, ensure that the red flagged
transportation clip is installed as illustrated. When transporting the crane
long distances, ensure that you place the transportation clip in the bottom of
the switch. This is done by allowing the weight to pull the switch into the
non-2-block position, and inserting the red flagged transportation clip on the
cable between the bottom of the aluminum collar on the switch and the metal
grommet about 5/8th’s inch below on the cable.
D If you loose this transportation clip it will not affect the normal operation of
the anti-2-block system
D Please note: The red flagged transportation clips are to be removed from
the bottom of the switch for normal system operation. If left in the switch the
crane: WILL NOT HAVE ANTI-2-BLOCK PROTECTION.
T H E
L O A D
&
A - 2 - B
CO
*IMPORTANT*
REMOVE RED FLAGGED TRANSPORTATION CLIP FOR
SYSTEM OPERATION
REPLACE WHEN MOVING OR TRANSPORTING CRANE
Red flagged transportation clip.
12
Figure ‘A’ Figure ‘B’
T H E
L O A D
&
A - 2 - B
C O
T H E
L O A D
&
A - 2 - B
C O
Weld plate
Anchor loop on weld plate
Snap link on chain
To counterweight
Transportation Position
Ensure the chain is clipped by the snap link to
the anchor loop on the weld plate when
transporting the crane. See Figure ‘A’. This will
prevent damage and/or premature wearing of the
cable at the bottom of the anti-2-block switch.
Use the snap link to attach the chain to the
anchor loop on the weld plate. Chain assembly
should look like Figure ‘A’. Please note: The
A-2-B system will report a TWO-BLOCK
ALARM when the blue receiver panel is
powered up to remind the crane operator to
unclip the chain for operation.
13
To counterweight
Operating Position
Ensure the chain is not clipped to the anchor
loop by the snap link when operating the crane.
The snap link should be hanging freely.
(as illustrated in above Figure ‘B’).
Chain assembly should look like Figure ‘B’.
Please note: Test the system daily by lifting
the counterweight and confirm an audio and
visual alarm on the blue receiver panel.
Radio boom angle sensor installation instructions
D The angle sensor must be installed on the boom at a minimum distance of ten feet from the antenna on the
cab of the crane. The sensor can be mounted on either side of the boom however the default setting is
for installation on the LEFT SIDE of the boom. If you determine that the right side of the boom is a more
desirable location for the sensor you must program the panel for right boom operation – see section 3 of
this manual after you have installed the angle sensor on the boom. Line of sight between sensor antenna
and antenna should exist in all positions. Do not mount sensor on the top or bottom of the boom. Position
the sensor weld plate assembly parallel with the boom line. Use the illustration on the Sensor label as an
alignment aid.
BOOM LINE
D Exact alignment is preferred but not necessary. Small alignment error can be zeroed out at the panel in the
cab of the crane. Mark or scribe the boom where the weld plate will be mounted. Unbolt the weld plate
from the angle sensor and lightly tack weld, do not permanently weld the plate yet. (see figure A below)
PLEASE NOTE: Lightly tack weld plate where you think it should go, leaving the opportunity to move, adjust
and re-weld if necessary, before testing the system for operation. Make certain that the antenna on the
boom angle sensor will not be touching any metal once mounted. DO NOT ATTEMPT TO WELD THE
WELD PLATE WHILE ATTACHED TO THE SENSOR. THE SENSOR WILL BE PERMANENTLY
DAMAGED. Once the weld has cooled, mount the sensor to the weld plate (see figure B below) using the
bolts and lock washers supplied.
D Now you will need to raise your boom to a minimum of a 45 degree angle then return it to level. Now you
should proceed to zeroing the angle. You will find these simple instructions on page 33-35 of this manual.
Weld plate
STEP 1:
Attach weld plate to
boom as illustrated
Figure ‘A’
LINE OF BOOM
RADIO BOOM ANGLE INDICATOR
Mount on base section of boom – see manual
For sales or service call:
THE LOAD & A-2-B COMPANY INC.
BOOM LINE
1-888-562-3222
Figure ‘B’
LINE OF BOOM
14
Use screws
and lock
washers
provided
Boom Angle
Indicator
STEP 2:
Bolt angle
sensor to weld
plate on boom
as illustrated
Display panel installation instructions
D Display panel mounting: The installation of the display panel consists of drilling two holes for mounting in
the operator cab. First find a suitable location in the cab on the dash where the crane operator has an
unobstructed view of the display. Using the removable bottom portion of the mounting bracket align, mark and
drill two holes in the cab of the crane. Securely attach the bottom portion of the mounting bracket
assembly to the dash. Place panel into the carriage holes of the lower mounting bracket and with the two
fluted knobs and star washers, securely attach panel with the front of the display facing the operator.
D WITH ALARM HUB – Display panel power: is provided to the panel using the four (4) pin interconnect cable
included The interconnect cable joins the alarm hub and the display panel together. When attaching either
end of the interconnect cable to the alarm hub and or the display panel, align the groove in the plug
head with the groove in the panel or hub plug receptacle and insert gently – do not force. Lock plug
on by gently rotating the collar of the plug a half turn clockwise.
D alarm hub wiring and alarm output instructions on next page.
CRANE SMART SYSTEM
CRANE SMART LOAD MOMENT INDICATOR
The Load & A-2-B Company Inc.
TEST
BY
PASS
MODE
©
©
Attach antenna
lead here
Non – ALARM HUB
power cable
Attach 3 pin power cable here
1 Red
1 White
1 Black
3 Pin
to base
With ALARM HUB
power cable
Attach 4 pin interconnect cable
4 Pin
4 Pin
to alarm hub
to display
panel
D Display panel power with NO ALARM HUB: is provided to the panel using the three conductor cable
included. Connect the red wire to a positive (+12VDC) terminal and the black wire to a solid ground on the
crane. The third white wire is for optional shut offs or to sound external horns. ATTENTION
: Ensure that a
continuous +12 VDC (11 volts minimum and typically 13.25 VDC with the engine running) is available
to the panel at all times while the crane is in operation
. Otherwise the system will not operate
correctly. When attaching power cable to panel gently push male end of plug into female panel
receptacle. Slide plug neck back towards panel and tighten clockwise ½ turn.
PLEASE NOTE: If you have ordered your Cranesmart with classified area approvals such as
Class I, Division II, for example – you must ‘lock on’ each end of the interconnect cable and
alarm ports. Use the allen key provided to lock/unlock the cabling.
15
Display panel installation instructions – With ALARM HUB
The alarm hub is an outboard extension of the Cranesmart display which allows up to three 12V 7.5A alarm
outputs to be added to the Cranesmart system according to customer specifications. The alarm hub has an on
board microcontroller which supervises the alarm relays for proper operation, hot or cold. The alarm hub
communicates with the Cranesmart via an RS232 serial connection. You may mount this component out of the
way, under the dash or on the side of the cab for example. It does not have to be visible by the operator.
CRANE SMART SYSTEM
3 Pin
to base
Wiring instructions – four easy steps: please take care when plugging in the finished connections. You must
align the slot of the plug in the hole and then press together gently before locking.
1. ALARM OUTS: Plug the 3 pin connector tagged Alarm Outs into the plug hole immediately below the ALARM
OUTS label. The other end of the cable will have up to three wires. You will find a tag on the cable itself
which will identify what output (load, angle or A-2-B) is signaled on each wire.
2. 12V POWER: Plug the 3 pin connector tagged 12V POWER into the plug hole immediately below the 12V
POWER label. The other end of the cable will have a single wire to attach to power.
3. GROUND: Plug the 2 pin connector tagged GROUND into the plug hole immediately below the GROUND
label. The other end of the cable will have a single wire to attach to ground.
4. SERIAL or INTERCONNECT cable: Locate the power cable with a 4 pin plug on either end. To power the
Cranesmart display panel you will need to plug one end of the 4 pin cable into the port labeled SERIAL on the
ALARM HUB and the other into the Cranesmart display panel. This will provide both power and ground to the
Cranesmart panel, while supporting the output relays for your crane shut-offs.
The LOAD & A-2-B CO., INC. 1-888-562-3222
ALARM OUTS
12V 7.5A
1 Red
1 White
1 Black
ALARM HUB
12V POWER
3 Pin
to base
Single wire
to 12V power
GROUND SERIAL
2 Pin
to base
Single wire
to ground
4 Pin
to base
Plug this 4 pin connector
to the right side of
Crane Smart Panel
PLEASE NOTE: When a Cranesmart system is programmed for use with an alarm hub, the alarm hub must
be present and working or the display will indicate an error condition as follows:
* * * ALARM HUB MALFUNCTION * * *
Please Correct
16
Shut off configurations for your system:
Normally each wire is identified with a tag to make installation of the shut-off circuits
simple. If the tags are missing or if you are unsure – call our service department. Due
to the many possible shut down configurations which your system may operate with,
please consult THE LOAD & A-2-B Company for your particular crane. Please have
the serial number of your system handy when you call 1-888-562-3222 or
1-780-437-2986.
——————————————————————————————————————
Antenna installation
Depending on the length or type of boom, four antenna installations and placements are possible.
With your system you may have received:
(A) One ten inch rubber antenna.
(B) One ten inch rubber antenna with an external magnetic mount base, attachment cable and plug.
(C) One metal whip antenna with an external magnetic mount base, attachment cable and plug.
(D) Marine specific antenna kit.
(A) Outside operator cab – up to 150 feet of boom: Where the receiver panel is installed outside a cab
simply install the 10 inch rubber antenna directly onto the blue receiver panel. Attach the base of the
rubber antenna to the side of the receiver panel by inserting it GENTLY with a simple half turn.
(B) Inside operator cab – up to 150 feet of boom: For installations inside the operator cab and where your
boom is less than 150 feet of length, place the magnetic mount base with the 10 inch rubber antenna on
the top of the operator cab and attach the antenna lead to the side of the receiver panel.
(C) Inside operator cab – more than 150 feet of boom: For installations inside the operator cab and where
your boom is more than 150 feet of length, place the magnetic mount base with the metal whip antenna
on the top of the operator cab and attach the antenna lead to the side of the receiver panel. Please
ensure the small allen screw for holding the whip antenna to the magnetic base is firmly tightened.
(D) Any MARINE application: attach base with the metal whip antenna on the top of the operator cab on the
crane attaching the antenna lead to the side of the receiver panel.
At all times ensure that the lines of sight between the load cells, anti-2-block
switches, angle transducers and the antenna on the cab of the crane are
unobstructed. It is important that the receiver antenna NOT be touching glass
or metal.
17
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