GS820 Display
& GS Series Sensors
INSTALLER AND USER’S MANUAL
INSTALLER AND USER’S MANUAL
GM820 REV.20090409 www.loadsystems.com
Manufacturers of Wireless
Weighing Systems
WARNING!
The GS820 system is designed as an operator aid and is in no way a
substitute for safe operating practice.
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WARNING!
Carefully read and understand this manual before proceeding.
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2
2
The GS820 System
The GS820 System
Read and understand the following:
For your safety and that of the people that come
into contact with
LSI
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: this denotes an instruction that if not
complied with may lead to serious injury or death.
Caution: this denotes an instruction that if not
complied with may lead to product failure or
property damage.
Important: this denotes an instruction that if not
complied with may lead to product performance
issues.
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IMPORTANT!
WARNING!
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CAUTION!
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BEFORE PROCEEDING
BEFORE PROCEEDING
WARNING!
Installation must be made in
compliance with
LSI
LSI instructions and using
LSI
LSI supplied components only. Failure to
install all parts, or replacing parts or
components with parts or components not
supplied by
LSI
LSI, may lead to system failure,
serious injury or death.
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!
TABLE OF COTETS
TABLE OF COTETS
3
3
1. INTRODUCTION
1.1 OVERVIEW........................................5
1.2 START-UP..........................................5
2. INSTALLATION
2.1 DISPLAY GS820 ................................6
2.1a Mounting Bracket........................................6
2.1b Antenna Position ........................................7
2.1c Power Supply and Lockout Connection ......7
2.1d Lockout Settings ........................................8
2.1e Password Settings ......................................9
2.2 LOAD CELL ....................................10
2.3 ANGLE SENSORS ..........................11
2.3a Mounting Procedure..................................11
2.3b Angle Calibration Procedure № 1:
Mechanical Set-Up....................................11
2.3c Angle Calibration Procedure № 2: Correct
with the GS820 ........................................12
2.4 ANTI-TWO-BLOCK SWITCH ..........12
2.4a GS050 Installation ....................................12
2.4b GS075 Installation ....................................14
2.4c Chain length adjustment ..........................14
2.5 LENGTH SENSOR CABLE REEL ....15
2.5a Maximum Boom Extension ......................15
2.5b Mounting the Cable Reel ..........................15
2.5c Boom Length Calibration Procedure № 1:
Mechanical Set-Up....................................16
2.5d Boom Length Calibration Procedure № 2:
Correct with the GS820 ............................16
2.6 RADIUS ..........................................17
2.6a Radius Verification and Adjustment ..........17
2.6b Radius Settings ........................................18
2.6c Basic Radius Parameters for a Lattice
Crane ......................................................19
2.6d Basic Radius Parameters for a Telescopic
Boom Crane..............................................19
2.6e Advanced Radius Parameters ..................20
2.7 WIRELESS WIND SPEED SENSOR
GS020 ..............................................21
2.8 WIRELESS LOAD PINS..................22
2.8a LP011, LP015, and LP026 ........................22
2.8b Load Pin Transmitter GS001 ....................22
2.9 LINE RIDING TENSIOMETER ........23
2.9a Line Riding Tensiometer Installation ........23
2.9b Line riding tensiometer installation on a
swing arm..................................................24
2.10 LOAD PINS, LINE RIDING
TENSIOMETERS AND
COMPRESSION CELLS:
CALIBRATION ................................25
2.11 FOUR POINT LIFT ..........................26
2.11a Sum Load Indication ................................26
2.11b Imbalance ................................................26
2.11c Slack Rope................................................27
2.12 LIST AND TRIM ANGLE SENSOR....28
2.12a Programming the GS820 for List and Trim
Indication ..................................................28
2.12b Mounting Instructions ................................28
2.12c List and Trim Angle Calibration Procedure ..29
2.13 ROPE PAYOUT................................30
2.13a Rope Payout Calibration Procedure № 1:
Mechanical Set-Up....................................30
2.13b Rope Payout Calibration Procedure № 2:
Correct with the GS820 ............................30
2.13c Rope Payout Limits ..................................31
2.13d Electrical connections ..............................31
2.14 DATA LOGGER ..............................32
2.14a Recording Modes ......................................32
2.14b Date and Time ..........................................32
2.15 SENSOR LIST ................................33
2.15a How to Add a Sensor to the GS820 ..........33
2.15b How to Remove a Sensor from the GS820 ..33
2.16 NETWORK OPTIONS ....................33
2.16a Listen Only Mode ......................................33
2.16b Repeater ..................................................34
2.16c Wireless Sensor Update ..........................34
3. OPERATION
3.1 DISPLAY GS820 ..............................35
3.2 USB PORT ......................................35
3.3 KEYPAD ..........................................35
TABLE OF CONTENTS
TABLE OF CONTENTS
4
4
The GS820 System
The GS820 System
3.4 DISPLAY LIGHTS ............................35
3.5 MENU SYSTEM ..............................36
3.5a Menu Numbers ........................................36
3.5b Menu Navigation ......................................36
3.5c Password Protection ................................36
3.5d Menu Layout ............................................36
3.5e Parts of Line ..............................................37
3.6 RATED CAPACITY INDICATORS ..37
3.6a Display Programming................................37
3.6b Crane Rigging ..........................................37
3.6c Chart Wizard ............................................37
3.7 DISPLAY SETTINGS ......................38
3.7a Units ..........................................................38
3.7b Backlight Mode ........................................38
3.7c Wind speed units ......................................38
3.8 SYSTEM DIAGNOSTIC ..................38
3.8a System Sensors Diagnostic ......................38
3.8b Radio Network Diagnostic ........................39
3.8c Lockout Diagnostic....................................39
3.8d Display Diagnostic ....................................39
3.8e Digital Input Diagnostic ............................39
3.9 SYSTEM LIMITS..............................40
3.10 TARE................................................40
3.11 INFORMATION ................................40
4. USB TOOL
4.1 DATA LOGGER TRANSFER FROM
DISPLAY ..........................................42
4.1a Transfer from display to USB ....................42
4.1b Transfer from USB device to PC ..............42
4.1c Troubleshooting ........................................42
4.2 UPLOAD CAPACITY CHARTS ......43
4.3 DATA LOGGER VIEWER ..............43
4.3a Installation on a PC ..................................43
4.3b Quick Start ................................................43
4.3c Full Report ................................................43
4.3d Wind Report ..............................................44
5. MAINTENANCE
5.1 SENSORS........................................45
5.1a Replacing Sensor Battery ........................45
5.2 ANTI-TWO-BLOCK SWITCH ..........46
5.2a Replacing the GS050 Batteries ................46
5.2b Replacing the GS075 Battery ..................46
5.3 REPLACING A SENSOR
ANTENNA........................................47
5.4 LOAD CELLS ..................................48
5.4a Reading Accuracy ....................................48
5.4b Load Testing ..............................................48
5.4c Care ..........................................................48
6. TROUBLESHOOTING ..................49
7. CERTIFICATION NOTES
7.1 FCC AND IC – INSTRUCTIONS TO
THE USER ......................................50
8. GS820 MENU OUTLINE
9. LSI PRODUCT LIMITED
WARRANTY - 2009/02/16
9.1 LIMITED WARRANTY ....................53
9.2 WARRANTY SERVICES
PROCEDURES................................53
9.3 EXCLUSION OF OTHER
WARRANTIES ................................53
9.4 EXCLUSION ....................................54
9.5 LIMITATION OF LIABILITY ............54
9.6 RECOMMENDED PRACTICES ......54
9.7 CHOICE OF LAW ............................54
9.7a Entire Agreement ......................................54
ITRODUCTIO
ITRODUCTIO
5
5
1.1
1.1
Overview
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 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). 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
includes a USB port to facilitate software and chart
updates and data logger downloads using a USB
mass storage device (USB key).
1.2
1.2
Start-Up
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
LSI
LSI representative or
LSI
LSI technical support
representative.
1.1.INTRODUCTION
INTRODUCTION
Figure: Key components in a typical system installation. Your product may vary. Not to scale.
WARNING!
The GS820 system is designed
as an operator aid and is in no way a
substitute for safe operating practice.
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GS075 All-In-One
Anti-Two-Block
Switch and weight
GC Series
Load Cell
GS050 Anti-Two-
Block Switch
GS820 Display
GS101 Angle and
Length Sensor
6
6
The GS820 System
The GS820 System
2.1
2.1
Display GS820
Display GS820
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
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 sight 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.
3. Install the display with bolts. Add washers and lock
nut behind the mounting surface and tighten
sufficiently (bolts, nuts and washers not included).
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.
2.2.INSTALLATION
INSTALLATION
Figure: Display mounting bracket footprint. Not to scale.
Figure: Install the display and adjust orientation
Figure: Display GS820
Figure: Display dimensions (inches). Not to scale.
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.
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Note: If the nuts are on the outside of the cab,
caulk with silicone between the washers and the
cab to prevent water entry.
WARNING!
Installation must be made in
compliance with
LSI
LSI instructions and using
LSI
LSI supplied components only. Failure to
install all parts, or replacing parts or
components with parts or components not
supplied by
LSI
LSI, may lead to system failure,
serious injury or death.
!
!
Note: Refer to the Operation section for detailed menu navigation instructions for all calibration procedures
Field replaceable
antenna
Rugged
aluminium
enclosure
Part number: TA008
Two way radio
system
0.906
120° TYP
ø2.5 in. min.
flat surface
0.594
0.594
ø0.218
0.750 0.750
Adjustable
Ram-Bracket
with dual ball joints.
Waterproof
design
5.74
8.75
10.73
7.23
Part number:
LB002B
2.25
2.44
7.37
Wing
Nut
Cab mounting
surface
ISTALLATIO
ISTALLATIO
7
7
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. 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.
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.
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 (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.
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.
Figure: Connection without lockout.
Figure: Connection with white wire lockout and recommended
Bosch relay.
Figure: GS820 power supply connector
Troubleshooting: if no voltage is present on the
white wire remove the load connected to the lockout.
To GS820 power supply
connector (Step 5)
To valve coil if
norm ally open is
required
Yellow cable
Blue wire
Orange wire
Green wire
White wire
Red wire
Black
wire
Lockout #4 - Optional
Lockout #3
Lockout #2
Lockout #1
Power Supply
or Battery
+12 V or +24 V
Bosch relay
n.c.
n.o.
co
To valve coil if
norm ally closed
is required
Yellow cable
Blue wire
Orange wire
Green wire
White wire
Red wire
Black
wire
Lockout #4
Lockout #3
Lockout #2
Lockout #1
Power Supply
or Battery
+12 V or +24 V
Orange wire: Lockout #3
Green wire: Lockout #2
Red wire: Positive 12 or 24 volts
Blue wire: Lockout #4
White wire: Lockout #1
Black wire: Negative (ground)
Yellow cable
8
8
The GS820 System
The GS820 System
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. 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 4G) L
OCKOUT SETTINGS.
2. Enter the user password (using Back, Next, Up
and Down as described in Password settings
section) and press Enter.
3. Select 1) W
ARNING 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) A
LARM 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 4G), select 2) A
LARM 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 4G) 8) L
OCKOUT RELAY
INVERTED). When a lockout level is reached voltage
is cut on all lockout wires linked to the lockout
condition (see menu 4G) 4) through 4G) 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 4G), select 3) L
OCKOUT 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 4G), select 4) W
HITE WIRE LOCKOUT
TRIGGER and press Enter to modify.
2. Select which alarm conditions will trigger
lockout on the white 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4301
Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Orange . . . . . . . . . . . . . . . . . . . . . . . . . . 32767
Table: Lockout Codes
Condition Code
Maximum wind speed . . . . . . . . . . . . . . . . . . 1
Minimum angle. . . . . . . . . . . . . . . . . . . . . . . . 2
Maximum angle . . . . . . . . . . . . . . . . . . . . . . . 4
Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Not used. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maximum radius. . . . . . . . . . . . . . . . . . . . . . 32
Maximum length. . . . . . . . . . . . . . . . . . . . . . 64
Two-block. . . . . . . . . . . . . . . . . . . . . . . . . . 128
Maximum wind gust . . . . . . . . . . . . . . . . . . 256
Maximum rope payout . . . . . . . . . . . . . . . . 512
Minimum slew . . . . . . . . . . . . . . . . . . . . . 1024
Maximum slew . . . . . . . . . . . . . . . . . . . . . 2048
Maximum tip height . . . . . . . . . . . . . . . . . 4096
Maximum imbalance factor . . . . . . . . . . . 8192
ISTALLATIO
ISTALLATIO
9
9
Table: Lockout Codes (Continued)
Condition 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
Default green wire trigger . . . . . . . . . . . . . = 34
Table: Example № 2
Maximum wind speed . . . . . . . . . . . . . . . . . . 1
Maximum angle . . . . . . . . . . . . . . . . . . . . . . . 4
Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maximum length. . . . . . . . . . . . . . . . . . . . . . 64
Two-block. . . . . . . . . . . . . . . . . . . . . . . . . . 128
Maximum tip height. . . . . . . . . . . . . . . . + 4096
Default white wire trigger . . . . . . . . . . . = 4301
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.
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
triggered lockout condition. In this case if the
display fails, crane functions will not lockout.
1. In menu 4G), select 8) L
OCKOUT 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
LSI technical support. Menus
accessible from the operation display can be
individually protected by the user password.
1. Go to menu 4) I
NSTALLATION and select 4H)
PASSWORD SETTINGS.
2. Enter the administrator password and press
Enter.
3. Select 1) A
DMINISTRATOR 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 4G), select 2) U
SER 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 4G), select 3) T
ARE PROTECTED and
press Enter to modify.
8. Use Up and Down to switch between “
YES” and
“NO” and press Enter to save any changes.
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)
I
NSTALLATION. If there are any unsaved changes
the display will request confirmation: press
Enter to save before quitting or press Exit to
quit without saving.
WARNING!
Inverting lockout relays will
allow crane operation in the 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.
!
!
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