LSI GS820, GS020, GS001, GS010-03 Installer And User Manual

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Page 1

GS820 Display

& GS Series Sensors

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.

WARNING!

Carefully read and understand this manual before proceeding.

Page 2

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.

IMPORTANT!

WARNING!

CAUTION!

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.

Page 3

TABLE OF COTETS

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

Page 4

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

Page 5

ITRODUCTIO

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 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

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.

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

Page 6

The GS820 System

2.1

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.

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

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

Page 7

ISTALLATIO

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.

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

Page 8

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

Page 9

ISTALLATIO

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.

Page 10

The GS820 System

2.2

Load Cell

1. Install load cell bushings as supplied by

LSI

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

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.

5. Secure the pins with the nuts and cotter pins provided.

6. 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.

Figure: Typical load cell and adapter plate assembly installed.

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.

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.

Crane dead end

Plate kit for loadlink

Loadcell

C/C

Wedge socket to loaded cable

Page 11

ISTALLATIO

2.3

Angle Sensors

2.3a Mounting Procedure

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.

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.

5. If the 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.

2.3b Angle Calibration Procedure

№ 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.

Figure: Angle sensor level with the boom (typical installation) -

Side View

Figure: Angle sensor top/bottom axis within 15° of vertical

(typical installation) - Front View

Figure: Wedge used to mount the angle sensor with its

top/bottom axis within 15° of vertical (typical installation) - Front View

Figure: Typical operation page with boom angle indication

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.

WARNING!

The angle reading may be

affected by vibration and may fluctuate; the

angle sensor should not be installed in close

proximity to a high RPM electric motor or other

source of high frequency vibration.

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.

Cabin

Boom

Angle Sensor

Cabin

Boom

Cabin

Boom

Angle Sensor

Wedge

Page 12

The GS820 System

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.

4. Pivot the angle sensor slightly until angle indication is correct. Repeat the angle validation (step 1) as required.

2.3c Angle Calibration Procedure

№ 2: Correct with the GS820

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.

1. Position the boom at a precisely known angle.

2. Go to menu 4) and select 4B) S

ENSOR CALIBRATION.

3. Enter the user password and press Enter.

4. Select 4B2) M

ANUAL PARAMETER ADJUSTMENT.

5. Use Up and Down to select the angle sensor to be calibrated and press Enter.

6. Select 2) T

RIM: and press Enter to modify.

7. Use Up and Down to modify the trim value.

Example: If angle indicated is 0.3° over the actual angle, adjust 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.

2.4

Anti-Two-Block Switch

Verify the anti-two-block switch is programmed to the GS820 display. Switches shipped with displays are pre-programmed in the factory. Test

: if the switch has been programmed to the display then the display will go in to two-block alarm when the wire rope of the switch is released. Press Bypass

to silence the 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 GS050 Installation

1. 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.

Figure: Angle Calibration Procedure № 2

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.

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 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:

• The antenna of the anti-two-block switch should not be in contact with metal.

• 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 GS820 display.

• The anti-two-block switch antenna should have a clear line of sight to the GS820 display; in most cases this means mounting the sensor on the same side of the boom as the operator's cab.

Page 13

ISTALLATIO

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.

For live end mounting on multiple sheave blocks with sheaves greater than 16 inches (41 centimetres) in diameter consult your service representative.

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. 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.

2. 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.

3. Install the weight and chain assembly around the cable and attach the other end of the chain to the GS050. Tighten all the chain links of the chain assembly.

4. Adjust chain length as required, see sub-section Chain length adjustment.

5. Test system function.

2.50

Figure: Anti-two-block switch placement on a telescopic boom

Figure: Anti-two-block switch placement for live end mounting

on a lattice boom

Figure: Anti-two-block switch placement for dead end

mounting on a lattice boom

Figure: Jib, rooster or other extension; anti-two-block switch

placement for single part of line operation only

Figure: Fast line weight installation

Figure: Bracket footprint and orientation,

All dimensions are in inches. Not to scale.

2.125

0.25

Mount bracket 4 in.

(10 cm) below sheave

center.

Boom

base

0.375

1.9375

2.5

0.75

Up to 8 in. (20 cm)

diameter

Mount bracket below

and behind sheave

center.

Pivot Center

(Anchor shaft)

ø0.38

30°

Boom

base

8-16 in. (20-41 cm)

diameter

Boom

base

Mount bracket directly

below sheave

Fast line

mounting

bracket

Chain

hole

Front View

center as low as

possible.

Boom

base

Anti-two-block switch GS050

Fast line weight

Mount bracket 4 in.

(10 cm) below sheave

8-16 in. (20-41 cm)

Mount bracket 4 in.

(10 cm) in front of the

dead end pin.

center.

diameter

Boom

base

Dead end pin

Page 14

The GS820 System

2.4b GS075 Installation

1. Optional Bracket: Position the optional mounting bracket on the boom. Bolt or weld securely.

2. Attach one end of the chain assembly to the optional bracket or to the boom and the other end to the eye bolt of the GS075. Tighten all the chain links of the chain assembly.

3. Remove the hair pin and the clevis pin and open the back end of the GS075. Install the GS075 around the cable and then put the clevis pin back in.

4. Adjust chain length as required, see sub-section Chain length adjustment.

5. Test system function.

2.4c Chain length adjustment

1. Chain length adjustment № 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.

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 № 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 angle.

3. Chain length adjustment № 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 test at minimum angle

Figure: Chain length test at maximum angle

Figure: Chain length adjustment

Figure: Install the GS075 around the cable

IMPORTANT!

GS050: to increase chain length, only use

lightweight chain.

Eye bolt

Clevis pin

Boom

base

Boom

base

Boom

base

B) Hook block stop A) Anti-two-block switch triggers two-block alarm

rising, two-block

prevented with

safety margin

Increase

GS050

weight

Increase

GS075

A) Anti-two-block switch triggers two-block alarm

B) Hook block stops rising, two-block prevented with safety margin

Page 15

ISTALLATIO

2.5

Length Sensor Cable Reel

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 № 1: Mechanical Set-Up and Angle Calibration Procedure № 2: Correct with the GS820, sections of this manual.

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.

A = ____________________

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 – C =____________________

Maximum cable reel extension must be greater than maximum boom extension.

2.5b 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.

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

Figure: GS101 angle & length sensor

Figure: Cable reel mounting position

WARNING!

Arc welding may damage

LSI

sensors, causing immediate failure or greatly

reducing functional life. Arc welding on or near

LSI

LSI equipment will void warranty. Keep

LSI

equipment well clear of any arc welding.

Note: When factory installed the GS011 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.

Welding

pad holes

tapped 3/8-16

Boom tip

Welding pads level and in line with the boom at

0 degrees from horizontal

Boom

base

GS011 angle/length

sensor antenna

LS011 length sensor

cable reel

Welding

pads

Welding

pads holes

16 1/8 in. apart,

centre-to-centre

Welding

pad holes

2 1/4 in. apart,

centre-to-centre

Page 16

The GS820 System

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. 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 from the actual length.

2.5c Boom Length Calibration

Procedure № 1: Mechanical Set-Up

1. Fully retract the boom

2. Adjust the loose wire rope at the boom tip so that the displayed boom length matches the 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 № 2: Correct with the GS820.

2.5d Boom Length Calibration

Procedure № 2: Correct with the GS820

If the displayed boom length does not match the actual length of the boom retracted or extended and if it is not possible to easily correct by following 2.6c Boom Length Calibration Procedure № 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) I

NSTALLATION and select 4B)

ENSOR CALIBRATION.

2. Enter the user password, press Enter and go to menu 4B1) A

UTOMATIC CALIBRATION WIZARD.

3. Use Up and Down to select the length sensor, and then press Enter to confirm communication with the sensor is possible.

4. Start the wizard.

5. Press Enter to confirm the units that will be used during the calibration wizard.

Cable anchor

Cable guide

Cable

reel

Boom length

Boom

base

Figure: The actual boom length. Typical installation.

Figure: Typical operation page with boom length indication

Figure: The boom length calibration wizard, confirm minimum

boom length.

CAUTION!

Visually monitor remaining

length on the cable reel as the boom is

extended for the first time following

installation. This generally requires a second

person (in addition to the operator).

Page 17

ISTALLATIO

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

actual fully extended boom length, and then

press Enter to confirm.

8. Note the new trim and scale values.

9. Press Enter to send the new calibration to the length sensor.

10.Press Exit to return to the operation display.

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. Test № 1: measure the actual radius and

compare to the radius indicated. Repeat with the boom at minimum angle, at 45 degrees, and at maximum angle; repeat at minimum and maximum boom length**. If radius indication is not accurate then go to step 4.

4. Measure the basic radius parameters on the

crane.

5. Program the basic radius parameters in the

RADIUS SETTINGS menu.

6. Test № 2: measure the actual radius and

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.

7. If the crane is rigged with the main boom only,

then go directly to step 11.

8. If the crane is rigged with a rooster, jib, or other

extension then the advanced radius parameters must be measured on the crane and then programmed in the

RADIUS SETTINGS menu of the

display.

9. Test № 3: measure the actual radius and

* 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

Figure: The boom length calibration wizard, confirm maximum

boom length.

Figure: The boom length calibration wizard, Trim and Scale

values.

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.

Page 18

The GS820 System

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. Repeat until the radius displayed equals the actual radius.

11. Test № 4: measure the actual radius and 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 refer to Radius Settings.

2.6b Radius Settings

1. Go to menu 4) INSTALLATION and select 4C) R

ADIUS SETTINGS.

2. Enter the user password and press Enter.

3. Use Up and Down to navigate between the radius settings, press Enter to modify and use Up and Down to adjust the settings.

4. Press Enter to save any changes and press

Exit to return to the operation display.

4C) R

ADIUS SETTINGS

* 1) Boom length * 2) Slew offset

3) Height offset

4) Boom deflection

5) Boom top length

6) Boom top offset

7) No load deflection

8) Jib offset

9) Lattice extension offset

10) Jib mounting point perpendicular

11) Jib mounting point parallel

12) Main hoist 12A) Jib length 12B) Luffing jib length 12C) Lattice extension length 12D) Manual length

* 12E) Sheave head length perpendicular

12F) Sheave head length parallel

* 12G) Sheave radius

12H) Deduct

13) Auxiliary hoist ...13A) to 13H): same as 12A) to 12H)

14) Auxiliary hoist 2 ...14A) to 14H): same as 12A) to 12H)

15) Auxiliary hoist 3 ...15A) to 15H): same as 12A) to 12H)

16) Auxiliary hoist 4 ...16A) to 16H): same as 12A) to 12H)

17) Auxiliary hoist 5 ...17A) to 17H): same as 12A) to 12H)

** Telescopic boom cranes only

Figure: Radius settings menu

* Basic radius parameters

Note: with the boom at 45° and the maximum load on the hoist, the boom deflection value should equal the difference between the actual and the displayed radius. With the boom at 45° and half the maximum load on the hoist, the boom deflection value should equal twice the difference between

the actual and the displayed radius.

IMPORTANT!

Radius settings 4C 12) to 4C

17) are specific to the hoist line.

Page 19

ISTALLATIO

2.6c Basic Radius Parameters for a Lattice Crane

2.6d Basic Radius Parameters for a Telescopic Boom Crane

Figure: Basic radius parameters for a lattice crane. Typical installation. Not to scale.

Figure: Basic radius parameters for a telescopic boom crane. Typical installation. Not to scale.

Jib mounting

point

Sheave head

length parallel

Jib

Head

sheave

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.

(Your measurement)

length

Jib offset

angle

Boom

base pin

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.

(Your measurement)

Crane center

of rotation

Menu 4C) 1) BOOM LENGTH

The distance from the boom base

pin to the head sheave centre.

(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.

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.

(Your measurement)

Boom

base pin

(Your measurement)

Crane center

of rotation

Page 20

The GS820 System

2.6e Advanced Radius Parameters

Figure: Advanced radius parameters. Typical installation. Not to scale.

Typical sheave heads:

• S

HEAVE HEAD LENGTH PERPENDICULAR = D1 HEAVE HEAD LENGTH PARALLEL = 0 (typical)

• S

Special top sheaves (example: rooster):

HEAVE HEAD LENGTH

• S

PERPENDICULAR = D2

• S

HEAVE HEAD LENGTH

PARALLEL = D3

Extensions, two possibilities:

ANUAL LENGTH: the offset is

1) M

always zero degrees.

ATTICE EXTENSION LENGTH: the

2) L

offset angle must be adjusted.

LATTICE EXTENSION LENGTH

LUFFING JIB LENGTH

(CENTRE SHEAVE TO

CENTRE SHEAVE)

FIXED JIB LENGTH

& OFFSET ANGLE

JIB MOUNTING POINT

PARALLEL & PERPENDICULAR

Luffing jib

angle sensor

LATTICE EXTENSION

LENGTH

& OFFSET ANGLE

BOOM TOP LENGTH

& OFFSET ANGLE

LATTICE EXTENSION OFFSET

ANGLE

BOOM TOP LENGTH

BOOM TOP OFFSET

ANGLE

BOOM LENGTH

includes boom top

Boom

angle sensor

heel pin

Boom

MAIN BOOM

Crane center

of rotation

SLEW OFFSET

Page 21

ISTALLATIO

2.7

Wireless Wind Speed

Sensor GS020

1. Remove the mounting rod from the wind speed

sensor.

2. Determine the mounting rod position.

a. Install the mounting rod on the same side

of the boom as the cabin mounted display, 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.

c. The wind cups must be fully exposed to

the wind and spin freely at all boom angles.

d. There should be a clear and unobstructed

line of sight between the wind speed sensor antenna and the cabin mounted display unit.

e. The transmitter antenna should not

contact any metal object.

3. Weld or screw the mounting rod to the boom at the selected position.

4. Re-position the wind speed sensor on the mounting rod, add the washer and secure with the cotter pin.

Figure: GS020 wireless wind speed sensor

Figure: Swivel orientation

Figure: Wind clearance

Figure: Radio line of sight - Crane top view

IMPORTANT!

Do not weld in proximity to

LSI

LSI sensor/transmitters.

Note: Angle iron can be used to extend the mounting position to be clear of the boom top.

Mounting rod

Page 22

The GS820 System

2.8

Wireless Load Pins

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.

2. Secure the load pin in place with a cotter pin or other suitable keeper device.

2.8b Load Pin Transmitter GS001

1. Determine the transmitter mounting position.

a. 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.

b. 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).

c. The transmitter antenna must not be in

contact with any metal object.

2. Weld the mounting blocks where required.

3. Mount the load pin transmitter on the mounting blocks.

Figure: Load pin

Figure: Load pin LP011, LP015 or LP026 -

Installation on a single part block

AA10K11

LINE PULL

Wedge socket

Load pin

Cotter pin

Pigtail

Boom tip

Figure: Load pin LP011, LP015 or LP026 - Installation at boom tip

Figure: Install the load pin transmitter GS001

IMPORTANT!

Do not pull on a load pin

by the pigtail, pull on the handle wire.

IMPORTANT!

Do not weld in proximity to

LSI

LSI sensor/transmitters.

Note: When installed at the boom tip the lot number can be read 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.

Handle wire

Pigtail

Wedge socket

Load pin

Hook ball or block

LINE PULL

AA10K11

Connect the

transmitter pigtail

to the Load pin

pigtail

Mounting

block

Page 23

ISTALLATIO

2.9

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.

Figure: Line riding tensiometer

Figure: Example of a typical installation on a lattice boom

crane, allows for lower clearance (not to scale)

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.

The Ratio of the distance between the line

riding tensiometer and the hoist drum must

be 18:1 as minimum to allow a normal

winding on the drum.

The angle between the swing arm and the

measured rope shouldn’t exceed 30 degrees.

Two Landing Pads (Wooden cushion) must be

added to allow line riding tensiometer sitting

when the boom is down.

Nothing should limit free displacement of

the swing arm & line riding tensiometer

assembly at any boom angle or configuration.

Figure: Example of a typical installation on a telescopic boom

crane (not to scale)

Figure: Typical installation (not to scale)

Swing Arm

Line Riding

Tensiometer

Line Riding

Tensiometer

Swing Arm

Hoist drum

Landing

Pads

Swing Arm

Line Riding

Tensiometer

Landing

Pads

Swing Arm

Line Riding

Tensiometer

Mounting

Bracket

(for swing arm)

Bracket and

Landing Pad

(wooden cushion)

Page 24

The GS820 System

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.

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 & 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

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. If the line riding tensiometer has been supplied with rope payout, 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).

Frame

Sheave

Size

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 (4.25") LD012 GD004-0750 3/4"

Medium (6") LD015 GD006-0875 7/8"

Medium (6") LD017 GD006-0945 (24mm)

Medium (6") LD016 GD006-1000 1"

Medium (6") LD018 GD006-1125 1 1/8"

Medium (6") LD020 GD006-1250

1 1/4"

(32mm)

Large (8") LD022 GD008-1375

1 3/8"

(36mm)

Large (8") LD024 GD008-1500 1 1/2"

Large (8") LD026 GD008-1625 1 5/8"

X-Large (10") LD028 GD010-1750 1 3/4"

X-Large (10") LD031 GD010-1890 (48mm)

X-Large (10") LD032 GD010-2000 2"

X-Large (10") LD036 GD010-2250 2 1/4"

* The hoist rope can also be installed by passing

the wire rope around the pulleys when the hook does not interfere.

Pulley

Page 25

ISTALLATIO

2.10

Load 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) I

NSTALLATION and select 4B)

SENSOR CALIBRATION.

2. Enter the user password, press Enter and select 4B1) A

UTOMATIC 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

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.

8. Note the new 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.

Figure: The automatic load calibration wizard, adjust the actual

parts of line

Figure: The automatic load calibration wizard, adjust the load

Figure: The automatic load calibration wizard, trim and scale

values

Page 26

The GS820 System

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.

• Sum load indication

• Imbalance

• 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 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 and press Enter to modify.

4. Determine the sum load cell “ID number”. For example: ID 1234 to indicate the sum of load sensors № 1, № 2, № 3, and № 4, or ID 34 to indicate the sum of load sensors № 3 and № 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 6)

YSTEM LIMITS.

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:

Program the imbalance sensor

1. Go to menu 4) 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

Imbalance factor calculation for load sensor № 1

A = Load № 1 B = Load № 2 C = Load № 3 D = Load № 4

Load № 1 (A) Imbalance Factor = 100 x

(Average B,C,D) - A

(Average B,C,D)

If the imbalance factor limit is 15%, then the system is safe.

A = 7500 B = 8100 C = 8000 D = 8200

Load № 1 (A) Imbalance Factor = 100 x = 7.5 %

8100 - 7500

8100

If the imbalance factor limit is 15%, then an imbalance alarm is generated.

A = 6800 B = 8100 C = 8000 D = 8200

Load № 1 (A) Imbalance Factor = 100 x = 16 %

8100 - 6800

8100

Page 27

ISTALLATIO

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) S

YSTEM

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) INSTALLATION and select 4A1) S

ENSOR 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)

YSTEM LIMITS.

Page 28

The GS820 System

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).

2.12a 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 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

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.

Figure: Trim and list angle indication

Figure: List and Trim axes

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.

List (roll)

Trim (pitch)