Load Systems LS050 A2B Switch User Manual LS420 Universal V2 91 2003 01 21

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Document Title	LS420 Universal User Manual V2.91 2003-01-21.doc
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LSI Load Systems International
LS 420 – Two lines display – Universal User Manual
GENERAL:
The LS420 is a wireless capable display which shows the measurements taken by up to
nine sensors linked in a local radio frequency network that can include any combination
of load cells, angle sensors, anti-two-block switches and a wind sensor. This unit is
compatible with the LSI network allowing full expansion. New LSI sensors may be
added and existing LSI sensors may remain in use when upgrading to a future display
generation.
LS420 Universal User Manual V2.91 2003-01-21.doc
Table of Contents
System Description and Features .........................................................................................3
Important Note on System Operation and Start-up:........................................................4
Contact Information: ..................................................................................................................4
1.1 LS420 Indicator Lights........................................................................................................... 5
1.2 LS420 Display Screen Abbreviations.................................................................................... 5
1.3 LS420 Buttons ....................................................................................................................... 6
1.4 LS420 Display Options .......................................................................................................... 8
Chapter 2: Installation ..............................................................................................................9
2.1 Display Unit Installation ......................................................................................................... 9
2.2 Load Cell Installation V1.2................................................................................................... 13
2.3 Angle Sensor Installation..................................................................................................... 14
2.4 Anti-two-block switch installation V2.0 ................................................................................ 16
2.5 Installation of a length sensor cable reel............................................................................. 19
2.6 Installation of radius calculation V1.0.................................................................................. 20
Chapter 3: Changing Batteries ............................................................................................24
3.1 Changing Load Sensor Batteries V1.4 ................................................................................ 24
3.2 Changing Angle Sensor Batteries V1.4 .............................................................................. 27
3.3 Changing Anti-two-block Batteries V1.5 ............................................................................. 30
Chapter 4: Replacing Antennae..........................................................................................31
4.1 Replacing Load, Angle and Two-block Sensor Antennae V2.1.......................................... 31
Chapter 5: Adding and Removing Sensors .....................................................................33
5.1 How To Add A Sensor to the LS420. .................................................................................. 33
5.2 How to Remove A Sensor from the LS420......................................................................... 34
5.3 Changing Sensor Configuration of the LS420 .................................................................... 34
Chapter 6: Troubleshooting 1.0...........................................................................................36
6.1 The Display Unit Does Not Light Up ................................................................................... 37
6.2 The Lock-out Doesn't Engage ............................................................................................. 38
6.3 The Display Unit Is Always In Alarm Mode, The "2 Block" warning light is on................... 39
6.4 The Display Unit Is Always In Alarm Mo de, the main hoist green light is flashing............. 39
6.5 The Display Unit Is Always In Alarm Mode, the Load warning light is on .......................... 40
6.6 The Display Unit Is Always In Alarm Mode, the Limit+ or Limit- warning light is flashing.. 41
6.7 The Display Unit Is Always In Alarm Mode, the wind speed alarm message is flashing... 42
6.8 Radio Communication Problem .......................................................................................... 43
Chapter 7: Purchasing and Customer Service ...............................................................44
LS420 Universal User Manual V2.91 2003-01-21.doc
System Description and Features
The LS420 system detects and displays load and capacity related information and can
warn the operator when a limit is exceeded or a two-block event is pending. This system
is an operator aid and should not be solely relied upon for safe hoist operation. The operator must at all times be fully aware of the approach of the hook block to the head
sheave, the length and angle of the boom and jib, the hoist and crane configuration and
rigging (including parts of lines, counter-weights, outriggers, rotation etc.) and the appropriate capacity charts. This system is designed as a backup to the operator in the
event that he has exceeded the safe limits of the crane.
- Displays information from up to nine wireless sensors including load cells, angle sensors, wind speed sensors and anti-two-block switches.
- Adjustable load limits and overload warning for hoists.
- Adjustable maximum and minimum angle limits with warning for booms and luffing jibs.
- Anti-two-block alarm and bypass.
- Waterproof.
- Multi-position mounting bracket.
- All sensors pre-calibrated.
- Parts of lines setting.
- Tare function.
- Bar graph display of percentage of load limit on load cells.
- Sensor battery status display and low battery warning.
LS420 Universal User Manual V2.91 2003-01-21.doc
Important Note on System Operation and Start-up:
For proper operation of the LS420 display unit it must be calibrated for the configuration
of installed sensors. The display unit powers up with several green lights flashing, this
indicates that a radio communication link is being created with all load sensors, angle
sensors, wind sensors and anti-two-block switches. Once a reliable radio communication
link is established, all green lights will remain lit without flashing.
This process takes about two minutes for sensors in sleep mode. The delay is created by
the battery management function and does not affect system security. If an anti-twoblock switch detects a pending two-block event, if a load cell detects a change in load, or
if an angle sensor detects a change in angle, the appropriate radio link will be established in less than 1/10th of a second. To immediately wake-up a load cell, lift the hook
with a load; to immediately wake up an angle sensor, change the boom angle.
In special conditions of lockout created by a missing sensor, you may bypass that sensor until the next display power up by pressing bypass for 10 seconds. That sensor
green light should stop flashing and then turn off.
Contact Information:
Corporate Office:
Load Systems International
P.O. Box 820486
Vancouver, WA 98682
Toll Free Ph.: (888) 819-4355
Dir. Ph.: (360) 666-5028
sales@loadsystems.com
U.S. Western Regional Office:
Scott Colberg
Toll Free Ph.: (877) 287-7011
Dir. Ph.: (360) 575-9518
Fax: (360) 575-8532
scolberg@loadsystems.com
Central/Gulf Regional Office:
Randall Perrin
Toll Free Ph.: (877) 278-7340
Phone (337) 893 -2322
Fax (337) 893-0026
rperrin@loadsystems.com
Toll Free Fax: (888) 238 -4099
Dir. Fax: (360) 258 -4093
For any information visit our website www.loadsystems.com
North Central Regional Office:
Terry Petzold
Toll Free Ph.: (877 ) 256-1674
Phone (920) 894-2785
Fax (920) 894-4934
tpetzold@loadsystems.com
LS420 Universal User Manual V2.91 2003-01-21.doc
Chapter 1: LS420 Front Panel
1.1 LS420 Indicator Lights
WARNING! “Two-Block” light
indicates two-block condition
“M” = main, “A” = auxiliary.
Steady green indicates a2b
sensor online and functioning
Load indicated in pounds
WARNING! “Load” light
indicates that a load limit
has been exceeded.
“M” = main, “A” = auxiliary.
Steady green indicates load
cell online and functioning
WARNING! “Low Batt” light
indicates that one or more
sensors need new batteries.
WARNING! “Limit –” light flashes
when minimum angle limit is passed.
WARNING! “Limit +” light flashes
when maximum angle limit is passed.
1.2 LS420 Display Screen Abbreviations
"A" = angle
"AH" = auxiliary hoist
"L" = length
"MA" = maximum or minimum angle, whichever actual angle is closest to
"MH" = main hoist
"MN" = minimum
"MX" = maximum
"R" = radius
"W" = wind speed
LS420 Universal User Manual V2.91 2003-01-21.doc
1.3 LS420 Buttons
Bypass
1) The basic function of the bypass button is to bypass the anti-two block lockout for emergency purposes. The alarm will remain silent until the next two-block
event; lockout will re-engage as soon as the button is released.
2) When one of the operating screens is displayed, pressing the bypass button automatically
returns the display to the main hoist operating screen.
3) When adjusting a limit, a parts of lines or tare, pressing bypass the button automatically returns the display to the operating screen from which the limit, parts of lines or tare function was
accessed.
Hoist
1) The hoist button allows the operator to scroll the display from the main operating screen to the sensor specific operating screens appropriate to system configuration. Operating screens may include:
a) The main hoist operating screen which shows the parts of lines for the
main hoist, the load on the main hoist including the tare/no tare indicator and potentially
the current wind speed, the main boom angle and the luffing jib angle.
b) The auxiliary hoist operating screen which shows the parts of lines for the auxiliary hoist,
the load on the auxiliary hoist including the tare/no tare indicator and potentially the current wind speed, the main boom angle and the luffing jib angle.
c) The main and auxiliary hoists' load maximum limits screen.
d) The boom angle maximum and minimum limits screen.
e) The luffing jib angle maximum and minimum limits screen.
f) The wind speed maximum limit screen.
Note: the precise order and aspect of operating screens depends on system configuration.
2) When adjusting limits (after pushing either the limit+ or limit- buttons) the hoist button allows the operator to scroll the display between adjustable limits of the system configuration.
For example: the main and auxiliary hoists' maximum load, the boom and luffing jib maximum
and minimum angles, and the wind maximum speed.
3) When adjusting the parts of lines (after pushing the parts button) or using the tare function
(after pushing the tare button) the hoist button allows the operator to scroll between the main
and auxiliary hoists.
Parts
1) The parts button allows the operator to adjust the parts of lines displayed for
the main and auxiliary hoists. Use the limit+ and limit- buttons to adjust the parts
of lines and the hoist button to scroll the display between the main and auxiliary
hoists.
2) Precise concordance between crane configuration and parts of lines indicated by the LS420
is necessary for accurate load display.
3) When the battery status of a wireless sensor is displayed in the test function, press the
parts button to select and hold the radio reception diagnostic screen.
LS420 Universal User Manual V2.91 2003-01-21.doc
Tare
1) The tare function enables the operator to zero the hook and rigging weight.
The operating screen will show the net weight. Pushing the tare button accesses
the tare function. The tare can now be enabled, or disabled, by again pushing the
tare button. The hoist button allows the operator to scroll between the main and
the auxiliary hoists. When the tare function is not in use, the load displayed is preceded by the
hook and ball symbol:
. With the tare function enabled, the tared load is displayed preceded
by the ho ok symbol: . When the tare function is enabled for any hoist the tare light will light.
2) When the battery status of a wireless sensor is displayed in the test function, press the tare
button to select and hold the radio power diagnostic screen.
Limit+ And LimitPushing the limit+ or limit- button allows the operator to adjust the
limits coherent with the system configuration. For example: the
main and auxiliary hoist load limits, the boom and luffing jib angle
maximum and minimum limits and the wind speed maximum limit.
The hoist button allows the operator to scroll between these limits. Further use of the limit+
and limit- buttons will adjust the limit chosen accordingly. While adjusting a limit, if both limit
buttons are pressed simultaneously, that limit will return to a factory default value.
Test
Pushing the test button engages the battery test function of the LS420 and permits the adjustment of indicator light intensity, display screen contrast, and display
screen back-light. The display screen will report the crane battery status (for about
16 seconds) then successively the battery status of each sensor (for about 8 seconds each). Pushing the test button advances from one battery report to the next, bypassing
the 8 second delay. Additionally, the intensity of the indicator lights may be adjusted using the
limit+ and limit- buttons during the first 8 seconds of the test function. The contrast of the display screen may be adjusted during the second 8 seconds using the limit+ and limit- buttons.
During the third 8 seconds use of the limit+ or limit- buttons will switch the back-light operation
between "automatic mode" and "always on". (The default automatic mode will switch the backlight off or on, based on system temperature and portable batteries options. The "always on"
setting will force the back-light to stay lit.)
"Batt: 40%" indicates 40% of battery life remains. 40% typically represents several months of
battery life. Batteries should be changed when 10-20% of life remains.
"NoSignYet" indicates that a communication link with the sensor indicated has not yet been established.
"NoBattYet" indicates that a communication link has been established but battery life remaining
has not yet been measured. Battery measurement is a low priority task, many other functions
have a higher priority. Battery life remaining can usually be known within 5 minutes.
When less than 10% of battery life remains for any sensor the Low Batt indicator will light. Use
the test function to determine which sensor is implicated. Usually, several days or weeks of operation remain from the moment the Low Batt indicator first lights.
LS420 Universal User Manual V2.91 2003-01-21.doc
1.4 LS420 Display Options
1.4.1 Weight units
To change from pounds (lbs.) to kilograms (kg) or vice versa:
Step 1) Press the bypass and tare buttons simultaneously to enter the calibration menu.
Step 2) Press the hoist button to advance to the weight units selection screen.
Step 3) Press either the limit+ or limit- button to change from pounds to kilograms.
Step 4) Turn the display off, then on again. Adjust all load limits to conform to the new units.
1.4.2 Lock limits
To prevent the operator from changing the set limits.
Step 1) Press the bypass and tare buttons simultaneously to enter the calibration menu.
Step 2) Press the hoist button to advance to the limit locked selection screen.
Step 3) Press either the limit+ or limit- button to lock or unlock the set limits.
1.4.3 Indicator light intensity
To adjust indicator light intensity,
Step 1) Press the test button to enter the test function.
Step 2) Press the limit+ or limit- button to raise or lower indicator light intensity.
1.4.4 Display screen contrast
To adjust display screen contrast,
Step 1) Press the test button to enter the test function.
Step 2) Press the hoist button to select the display screen contrast control screen.
Step 3) Press the limit+ or limit- button to increase or decrease display screen contrast.
1.4.5 Display Screen Back-light
There are two different control systems that regulate the display screen back-light.
1) The back-light generates heat: the temperature control system permits the LS420 display to
turn the back-light on or off in reaction to extremes in internal temperature. This allows the
system to better maintain its optimum working temperature. To override the temperature
control system (i.e. when operating the display unit from a battery pack in low temperatures
or when conditions are both hot and poorly lit):
Step 1) Press the test button to enter the test function.
Step 2) Press the hoist button to select the back-light control screen.
Step 3) Press the limit+ or limit- button to select the temperature control system or the
back-light always on override.
2) When the display is operated from a battery pack, using the 4-second standby mode can
double battery life. In this mode the back-light will turn off after four seconds and turn on
immediately when a display button is pressed. To engage the standby mode:
Step 1) Press bypass and tare simultaneously to enter the calibration menu.
Step 2) Press the hoist button to advance to the back-light control screen.
Step 3) Press either the limit+ or limit- button to select the 4-second standby mode or
the normal back-light always on mode.
LS420 Universal User Manual V2.91 2003-01-21.doc
Chapter 2: Installation
2.1 Display Unit Installation
To ensure reliable radio communication between the display unit and the installed sensors), the display unit antenna must not be in contact with metal and must have a direct,
clear line of sight to the antennae of all sensors.
2.1.1 Mounting the display
The display box may be installed either inside or outside the cab; though water can penetrate
the display box, the interior is fully potted and will function properly in up to 1 ft (30 cm) of water.
The mounting bracket is designed with three pivoting axes so that it can be mounted on the
dash, on either sidewall or on the ceiling of the cab.
One 3/8'' bolthole must be drilled to mount the display. The 3/8'' stainless bolt, washers and
stainless lock nut are supplied with the display. Choose a flat surface of at least 1-1/2'' in diam eter on both sides and where the back of the surface is accessible in order to tighten the nut. Drill
the hole with a 3/8'' bit. Place the display with the bolt through the hole. Mount the 2 large
washers and the lock nut behind and tighten sufficiently. If the nut is on the outside of the cab,
caulk with silicone between the large washer and the cab to prevent water entry. Orient the display to face the operator. Make sure the display antenna is not close to any metal surface and
has a direct line of sight to the antennae of all sensors.
For a boom truck with two operator stations, weld or bolt a pivoting arm in the center of the column facing the rear. The bracket should be above the rear ledge in order to pivot easily. Bolt the
display in place. Use a wing nut instead of the mounting nut in order to make the display more
easily removable.
2.1.2 Yellow Power Cable Wiring:
The connector of the yellow power cable 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 display can be connected to a power source between 10 and 28V positive or to a power
source between 12 and 28V AC. The display will automatically detect the voltage level and adjust itself; it is almost impossible to damage the unit when connecting.
•
Black wire: ground. The ground connection must be bolted to the body of the machine.
Use a 1/4'' or 5/16'' bolt. The ground connection must be strong enough to sustain 3 Amp.
• Red wire: +12 or +24 volts. The red wire terminal must be connected to an accessory
source rated at least 10 Amps if the display is to be connected to a lockout system. The red
wire terminal must be connected to an accessory source rated at least 2 Amps if the display is
not to be connected to a lockout system. An accessory source is a terminal, a fuse or wire
providing fused voltage only when the crane or the ignition is on.
• White wire: optional lockout. If optional lockout is to be connected, the red wire must be
connected to an accessory source rated at least 10 Amps. Ideally, the white wire should be
connected to a Bosch relay coil and the other lead of the relay solenoid connected to the
ground. Alternately, the white wire may be connected directly to the valve or valves solenoid
lead and the other lead of solenoid connected to the ground. When operating properly, the
white wire will be energizing at the battery positive level. If no voltage is present, try to remove
LS420 Universal User Manual V2.91 2003-01-21.doc
the load connected on the lockout. An internal auto-re-settable fuse limits the current to 1
Amp. If a current higher than 1.5 Amp appears on the white wire, the fuse will trigger, cutting
the current on this circuit. The fuse will permit the normal current flow to resume a few seconds after short-circuit removal. Fuse model #60R075 from www.littlefuse.com.
• Green wire: normally not used. For optional second lockout, only when ordered.
• Orange wire: do not connect. Display units made before July 2001 (s/n lower than 22545)
were powered with the orange wire instead of the red. This was changed to conform to industry standard. Now for optional cabled A2B, only when ordered.
Black wire: negative (ground)
Red wire: +12 or 24 volts (crane power supply)
White wire: standard lockout
Green wire: for optional second lockout, only when ordered
Orange wire: do not connect. For optional cabled A2B, only when ordered.
Wiring example without lockout
Yellow cable
Red wire
Black
wire
Battery +12V
or +24V
10
LS420 Universal User Manual V2.91 2003-01-21.doc
Wiring example with lockout and recommended Bosch Relay
Yellow cable
Bosch relay
White wire
To valve coil if
n.c. is required.
n.c.
Red wire
Black
wire
n.o.
co
Battery +12V
or +24V
To valve coil if
n.o. is required.
Wiring example with lockout for valve requiring less
than 0.75 Amp, without recommended Bosch Relay
Yellow cable
White wire
Black
wire
Red wire
Battery +12V
or +24V
11
Valve coil
Diode
LS420 Universal User Manual V2.91 2003-01-21.doc
2.1.3 LS420 Display Unit Datasheet
Dimensions :
Weight: 1.5 pounds
Hardware Electronics:
4) Antenna length: 3.25"
3) Height: 4.45"
•
Voltage: 10Vdc to 28Vdc
•
Radio Frequency: 925.43 MHz
•
Temperature: 0°F to 140°F (-20°C to +60°C)
•
Power requirement: 0.3 Amp
•
Output: 1 Amp mosfet relay (for lock out relay)
•
Antenna: 3.25" semi-rigid, replaceable
Hardware Housing:
•
Rugged aluminum box. Electronic circuit com partment completely filled with neutral gel.
1) Thickness: 2.30"
For any information visit our website
www.loadsystems.com
or contact:
2) Width: 4.45"
LSI Corporate Offices:
Dave Smith
PO Box 820486
Vancouver, WA 98682
Phone (888) 819-4355
Fax (360) 256-3344
sales@loadsystems.com
Western Regional Office:
Scott Colberg
Phone (877) 287-7011
Fax (360) 575-8532
scolberg@loadsystems.com
5) Bracket length: 4.5"
The yellow cable should have this
4.5" room to protect the connector.
12
Central Regional Office:
Randall Perrin
Phone (337) 893-2322
Fax (337) 893-0026
rperrin@loadsystems.com
LS420 Universal User Manual V2.91 2003-01-21.doc
2.2 Load Cell Installation V1.2
The load cell must be placed such that the antenna is not in contact with metal as this
will interfere with radio communication between the load cell and the display unit.
Step 1) The load cell has two different pin assembly sizes. Assembly of the load cell and
adapter plates (fish-plates) must be configured to the pin size required by the specific dead end
or hook to which it is to be attached. If the smaller of the two sizes fits the dead end or hook to
which the load cell will be attached, the load cell will be attached to the adapter plates with the
larger pin and the larger adapter plate holes.
If the larger of the two sizes fits the dead end
or hook, the load cell will be attached to the
adapter plates with the smaller pin. In both
cases, the copper bushing must be placed in
the hole of the load cell to which the smaller
pin is destined.
Step 2) The copper bushing must be secured in place by the two hex screws, one to
each side.
Step 3) The spacers should be placed on
the pin linking the load cell to the adapter
plates between the adapter plates and the
cotter pins to inhibit excessive lateral movement of the load cell and the adapter plates
along the pin.
Step 4) If the dead end or hook to be connected to the adapter plates requires a larger
opening, spacers may be placed between the
load cell and the adapter plates.
Step 5) In some cases spacers may also be
necessary on either side of the load cell on
the pin connecting it to the dead end or hook.
In all cases the spacers must be placed
symmetrically such that the load cell is
centered on the pins.
Step 6) Once the pins are correctly placed and spaced, they must be secured with the cotter
pins provided.
13
LS420 Universal User Manual V2.91 2003-01-21.doc
2.3 Angle Sensor Installation
Warning! The angle sensor must be installed such that the antenna is not in contact with
a metal surface or object (boom, jib, wire, chain etc.). Such contact will interfere with radio communication between the angle sensor and the display unit.
Warning! When welding the metal lugs to the boom the angle sensor must be kept well
away from the weld site and any touching metal objects.
The angle sensor is pre-calibrated at the factory; for correct installation it must be positioned
carefully, then zeroed. The bracket has two boltholes, one of which is a curved slot for fine adjustment. See the diagrams below for correct orientation. The angle sensor should be mounted
on the left side of the boom (as viewed from the cab) with the indicator light towards the boom
tip.
Left side
Front
Cabin
Cabin
Boom
Boom
centerline.
The angle sensor is
mounted with its hor izontal axis parallel to
the boom centerline.
The angle sensor is mounted
with its top/bottom axis within
15 degrees of vertical.
Boom
Front
Front
Cabin
Cabin
Boom
The angle sensor must
not be mounted with its
top/bottom axis more than
15 degrees from vertical.
Boom
A wedge can be used to mount the
angle sensor with its top/bottom
axis within 15 degrees of vertical.
Indicator light
Towards
boom tip
14
The angle sensor is mounted with its horizontal axis parallel to the boom centerline.
Towards
boom base
LS420 Universal User Manual V2.91 2003-01-21.doc
Manual zeroing: the easiest method for two people
Mount the angle sensor with the indicator light pointing to the boom tip. Set the boom at a
known angle such as forty-five degrees. Finely adjust the position of the bolt in the curved
slot until the angle sensor displays the correct value; allow the sensor a few seconds to ensure it has the most accurate reading. The system should then show the correct angle from
zero to ninety degrees.
Angle sensor assisted zeroing: the easiest method for a single person
Step 1)
Place the boom at zero degrees.
Step 2)
Mount the angle sensor with a bolt in the fixed position hole and tighten loosely.
Step 3) Rotate the angle sensor to vertical and hold steady until the indicator light stops
flashing for ten seconds. Rotate the angle sensor to horizontal (with the indicator light
pointing to the boom tip). The indicator light will flash while changing from green to red depending on slight changes in the angle: this indicates that the angle sensor is in ins tallation
mode. The angle sensor should stay in installation mode for one or two minutes.
Step 4) The colour of the light will help to place the angle sensor at zero degrees from
horizontal. The goal is to position the angle sensor such that the indicator light is green
without flashing: this indicates that zero has been obtained (the angle sensor is placed at 0
to 1 degrees above horizontal). Then place the second bolt in the curved slot and tighten
both bolts securely. When the sensor angle is between 1 and 5 degrees, the light will flash
green. Below 0 degrees, the light will flash red. Around zero, if the indicator light flashes red
the curved slot side of the angle sensor must be raised and if it flashes green the curved slot
side of the angle sensor must be lowered. If the indicator light goes out before zero has
been obtained, repeat step 3. Zero could be hard to obtain; this is normal.
Indicator light in 'installation mode'
Angle Sensor at 30 degrees
Angle Sensor at 90 degrees
15
LS420 Universal User Manual V2.91 2003-01-21.doc
2.4 Anti-two-block switch installation V2.0
To ensure reliable radio communication between the sensor (anti-two-block switch) and
the display unit the sensor must be placed such that its antenna is not in contact with
metal and has a direct, clear line of sight to the display unit antenna. Mount the sensor
on the same side of the boom as the operator's cab.
Before mounting any anti-two-block switch, verify that it is calibrated to the display unit. All
switches shipped with display units are pre-calibrated in the factory. The display unit should go
into alarm when the wire rope of a calibrated switch is pulled and released. Please note that the
black travel clip must be removed to permit the switch to function. If a switch does not appear
correctly calibrated to the display unit please follow the instructions in the calibration section
(chapter 5) of this manual.
Step 1)
Remove the black travel clip.
Depress the small button to
release the locking mechanism
and simultaneously…
…slide the locking ring back.
The clip can now be opened
to release the wire rope.
•
Leave the black travel clip attached to the sensor by the thin
wire: it will be useful if the sensor is
to be removed and stored in the future.
•
Releasing the wire rope will
cause the alarm buzzer of the display to which it is calibrated to
sound. Pressing the bypass button
of the display will silence the buzzer
until the next two-block event or
simulation.
Step 2)
Position the sensor mounting bracket.
Pin up
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.
30° from
horizontal
a) A2B switch placement on a telescopic crane.
For both live end and dead end mounting:
Up to 8”
diameter
Mount bracket below and
behind sheave center (see
shaded region of diagram).
16
LS420 Universal User Manual V2.91 2003-01-21.doc
b) A2B switch placement on a lattice crane.
On sheaves between 8” and 16” in diameter two mounting brackets are necessary to
permit both live end and dead end mounting.
For live end mounting:
For dead end mounting:
8” to 16” diameter
8” to 16”
diameter
Dead end pin
Mount bracket 4” (10 cm)
below sheave center (see
shaded region of diagram).
Mount bracket 4”
(10cm) forwards of
dead end pin.
For live end mounting on multiple sheave blocks with sheaves greater than 16” in diam eter, consult your service representative.
c) A2B switch placement when used on one part of line only (jib, rooster et.c.)
Mount bracket 2” to 4” below sheave
center (see shaded region of diagram).
d) Fast line weight installation
Place the sensor mounting bracket directly below the sheave center as low or as close
to the edge of the sheave as possible. Place the auxiliary chain mounting bracket on the
opposite side of the sheave such that the chain hole is lined up opposite the pivot of the
sensor mounting bracket and such that the chain hole points down.
Sheave center
Auxiliary chain
mounting
bracket.
A2B switch mounting
bracket directly below
sheave center and as low
as possible.
Chain hole.
A2B switch
mounting
bracket.
Fast line
weight.
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LS420 Universal User Manual V2.91 2003-01-21.doc
Step 3) Test chain length.
i) At minimum boom angle, with no additional weight on the hook block and one part of line
only, lift the boom just enough to have the hook block suspend and clear the sensor chain
and weight.
ii) Hoist slowly until the red two-block warning lights up and the buzzer sounds. Note the
hoisting distance remaining; this distance must be great enough to allow the operator or the
lockout system, if installed, to prevent a two-block event. If necessary, add lightweight chain
between the sensor and weight to increase warning distance. If still insufficient, contact your
service representative.
Boom at
minimum
angle, twoblock alarm
triggered.
Hook block stops
rising, two-block
prevented with
safety margin.
iii) Raise the boom to the maximum angle and repeat the procedure detailed in Step 2 very
carefully. It will help to have a second person standing off to the side of the crane to closely
monitor the hoisting distance from the hook block to the head sheave block. Verify that the
warning distance is equal to or greater than that determined at the minimum boom angle.
Boom at
maximum
angle, twoblock alarm
triggered.
Hook block stops
rising, two-block
prevented with
safety margin.
iv) 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 (if
installed) work within acceptable amount of time and distance. Increase the length of the
small chain if needed.
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2.5 Installation of a length sensor cable reel
Step 1) Install the reel on its solder tab on the main boom. The cable reel is usually installed
on the main boom’s lower section on a clear area. Guides should be placed along the boom
sections and a cable anchor near the boom head.
Step 2) Feed the cable through the cable guides and pull on it to attach it to the cable anchor.
There should be minimal tension on the cable reel spring when the boom is fully retracted. Verify the boom length as shown on the appropriate operation
screen of the display unit. Please consult your Quick Reference
Guide to find the length display for your specific LS420 system
configuration. The boom length should represent the actual total
boom length from the boom pin to the head sheave center, however, depending on the exact
placement of the cable reel and cable anc hor the displayed length may differ from the actual
length. Note the difference to the tenths of feet.
Step 3) Adjust the length displayed: press the hoist button repeatedly until the display shows the advanced options entry
screen. Press the test button to enter the advanced options, and
then press the hoist button until the display shows “Trim
Length” or “Offset AD1”. Use the limit+ and limit– buttons to
enter the difference noted above, to the tenths of feet. Note: For
“Offset AD1” the decimal point may be hidden so, if the length
displayed is 10 feet too short, the trim length factor must be set
to 100 (10.0 ft) and if the length displayed is 6 feet 6 inches too
long, the trim length must be set to – 65 (- 6.5 ft). When finished,
press bypass to return to the main operation screen. For help with the buttons of the display
please refer to the quick reference guide or section 1.3 of the user manual.
IMPORTANT! Step 4) Test: verify that the display correctly shows boom length when completely retracted and when fully extended. It is safer to have someone helping to ensure that the
reel has enough cable to reach full crane extension.
Cable anchor
Boom base pin
Cable guide
Cable reel
Boom length: distance
from boom base pin to
head sheave center.
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LS420 Universal User Manual V2.91 2003-01-21.doc
2.6 Installation of radius calculation V1.0
Before proceeding with radius calibration:
•
•
•
•
•
•
Install the display unit (see section 2.1 of this manual).
Install the angle sensor (see section 2.3 of this manual). If a pendulum type angle
sensor is to be used it must be properly calibrated (see section 2.6.5 of this manual).
Install the length sensor (hydraulic cranes only) (see section 2.5 of this manual)
Enter the boom length on the boom length adjustment
screen of the display (lattice cranes only). This value
must be adjusted every time the length of the lattice
boom is changed.
Enter the jib length if the working hoist is rigged to a jib.
This value must be adjusted every time the length of
the lib is changed.
Enter the jib-offset angle if the working hoist is rigged to
a jib. This value must be adjusted every time the angle
of the jib is changed. Note: for accurate radius display
when working with a luffing jib, an angle sensor must be installed on the luffing jib.
2.6.1 Radius calibration
The boom length (lattice cranes only), jib length and jib offset angle must be correctly entered in
the LS420 for accurate radius display. Furthermore, upon installation the LS420 must be calibrated for several crane specific angle and length parameters. Default values may have been
programmed at the factory before shipping. Upon installation these parameters must be confirmed and accurate radius display verified.
Step 1) Determine the following measurements to within a
tenth of a foot: slew offset, sheave head length and sheave radius. These measurements are described in sections 2.6.2 (lattice cranes) and 2.6.3 (hydraulic cranes).
Step 2) Confirm the parameters entered in the advanced options of the LS420 display. Press the hoist button until the advanced options entry screen is displayed. Press the test button
to proceed to the advanced options. Verify that the radius parameters have been set correctly; the values may be adjusted
with the limit + and limit - buttons. Press the hoist button to
proceed from one parameter to the next.
Step 3) Test radius display. Compare the radius displayed with
the actual radius at different lengths of boom extension and different boom angles. If the radius displayed by the LS420 corresponds to the actual radius in all
cases, the radius function is correctly calibrated. Be sure that all radius parameters have been
carefully noted to facilitate re-calibration in the event of component or system upgrade, change,
or re-installation. If there is a difference between displayed radius and actual radius that remains
constant during changes in boom length and angle the slew offset can be adjusted to compensate (see step 2 above). E.g. if the radius displayed is always 2.3 feet longer than the actual radius subtract 2.3 from slew offset. If the radius displayed is still different from the actual radius
proceed to section 2.6.4 of this manual (radius display trouble shooting).
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LS420 Universal User Manual V2.91 2003-01-21.doc
2.6.2 Radius parameters for a lattice crane.
The radius calculation parameters highlighted in green must be measured
on the crane and set into the advanced menu of the LS420 display unit.
Jib mounting point.
Jib offset angle.
Head sheave.
Distance from head
sheave center to jib
mounting point.
(Your measurement)
Head sheave radius.
Jib
length.
(Your measurement)
Sheave head length:
distance from head
sheave center to
boom centerline.
(Your measurement)
The radius equation is roughly:
slew offset
+ boom length x cos(angle)
+ sheave length x sin(angle)
+ sheave radius
= radius
Boom
base
pin.
Boom length: distance
from boom base pin to
head sheave center.
Slew offset: distance from boom base
pin to crane center of rotation. If the
boom base pin is behind the crane center
of rotation this value must be negative.
Crane center of rotation.
(Your measurement)
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LS420 Universal User Manual V2.91 2003-01-21.doc
2.6.3 Radius parameters for a hydraulique crane.
The radius calculation parameters in green must be measured on the crane and set into the
advanced menu in the LS420 display.
The radius equation is roughly:
slew offset
+ boom length x cos(angle)
+ sheave length x sin(angle)
+ sheave radius
= radius
The sheave head length is the distance
between the boom centerline and the
center of the lower sheave.
(Your measurement)
Crane center of rotation
Boom length: distance
from boom base pin to
head sheave center.
Boom base pin
Sheave radius.
(Your measurement)
The slew offset is the distance between
the boom pin and the center of rotation.
If the boom pin is behind the center of
rotation, the value must be negative.
(Your measurement)
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LS420 Universal User Manual V2.91 2003-01-21.doc
2.6.4 Radius display troubleshooting
For accurate radius calculation the actual boom length and angle, and the jib length and angle
must be correctly displayed by the LS420 and the calibration parameters described in section
2.6.1 must be correctly measured and entered in the advanced options of the LS420 display.
Before proceeding with troubleshooting confirm that the radius calibration procedure described
in section 2.6.1 has been followed correctly. The most common reason for error is caused by
incorrect slew offset compensation. If the difference between the radius displayed and the actual radius remains constant through all boom angles and boom lengths the slew offset should
be adjusted accordingly.
Some booms bend significantly with a load on the hook, thus reducing effective radius. Boom
deflection can be verified if the displayed radius is equal to the actual radius with the boom at 0°
and at 90° but greater at a boom angle of 45° (boom deflection is greatest at 45°). Furthermore,
the effect of boom deflection is greater when the boom is longer. To compensate for boom deflection adjust the boom deflection value in the advanced options of the LS420 display. Follow
the steps below to determine the appropriate boom deflection compensation value.
Step 1) Raise the boom to 45° with a known load.
Step 2) Compare the radius displayed with the actual radius. Change the boom deflection
compensation value and again compare the radius displayed with the actual radius. Adjust
the boom deflec tion value until the radius displayed equals the actual radius.
Tip:
with the boom at 45° and the maximum load on the hoist, the boom deflection
compensation value should equal the difference in feet between the radius displayed
and the actual radius. With the boom at 45° and half the maximum load on the hoist,
the boom deflection compensation value should equal twice the difference in feet between the radius displayed and the actual radius. Etc.
Note: the "No Ld Defl" (no load deflection) value permits compensation for booms that deflect
significantly under their own weight, even with no load on the hoist. This value should only be
adjusted in consultation with LSI. For any information contact LSI: see page 2 of this manual.
2.6.5 Calibration of angle display with non-LSI angle sensors.
LS420 requires accurate boom angle information to display radius correctly. If a non-LSI
pendulum type angle sensor is to be used it must be correctly calibrated before procee ding with radius calibration.
Step 1) Place the boom at a known angle.
Step 2) Compare the angle displayed with the actual angle. Adjust the angle offset (or offset
AD2) in the advanced options of the LS420 display to compensate, e.g. if the angle displayed is
1.5° greater than the actual angle, subtract 1.5 from the angle offset value.
Step 3) Verify that the boom angle displayed equals the actual boom angle.
Note: the "scale ADC2" value should only be adjusted in consultation with LSI. For any inform ation contact LSI: see page 2 of this manual.
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LS420 Universal User Manual V2.91 2003-01-21.doc
Chapter 3: Changing Batteries
3.1 Changing Load Sensor Batteries V1.4
DO NOT change load sensor batteries without first
reading these instructions.
Many operators of LS401 and LS420 systems damage their load
sensors with incorrect battery changing procedures.
ALWAYS replace all three batteries of a load sensor at the same
time. Replacing just one or two batteries will cause the unchanged batteries
to reverse polarity, dramatically reducing the efficiency and life of the new batteries. This means all batteries will need to be changed again within the next
couple of days or even hours…
ONLY use an RTV non-corrosive silicone (available where autoparts are sold) to reseal the box after batteries have been changed.
Many silicones give off corrosive gasses that destroy the battery contacts;
this renders the sensor useless.
ALWAYS remove the battery closest to the indicator light first, by
applying pressure to the NEGATIVE pole ( – ) only. When metal (i.e. a
screwdriver) touches the steel box and any battery pole other than the negative pole of the battery closest to the indicator light, a short is caused which
may burn the sensor's internal circuits.
FOLLOW all the instructions detailed below. Carefully following every
step described below is the quickest, easiest way to successfully change batteries without damaging the load sensor.
•
Batteries should be changed when reduced to 10 – 20 % of full charge.
•
a)
b)
c)
d)
e)
f)
The following items are necessary to successfully change the batteries of the load sensor:
Three new, high quality, alkaline “C” cell batteries (e.g. Duracell Ultra or Energizer E2).
A Phillips head screwdriver
A small knife
A flat head screwdriver
Optionally, a very small flat head screwdriver
An RTV non-corrosive silicone (available where auto parts are sold)
Step 1.
Remove the load sensor from the crane
Step 2.
Clean off dust and grime.
During the following operations the interior of the battery box must be protected from dirt and
humidity at all times.
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LS420 Universal User Manual V2.91 2003-01-21.doc
Do not unscrew the white nylon hex bolt of the antenna.
Do not unscrew the four round topped hex bolts
Do not cut any wires
Step 3.
Unscrew the two Phillips head screws about ¼ inch. Do
not fully unscrew or remove these screws to avoid destroying
the seal in which they are set.
Step 4.
Carefully cut the silicone seal all around the base of the
box where it meets the link.
Step 5.
Carefully separate the box from the link by inserting a
flat head screwdriver in the notch where the box meets the link
and turning. Do not damage the wires that run between the link
and the box.
Notch
Step 6.
Gently pull
on the connecting
wires to disconnect
the plug in the battery box.
Avoid all contact with
the tiny white interrupter switches.
Step 7.
To remove the batteries, always remove the
battery closest to the indicator light first, the middle battery second, and the battery furthest from the
indicator LED last. The batteries can easily be removed by hand. Gently apply pressure in the direction of the negative pole while lifting out the positive
pole.
Tip:
Alternative method: use a very small, flat head
screwdriver. Gently place the tip of the screwdriver
against the top of the negative pole of the battery closest to the indicator light and, using the
side of the box for support, lift the battery up until it can be grasped and removed by hand.
The battery closest to
the indicator light is
removed first.
The screwdriver
is applied to the
negative contact
only.
Indicator light
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LS420 Universal User Manual V2.91 2003-01-21.doc
Step 8.
To install the three fresh, top quality, alkaline “C”
cells the positive/negative alig nment of the batteries as indicated on the interior walls of the box must be respected.
Insert the negative pole first. Once the negative pole is
halfway in, gentle pressure in the direction of the negative
pole will allow the positive end of the battery to be pushed
in. Do not force more than is necessary. Upon installation of the third battery, the indicator LED will light briefly,
indicating correct placement of the batteries
Step 9.
Clean the leading edges of the box and
the surface of the load cell where contact is to be
made.
Step 10.
Apply the RTV non-corrosive silicone to the link to create a joint of 1/8th inch.
Step 11.
Reconnect the wire connector. Only one orientation is possible. When correct orientation is achieved, press down to mate securely.
Once again the small flat
head screwdriver may help:
use extreme caution!
Step 12.
Reposition the box over the link. Avoid pinching the connecting wire between the
box and the link or between the batteries and the link. Verify that the silicone forms an effective seal all around the joint between box and link.
Step 13.
Secure the box to the link by tightening the two Phillips head screws.
Step 14.
Clean off excess silicone.
Step 15.
If battery replacement has been successful, the “Low Batt” icon of the cabinmounted display will no longer be lit. Use of the test function will confirm new battery
status.
Step 16.
26
Reinstall load sensor.
LS420 Universal User Manual V2.91 2003-01-21.doc
3.2 Changing Angle Sensor Batteries V1.4
DO NOT change angle or wind sensor batteries without first reading these instructions.
Many operators of LS401, 420, 425 and 2002 systems damage their
angle and wind sensors with incorrect battery changing procedures.
ALWAYS replace all three batteries of an angle or wind sensor at
the same time. Replacing just one or two batteries will cause the unchanged
batteries to reverse polarity. This means that all batteries will need to be
changed again within the next couple of days or even hours…
ONLY use an RTV non-corrosive silicone (available where auto
parts are sold) to reseal the box after batteries have been changed.
Many silicones give off corrosive gasses that destroy the battery contacts;
this renders the sensor useless.
ALWAYS remove the battery closest to the indicator light first, by
applying pressure to the NEGATIVE pole ( – ) only. When metal (i.e. a
screwdriver) touches the steel box and any battery pole other than the negative pole of the battery closest to the indicator light, a short is caused which
may burn the sensor's internal circuits.
FOLLOW all the instructions detailed below. Carefully following every
step described below is the quickest, easiest way to successfully change batteries without damaging the angle or wind sensor.
•
Batteries should be changed when reduced to 10 – 20 % of full charge.
•
An angle sensor must be re-calibrated after this procedure. Follow instructions in the angle
sensor installation chapter of this manual.
•
The following items are necessary to successfully change angle or wind sensor batteries:
a) Three new, high quality, alkaline “C” cell batteries (e.g. Duracell Ultra or Energizer E2).
b) A Phillips head screwdriver
c) A small knife
d) A flat head screwdriver
e) Optionally, a very small flat head screwdriver
f) An RTV non-corrosive silicone (available where auto parts are sold)
Step 1.
Remove the angle or wind sensor from the crane.
Step 2.
Clean off dust and grime.
During the following operations the interior of the angle or wind sensor box must be protected
from dirt and humidity at all times.
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LS420 Universal User Manual V2.91 2003-01-21.doc
Do not unscrew the white nylon hex bolt of the antenna.
Do not unscrew the four round topped hex bolts
Step 3.
Unscrew the two Phillips head screws about ¼ inch. Do not fully unscrew or remove
these screws to avoid destroying the seal in which they are set.
Step 4.
Carefully cut the silicone seal all around the base of the box where it meets the
mounting plate.
Step 5.
Carefully separate the box from the mounting plate by inserting a flat head screwdriver in the notch where the box meets the link and turning.
Notch
Avoid all contact with the tiny white interrupter switches.
Step 6.
Remove the battery closest to the indicator
light first, the middle battery second, and the battery
furthest from the indicator LED last. The batteries can
easily be removed by hand. Gently apply pressure
in the direction of the negative pole while lifting out
the positive pole.
Tip:
Alternative method: use a very small, flat head
screwdriver. Gently place the tip of the screwdriver
against the top of the negative pole of the battery closest
to the indicator light and, using the side of the box for support, lift the battery up until it can be
grasped and removed by hand.
The battery closest
to the indicator light
is removed first.
The screwdriver
is applied to the
negative contact
only.
Indicator light
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LS420 Universal User Manual V2.91 2003-01-21.doc
Step 7.
Install the three fresh, top quality, alkaline “C” cells;
the positive/negative alignment of the batteries must be respected as indicated on the interior walls of the box. Insert
the negative pole first, keeping the battery as parallel to its
final position as possible. Once the negative pole is halfway in, gentle pressure in the direction of the negative pole
will allow the positive end of the battery to be pushed in.
Do not force more than is necessary. Upon installation of
the third battery, the indicator light will flash briefly, indicating correct battery placement.
Step 8.
Clean the leading edges of the sensor box and the surface of the mounting plate
where contact is to be made.
Step 9.
Apply the RTV non-corrosive silicone to the mounting plate to create a 1/8th inch
joint.
Step 10.
Reposition the sensor box over the mounting plate. Verify that the silicone forms
an effective seal all around the joint between box and plate.
Step 11.
Secure the box to the mounting plate by tightening the two Phillips head screws.
Step 12.
Clean off excess silicone.
Step 13.
If battery replacement has been successful, the “Low Batt” icon of the cabinmounted display will no longer be lit. Use of the test function will confirm new battery
status.
Step 14.
Reinstall the angle or wind sensor; calibrate an angle sensor following the installation procedure outlined in the angle sensor installation chapter of this manual.
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3.3 Changing Anti-two-block Batteries V1.5
ALWAYS replace all four batteries of a two-block sensor at the
same time. Replacing just one, two or three batteries will cause the unchanged batteries to reverse polarity. This means that all batteries will need to
be changed again within the next couple of days or even hours…
•
Batteries should be changed when reduced to 10 – 20 % of full charge.
•
The following items are necessary to successfully change the batteries of the anti-twoblock:
a) A monkey wrench.
b) Four new, high-quality, alkaline “C”-cell batteries (Duracell Ultra or Energizer E2 recommended).
Step 1)
Remove the anti-two-block from the crane and clean off dust and grime.
During the following operations the interior of the anti-two-block
must be protected from dirt and humidity at all times.
Do not unscrew the white nylon hex bolt of the antenna.
Do not unscrew the small screw to the left of the antenna.
Do not remove the small black plastic plug on the bottom of the anti-two-block.
Step 2)
Place the anti-two-block on the edge of flat surface. Using a monkey wrench, partly
unscrew (about a half-inch) the large white nylon hex bolt through which the wire rope passes.
Step 3)
Carefully remove the plunger assembly, without
separating it from the cover, and place it on a clean and dry surface.
Step 4)
The four batteries will easily slide out.
Step 5)
Insert the four fresh, clean, top quality, alkaline “C”
cells according to +/- schema printed on the back of the sensor.
Step 6)
Replace the plunger
assembly. Correctly align the bottom cover before screwing in the
white nylon hex bolt through which
the wire rope passes. This hex
bolt should be well tightened with
the monkey wrench.
If battery replacement has been successful the LED on the bottom of the sensor will flash red
when the wire rope is pulled and the “Low Batt” icon of the cabin-mounted display will no longer
be lit. Use the test function of the cabin-mounted display unit to confirm new battery status.
Step 7)
30
Reinstall the anti-two-block.
LS420 Universal User Manual V2.91 2003-01-21.doc
Chapter 4: Replacing Antennae
4.1 Replacing Load, Angle and Two-block Sensor Antennae V2.1
•
•
There are two types of sensor antennae:
1. Two-block sensor antennae: a blue tape identifies
those made in the spring of 2002 and thereafter, they
are replaceable. The antennae of two-block sensors
made before February 16th, 2002 are not replaceable
in the field: please contact your service representative.
2. Load/angle/wind sensor antennae: a green tape identifies those made in the spring of 2002 and thereafter.
All load/angle/wind sensor antennae are replaceable.
Note: two-block sensor antennae are not compatible with
load, angle or wind sensors. Only a two-block antenna is
compatible with a two-block sensor.
Load/
angle/
wind antenna
with identifying
green strip
Anti-twoblock antenna with
identifying
blue strip
Slightly damaged antennae (bent, sheathing scratched,
plastic head cap missing etc.) should not be replaced
unless otherwise identified as preventing proper sensor
function. Heavily damaged antennae (ripped out, sheared
off, wire exposed and fraying etc.) should be replaced to
ensure communication between the sensor and the cabin mounted display unit.
•
The following items are necessary to successfully replace the antenna of a load or angle
sensor:
a) a new antenna, of the appropriate type (load/angle/wind sensor or two-block sensor),
with white nylon hex bolt
b) a small pair of pliers
c) an electrical insulating compound
Step 1.
Place the crane, boom, jib or ball hook such that the sensor is safely accessible.
This procedure may be followed without removing the sensor from the crane only if it is safe to
do so; avoiding removal and reinstallation procedures may save time. If removed, an angle
sensor must be re-calibrated during reinstallation for correct angle display (see the angle sensor
installation section of the user manual).
During this procedure the interior of the sensor must be protected from dust, grime and water at
all times. If it rains during the procedure an umbrella or other suitable means of protection
should be used.
Step 2.
Clean dust, grime and water from the sensor.
Step 3.
Identify the short black whip antenna and the
white hex bolt securing it.
Step 4.
Inspect the antenna for signs of obvious
physical damage.
Step 5.
Carefully unscrew the white nylon hex bolt
completely and slide it up the antenna.
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Step 6.
Grip the antenna by the base of the black
plastic sheathing and pull it straight out of the hole in
which it is seated. Place the old antenna aside.
Step 7.
Slide the white nylon hex bolt to the middle of
the length of the new antenna.
Step 8.
Coat the exposed metal foot of the new antenna with an electrical insulating compound by carefully inserting it in the mouth of the compound tube.
White nylon hex bolt
Antenna
Step 9.
Hold the new antenna by the black
plastic sheathing and guide it through the
hole in the sensor box. Carefully seat the
antenna in its mating connector. When
the antenna is correctly seated, pulling on
it will be met with light resistance.
Step 10.Carefully
re-thread, screw-in and
tighten the white nylon hex bolt to secure
the antenna in place.
Sensor box
Antenna receptacle
Step 11.Reinstall the sensor if necessary (if removed from the boom or jib, an angle sensor
will require re-calibration during the installation procedure, see the angle sensor installation
section of the user manual).
Step 12.Verify that the sensor functions properly.
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Chapter 5: Adding and Removing Sensors
•
•
If in difficulty, disconnect and reconnect the yellow cable of the LS420, then press the test
button to verify all calibrated sensors. If in serious difficulty, simply start over by erasing all
sensors from the system (section 5.2), then re-entering them one by one (section 5.1).
Correctly set the parts of line, tare and all applicable limits for any newly added sensor. The
buzzer will usually sound when a sensor is added until the appropriate limits have been set;
this is to ensure that the limits will be verified. While adjusting limits or parts of line, press
the limit + and the limit - buttons simultaneously to set a default value.
5.1 How To Add A Sensor to the LS420.
5.1.1 The Manual Calibration Mode
Step 1) Determine the ID (a number between 0 and 60000) of the sensor to be added; the ID
is engraved on the sensor. The LS420 uses the ID to identify the sensor.
Sensors should be installed on the crane before engaging in the calibration procedure. Sensors
must transmit to be identified by the LS420; lifting a load with a load cell or changing the angle
of an angle sensor will ensure immediate transmission.
Step 2) To enter the manual calibration mode, hold the bypass button down continuously and
press the tare button once. Release the bypass button when the screen displays "Calibration Mode".
Step 3) Press the hoist button until the second line of the screen displays “No Sensor”. Use
the parts button to select the type of sensor to be added. Use the limit + and limit - buttons to
set the ID number of the sensor to be added. Use the parts button to select the type of sensor
to be added. Press the bypass button to exit the manual calibration mode at any time.
5.1.2 The Automatic Calibration Mode (An Alternative Method for Adding Sensors)
In the automatic calibration mode the LS420 detects and identifies all functioning LSI sensors
not calibrated to the LS420 and within radio transmission distance. This facilitates adding a sensor that’s ID is not easily determined (e.g.: an a2b at the end of a 300’ boom). Care must be
taken not to add the wrong sensor to the system (e.g.: an a2b on a neighboring crane).
Step 1) To enter the automatic calibration mode hold the bypass button down continuously and
press the limit - button once. Release the bypass button when the screen displays "Auto Calibr
Mode". Press the hoist button twice. The buzzer may make small noises depending on surrounding radio signals.
Step 2) Press the hoist button until the LS420 shows the sensor to be added with the correct
ID. Press the test button to add the sensor to the system. Press the bypass button to exit the
automatic calibration mode at any time.
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5.2 How to Remove A Sensor from the LS420
Step 1) To enter the manual calibration mode, hold the bypass button down continuously and
press the tare button once. Release the bypass button when the screen displays "Calibration
Mode".
Step 2) Press the hoist button until the sensor to be removed is shown with the correct ID and
sensor type (Load, Angle etc.). Press the tare button to remove the sensor. The display will
show "ID = 0" on the first line and "No Sensor" on the second line. Press the bypass button to
exit the manual calibration mode at any time.
5.3 Changing Sensor Configuration of the LS420
When a sensor is added or removed, the system configuration number is automatically adjusted. Use the table below to determine the appropriate configuration number by crossreferencing the appropriate combination of sensors. If necessary the configuration number can
be adjusted manually. To enter the manual calibration mode, hold the bypass button down continuously and press the tare button once. Release the bypass button when the screen displays
"Calibration Mode". Press the hoist button until the screen displays "Select Configur." Use the
limit + and limit - buttons to select the appropriate configuration number. Press the bypass
button to exit the manual calibration mode at any time.
x 64
x 32
x 16
x8
x4
Config.
Number Custom Length Radius Wind Angle Load
10
11
12
13
14
15
16
17
18
19
20
21
22
34
Comment
1 load sensor
2 load sensors
3 load sensors
1 angle sensor
1 load, 1 angle
2 load, 1 angle
3 load, 1 angle
1 wind sensor
1 angle, 1 wind
1 load, 1 angle, 1 wind
2 load, 1 angle, 1 wind
2 wind speed sensors
1 load, 1 angle, 1 radius
2 load, 1 angle, 1 radius
LS420 Universal User Manual V2.91 2003-01-21.doc
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
l load, 2 angle, 1 wind
For systems with only a2bs
1 load, 1 angle, 1 radius, 1 length
LS2002 configuration
2 load with sum
2 load with sum, 1 angle
2 load, 2 angle, 1 wind, 1 radius
LS425
5 load
load and a2b with dual lock-out outputs
1 load, 1 angle, 1 wind, 1 radius
2 load, 1 angle, 1 wind, 1 radius
Configurations
used in custom
applications
4 load cells, A, B, C & D
x64
35
2 load, summation, angle
x32
x4
x16
x8
1 angle, 1 radius, 1 length
1 load, 1 angle, 1 radius, 1 length
2 load, 1 angle, 1 radius, 1 length
1 load, 1 angle, 1 radius, 1 length, 1 wind
2 load, 1 angle, 1 radius, 1 length, 1 wind
LS420 Universal User Manual V2.91 2003-01-21.doc
Chapter 6: Troubleshooting 1.0
Troubleshooting Index
6.1 The Display Doesn't Light Up
6.2 The Lock-out Doesn't Engage
6.3 The Display Unit Is Always In 2 Block Alarm Mode
6.4 The Display Unit Is Always In Alarm Mode, the main hoist green light is flashing
6.5 The Display Unit Is Always In Overload Alarm Mode
6.6 The Display Unit Is Always In Limit Alarm Mode
6.7 The Display Unit Is Always In Wind Speed Alarm Mode
6.8 Radio Communication Problem
36
LS420 Universal User Manual V2.91 2003-01-21.doc
6.1 The Display Unit Does Not Light Up
The display won't light up
Press "Test" button
Is there
a change in the
display?
Please call your service
representative
Yes
No
Verify the connections of the black
wire, the red wire and, if appropriate, the white wire of the yellow
cable as described in section 2.1
of the Universal User Manual.
Is there a bad
connection?
Yes
No
Is there
a change in the
display?
Verify the voltage on the black wire,
the red wire and, if appropriate
according to the specifications in
the user manual, the white wire of
the yellow cable.
Is the
voltage on the wires
equal to that of the crane
battery?
No
Verify the crane battery. Verify the
crane fuse. Verify the crane
accessory switch if applicable.
reconnect properly
No
Yes
Disconnect the
yellow cable from
the display unit
and reconnect it
carefully
Is there
a change in the
display?
No
Please call your service
representative
37
Yes
Press "Test" button
to verify communication and battery status of all sensors.
Yes
Press "Test" button
to verify communication and battery status of all sensors.
LS420 Universal User Manual V2.91 2003-01-21.doc
6.2 The Lock-out Doesn't Engage
Carefully create a lock-out using an A2B switch. If there is
no A2B switch in communication with the display lock-out
may be created by temporarily adjusting a load or angle limit.
The lock-out doesn't engage
Verify the connection of the
white wire of the yellow cable
Is there a bad connection?
Measure the voltage on the white wire of the yellow cable.
Yes
No
reconnect the
white wire
carefully
No
Is the voltage
on the white wire
equal to zero?
Everything seems
fine, return any limits
you may have changed
to their appropriate
values and verify
lock-out function
Disconnect the white wire
from the lock-out circuit
Is the
display in lock-out or
alarm mode?
Yes
Place the crane
in non-lock-out
condition
Yes
Wait 30 seconds and
measure the voltage on
the white wire.
No
Verify the voltage on the white wire of the yellow cable.
Is the voltage
on the white wire
equal to zero?
Is the voltage on the
white wire equal to that of the
crane battery?
Yes
Yes
No
Call customer service
Lock-out coils
may be connected to
the positive battery
voltage of the crane
instead of the negative
ground. Verify and
refer to the lock-out
section of the user
manual.
Yes
No
Disconnect the white wire from the lock-out circuit
Reconnect the white wire to the lock-out circuit
Wait 30 seconds and measure the voltage on the white wire.
Is the voltage on the
white wire equal to that of the
crane battery?
Yes
No
Measure current
drawn on white
wire by lock-out
system. Refer to
lock-out section in
the user manual.
Does lock-out system
draw more than 1A on the
white wire?
No
Disconnect the yellow
cable from the display
unit and reconnect it
carefully.
Wait 30 seconds
and measure the
voltage on the
white wire.
38
Yes
Measure the voltage
on the white wire.
The display should be
fine, verify lock-out
function
Yes
Is the
voltage on the
white wire equal to that
of the crane
battery?
Install a relay as
explained in the
lock-out section of
the user manual.
Is the voltage on the
white wire equal to that
of the crane battery?
No
Please call your
service representative
No
LS420 Universal User Manual V2.91 2003-01-21.doc
6.3 The Display Unit Is Always In Alarm Mode, The "2 Block" warning
light is on
6.4 The Display Unit Is Always In Alarm Mode, the main hoist green
light is flashing
The display is always in alarm mode,
the "2 Block" warning light is on?
The display is always in alarm mode,
the main hoist green light is on?
Yes
Yes
The load cell failsafe
warning is on. On
startup this is normal as
the load cell may take up
to fifteen minutes to
communicate its battery
status to the display unit,
until which time the
failsafe warning will
sound.
Place all A2B
switches in
safe condition.
Is the
"2 Block"
warning
light still
on?
The anti-two-block switch
appears to be working properly,
please refer to the lockout
section of the user manual.
No
Press the "Test" button to verify battery status.
Yes
Are load cell batteries low?
Press the "Test" button.
Yes
Are A2B
batteries low?
No
Take the A2B
switch off the
cable. Pull
on the wire
rope.
Verify battery installation or
change batteries if necessary,
see the changing load cell
batteries of the user manual.
No
Yes
The batteries
need changing.
Refer to the
changing anti-twoblock batteries
section of the
user manual.
Does the red
light on the A2B switch
flash after pulling on the
wire rope?
Yes
There
appears to be a
communication
problem, see
diagnostic
mode p. ?
No
Reinstall the batteries, carefully inspect
the battery and plunger cavities for
infiltration of water or dirt. Refer to the
changing batteries section of the user
manual.
Pull on the wire rope.
Does the red light on
the A2B switch flash after pulling on
the wire rope?
Yes
Verify
communication
between the load
cell and the display
unit (follow the
procedure).
No
Please call your
service representative
Reinstall the A2B
switch on the cable.
Verify A2B function.
39
LS420 Universal User Manual V2.91 2003-01-21.doc
6.5 The Display Unit Is Always In Alarm Mode, the Load warning light
is on
Remove weight
from load cell.
The display is
always in alarm
mode: the "Load"
warning light
is on.
If "Hoist" button green light is on press the "Hoist" button until it goes off.
Press the "Parts" button to verify that the parts of lines is consistent with actual
cable configuration. Refer to the "Parts" button section in the user manual.
If the "Tare" button light is on, press the "Tare" button once to disable the tare function
Press either the "Limit +" or the "Limit -" button to see the limit programmed for the hoist.Verify that
the limit programmed is consistent with the crane capacity in its present configuration.
If there is an auxilliary load cell press the "Hoist" button until the "Hoist" button light is on. Repeat
the previous three steps to verify the parts of lines, tare and laod limit for the auxilliary hoist.
Does the
load displayed now
correspond with the
weight on the
load cell?
No
Verify
communication
between load cell and
display unit (follow
procedure on page x)
then return here.
Verify overload
alarm function.
Does
the overload
alarm now function
properly?
Yes
Is the
overload alarm
still on?
No
Everything seems to be
functioning normally.
No
Press "Test" to verify
loadcell batteries.
Verify battery installation. Please pay special
attention to avoid infiltration of water or dirt and to
ensure that the load cell wires are properly connected
and not severed. Change the batteries if necessary.
Yes
Yes
Verify proper load
cell function.
Please call your
service representative
Does the
load displayed now
correspond with the
weight on the
load cell?
No
Please call
your service
representative
Yes
Is the
overload alarm
still on?
No
Everything seems to be
functioning normally.
Yes
Please call your
service representative
40
LS420 Universal User Manual V2.91 2003-01-21.doc
6.6 The Display Unit Is Always In Alarm Mode, the Limit+ or Limitwarning light is flashing
The display is always
in alarm mode: the
"Limit + " warning
light is flashing.
The display is always
in alarm mode: the
"Limit -" warning light
is flashing.
Press the "Hoist" button until
the boom angle is displayed.
Press the "Hoist" button until
the boom angle is displayed.
Does the angle
shown correspond to
actual boom angle.
No
Yes
Verify the angle sensor
installation. Reinstall or
recalibrate if necessary, see
the angle sensor installation
section of the user manual.
Does the angle
shown correspond to
actual boom angle.
No
Yes
Press the "Test" button to
verify battery status.
The maximum angle limit
appears to be reached: press
the "Limit +" button to verify
that this limit has been
correctly set, refer to the
adjusting angle limit section of
the user manual.
Are angle
sensor batteries
low?
The minimum angle limit
appears to be reached: press
the "Limit -" button to verify
that this limit has been
correctly set, refer to the
adjusting angle limit section
of the user manual.
No
Yes
Press the "Bypass" button to
return to the main operating
screen. Press the "Hoist"
button until the boom angle is
shown.
Is the
boom angle
shown less than the
maximum angle
limit set?
No
Yes
Is the
"Limit +" warning light
still flashing?
Yes
Please contact your
service representative.
41
Verify battery installation
or change batteries if
necessary, see the
changing angle sensor
batteries of the user
manual.
No
The maximum
angle limit warning
appears to be
functioning normally:
refer to the user
manual for a
description of this
warning.
Press the "Bypass" button to
return to the main operating
screen. Press the "Hoist"
button until the boom angle
is shown.
Verify
communication
between angle
sensor and display
unit (Section 6.4).
Is the
boom angle
shown greater than the
maximum angle
limit set?
No
Yes
The minimum
angle limit warning
appears to be
functioning normally:
refer to the user
manual for a
description of this
warning.
No
Is the
"Limit -" warning light still
flashing?
Yes
Please contact your
service representative.
LS420 Universal User Manual V2.91 2003-01-21.doc
6.7 The Display Unit Is Always In Alarm Mode, the wind speed alarm
message is flashing
The wind
speed alarm
message is always
flashing
Does the
wind speed shown
correspond to actual
wind speed?
No
Yes
Is wind
speed greater than
set wind speed
limit?
No
Visually inspect the wind
speed sensor for
physical damage. Verify
proper installation, refer
to wind speed sensor
installation instructions.
Yes
The maximum
wind speed warning
appears to be
functioning normally:
refer to the user
manual for a
description of this
warning.
Press the "Test" button
to verify battery status.
Are wind
speed sensor
batteries low?
No
Verify
communication
between wind
speed sensor and
display unit
(Section 6.4).
Yes
Verify battery installation
or change batteries if
necessary, see the
changing wind speed
sensor batteries of the
user manual.
42
LS420 Universal User Manual V2.91 2003-01-21.doc
6.8 Radio Communication Problem
Radio communication between sensor(s) and cabin mounted display unit faulty.
Press the "Test" button and verify the sensor ID #. The ID # for each sensor can be found on the sensor itself or on any invoice
or shipping document for that sensor. Note that the ID # of older A2B switches is indicated on the A2B switch body in binary
form. The binary to decimel conversion procedure is detailed in the A2B calibration mode section of the distributor manual.
Does the
display unit indicate
the correct ID # for
the sensor?
Does the
display unit indicate
"0" or "5535" as the
sensor ID #?
No
If either the sensor or the display unit has
recently been installed or replaced, the display
unit may require recalibration. If display unit's
memory has been affected by a lightning strike or
other electrical event it may need reprogramming.
Refer to the technical manual or contact your
service representative.
No
Yes
Yes
Visually inspect the antennas of the sensor
and the cabin mounted display unit.
The sensor chip's memory has been erased, please refer to
the technical manual or contact your service representative.
Is there a clear and
direct line of sight between the sensor antenna and the
antenna of the display unit?
No
Reinstall either the display unit, the
sensor or both such that there is a clear
and direct line of sight between the two
antennas at all times.
No
Reinstall either the display unit or
the sensor such that both antennas are
clear of all contact with any metal
including cables, chains, the boom,
or the cabin itself.
Yes
Are both the sensor and
the display unit antennas clear of all contact with any metal
object at all times?
Yes
Are both the sensor
and the display unit antennas complete and
undamaged?
No
Yes
A damaged antenna may need replacing.
To replace the antenna of a load cell, an angle
sensor or a wind speed sensor please see the
appropriate section of the user manual. If an
A2B switch antenna needs to be replaced please
contact your service representative.
If it is safe to do so, verify that the sensor is operational by observing its red LED during a change
in condition (change the boom angle for an angle sensor, pull the wire whip for an A2B switch,
change the load for a load cell, change the apparent wind speed for a wind sensor).
Does the
sensor appear
operational?
No
Verify sensor batteries,
reinstall or replace if
necessary, see the
appropriate section of
the user manual.
Does the
sensor appear
operational?
43
No
There appears to be a
problem with the sensor,
please contact your service
representative.
LS420 Universal User Manual V2.91 2003-01-21.doc
Chapter 7: Purchasing and Customer Service
Always call your service representative first, as he or she already knows the details of the sale
and applications. They may also supply lockout and be able to provide the required service for
that application.
If not available please contact:
LSI Corporate Offices:
Dave Smith
PO Box 820486
Vancouver, WA 98682
Phone (888) 819-4355
Fax (360) 256-3344
sales@loadsystems.com
Western Regional Office:
Scott Colberg
Phone (877) 287-7011
Fax (360) 575-8532
scolberg@loadsystems.com
Central Regional Office:
Randall Perrin
Phone (337) 893-2322
Fax (337) 893-0026
rperrin@loadsystems.com
Our service personnel will do their best to help customers as quickly as possible and in the most
courteous manner.
Please be ready to give the following information:
i) Your name, company name, shipping address (no mail box), your phone number, fax
number and emergency phone number
ii) A credit card number - either Visa or MasterCard.
And for technical support, replacement, exchange or warranty:
iii) The part number of the defective or broken part
iv) The serial number of each display or sensor (If re-calibration is possible, it will be done)
In the event of exchange, replacement or warranty, a return tag will be in the box for returning defective or broken parts. The customer can reuse the original box and the prepaid return tag to return defective or broken parts.
Note: Some parts may not need to be returned.
Please note: although we design our products to fit the majority of cranes, there are exceptions
that will prevent the product from working or cause installation or operational problems. Our
technical staff will do their best to assist, help and advise any customer with such problems. We
strive to resolve problems as they may arise.
44
LS420 Universal User Manual V2.91 2003-01-21.doc
INSTRUCTION TO THE USER
This equipment has been tested and found to comply with the limits for a class B digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses
and can radiate radio frequency energy and if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause
harmful interference to radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the interference by one or more of
the following measures:
•
•
•
•
Reorient or relocate the receiving antenna.
Increase the separation between the equipment and receiver.
Connect the equipment into an outlet on a circuit different from that to which the receiver
is connected.
Consult the dealer or an experienced radio/TV technician for help.
In order to maintain compliance with FCC regulations, shielded cables must be used with this
equipment. Operation with non-approved equipment or unshielded cables is likely to result in
interference to radio and TV reception. The user is cautioned that changes and modifications
made to the equipment without the approval of manufacturer could void the user's authority to
operate this equipment.
45
LS420 Universal User Manual V2.91 2003-01-21.doc

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