QVBGS001GS012: Angle Length Sensor; GS035: Pressure Transducer

GS820 Display & GS Series Sensors INSTALLER AND USER’S MANUAL INSTALLER AND USER’S MANUAL GM820 REV.20100402www.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. ! ! 2 2 The GS820 System The GS820 System Read and understand the following: For your safety and that of the people that come into contact with LSI LSIproducts, 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 BEFORE PROCEEDING WARNING!Installation must be made in compliance with LSI LSIinstructions 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. ! ! TABLE OF COTETS TABLE OF COTETS 3 3 1. INTRODUCTION 1.1 OVERVIEW........................................5 1.2 START-UP..........................................5 2. INSTALLATION 2.1 DISPLAY GS820................................6 2.1a Mounting Bracket........................................6 2.1b Antenna Position ........................................7 2.1c Power Supply and Lockout Connection......7 2.1d Lockout Settings ........................................8 2.1e Password Settings ......................................9 2.2 LOAD CELL ....................................10 2.3 ANGLE SENSORS ..........................11 2.3a Mounting Procedure..................................11 2.3b Angle Calibration Procedure No 1: Mechanical Set-Up....................................11 2.3c Angle Calibration Procedure No 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 No 1: Mechanical Set-Up....................................16 2.5d Boom Length Calibration Procedure No 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 2.6f Radius Parameters for a Lattice Crane with Mast ..........................................................21 2.7 WIRELESS WIND SPEED SENSOR GS020..............................................22 2.8 WIRELESS LOAD PINS..................23 2.8a LP011, LP015, and LP026........................23 2.8b Load Pin Transmitter GS001 ....................23 2.9 LINE RIDING TENSIOMETER ........24 2.9a Line Riding Tensiometer Installation ........24 2.9b Line riding tensiometer installation on a swing arm..................................................25 2.10LOAD PINS, LINE RIDING TENSIOMETERS AND COMPRESSION CELLS: CALIBRATION ................................26 2.11 FOUR POINT LIFT ..........................27 2.11a Sum Load Indication ................................27 2.11b Imbalance ................................................27 2.11c Slack Rope................................................28 2.12LIST AND TRIM ANGLE SENSOR 29 2.12a Programming the GS820 for List and Trim Indication ..................................................29 2.12b Mounting Instructions................................29 2.12cList and Trim Angle Calibration Procedure..30 2.13ROPE PAYOUT................................31 2.13a Rope Payout Calibration Procedure No 1: Mechanical Set-Up....................................31 2.13b Rope Payout Calibration Procedure No 2: Correct with the GS820 ............................31 2.13c Rope Payout Limits ..................................32 2.13d Electrical connections ..............................32 2.14DATA LOGGER ..............................33 2.14a Recording Modes......................................33 2.14b Date and Time ..........................................33 2.15SENSOR LIST ................................34 2.15a How to Add a Sensor to the GS820..........34 2.15bHow to Remove a Sensor from the GS820..34 2.16NETWORK OPTIONS ....................34 2.16a Listen to sensor only ................................34 2.16b Remote monitoring....................................35 2.16c Repeater ..................................................35 2.16d Wireless Sensor Update ..........................36 3. OPERATION 3.1 DISPLAY GS820..............................37 3.2 USB PORT ......................................37 3.3 KEYPAD ..........................................37 3.4 DISPLAY LIGHTS............................37 3.5 MENU SYSTEM ..............................38 3.5a Menu Numbers ........................................38 TABLE OF CONTENTS TABLE OF CONTENTS 4 4 The GS820 System The GS820 System 3.5b Menu Navigation ......................................38 3.5c Password Protection ............................…

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ISTALLATIO ISTALLATIO 21 21 2.6f Radius Parameters for a Lattice Crane with Mast Crane center of rotation Boom base pin Jib offset angle Jib length Menu 4E) 5) MAST BOOM LENGTH (Your measurement) Menu 4E) 6) MAST SLEW OFFSET (Your measurement) Jib mounting point Mast Head sheave Mast sheave head length parallel Menu 4E) 7) MAST SHEAVE HEAD LENGTH PERPENDICULAR (Your measurement) Menu 4E) 9) MAST SHEAVE RADIUS (Your measurement) Figure: Advanced radius parameters - Lattice crane with Mast. Typical installation. Not to scale. 22 22 The GS820 System The GS820 System 2.7 2.7 Wireless Wind Speed Wireless Wind Speed Sensor GS020 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. Mounting rod 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 LSIsensor/transmitters. ! ! Note: Angle iron can be used to extend the mounting position to be clear of the boom top. ISTALLATIO ISTALLATIO 23 23 2.8 2.8 Wireless Load Pins 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. Pigtail Handle wire Figure: Load pin AA10K11 LINE PULL Wedge socket Load pin Hook ball or block 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 Connect the transmitter pigtail to the Load pin pigtail Mounting block 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 LSIsensor/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. 24 24 The GS820 System The GS820 System 2.9 2.9 Line Riding Tensiometer 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. Swing Arm Line Riding Tensiometer Figure: Line riding tensiometer Line Riding Tensiometer Swing Arm Bracket and Landing Pad (wooden cushion) Mounting Bracket (for swing arm) 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. ! ! Swing Arm Line Riding Tensiometer Landing Pads Figure: Example of a typical installation on a telescopic boom crane (not to scale) Swing Arm Line Riding Tensiometer Hoist drum Landing Pads Figure: Typical installation (not to scale) ISTALLATIO ISTALLATIO 25 25 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 object…

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OPERATIO OPERATIO 41 41 3.8b Radio Network Diagnostic 1. Go to menu 5B2) LAST SENSORS RECEIVED. Sensors are shown with their radio ID number and the sensor type. a. Use Upand Downto scroll through the list. b. Press Exitto return to menu 5B). 3. Go to menu 5B3) S EARCH FOR SENSORS. a. Press Enterto launch a sensor search. 4. Go to menu 5B4) B IT ERROR RATE TEST. This test should only be conducted by LSI LSI technical service personnel. 5. Press Exitto return to the operation display. 3.8c Lockout Diagnostic Menu 5C) LOCKOUT DIAGNOSTCshows the lockout condition of the output (alarmor safe) and the self- test (passor fail); it is recommended to manually test the lockout condition; 1. Go to menu 5C) L OCKOUT. Select N° 1 WHITE WIRE. To temporarily activate or desactivate the lockout relay press Enter. Figure:Menu 5C) Lockout, condition example 2. Press Downto go to N° 2 GREEN WIRE. Repeat lockout diagnostic test. 3. Press Downto go to N° 3 O RANGE WIRE. Repeat lockout diagnostic test. 4. Press Exitto return to the operation display. 3.8d Display Diagnostic 1. Go to menu 5D) DISPLAYDIAGNOSTIC. The page shows different informations; 1) T IME: current time according to the GS820 internal clock. 2) D ATE: current date according to the GS820 internal clock. 3) T IME CLOCK BATTERY: self-test passor fail. 4) E XTERNAL POWER: external power supply voltage. 5) Display Internal temperature. 6) Base station ID. The base station ID should be the same as the GS820 display serial number printed on the left side of the box. 7) Power supply 8) Radio certification: “FCC”, “IC” indicates Federal Communications Commission (U.S.A.) and Industry Canada certification, “CE” indicates European Community certification. 9) Radio frequency: the frequency used by the system network. 8. Press Exitto return to the operation display. 3.8e Digital Input Diagnostic 1. Go to menu 5E) DIGITALINPUTDIAGNOSTIC. The page shows the wires digital input status (white, green, orange and blue wires). 2. Press Exitto return to the operation display. CAUTION!The list of “last sensors received” includes all functioning GS series sensors within range. Programming a GS820 display for sensors from a different system will disable that system and render indication by both systems inaccurate. ! ! 42 42 The GS820 System The GS820 System 3.9 3.9 System Limits System Limits Set hoist limits The limit menu displays the limits for each sensor in the sensor list. 1. Go to menu 6) S YSTEMLIMITS. 2. Use Upand Downto select a sensor and press Enterto modify. 3. Use Upand Downto adjust the limit and press Enter. 4. Press Exitto return to the operation display. When using the GS820 as a load indicator without programmed crane specific rated capacity charts the load limit is typically set to the lesser of the rope limit, the hoist limit, and the maximum allowed capacity as determined from the capacity charts. When using the GS820 as a rated capacity indicator with programmed crane specific rated capacity charts the load limit is typically set to the lesser of the rope limit and the hoist limit. 3.10 3.10 Tare Tare Zero the hook 1. Go to menu 7) T ARE. 2. Select the load sensor. 3. Press Enterto set or clear tare weight. 4. Press Exitto return to the operation display. 3.11 3.11 Information Information Go to Menu 8) INFORMATION. Standard info menu pages include: 1. Software package 2. Firmware 3. Language pack 4. Graphic library 5. Capacity chart 6. Sensor update pkg 7. BIOS (Bootloader) number and version 8. USB driver Critical system alerts or information messages are also displayed on the top part of the LCD. See examples below: Note: Press Leftand Rightsimultaneously to return a limit to the factory default setting. The factory default maximum limit for load sensors is 10 000 lb per part of line. Note: When the weight units are tons the minimum load limit increment is 0.1 ton per part of line. Figure: the GS820 displays “system ok” Figure: the GS820 displays an information alert OPERATIO OPERATIO 43 43 Table: Information AlertsTable: Information Alerts (Continued) * If the lockout relay is inverted this alert will occur when voltage is detected on the wire when safe. **If the lockout relay is inverted this alert will occur when voltage is not detected on the wire in alarm. Alert: “L OADID: G15000 MAXIMUM LIMIT” Description: The sensor indicates a value greater than the operator adjusted limit. • Verify operator adjusted limits in the limit menu. WARNING!Do not operate the crane beyond the limits specified by the manufacturer. ! ! Alert: “A NGLEID: G15000 MINIMUM LIMIT” Description: The sensor indicates a value less than the operator adjusted limit. • Verify operator adjusted limits in the limit menu. WARNING!Do not operate the crane beyond the limits specified by the manufacturer. ! ! Alert: “L OADID: G15000 LOW BATTERY” Description: Less than 10% of battery life remains in the sensor. • Schedule battery replacement for the next available opportunity. Typically several weeks of operation remain from the moment the sensor low battery warning is first triggered. Alert: “L OADID: G15000 NOT RECEIVED” Description: The display isn’t receiving communication from the sensor. • Verify that the sensor ID number programmed matches the ID number of the sensor installed on the crane. Go to menu 5A1. Alert: “V ERIFY WHITE WIRE(UNEXPECTED VOLTAGE)” Description: Voltage is detected on the lockout wire when in alarm*. With the standard relay configuration voltage should not be present on a lockout wire in alarm condition. • Verify the wire connection. Refer to the Power Supply and Lockout Connection sub section of this manual. Alert: “V ERIFY WHITE WIRE(SHORTED TO GROUND)” Description: Voltage is not detected on the lockout wire when safe**. With the standard relay configuration voltage should be present on a lockout wire in safe condition. • Verify the wire is not shorted to ground. • Verify the wire is not connected directly to the valve coils; a relay should b…

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LSI Research / Recherche LSI Inc Page 1 of 3 GS012: Angle Length Sensor LSI Research / Recherche LSI Inc Page 2 of 3 GS035: Pressure Transducer LSI Research / Recherche LSI Inc Page 3 of 3

REVISIONS REV.DESCRIPTIONDATEAPPROVED SCALE : 1:1 SIZE DWG. NO. A REV. MAT. UNLESS OTHERWISE SPECIFIED DIMENSION ARE IN INCHES TOLERANCE ARE : DECIMALS FRACTIONS X 0.1 < 1/4 1/64 X.X 0.05 > 1/2 1/32 X.XX 0.01 >=1/2 1/16 X.XXX 0.002 ANGLE 0.5 X.XXXX 0.0005 ROUGHTNESS 125 DATE CHECKED SHEET 1 OF 1 RELEASE DATE : THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF LOAD SYSTEMS INTERNATIONAL. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF LOAD SYSTEMS INTERNATIONAL IS PROHIBITED. PROPRIETARY AND CONFIDENTIAL Treatment: UB312_rev20100329GS012 WEIGHT PRODUCT TITLE DRAWN APPROVALS 2010-03-29 www.load-systems.com M. Cloutier UB312 Label Background color: Pantone PMS 5C Material must be rated for outdoor use (sunlight, water and marine exposure, temperature -40°-85°C) 3mm white vinyl Laminated adhesive 3M 9472LE (#300SLE) Unique serial numbers, 16 pt, Times New Roman Bold Black FCC ID: QVBGS001 IC: 7076A-ICGS001 * This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1) This device may not cause harmful interference, and 2) This device must accept any interference received, including interference that may cause undesired operation. WARNING! This device is intended as an operator aid only and is not a substitute for safe operating practices. Read and understand the operator’s manual. Test before every use. Model No: GS012 Angle Length Sensor USA: (888) 819 4355 Int.: +1 281 664 1330 ID: WWW.LOADSYSTEMS.COM 4,000 2,875 1,003 0,583 R 0,100 Century Gothic, 14 pt Arial Black, 11 pt color: Black 50% Arial, 7 pt Arial Black, 9 pt Arial, 7 pt Ø 0,270 Ø 0,130 Arial Bold, 11 pt 2,015 2,885

REVISIONS REV.DESCRIPTIONDATEAPPROVED SCALE : 1:1 SIZE DWG. NO. A REV. MAT. UNLESS OTHERWISE SPECIFIED DIMENSION ARE IN INCHES TOLERANCE ARE : DECIMALS FRACTIONS X 0.1 < 1/4 1/64 X.X 0.05 > 1/2 1/32 X.XX 0.01 >=1/2 1/16 X.XXX 0.002 ANGLE 0.5 X.XXXX 0.0005 ROUGHTNESS 125 DATE CHECKED SHEET 1 OF 1 RELEASE DATE : THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF LOAD SYSTEMS INTERNATIONAL. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF LOAD SYSTEMS INTERNATIONAL IS PROHIBITED. PROPRIETARY AND CONFIDENTIAL Treatment: UB313_rev20100401GS035 WEIGHT PRODUCT TITLE DRAWN APPROVALS 2010-04-01 www.load-systems.com M. Cloutier UB313 Label Background color: Pantone PMS 5C Material must be rated for outdoor use (sunlight, water and marine exposure, temperature -40°-85°C) 3mm white vinyl Laminated adhesive 3M 9472LE (#300SLE) Unique serial numbers, 16 pt, Times New Roman Bold Black FCC ID: QVBGS001 IC: 7076A-ICGS001 * This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1) This device may not cause harmful interference, and 2) This device must accept any interference received, including interference that may cause undesired operation. WARNING! This device is intended as an operator aid only and is not a substitute for safe operating practices. Read and understand the operator’s manual. Test before every use. Model No: GS035 Pressure Transducer USA: (888) 819 4355 Int.: +1 281 664 1330 ID: WWW.LOADSYSTEMS.COM 4,000 2,875 1,003 0,583 R 0,100 Century Gothic, 14 pt Arial Black, 11 pt color: Black 50% Arial, 7 pt Arial Black, 9 pt Arial, 7 pt Ø 0,270 Ø 0,130 Arial Bold, 11 pt 2,015 2,885

Prediction of MPE limit at a given distance Equation from page 18 of OET Bulletin 65, Edition 97-01where: S = power density P = power input to the antennaG = power gain of the antenna in the direction of interest relative to an isotropic radiatorR = distance to the center of radiation of the antenna Maximum peak output power at antenna input terminal: 10.76 (dBm) Maximum peak output power at antenna input terminal: 11.91242008 (mW) Antenna gain(typical): 0.5 (dBi) Maximum antenna gain: 1.122018454 (numeric) Prediction distance: 20 (cm) Prediction frequency: 927 (MHz) MPE limit for uncontrolled exposure at prediction frequency: 0.618 (mW/cm^2) Power density at prediction frequency: 0.002659 (mW/cm^2) Maximum allowable antenna gain: 24.1625833 (dBi) Margin of Compliance: 23.6625833 2 4 R PG S π =

www.nemko.com Report Reference ID: 147485-2TRFWL Test specification: Title 47-Telecommunication Chapter I - Federal Communications Commission Subchapter A - General Part 15 - Radio Frequency Devices Subpart C - Intentional Radiators §15.247 - Operation within the bands 902–928 MHz, 2400–2483.5 MHz and 5725–5850 MHz Applicant: Load Systems International Inc. 4495 Blvd Hamel, Suite 110, Quebec, QC, Canada G1P 2J7 Apparatus: Angle Length Sensor and Pressure Transducer FCC ID: QVBGS001 Model: GS012 Model Variant: GS035 Testing laboratory: Nemko Canada Inc. 303 River Road Ottawa, ON, Canada K1V 1H2 Telephone: (613) 737-9680 Facsimile: (613) 737-9691 Name and title Date Tested by: David Duchesne, Senior EMC Specialist May 4, 2010 Reviewed by: Andrey Adelberg, Senior Wireless/EMC Specialist May 5, 2010 Nemko Canada Inc., a testing laboratory, is accredited by the Standards Council of Canada. The tests included in this report are within the scope of this accreditation. 15.247.doc - Date: April 13, 2010 Product: Angle Length Sensor and Pressure Transducer Nemko Canada Inc., 303 River Rd, Ottawa, ON, Canada, K1V 1H2 Report reference ID: 147485-2TRFWL Page 2 of 29 Table of contents Section 1: Report summary.........................................................................................................................................................3 1.1 Test specification.........................................................................................................................................................3 1.2 Statement of compliance.............................................................................................................................................3 1.3 Exclusions....................................................................................................................................................................3 1.4 Registration number....................................................................................................................................................3 1.5 Test report revision history...........................................................................................................................................3 1.6 Test location................................................................................................................................................................3 1.7 Limits of responsibility..................................................................................................................................................3 Section 2: Summary of test results.............................................................................................................................................4 2.1 FCC Part 15 Subpart C Test results............................................................................................................................4 Section 3: Equipment under test (EUT) details..........................................................................................................................5 3.1 Sample information......................................................................................................................................................5 3.2 EUT information...........................................................................................................................................................5 3.3 EUT technical specifications........................................................................................................................................6 3.4 Operation of the EUT during testing............................................................................................................................6 3.5 EUT setup diagram......................................................................................................................................................6 Section 4: Engineering considerations.......................................................................................................................................7 4.1 Modifications incorporated in the EUT.........................................................................................................................7 4.2 Technical judgment......................................................................................................................................................7 4.3 Deviations from laboratory tests procedures................................................................................................................7 Section 5: Test conditions...........................................................................................................................................................8 5.1 Power source and ambient temperatures....................................................................................................................8 Section 6: Measurement uncertainty..........................................................................................................................................9 Section 7: Test equipment.........................................................................................................................................................10 Section 8: Testing data...............................................................................................................................................................11 8.1 Clause 15.31(e) Variation of power source................................................................................................................11 8.2 Clause 15.31(m) Number of operating frequencies...................................................................................................12 8.3 Clause 15.203 Antenna requirement.........................................................................................................................13 8.4 C…

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