FCC ID: QVBLS001 Load Cell Amplifier

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. 1 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 2 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 op-

erator 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 ap-

propriate 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 sen-

sors, 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. 3 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-two-

block 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 estab-

lished 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 sen-

sor 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:

Toll Free Ph.: (888) 819-4355 Dir. Ph.: (360) 666-5028 sales@loadsystems.com For any information visit our website www.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 North Central Regional Office:

Terry Petzold Toll Free Ph.: (877 ) 256-1674 Phone (920) 894-2785 Fax (920) 894-4934 tpetzold@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 Corporate Office:

Load Systems International P.O. Box 820486 Vancouver, WA 98682 Toll Free Fax: (888) 238 -4099 Dir. Fax: (360) 258 -4093 4 LS420 Universal User Manual V2.91 2003-01-21.doc Chapter 1: LS420 Front Panel 1.1 LS420 Indicator Lights Load indicated in pounds WARNING! Two-Block light indicates two-block condition M = main, A = auxiliary. Steady green indicates a2b sensor online and functioning 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 maximum angle limit is passed. WARNING! Limit light flashes when minimum 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 5 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 lock-

out 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 re-

turns 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 oper-

ating screen to the sensor specific operating screens appropriate to system con-

figuration. 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 cur-

rent 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 al-

lows 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. 6 LS420 Universal User Manual V2.91 2003-01-21.doc

. When the tare function is enabled for any hoist the tare light will light. 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 hook symbol:

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 Limit-

Pushing 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 per-

mits 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 sec-

onds 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 dis-

play 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 back-

light 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 es-

tablished.

"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 op-

eration remain from the moment the Low Batt indicator first lights. 7 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. 8 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 sen-

sors), 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 e-

ter 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 dis-

play 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 col-

umn 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 con-

nector 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 ad-

just 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 9 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 sec-

onds 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 indus-

try 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 op-

tional cabled A2B, only when ordered. Wiring example without lockout Black wire Yellow cable Red wire Battery +12V or +24V LS420 Universal User Manual V2.91 2003-01-21.doc 10 Wiring example with lockout and recommended Bosch Relay Yellow cable White wire Bosch relay To valve coil if n.c. is required. Black wire Red wire Battery +12V or +24V n.c. n.o. co 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 Valve coil Black wire Red wire Battery +12V or +24V Diode 11 LS420 Universal User Manual V2.91 2003-01-21.doc 2.1.3 LS420 Display Unit Datasheet Dimensions :

4) Antenna length: 3.25"

3) Height: 4.45"

1) Thickness: 2.30"

2) Width: 4.45"

5) Bracket length: 4.5"

The yellow cable should have this 4.5" room to protect the connector. Weight: 1.5 pounds Hardware Electronics:

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. For any information visit our website www.loadsystems.com or 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 12 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 se-

cured 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 move-

ment of the load cell and the adapter plates along the pin. Step 4) If the dead end or hook to be con-

nected 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 ra-

dio 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 ad-

justment. 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 The angle sensor is mounted with its hor i-

zontal axis parallel to the boom centerline. Boom The angle sensor is mounted with its top/bottom axis within 15 degrees of vertical. Front Cabin Cabin 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. Boom Boom centerline. Front Boom Indicator light Towards boom tip The angle sensor is mounted with its hori-

zontal axis parallel to the boom centerline. Towards boom base 14 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 en-

sure 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 de-

pending 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 at-

tached to the sensor by the thin wire: it will be useful if the sensor is to be removed and stored in the fu-

ture. Releasing the wire rope will cause the alarm buzzer of the dis-

play 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. Pin up 30 from horizontal Up to 8 diameter Step 2) Position the sensor mounting bracket. To ensure that the sensor can pivot securely on the mounting bracket throughout the full range of boom angle, the mounting bracket must be positioned at a 30 from horizontal with the boom parallel to the ground and such that the locking pin of the mounting bracket points up. Bolt or weld securely. a) A2B switch placement on a telescopic crane. For both live end and dead end mounting:

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 Mount bracket 4 (10 cm) below sheave center (see shaded region of diagram). 8 to 16 diameter Dead end pin Mount bracket 4

(10cm) forwards of dead end pin. For live end mounting on multiple sheave blocks with sheaves greater than 16 in diam e-

ter, 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. A2B switch mounting bracket directly below sheave center and as low as possible. Chain hole. Fast line weight. 17 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, two-

block alarm triggered. Hook block stops rising, two-block prevented with safety margin. Boom at maximum angle, two-

block alarm triggered. 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. iv) Lower the boom until the weight height becomes visually clear to the operator. Repeat-

edly 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. Hook block stops rising, two-block prevented with safety margin. 18 LS420 Universal User Manual V2.91 2003-01-21.doc 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 booms 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. Ver-

ify 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 anchor 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 re-

peatedly 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 com-

pletely 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 Cable guide Boom base pin Cable reel Boom length: distance from boom base pin to head sheave center. 19 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 cali-

brated 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 con-

firmed 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 ra-

dius. These measurements are described in sections 2.6.2 (lat-

tice cranes) and 2.6.3 (hydraulic cranes). Step 2) Confirm the parameters entered in the advanced op-

tions of the LS420 display. Press the hoist button until the ad-

vanced options entry screen is displayed. Press the test button to proceed to the advanced options. Verify that the radius pa-

rameters 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 dif-

ferent 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 compen-

sate (see step 2 above). E.g. if the radius displayed is always 2.3 feet longer than the actual ra-

dius 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). 20 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. Head sheave. Jib offset angle. Distance from head sheave center to jib mounting point.

(Your measurement) Head sheave radius.

(Your measurement) Jib length. 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. Crane center of rotation. 21 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.

(Your measurement) 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

(Your measurement) The sheave head length is the distance between the boom centerline and the center of the lower sheave. 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) 22 LS420 Universal User Manual V2.91 2003-01-21.doc Crane center of rotation Boom length: distance from boom base pin to head sheave center. Boom base pin 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 ac-

tual 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 de-

flection 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 deflection 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 be-

tween 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 d-

ing 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 a-

tion contact LSI: see page 2 of this manual. 23 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 bat-

teries. 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 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 nega-

tive 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 bat-

teries without damaging the load sensor. Batteries should be changed when reduced to 10 20 % of full charge. The following items are necessary to successfully change the batteries of the load sen-

sor:

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 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. 24 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 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 bat-

tery box. Avoid all contact with tiny white the inter-

rupter switches. Step 7. To remove the batteries, always remove the battery closest to the indicator light first, the mid-

dle battery second, and the battery furthest from the indicator LED last. The batteries can easily be re-

moved by hand. Gently apply pressure in the direc-

tion 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. Indicator light 25

The screwdriver is applied to the negative contact only. 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 in-

dicated 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 installa-

tion 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 ori-

entation is achieved, press down to mate securely. Once again flat head screwdriver may help:

use extreme caution!

the small 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 ef-

fective 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 cabin-

mounted display will no longer be lit. Use of the test function will confirm new battery status. Step 16. Reinstall load sensor. 26 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 with-

out 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 nega-

tive 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 bat-

teries 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. 27 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 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 screw-

driver 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 screwdriver is applied to the negative contact only. The battery closest to the indicator light is removed first. Indicator light 28 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 re-

spected 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 half-

way 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, indicat-

ing 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 cabin-

mounted 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 installa-

tion procedure outlined in the angle sensor installation chapter of this manual. 29 LS420 Universal User Manual V2.91 2003-01-21.doc 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 un-

changed 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-two-

a) A monkey wrench. b) Four new, high-quality, alkaline C-cell batteries (Duracell Ultra or Energizer E2 rec-

block:

ommended). 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 sur-

face. 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 bot-

tom 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) Reinstall the anti-two-block. 30 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 identi-

fies 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 an-

tenna with identi-

fying green strip Anti-two-

block an-

tenna 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. sensor:

The following items are necessary to successfully replace the antenna of a load or angle 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. 31 LS420 Universal User Manual V2.91 2003-01-21.doc 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 an-

tenna with an electrical insulating compound by care-

fully inserting it in the mouth of the compound tube. 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. White nylon hex bolt Antenna 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. 32 LS420 Universal User Manual V2.91 2003-01-21.doc 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 "Calibra-

tion 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 sen-

sor thats 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 sur-

rounding 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. 33 LS420 Universal User Manual V2.91 2003-01-21.doc 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 ad-

justed. Use the table below to determine the appropriate configuration number by cross-

referencing 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 con-

tinuously 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 x 8 x 4 Config. Number Custom Length Radius Wind Angle Load Comment 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 2 0 0 0 0 0 0 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 0 1 2 3 0 1 2 3 0 1 2 3 0 1 2 3 0 1 2 3 0 1 2 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 34 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 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 l load, 2 angle, 1 wind 0 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 3 0 1 2 3 0 1 2 3 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 4 load cells, A, B, C & D 2 load, summation, angle 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 x32 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 x16 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 x8 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 x4 0 1 2 3 0 1 2 3 0 1 2 3 0 1 2 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 x64 Configurations used in custom applications 1 load, 1 angle, 1 wind, 1 radius 2 load, 1 angle, 1 wind, 1 radius 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 35 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?

No Yes Please call your service representative Verify the connections of the black wire, the red wire and, if appro-

priate, the white wire of the yellow cable as described in section 2.1 of the Universal User Manual. Is there a bad connection?

No 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. Yes reconnect properly Is there a change in the display?

No Yes Disconnect the yellow cable from the display unit and reconnect it carefully Is there a change in the display?

Yes Press "Test" button to verify communica-

tion and battery sta-

tus of all sensors. Yes No Please call your service representative Press "Test" button to verify communica-

tion and battery sta-

tus of all sensors. 37 LS420 Universal User Manual V2.91 2003-01-21.doc 6.2 The Lock-out Doesn't Engage 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. Verify the connection of the white wire of the yellow cable Measure the voltage on the white wire of the yellow cable. Is there a bad connection?

Yes No reconnect the white wire carefully Yes Place the crane in non-lock-out condition Is the display in lock-out or alarm mode?

No Verify the voltage on the white wire of the yellow cable. Is the voltage on the white wire equal to zero?

Yes No Disconnect the white wire from the lock-out circuit Yes Wait 30 seconds and measure the voltage on the white wire. Everything seems fine, return any limits you may have changed to their appropriate values and verify lock-out function Is the voltage on the white wire equal to zero?

Yes Lock-out coils may be connected to the positive battery voltage of the crane Yes Is the voltage on the white wire equal to that of the crane battery?

No Call customer service instead of the negative ground. Verify and refer to the lock-out section of the user manual. 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. No Measure the voltage on the white wire. Is the voltage on the white wire equal to that of the crane battery?

Yes 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. Yes The display should be fine, verify lock-out function Is the voltage on the white wire equal to that of the crane battery?

Is the voltage on the white wire equal to that of the crane battery?

Yes Install a relay as explained in the lock-out section of the user manual. No Please call your service representative No 38 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 Place all A2B switches in safe condition. Is the

"2 Block"

warning light still on?

No The anti-two-block switch appears to be working properly, please refer to the lockout section of the user manual. Yes Press the "Test" button. Are A2B batteries low?

No Yes Take the A2B switch off the cable. Pull on the wire rope. 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. Press the "Test" button to verify battery status. Are load cell batteries low?

Yes Verify battery installation or change batteries if necessary, see the changing load cell batteries of the user manual. No The batteries need changing. Refer to the changing anti-two-

block batteries section of the user manual. Does the red light on the A2B switch flash after pulling on the wire rope?

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. Yes Pull on the wire rope. Verify communication between the load cell and the display unit (follow the procedure). There appears to be a communication problem, see diagnostic mode p. ?

Does the red light on the A2B switch flash after pulling on the wire rope?

Yes Reinstall the A2B switch on the cable. Verify A2B function. No Please call your service representative 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 The display is always in alarm mode: the "Load"

warning light is on. Remove weight from load cell. 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. Yes Verify overload alarm function. Does the overload alarm now function properly?

No Press "Test" to verify loadcell batteries. Is the overload alarm still on?

No Everything seems to be functioning normally. Yes 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 Please call your service representative Verify proper load cell function. No Please call your service representative Everything seems to be functioning normally. Does the load displayed now correspond with the weight on the load cell?

Yes Is the overload alarm No still on?

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 Limit-

warning 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 Verify the angle sensor installation. Reinstall or recalibrate if necessary, see the angle sensor installation section of the user manual. No Does the angle shown correspond to actual boom angle. Yes 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. 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?

Yes Is the

"Limit +" warning light still flashing?

No Yes Please contact your service representative. Press the "Test" button to verify battery status. Yes Are angle sensor batteries low?

No Yes Verify battery installation or change batteries if necessary, see the changing angle sensor batteries of the user manual. Verify communication between angle sensor and display unit (Section 6.4). No No The maximum angle limit warning appears to be functioning normally:

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. 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 greater than the maximum angle limit set?

Yes refer to the user manual for a description of this warning. The minimum angle limit warning appears to be functioning normally:

Is the

"Limit -" warning light still flashing?

No refer to the user manual for a description of this Yes warning. Please contact your service representative. 41 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 Yes The maximum wind speed warning appears to be functioning normally:

refer to the user manual for a description of this warning. 42 Visually inspect the wind speed sensor for physical damage. Verify proper installation, refer to wind speed sensor installation instructions. Press the "Test" button to verify battery status. Verify communication between wind speed sensor and display unit

(Section 6.4). Are wind speed sensor batteries low?

No Yes Verify battery installation or change batteries if necessary, see the changing wind speed sensor batteries of the user manual. 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?

No 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 Yes Visually inspect the antennas of the sensor and the cabin mounted display unit. service representative. Yes The sensor chip's memory has been erased, please refer to the technical manual or contact your service representative. direct line of sight between the sensor antenna and the Is there a clear and antenna of the display unit?

Yes the display unit antennas clear of all contact with any metal Are both the sensor and object at all times?

Yes Are both the sensor and the display unit antennas complete and undamaged?

No Yes No 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. 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. 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?

No There appears to be a problem with the sensor, please contact your service representative. 43 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 return-

ing defective or broken parts. The customer can reuse the original box and the prepaid re-

turn 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 protec-

tion 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 in-

structions, may cause harmful interference to radio communications. However, there is no guar-

antee 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. Connect the equipment into an outlet on a circuit different from that to which the receiver Increase the separation between the equipment and 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