Trimble GS 222-05 Wireless Gateway, GS Sensors Install & Operation Manual
The GS 222-05 Wireless Gateway acts as a base station for GS series wireless sensors. The Gateway can be used in a wide range of industrial process monitoring situations.
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GS222-05 System
& GS Series Sensors
Install & Operation Manual
ENGLISH
GM222-05_ENG_rev20160129
GS222-05 SYSTEM & GS SERIES SENSORS
TABLE OF CONTENTS
1: GENERAL ..................................................... 3
1.1 Overview ................................................... 3
1.2 About This Manual .................................... 3
1.2a Notifications Included in Document .......... 3
1.2b How To Provide Feedback To
Trimble Lifting Solutions .................................. 3
1.2c How This Manual Is Updated. .................. 3
1.2d How to Contact Trimble Lifting Solutions. ... 3
1.3 Start-Up .................................................... 3
2: OPERATION ................................................. 4
2.1 Normal Operation ...................................... 4
3: CONFIGURATION ........................................ 5
3.1 PC Installation ........................................... 5
3.1a System Requirements .............................. 5
3.1b WM Configurator and USB
Driver Installation ............................................. 5
3.1c Gateway Connection ................................ 5
3.2 Application Overview ................................ 6
3.2a Settings ................................................... 6
3.2b Communication Port ............................... 6
3.2c Configuration ........................................... 6
3.2d Firmware Update ..................................... 7
3.2e Data Logger Mode .................................. 7
3.2f Sensor Settings ........................................ 7
3.3 Sensor List ............................................... 7
3.4 Custom RS232 ......................................... 8
3.5 Firmware Update (Gateway Only) .............. 9
3.6 Import/Export Gateway Configuration ....... 9
3.7 Packet Format ........................................ 10
3.5a Low Battery Signal .................................10
3.5b Missing Sensor .......................................10
3.8 Changing Sensors ...................................11
3.8a Automatic Sensor Settings .....................11
3.8b Manual Sensor Setting ...........................11
4. INSTALLATION ........................................... 12
4.1 GS222-05 Gateway Installation .................12
4.1a Antenna Position .....................................12
4.1b Power Supply Connection ......................12
4.1c Wiring .....................................................12
4.2 Load Cell ................................................ 13
TABLE OF CONTENTS
4.3 Angle Sensors for the Boom or Jib ...........14
4.3a Mounting Procedure ...............................14
4.3b Angle Calibration Procedure No. 1:
Mechanical Set-Up .........................................15
4.3c Angle Calibration Procedure
No. 2: Correct with the GS222-05 ..................15
5. MAINTENANCE .......................................... 16
5.1 Replacing Sensor Battery ........................ 16
5.1a Tools Required ........................................16
5.1b Procedure ...............................................16
5.2 Replacing a Sensor Antenna ....................17
5.3 Load Cells ............................................... 18
5.3a Reading Accuracy ..................................18
5.3b Load Testing ...........................................18
5.3c Care .......................................................18
6: CERTIFICATION NOTES ........................... 20
6.1 FCC and IC—Instructions to the User ...... 20
6.2 CE .......................................................... 21
6.2a Declaration of Conformity ...................... 21
6.2b CE Safety .............................................. 22
6.3 Applicable to the Class 1 Division 2
Certified Gateway ......................................... 22
7: LIMITED WARRANTY ....................................23
REVISION HISTORY ...................................... 24
NOTES ............................................................ 25
2
3
GS222-05 SYSTEM & GS SERIES SENSORS
1: GENERAL
1.1 Overview
The GS222-05 Wireless Gateway acts as a base station for GS series wireless sensors. Not limited to crane applications, the Gateway can be used in a wide range of industrial process monitoring situations. The WRCM doesn’t have an integrated display; it provides a bridge from GS wireless sensors to an existing RS232 automotive or industrial automation network. The system is primarily configured via a USB cable using the PC software tool WM Configurator.
1.2 About This Manual
This installation and operation manual describes how to install, operate and maintain the GS222-05.
For your safety and that of the people that come into contact with Trimble products, understand the significance of the instructions included in this guide, respect all laws and regulations and comply with applicable standards.
1.2a Notifications Included in Document
The following notations may be used in this manual:
✓
NOTE
INDICATES PRACTICES NOT RELATED TO
PERSONAL INJURY.
CAUTION
INDICATES A HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, COULD RESULT IN
MINOR OR MODERATE INJURY.
WARNING
INDICATES A HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, COULD RESULT IN
DEATH OR SERIOUS INJURY .
DANGER
INDICATES A HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, WILL RESULT IN
DEATH OR SERIOUS INJURY .
1.2b How To Provide Feedback To
Trimble Lifting Solutions
Trimble Lifting Solutions welcomes your feedback on the accuracy and effectiveness of this document.
Please send feedback to [email protected].
Please include the title of the manual and version
(this information is located in the Document’s
Revision History on page 24) with your feedback.
1.2c How This Manual Is Updated
Trimble Lifting Solutions will issue new releases of this manual as new material becomes available.
Refer to the Document Revision History on page
24 of the manual for more information.
1.2d How to Contact Trimble Lifting Solutions
Please contact Trimble Lifting Solutions if you encounter problems or require advice. Contact details are located on the back cover.
1.3 Start-Up
The Gateway has been pre-configured for the system with which it shipped. It starts up with its green light flashing as it wakes up the system sensors and creates a radio communication link with each. Once a reliable communication network is established, the green light stops flashing. This process may take up to 60 seconds. Thereafter the green light flashes only when the Gateway communicates with sensors.
WARNING
THE gS222-05 SYSTEM IS DESIgNED
AS AN OPERATOR AID AND IS IN
NO WAY A SUBSTITUTE FOR SAFE
OPERATINg PRACTICE.
CHAPTER 1: gENERAL
2: OPERATION
2.1 Normal Operation
Radio communication between sensors and the Gateway is made in packets. Radio packets include both the source and destination ID numbers. This allows the Gateway to send acknowledgements back to the transmitter.
On start-up the Gateway sends a radio packet to each of the system sensors. This communication wakes the sensor and identifies the Gateway as the network controller. The sensor then sends future communications to the Gateway.
Sensors transmit once every 60 seconds and whenever their measurement changes by more than a default threshold. Example: A wind speed sensor transmits when wind speed varies by 2 mph or more.
The Gateway sends a packet on the RS232 network every time a sensor communication is received.
GS222-05 SYSTEM & GS SERIES SENSORS
CHAPTER 2: OPERATION 4
GS222-05 SYSTEM & GS SERIES SENSORS
3: CONFIGURATION
Configuration of the GS222-05 Wireless Gateway requires access to a PC with a USB port; initial configuration may be easier prior to physical installation of the Gateway. Refer to the Installation section as required.
3.1 PC Installation
3.1a System Requirements
Windows 2000, XP, Vista (32/64bit), Windows 7
(32/64bit), Windows 8 (32/64bit) or Windows 10
(32/64bit).
3.1b WM Configurator and USB Driver Installation
✓
NOTE
BEFORE STARTINg INSTALLATION,
MAKE SURE THAT NO gATEWAYS ARE
CONNECTED TO THE COMPUTER.
1. Download the installation file from www.loadsystems.com/wmconfigurator
2. Install the file and follow the steps from the installation wizard.
3. When transferring the files, the installation wizard will automatically execute the USB driver installation; a Windows warning will recommend to stop the installation, ignore this warning and select Continue Anyway (Windows XP) or Install this driver anyway (Windows Vista, Windows 7).
3.1c Gateway Connection
Windows Vista / Windows 7/8/10:
1. Connect the Gateway to the computer; the device will automatically be installed.
Windows XP:
1. Connect the Gateway to the computer; Found
New Hardware Wizard will appear.
2. If Windows asks to connect to Windows
Update to search for software, select No, not this time and then click Next.
3. Select Install the software automatically, then click Next to continue.
4. A Windows warning indicating that the driver has not been tested will recommend to stop the installation, ignore this warning and select
Continue Anyway.
5
5. When the installation wizard has finished installing the software, click Finish to close the wizard.
When the installation is completed, the Device
Manager will appear as shown below;
Figure: Device Manager, Windows Vista / Windows 7
Figure: Device Manager, Windows XP
WARNING
THE SYSTEM MUST BE INSTALLED
IN COMPLIANCE WITH TRIMBLE
INSTRUCTIONS AND USINg TRIMBLE
SUPPLIED COMPONENTS ONLY. FAILURE
TO INSTALL ALL PARTS, OR REPLACINg
PARTS OR COMPONENTS WITH PARTS OR
COMPONENTS NOT SUPPLIED BY TRIMBLE,
MAY LEAD TO SYSTEM FAILURE, SERIOUS
INJURY OR DEATH.
CHAPTER 3: CONFIgURATION
GS222-05 SYSTEM & GS SERIES SENSORS
3.2 Application Overview
Access the menus from the treeview (in the upperleft) by clicking on it. The appropriate details will be displayed in the right section of the application.
Figure: Sensor List
Gateway Internal Ports:
The Gateway internal communication ports behavior can be configured in the LSI Gateway
Internal Ports section.
3.2a Settings
The data from the data logger mode can be saved on the computer disk.
1. Define the time interval and location folder of the logs.
Figure: Application Overview
2. Press Apply to save changes or Cancel to reload existing setting.
Figure: Settings
3.2b Communication Port
This section displays the communication port in use, the port type and status. The Open status indicates that the communication port is in use and that the Gateway is communicating information.
3.2c Configuration
Sensor List:
All sensors in the GS222-05 system are defined in the Configuration menu and are also displayed under Sensor Settings in the treeview section.
Refer to section 3.3 Sensor List to add, remove or modify sensor information.
Figure: LSI Gateway Internal Ports
• Step 1: Select the Gateway internal port to be configured.
• Step 2: Set the data logging options of the selected port.
The data logging options set are compatible with the Datalogger Mode from the left menu.
Data Filter: Defines the information sent to the internal communication port;
All Sensors: Surrounding sensors, including the system sensors.
System Sensors Only: Sensors configured in the Gateway.
• Step 3: Set advanced port settings.
Figure: Gateway Internal Ports
CHAPTER 3: CONFIgURATION 6
7
GS222-05 SYSTEM & GS SERIES SENSORS
3.2d Firmware Update
This section displays current Gateway firmware information and is used to update the firmware.
Refer to section 3.4 Firmware Update.
3.2e Datalogger Mode
In this mode, live information sent by the wireless sensors is displayed. The data can be logged to files; see the 3.2a Settings section to configure this feature.
3.2f Sensor Settings
When a sensor is selected under Sensor Settings, the following information is communicated to the
Gateway;
• Base Station ID: The radio id number of the
Gateway that has the sensor programmed in its sensor list.
• Heart Beat: When no change is detected in sensor value, the sensor status will be communicated to the GS222-05 in the interval
(in seconds) indicated.
• Communication Timeout Before Sleep Mode:
When the base station stops communicating information to the sensors, the sensors become inactive (sleep mode). The value indicated is the time (in seconds) before the sensors switch to the sleep mode.
• Calibration Offset: Sensor calibration.
• Calibration Scale: Sensor calibration.
• Tx Sensitivity: The minimum change in sensor value required to trigger communication.
3.3 Sensor List
1. In the Configuration menu, select Sensor List.
2. To add sensors to the sensor list, select a line and click on Configure Selected Line or doubleclick on the line.
3. Enter the sensor ID, the sensor type, units, parts of line and tare value.
✓
NOTE
DOUBLE-CLICKINg IN THE “ID” COLUMN
WILL OPEN A SERIES OF POP-UP WINDOWS
THAT WILL ALLOW YOU TO CONFIgURE
ALL SENSOR PARAMETERS. DOUBLE-
CLICKINg DIRECTLY ON OTHER COLUMNS
AT THE LEFT ALLOW THE USER TO MODIFY
FURTHER ONE PARAMETER DIRECTLY.
✓
✓
NOTE
Figure: Sensor List
PARTS OF LINE MAY BE USED FOR LOAD
SENSOR ONLY.
NOTE
IT IS POSSIBLE TO ASSIgN A TARE VALUE
TO MULTIPLE SENSOR TYPES, BUT BE
AWARE THAT IT MAY BE A SOURCE OF
POTENTIAL PROBLEMS WITH SOME
SENSOR TYPES. FOR EXAMPLE, ASSIgNINg
A TARE VALUE TO A SLEW SENSOR MAY
LEAD TO UNEXPECTED RESULTS.
Figure: Sensors Standard Setup
4. To remove any sensor from the sensor list, select the sensor line to remove and click on
Remove Selected Sensor.
5. Reload data from the Gateway and display data without saving any changes (the unsaved data in the Gateway will be replaced).
6. Save changes in the Gateway memory. Save to
Gateway is automatically followed by Update
Sensor Status.
CHAPTER 3: CONFIgURATION
GS222-05 SYSTEM & GS SERIES SENSORS
3.4 Custom RS232
The format of the data sent from the RS232 port can be configured in the Custom RS232 section.
Figure: Custom RS232
1. Use the RS232 Configuration section to set basic RS232 parameters.
Figure: RS232 Configuration
2. For other section, please refer to Figure: RS232
Configuration.
a. RS232 Communication is used to setup the interval that the data from a sensor is sent to the RS232:
• Disabled: data of the selected sensor won’t be forwarded on RS232 port
• Live: data from the selected sensor is forwarded when it is received by the Gateway
• Custom (milliseconds): data from the selected sensor is forwarded at the defined interval, even if the data did not change b. RS232 Packet Definition is used to configure the format of the data that will be sent on
RS232 port for each sensor configured.
Figure: RS232 Packet Definition
c. RS232 Packet Definition (nearby sensors) is used to configure the data format of received sensors that are not configured in the sensor list.
✓
NOTE
DO NOT FORgET TO CHECK THE CHECKBOX
SEND PACKETS OF ALL NEARBY NODES TO
RS232 TO ENABLE THAT FEATURE.
CHAPTER 3: CONFIgURATION 8
GS222-05 SYSTEM & GS SERIES SENSORS
When the selected Units of a configured sensor is displayed as floating point format, it is the task of the user to configure the size of the data as
“Floating point” or else the data shown on the
RS232 output may be wrongly interpreted.
3.5 Firmware Update (Gateway Only)
1. Select Firmware Update in the treeview section.
2. In the right section, click on Browse to select the update file (extension .220) and then click
Update Firmware Now.
✓
NOTE
A FIRMWARE UPDATE WILL RESET THE gATEWAY TO THE FACTORY DEFAULT
CONFIgURATION.
9
Figure: RS232 Configuration
For example, a load value of “1.23” Ton may be displayed as “123” if not properly configured with the floating point format.
The Units that require floating point format are
(suggested number of decimal points in parentheses):
Sensor Type
Wind/Gust
Load
Slew
Requires
Floating Point
Format
Knot (1), m/s (1), Ft/s (1) kip (2), kN (1),
Long ton (3),
Short ton (3),
Metric ton (3)
Degree (1)
DOES NOT
Require Floating
Point Format
mph, km/h kg, pounds
Pressure bar (1) psi
Angle, List, Trim Degree (1)
Length,
Rope Payout ft (1), m (3)
Rope Speed knot (1), m/s (1), ft/s (1) mph, km/h
Figure: Firmware Update
3.6 Import/Export Gateway Configuration
It is possible to export and import the global configuration of a Gateway.
Figure: Global Configuration
This will save the configuration of all 3 configuration sections: Sensor List, LSI Gateway Internal Ports and Custom RS232.
✓
NOTE
WHEN IMPORTINg A CONFIgURATION FILE,
THE FILE MUST HAVE BEEN CREATED WITH
THE SAME HARDWARE TYPE.
EX: THE CONFIgURATION FILE OF A gS221-
XX CANNOT BE IMPORTED TO A gS222-05.
CHAPTER 3: CONFIgURATION
GS222-05 SYSTEM & GS SERIES SENSORS
3.7 Packet Format
The ASCII module will receive data as shown in the example below.
Delim 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Delim
‘X’ ‘A’ ‘0’ ‘1’ ‘2’ ‘5’ ‘0’ ‘0’ B ‘0’ ‘0’ ‘0’ ‘0’ ‘0’ ‘0’ ‘C’ + ‘0’ ‘4’ ‘5’ ‘-’ ‘2’ CR
Delimiters:
Letter ‘X’, ASCII 88, is the RS232 start delimiters
Letters ‘A’ to ‘Z’ are individual sensor delimiters
Symbols LF and CR are RS232 stop delimiters
Packets always have the same length of 23 bytes
RS232 Protocol:
Baud rate: 115200
Format: 8n1 (8 bits, no parity, 1 stop bit)
Handshaking (or protocol): none
3.7a Low Battery Signal
A sensor low battery is indicated by a lower case sensor start delimiter
Example: if the second load cell has a low battery the second sensor delimiter will be a lower case “b”:
Delim 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Delim
‘X’ ‘A’ ‘0’ ‘1’ ‘2’ ‘5’ ‘0’ ‘0’ B ‘0’ ‘0’ ‘1’ ‘6’ ‘5’ ‘0’ ‘C’ + ‘0’ ‘4’ ‘5’ ‘-’ ‘2’ CR
3.7b Missing Sensor
A sensor that is out of range, has a dead battery, or that is damaged is indicated by dashes
Radio range is about 3000 ft with a direct line of sight
Example: the second load cell is out of range:
Delim 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Delim
‘X’ ‘A’ ‘0’ ‘1’ ‘2’ ‘5’ ‘0’ ‘0’ B ‘-’ ‘-’ ‘-’ ‘-’ ‘-’ ‘-’ ‘C’ + ‘0’ ‘4’ ‘5’ ‘-’ ‘2’ CR
CHAPTER 3: CONFIgURATION 10
GS222-05 SYSTEM & GS SERIES SENSORS
3.8 Changing Sensors
If a sensor needs to be changed, the Gateway must learn to recognize the replacement sensor.
Two mechanisms are available to change an ID in the sensor list of the Gateway.
1. Automatic ID change
2. Manual ID change
3.8a Automatic Sensor Settings
Trimble will supply a replacement sensor programmed to replace the original one. When the replacement sensor is detected by the Gateway it causes the Gateway to automatically update the sensor list, replacing the ID of the old sensor with the ID of the new sensor; the process may take up to two minutes to complete.
3.8b Manual Sensor Setting
See Configuration 3.1 to 3.4.
11
CHAPTER 3: CONFIgURATION
GS222-05 SYSTEM & GS SERIES SENSORS
4: INSTALLATION
✓
WARNING
INSTALLATION MUST BE MADE
IN COMPLIANCE WITH TRIMBLE
INSTRUCTIONS AND USINg TRIMBLE
SUPPLIED COMPONENTS ONLY. FAILURE
TO INSTALL ALL PARTS, OR REPLACINg
PARTS OR COMPONENTS WITH PARTS OR
COMPONENTS NOT SUPPLIED BY TRIMBLE,
MAY LEAD TO SYSTEM FAILURE, SERIOUS
INJURY OR DEATH.
NOTE
DO NOT POWER WASH THE gS222-05 gATEWAY. POWER WASHINg THE gATEWAY VOIDS WARRANTY COVERAgE.
4.1 GS222-05 Gateway
The GS222-05 Wireless Gateway should be installed on the same side of the cab as the sensors with a direct clear line of sight to the sensors at all boom angles. Avoid hiding the
Gateway behind a metal structure if at all possible.
Optimizing position to improve the radio link will increase sensor battery life.
4.1a Antenna Position
5.85
4.72
5.44
2.33
5.57
4.73
Figure: GS222-05 Gateway Dimensions, Not to Scale.
(Dimensions are in Inches)
For optimal performance the antenna should be positioned on its side such that it is parallel to the sensor antennas (but not pointing directly to or directly away from them).
1. Optimally, the antenna should have 5 inches of clear space all around it.
2. The antenna should have an unobstructed line of sight to all sensor antennas at all boom angles.
4.1b Power Supply Connection
1. Connect the black wire (ground) to the negative terminal of the battery or the panel connection; alternatively bolt the black wire to the body of the machine with a 1/4 inch or 5/16 inch bolt.
The ground connection must be strong enough to sustain 1 ampere.
2. Connect the red wire to a fused accessory source, rated at least 1 ampere, that supplies
+12 or +24 volts when the machine is in use.
The GS222-05 will automatically detect the voltage level and adjust itself.
4.1c Wiring
Wire Color – Power Cable
Red
Black
Description
Power Supply,
10 to 30 Volts
Ground
Wire Color – RS232 Cable
Red
Brown
Black
Description
GS222-05 - TX
GS222-05 - RX
RS232 Ground
Table: Wire Description
CHAPTER 4: INSTALLATION 12
GS222-05 SYSTEM & GS SERIES SENSORS
4.2 Load Cell
WARNING
CAPACITY AND SAFETY FACTOR FOR LOAD
CELLS AND ADAPTER PLATE ASSEMBLIES
ARE CALCULATED FOR LOADS ALONg
THE INTENDED AXIS OF LOAD (VERTICAL
WITH THE ASSEMBLY HANgINg FREE);
SIDE LOADINg MAY CAUSE LOAD CELL
AND ADAPTER PLATE ASSEMBLY TO FAIL,
CAUSINg LOAD TO DROP. LIFTS MUST BE
RIggED SUCH THAT THE LOAD CELL AND
ADAPTER PLATE ASSEMBLY HANg FREE
AND NOT BE SUBJECTED TO SIDE LOADINg.
CAUTION
THE LOAD CELL MUST BE CENTERED ON
THE PINS TO AVOID UNEVEN LOADINg ON
THE PLATE KIT ASSEMBLY.
✓
NOTE
THE LOAD CELL ANTENNA SHOULD NOT BE
IN CONTACT WITH METAL.
✓
NOTE
FOR OPTIMAL PERFORMANCE AND SIgNAL
RECEPTION, THE LOAD CELL ANTENNA
SHOULD HAVE A CLEAR LINE OF SIgHT TO
THE gS222-05 gATEWAY.
✓
NOTE
THE LOAD CELL ANTENNA SHOULD POINT
TO THE LEFT OR TO THE RIgHT OF THE
BOOM; IT SHOULD NOT POINT DIRECTLY TO,
OR AWAY FROM, THE gS222-05 gATEWAY.
pin that links the adapter plates to the load cell. Additional washers should be added equally to each end of the pin as required to inhibit excessive lateral movement of load cell
(maximum 1/8” total movement) and adapter plates along the pin.
3. If the dead end or hook to be connected to the adapter plates requires a larger opening, washers may be placed between the load cell and the adapter plates equally on both sides of the load cell.
4. In all cases the washers must be placed symmetrically such that the load cell is centered on the pins to avoid uneven loading.
5. Secure the pins with the nuts and cotter pins provided.
6. A qualified (lift supervisor or crane inspector) person must verify every lift assembly before first use and periodically thereafter (one to twelve months), including before any new, difficult or otherwise different lift.
Crane dead end
Plate kit for loadlink
Loadcell
C/C
1. Install load cell bushings as supplied by Trimble.
Assembly of the load cell and adapter plates must be configured to the pin size required by the specific dead end or hook to which it is to be attached. In all cases, the bushings supplied by
Trimble must be used where possible to adapt the holes in the load cell to the pins. Bushings must be secured with the two allen screws provided, one on each side of the load cell.
2. As required, place a washer between adapter plate and pin head or nut on each end of the
Wedge socket to loaded cable
Figure: Typical Load Cell and Adapter Plate
Assembly Installed
CHAPTER 4: INSTALLATION
13
GS222-05 SYSTEM & GS SERIES SENSORS
4.3 Angle Sensors for the Boom or Jib
✓
NOTE
KEEP THE ANgLE SENSOR AWAY FROM
THE BOOM AND ANY CONNECTINg METAL
STRUCTURES WHEN WELDINg THE
METAL LUgS TO THE BOOM. PROXIMITY
TO WELDINg MAY CAUSE PERMANENT
DAMAgE TO THE ANgLE SENSOR AND
PREVENT ACCURATE ANgLE INDICATION.
4.3a Mounting Procedure
The GS010 series angle sensors can be turned on by starting up the GS222-05 base station to which they are programmed or by clicking on Update
Sensor Status in WM Configurator. The angle sensor can then assist in levelling itself with the red and green LED.
Cabin
Boom
CL
Boom
Angle Sensor
Figure: Angle Sensor Level with the Boom
(Typical Installation) - Side View
Angle Sensor
Cabin
Boom
Figure: Angle Sensor Top/Bottom Axis Within 15° of Vertical
(Typical Installation) - Front View
Angle Sensor
Cabin
WARNING
THE ANgLE READINg MAY BE AFFECTED
BY VIBRATION AND MAY FLUCTUATE; THE
ANgLE SENSOR SHOULD NOT BE INSTALLED
IN CLOSE PROXIMITY TO A HIgH RPM
ELECTRIC MOTOR OR OTHER SOURCE OF
HIgH FREQUENCY VIBRATION.
1. Determine the angle sensor position.
a. The GS010-01 boom angle sensor can be mounted on either side of the boom.
b. The GS010-02 360° angle sensor must be mounted on the port side of the jib.
c. The angle sensor must be level with the boom or jib centerline.
d. The top / bottom axis of the angle sensor must be within 15 degrees of vertical.
e. The angle sensor should have a clear line of sight to the cabin mounted display.
f. The angle sensor antenna should not contact a metal object.
2. Install the welding pads; keep the angle sensor at least three feet from the weld site and any connecting metal objects while welding.
3. Mount the angle sensor to the weld pads with the screws and washers provided.
4. Verify the angle indication; the GS222-05 must be connected to a computer.
5. If the angle displayed by a GS010-01 boom angle sensor is a high negative value, then tilt the angle sensor up over 45 degrees, and then tilt back down to horizontal. The GS010-01 boom angle sensor will automatically detect on which side of the boom it is installed and correct angle indication accordingly.
Boom
Wedge
Figure: Wedge Used to Mount the Angle Sensor with its Top/
Bottom Axis within 15° of Vertical (Typical Installation) - Front View
CHAPTER 4: INSTALLATION 14
GS222-05 SYSTEM & GS SERIES SENSORS
4.3b Angle Calibration Procedure No. 1: Mechanical
Set-Up
✓
NOTE
THE gS222-05 MUST BE CONNECTED
TO A COMPUTER TO PROCEED WITH
CALIBRATION PROCEDURE.
1. Level the boom such that it is perfectly horizontal; use a high quality bubble or digital angle sensor. If the WM indicates 0.0 degrees then angle calibration is complete; if not then continue to step 2.
WARNING
FAILURE TO ENSURE THE BOOM IS
LEVELLED WILL RESULT IN FALSE READINg
OF THE CRANE’S RADIUS HENCE THE RISK
OF STRUCTURAL FAILURE OF THE CRANE
OR CRANE TIPPINg OVER.
✓
NOTE
PRESS UPDATE SENSOR STATUS IN WM
CONFIgURATOR TO DISPLAY THE CURRENT
ANgLE VALUE.
1. Position the boom at a precisely known angle.
2. Adjust the trim value in WM Configurator.
3. Example: If angle indicated is 0.3° over the actual angle, adjust the trim value to -0.3.
4. Example: If angle indicated is 0.9° below the actual angle, adjust the trim value to 0.9.
5. Verify accurate angle indication at both very high and very low angles.
2. For GS011 angle/length sensors only: Carefully remove the cover of the GS101 cable reel.
3. Loosen the mounting screw in the slotted hole of the angle sensor mounting plate.
4. Pivot the angle sensor slightly until angle indication is correct. Repeat the angle validation
(step 1) as required.
4.3c Angle Calibration Procedure No. 2: Correct with the GS222-05
✓
NOTE
THE gS222-05 MUST BE CONNECTED
TO A COMPUTER TO PROCEED WITH
CALIBRATION PROCEDURE.
Calibrate angle indication by adjusting the trim
(offset) value in WM Configurator; the GS222-05 will then communicate the updated trim value to the sensor.
CHAPTER 4: INSTALLATION
15
5: MAINTENANCE
5.1 Replacing Sensor Battery
Gasket Kit P/N: TB027-XX
5.1a Tools Required
• Alcohol/Cleaning Solvent
• 1/8” Allen Wrench
• 5/32” Allen Wrench
• Wire Brush
• Utility Razor Knife
• Flat Blade Screwdriver
• G Clamp
GS222-05 SYSTEM & GS SERIES SENSORS
Battery Cover Notch
5/32” Allen Screws
Figure: Tools Required
5.1b Procedure
Step 1: Opening Sensor
1. Unscrew the two allen screws with the 5/32” allen wrench and pull them free of transmitter case. Discard old screws.
2. Remove any excess RTV from around the transmitter base, especially from the battery cover notch.
3. Clamp the transmitter case to a rigid structure
(e.g., work bench).
4. Place the large screwdriver into the battery cover notch (ensure screwdriver tip fits snugly into battery cover notch) and use the 1/8” allen wrench as a fulcrum.
5. Push the screwdriver down until the transmitter case/housing lifts free of the base.
Figure: Opening Sensor
Step 2: Remove Battery and Clean
1. Remove existing battery and dispose of properly.
2. Using the utility razor knife, remove ALL existing
RTV on the outside and inside of the transmitter and ALL edges on the back plate.
3. Using a wire brush and alcohol/cleaning solvent, clean all areas that once had RTV. Any leftover residue may cause leaks once new gasket is fitted.
Figure: Remove Battery and Clean
CHAPTER 5: MAINTENANCE 16
GS222-05 SYSTEM & GS SERIES SENSORS
Step 3: Install
1. Install new gasket (QR040) around back plate with grooved side down / flat side up.
4. Inspect the antenna for signs of obvious physical damage.
5. Carefully unscrew the white nylon hex bolt completely and slide it up the antenna.
This Side Down
(Grooved)
Figure: New Gasket
This Side Up
(Flat)
2. Install two new retaining screws (QV338) into transmitter case.
3. Install new 3.6 Vdc lithium battery.
Step 4: Reassemble
1. Place transmitter onto gasket/back plate.
2. Use the 1/8” allen wrench to tighten screws to
12 inch/lbs (1.35 Nm) of torque.
If a proper torque driver is not available, apply half of one revolution to the screws once the thread of the screws is correctly engaged to ensure proper tightening.
5.2 Replacing a Sensor Antenna
Heavily damaged antennas (ripped out, sheared off, wire exposed and fraying etc.) should be replaced to ensure effective communication between the sensor and the cabin mounted display unit.
This procedure may be followed without removing the sensor from the crane if it is safe to do so. If removed, an angle sensor must be re-calibrated during reinstallation for correct angle display
(see the angle sensor installation section of the user’s manual).
✓
NOTE
THE INTERIOR OF THE SENSOR
MUST BE PROTECTED FROM DUST, gRIME
AND WATER AT ALL TIMES.
5
6
7/16 in.
wrench
Figure: Unscrew the White Nylon Hex
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.
Figure: Pull Out the Antenna
7. Slide the white nylon hex bolt to the middle of the length of the new antenna.
8. Coat the exposed metal foot of the new antenna with an electrical insulating compound by carefully inserting it in the mouth of the compound tube.
Electrical insulating compound
8
Figure: Coat the Exposed Metal Foot of the Antenna
1. Place the crane, boom, jib or ball hook so that the sensor is safely accessible.
2. Clean dust, grime and water from the sensor.
3. Identify the short black whip antenna and the white hex bolt securing it.
17
CHAPTER 5: MAINTENANCE
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.
White nylon hex bolt
TA011 Antenna
Sensor box
Antenna receptacle
Figure: Install the New Antenna
10. Carefully re-thread, screw in and tighten the white nylon hex bolt to secure the antenna in place. Do not overtighten.
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’s manual).
12. Verify that the sensor functions properly.
5.3 Load Cells
WARNING
HEAVY SHOCK MAY AFFECT LOAD
INDICATION ACCURACY. INSPECT THE
LOAD CELL REgULARLY FOR CLEARLY
VISIBLE DENTS OR SCRATCHES. TEST THE
LOAD INDICATION IF COLLISION DAMAgE
IS VISIBLE.
5.3a Reading Accuracy
Trimble flat bar load links are pre-calibrated at the factory. No “zeroing” or other calibration is required on installation. Each link is heat treated to age the steel and ensure stable readings for many years; the load cells are individually temperature compensated to guarantee accuracy. Trimble flat bar load links are calibrated to indicate between 100% and 104% of their Working Load Limit (WLL).
GS222-05 SYSTEM & GS SERIES SENSORS
Trimble load pins, line riding tensiometers and compression cells must be calibrated at installation and every time thereafter the installation, the load sensor or the transmitter is changed.
SAE J 159 4.2.1 recommends load indicating devices should show not less than 100% of the actual load and not more than 110% of the actual load.
5.3b Load Testing
Trimble recommends testing the load cell every year for accuracy. The simplest way of testing a load cell is to lift at least two known weights. A test weight should be known with an accuracy of ±1%.
If the load cell is installed at the boom tip dead end, all additional equipment such as blocks, slings, sensors, etc. should also be known to an accuracy of ±1%.
Determine the accuracy of the tested system with the following formula:
Indicated Load
Actual Load
X 100 = % of Load
(Reference: SAE-J-159 7.3)
The test loads must be significantly relative to the load cell capacity. The minimum test weight is about 20% of the working load limit; a good test weight is greater than 50% of the WLL. For example, a 30,000 lb load cell on four parts of line has a WLL of 120,000 lb; the minimum test load in this case would be 24,000 lb, a good test load would be 60,000 lb or more.
5.3c Care
Battery: Lithium batteries older than 18 months old (alkaline batteries over 6 months old) should be changed at the first available planned inspection even if there is not yet a low battery warning. This will avoid costly delays in the field.
Corrosion: Verify that no corrosion is visible on the battery holder inside the load cell transmitter. If some trace of corrosion is visible, rub it off gently and put a small amount of dielectric grease* on each battery holder post to protect the contacts.
* Dow Corning dielectric grease No. 4
CHAPTER 5: MAINTENANCE 18
GS222-05 SYSTEM & GS SERIES SENSORS
Mechanical Stresses: Verify the load cell sides for dents or heavy scratches. The side of the load cell under the transmitter box is the most sensitive region. Engraving a number in this area will affect load cell accuracy and reliability. If the transmitter box has been hit and the box does not fit perfectly to the underlying link, please call Trimble Lifting
Solutions to have it repaired. Engraving on the transmitter box sides will not affect reading.
Seal: If the transmitter box has been removed it must be correctly resealed with RTV non-corrosive silicone or with the gasket kit and sealing screws.
Antenna: Small scratches on the antenna will not affect radio communications. A heavy bending of the antenna or bare sections on the wire may reduce the radio efficiency.
Hex Bolts: The hex head bolts on the transmitter box are there to protect the antenna and to hold the transmitter box on the load cell link. If one or both hex nuts are scratched, it will not affect the load cell readings or operation. If the bolt head is bent or sheared verify that the transmitter box fits tightly to the load cell link before contacting Trimble Lifting
Solutions for replacement bolts.
19
CHAPTER 5: MAINTENANCE
GS222-05 SYSTEM & GS SERIES SENSORS
6: CERTIFICATION NOTES
6.1 FCC and IC—Instructions to the User
This equipment has been tested and found to comply with the limits for a class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation.
If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
In order to maintain compliance with FCC regulations, shielded cables must be used with this equipment.
Operation with non-approved equipment or unshielded cables is likely to result in interference to radio and
TV reception.
✓
NOTE
CHANgES OR MODIFICATIONS TO THIS
EQUIPMENT NOT EXPRESSLY APPROVED
BY THE PARTY RESPONSIBLE FOR
COMPLIANCE COULD VOID THE USER’S
AUTHORITY TO OPERATE THE EQUIPMENT.
FCC ID: QVBGS200 IC: 7076A-ICGS200
RF Exposure Warning:
Trimble Lifting Solutions sensors comply with FCC/IC radiation exposure limits set forth for an uncontrolled environment. To comply with RF exposure requirements, the unit must be installed and operated with 8 in (20 cm) or more between the product and your body. This product may not be collocated or operated in conjunction with any other antenna or transmitter.
This device has been designed to operate with the antennas listed below, and having a maximum gain of
3.0 dB. Antennas not included in this list or having a gain greater than 3.0 dB are strictly prohibited for use with this device. The required antenna impedance is 50 ohms.
To reduce potential radio interference to other users, the antenna type and its gain should be so chosen that the equivalent isotropically radiated power
(e.i.r.p.) is not more than that permitted for successful communication.
FCC ID: QVBGS000 IC: 7076A-ICGS000
FCC ID: QVBGS001 IC: 7076A-ICGS001
FCC ID: QVBGS050 IC: 7076A-ICGS050
FCC ID: QVBGS075 IC: 7076A-ICGS075
LSI-Robway P/N:
Description:
Manufacturer:
ANTENNA LIST
TA011
1/4 wave monopole
Load Systems International
CHAPTER 6: CERTIFICATION NOTES 20
GS222-05 SYSTEM & GS SERIES SENSORS
6.2 CE
6.2a Declaration of Conformity
21
CHAPTER 6: CERTIFICATION NOTES
6.2b CE Safety
WARNING
BURN HAZARD. DO NOT OPERATE SENSORS
WHEN THE AMBIENT TEMPERATURE IS
HIgHER THAN 183°F (84°C) AND DO NOT
OPERATE THE gATEWAY WHEN THE
AMBIENT TEMPERATURE IS HIgHER THAN
138°F (59°C).
WARNING
FOR THE OPERATOR’S SAFETY, TAKE
ONLY THE AMBIENT TEMPERATURE
RANgE INTO CONSIDERATION. THE
DEVICE SHOULD BE USED WITHIN THIS
RANgE SPECIFIED ABOVE.
WARNING
THE PROTECTION WILL BE IMPAIRED IF
THE MATERIAL AND EQUIPMENT ARE
USED IN A MANNER NOT SPECIFIED BY
THE MANUFACTURER.
✓
NOTE
THE IP OF EQUIPMENT CORRESPONDS
TO 65.
GS222-05 SYSTEM & GS SERIES SENSORS
Intrinsically safe and non-incendive equipment for use in hazardous locations.
• CSA Standard C22.2 No. 213-M1987: Nonincendive electrical equipment for use in Class
1, Division 2 hazardous locations.
• UL Standard 508, seventeenth edition:
Industrial control equipment.
• UL Standard 913, seventh edition: intrinsically safe apparatus and associated apparatus for use in Class 1, 2, 3, Division 1, hazardous
(classified) locations.
• ANSI/ISA–12.12.01–2007 – Nonincendive
Electrical Equipment for Use in Class 1 and
2, Division 2 and Class 3, Divisions 1 and 2 hazardous (classified) locations.
6.3 Applicable to the Class 1 Division 2
Certified Gateway
Class 1, Division 1 certification (intrinsically safe) is available for most Trimble sensors. Class 1, Division
2 certification (non-incendive) is available for the
Gateway.
The certificate CSA #1332949 on master contract
215780 is available on request.
Applicable requirements certified by CSA include:
• CSA Standard C22.2 No. 0.4-M2004:
Bonding and grounding of electrical equipment
(protective grounding).
• CSA Standard C22.2 No. 0-M1991: General requirements Canadian electrical code part II.
• CSA Standard C22.2 No. 0142-M1987:
Process control equipment.
• CSA Standard C22.2 No. 157-M1992:
CHAPTER 6: CERTIFICATION NOTES 22
GS222-05 SYSTEM & GS SERIES SENSORS
7: LIMITED WARRANTY
WARRANTY
LENGTH
24 months
12 months
12 months*
PRODUCT FAMILY
GC Series Load Cells, GD Series Line
Riders, GP Series Load Pins GS001,
GS002, GS003, GS004, GS005,
GS007, GS010, GS011, GS012,
GS020, GS030, GS031, GS035,
GS050, GS075-B, GS101, GS106,
GS110, GS112, GS220, GS221,
GS222, GS224, GS550, GS820, LP
Series Load Pins, LS051, LS055,
PT00100
GS026, GS085, GS320, GS375,
MBR100, MBR105
All cabled products
*Warranty duration for these Products may start from date of commissioning, provided a commissioning and calibration report is provided to us within six months of Delivery.
Please note that the Products are not intended for use in pile driving, wire rope activated clamshell or dragline applications, and any such use will be considered misuse of the Product and will exclude the Product from warranty coverage.
In connection with this limited warranty, we may require that we receive the data logging equipment used with the
Products. You hereby authorize us to retrieve all information from such data logging equipment, which we may use, for example, in order to confirm compliance with written instructions and applicable standards, including design factors. If we do not receive such information as requested, we shall have no obligations under this limited warranty.
Costs associated with providing us with data logging equipment shall be borne by you.
If you request and we agree to provide attendance on site, you will pay our current applicable service rate for time on site, along with travel time from the nearest service center with the requisite capabilities, and fares and expenses.
In the event a Product is determined to be covered by this limited warranty, we will pay ground freight shipping fees of replacement or repaired parts or Products to the destination in the countries in which we maintain a service center for the applicable Products (currently Canada, continental United
States of America, United Kingdom, Australia and the United
Arab Emirates), but shipping fees for any other destination will be borne by you.
Detailed terms of the warranty are set forth at http://www.trimble.com/support/terms_of_sale.aspx, subject to the additional terms set forth above.
23
CHAPTER 7: LIMITED WARRANTY
GS222-05 SYSTEM & GS SERIES SENSORS
REVISION HISTORY
Version
20160129
Date Summary of Change
Jan. 29, 2016
New template, 3.1a, 3.1c, 3.3, 3.4, 3.5, 3.6, text edits throughout
Approved By
R. Wadewitz
Table: Revision History
The content of this manual is subject to change without notice.
All trademarks and copyrights are the property of their respective owners.
Copyright © Trimble Navigation Limited 2016. All rights reserved.
This document contains confidential and proprietary information. No part of this document may be photocopied, reproduced, or translated into another language without the prior written consent of Trimble Navigation Limited.
REVISION HISTORY 24
GS222-05 SYSTEM & GS SERIES SENSORS
NOTES
25
NOTES
www.trimble.com/liftingsolutions
Technical support is available
24 hours a day, 7 days a week
[email protected]
AMERICAS
USA
9633 Zaka Road
Houston, TX 77064 USA
Toll Free Tel: +1.888.819.4355
Toll Free Fax: +1.888.238.4099
Tel: +1.281.664.1330
Fax: +1.281.664.1390
Canada
Production and R&D
2666 boul. du Parc Technologique
Suite 190
Quebec, QC G1P 4S6, Canada
EUROPE | MIDDLE EAST | AFRICA
UK
Unit 3, Kirkhill Place
Kirkhill Industrial Estate, Dyce
Aberdeen AB21 0GU
Scotland, UK
Tel: +44 (0) 1224.392900
Fax: +44 (0) 1224.392920
Dubai – UAE
Q3-171 SAIF Zone
PO Box 7976
Sharjah, UAE
Tel: 971.6.557.8314
Fax: 971.6.557.8315
AUSTRALIA | NEW ZEALAND | ASIA PACIFIC
Australia
32 West Thebarton Road
Thebarton, SA 5031, Australia
Tel: +61 (0) 8.8238.3500
Fax: +61 (0) 8.8352.1684
© 2016, Trimble Navigation Limited
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Key Features
- Wireless communication
- RS232 output
- PC configuration
- Data logging
- Firmware updates
