Joanna Sikorska

Liftlog™XL Advanced Crane Data Logger

Liftlog™XL Advanced Crane Data Logger - Sole Digital

Liftlog™XL Advanced Crane Data Logger Model LL300, Version 2.0 Installation and User Manual V1.8: 07/10/2013 © CASWA Pty Ltd – 2013

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liftlogXL user manual

LiftlogTMXL Advanced Crane Data Logger
Model LL300, Version 2.0
Installation and User Manual
V1.8: 07/10/2013 © CASWA Pty Ltd 2013

CONTENTS
1 OVERVIEW .......................................................................................................................... 4
1.1 LiftlogTMXL Versions ............................................................................................................................... 4
2 SPECIFICATIONS.................................................................................................................... 5
2.1 Operational Specifications .................................................................................................................... 5 2.2 Physical Specifications........................................................................................................................... 5 2.3 Electrical Specifications ......................................................................................................................... 6 2.4 Communication Specifications .............................................................................................................. 6
3 INSTALLATION DETAILS ......................................................................................................... 7
3.1 Prior to Installation ............................................................................................................................... 7 3.2 Inserting/Changing Your SIM Card ........................................................................................................ 7 3.3 Wiring Details ........................................................................................................................................ 7
3.3.1 Terminals .............................................................................................................................. 8 3.3.2 Connecting the Power Supply ............................................................................................. 11 3.3.3 Connecting Motion Inputs ............................................................................................... 13 3.3.4 Connecting Limit Inputs ................................................................................................... 14 3.3.5 Connecting Load Sensor Inputs ....................................................................................... 15 3.3.6 Connecting the Fault Output .............................................................................................. 17
4 COMMISSIONING DETAILS .................................................................................................. 18
4.1 Installing and Launching the FSU Application ..................................................................................... 18 4.1.1 FSU Program Installation .................................................................................................... 18 4.1.2 Installing the FSU application ............................................................................................. 18 4.1.3 Launching the application................................................................................................... 18
4.2 Connecting to the Device .................................................................................................................... 19 4.3 Checking for Firmware ........................................................................................................................ 19 4.4 Checking the Date/Time...................................................................................................................... 20 4.5 General Tab ......................................................................................................................................... 21
4.5.1 Setting Equipment Name .................................................................................................... 21 4.5.2 Upload Data to the Computer ............................................................................................ 21 4.6 Main and Aux Hoist Configuration ...................................................................................................... 21 4.6.1 Input Selection .................................................................................................................... 22 4.6.2 Using/Removing a HoistNet Input ...................................................................................... 22 4.6.3 Using the LiftlogXL with a ControlPro ................................................................................. 23 4.6.4 Checking the Gain ............................................................................................................... 24 4.6.5 Calibrating the Logger ......................................................................................................... 24

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4.6.6 Resetting the Calibration .................................................................................................... 25 4.7 Comms Tab.......................................................................................................................................... 25
4.7.1 3G configuration ................................................................................................................. 25 4.7.2 Link Status........................................................................................................................... 25 4.8 Inputs and Limits ................................................................................................................................. 26 4.8.1 Using XL devices with a HVDC IO Expander ........................................................................ 26 4.8.2 Tuning Sensitivity and Noise Immunity............................................................................... 27 4.9 Overloads ............................................................................................................................................ 27 4.9.1 Main, Aux and Combined.................................................................................................... 27 4.9.2 Overload Sensitivity ............................................................................................................ 27 4.9.3 Lockout ............................................................................................................................... 27 4.10 SD Card Management ......................................................................................................................... 28 4.10.1 Test SD Card ........................................................................................................................ 28 4.10.2 Reformat SD Card ............................................................................................................... 29 4.11 Running CheckIt Diagnostics ............................................................................................................... 29 4.12 Recording a Service ............................................................................................................................. 30
5 ROUTINE MAINTENANCE .................................................................................................... 31 6 OPERATING LIFTLOGTMXL ..................................................................................................... 32
6.1 Operating Status ................................................................................................................................. 32 6.2 Accessing Your Data ............................................................................................................................ 32
6.2.1 Downloading Data .............................................................................................................. 33
8 TROUBLESHOOTING............................................................................................................ 34 Appendix A: COMMUNICATION PROTOCOL ......................................................................... 35 Appendix B: COMMUNICATION OPTIONS ............................................................................ 37
B.1 How Much Data?................................................................................................................................. 37 B.2 Australian Carriers............................................................................................................................... 37
Appendix C: FSU SYSTEM REQUIREMENTS ........................................................................... 38 Appendix D: DATA FILE FORMAT .......................................................................................... 39

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1 OVERVIEW
LiftlogTMXL is an advanced remaining life and load limiting data-logger for cranes. It can simultaneously monitor two hoists and in addition to logging vertical lifting motions, also supervises long and cross travel. Overloads and dangerous usage will trigger immediate email or SMS alerts. Data is automatically downloaded in real time using GSM/3G/GPRS or WIFI connectivity.
LiftlogTMXL is particularly well suited to users seeking an integrated enterprise solution for crane monitoring and management, high risk applications requiring increased oversight of crane operation and dual hoist or process cranes.
1.1 LiftlogTMXL Versions
LiftlogTMXL V2 devices are marked with a serial number that begins with a 2 (e.g. 2-001, 2-974).
If you have a LiftlogTMXL with a two or 3 digit serial number that is smaller than 200 (e.g. 72, 196), you have a V1 device and you should refer to the LiftlogTMXL V1 Installation and User Manual.

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2 SPECIFICATIONS

2.1 Operational Specifications

Parameter Lcount Flog Tlog

Description Maximum number of logged events Frequency of logged events Duration of a logged event

Min Typ Max

10,000,000

30000

Units
Hz Sec

2.2 Physical Specifications

Overall length (mm): Overall width (mm): Overall height (mm): Weight (kg):
Mounting: Electrical connections:

157 86 58 0.3
Screwed or 30mm DIN rail 56 x screwed terminals

Detailed dimensions of the LiftlogTMXL case are provided in the following diagram (where all dimensions are shown in mm):

Figure 1: Case Dimensions © CASWA Pty Ltd 2013

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2.3 Electrical Specifications

Parameter Vin

Description Supply voltage

Iin Vlimit Ilimit Vlimit Lsense Rin I24

Supply current Overload relay voltage Overload relay current Limit Switch input voltage mv load sensor sensitivity Input impedance of 0-10V input 24V output current Operating temperature

Min Typ Max

250

100

0.5

1500

100

-40

85Note 2

Notes:
1. Power supply ve and GND pins are at chassis GND (0V) potential 2. Extended operation at maximum temperature will reduce the life the device.

Units VAC VDC mA VAC V VAC mV/V Ohms mA °C

2.4 Communication Specifications
Communications between the device and a host is usually via a Bluetooth radio link. The Bluetooth device name will be set to the Crane ID, the PIN is 0000.
For more details on the communication protocol used to communicate with the LiftlogTMXL, see Appendix A.

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3 INSTALLATION DETAILS
3.1 Prior to Installation
Before installing your LiftlogTMXL device visually inspect the unit and check that: (a) the case is not damaged and fits together securely; (b) terminals are secure; (c) terminal numbering is as per section 3.3.1 (i.e. stickers have been correctly placed).
If you have chosen to install your own SIM card, then this should be inserted now. Details are provided in the following section. The antenna can also be screwed into the front terminal now.
3.2 Inserting/Changing Your SIM Card
Remove the lid from the unit by releasing the clips at each end to reveal the internal circuit boards.
Locate the SIM card socket on the upper circuit board and insert a data SIM card into the socket shown. Push the card in fully so that it engages.
For details on what SIM cards are compatible with LiftlogTMXL see Appendix B: Communication Options.
Replace the cover.
3.3 Wiring Details
For the LiftlogTMXL to operate the following must be connected as a minimum:
a. Power supply; plus b. 1 or more inputs (motion, limit or load cell).
The following additional types or inputs are optional:
Up to 15 motion inputs; and/or Up to 9 limit inputs; and/or Up to 2 load cells (of any type); and/or 2 Fault outputs.

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3.3.1 Terminals
Please note that the terminals of LiftlogTMXL have changed slightly for different versions of the product. Label descriptions have also been altered slightly. Sticker orientations showing terminals, for LiftlogTMXL devices with serial numbers that start with a `2-' (i.e. numbers greater than 199) are as follows:
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
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Figure 2: Version 2 Sticker Orientations

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The following table describes each terminal on LiftlogTMXL units that have serial numbers starting with a `2-' (i.e. greater than 199).

Terminal Number
1.
2.
3.
4.
5.
6.
7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

Description
Negative reference for mV, mA and V sensors (black wire on RC-3 or RC-5 rope clamps) -ve sense input for MAIN Hook strain gauge (mV) load cell/pin (white wire on RC-3 or RC-5 rope clamps) +ve sense input for MAIN Hook strain gauge (mV) load cell/pin (green wire on RC-3 or RC-5 rope clamps) Excitation voltage (3.3V) for MAIN hook strain gauge (mv) load cell/pin (red wire on RC-3 or RC-5 rope clamps) Return connection for MAIN Hook 4-20mA strain gauge (mA) load cell/pin, or output from load display 0-10V input for MAIN hook from loadcell/pin amplifier or Konecranes ControlPro Connection for MAIN hook to terminal Q, F1, or F2, on an ABUS LIS Connection for MAIN hook to Ground on an ABUS LIS Drive voltage for 4-20mA sensor
Auxiliary inputs 1-3 can be used for any function (e.g. magnets, twist locks etc.) All are AC inputs across the range 48-240VAC
AC input indicating East-West motion is fast AC input indicating West Travel AC input indicating East Travel AC input indicating North-South travel is fast AC input indicating South Travel AC input indicating North Travel AC input indicating AUX Hook up/down is fast AC input indicating AUX hook lowering AC input indicating AUX hook raising AC input indicating MAIN Hook up/down is fast AC input indicating MAIN hook lowering AC input indicating MAIN hook raising Neutral (0VAC) power connection Live (48-240VAC) power connection Shield/0V

Label
GND
-
+
XCite
4-20mA
0-10V
Q-Link + Q-Link 24V Aux1 Aux2 Aux3 E-W Fast West East N-S Fast South North Fast Down Up Fast Down Up 0V AC 24-240V AC GND

MAIN
AUX MAIN

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28.

0-10V input for AUX hook from loadcell/pin amplifier or Konecranes Controlpro

0-10V

29.

Return connection for AUX hook 4-20mA strain gauge (mA) load cell/pin, or output from load display

4-20mA

30.

Excitation voltage (3.3V) for AUX hook strain gauge (mv) load cell/pin (red wire on RC-3 or RC-5 rope clamps)

XCite

31.

+ve sense input for AUX Hook strain gauge (mV) load cell/pin (green wire on RC-3 or RC-5 rope clamps)

32.

-ve sense input for AUX Hook strain gauge (mV) load cell/pin (white wire on RC-3 or RC-5 rope clamps)

33.

GND negative reference for mV, mA, and V sensors (black wire on RC-3 or RC5 rope clamps)

GND

34.

Connection for AUX hook to gnd on an ABUS LIS

- Q-Link

35.

Connection for AUX hook to terminal Q, F1, or F2, on an ABUS LIS.

+Q-Link

36.

Drive voltage for 4-20mA sensor

24V

37. Opto-isolated limit input, can be used for any limit function
38.

AUX2 AUX2

39. Opto-isolated limit input, can be used for any limit function
40.

AUX1 AUX1

41.

Opto-isolated side pull input for AUX Hook. Connect across up inputs on

42.

SideWise signal processor.

SidePull SidePull

43.

Top

Opto-isolated ultimate limit input for AUX Hook.

44.

Top

45.

Opto-isolated side pull input for MAIN Hook. Connect across up inputs on

46.

SideWise signal processor.

SidePull SidePull

47.

Top

Opto-isolated ultimate limit input for MAIN Hook.

48.

Top

49. AUX hook load limit output 48-240VAC 4A NO/NC
50.

Fault2 Fault2

51. MAIN hook load limit output 48-240VAC 4A NO/NC
52.

Fault1 Fault1

AUX
AUX Limits MAIN Limits

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3.3.2 Connecting the Power Supply
Series 2 LiftlogTMXL is designed to operate from 24-240VAC grounded neutral. (Note: Series 1 units could only operate from 48-240VAC.)
It can also operate from 12-48VDC, however this is not preferred as load limits cannot be used in this configuration. For more information on driving the LiftlogTMXL from a DC power source, contact tech@caswa.com.
LiftlogTMXL requires constant power so that it can maintain a connection to the 3G/GPRS network. Do not connect the unit after the K1 or E-Stop relay. Doing so will cause erratic behaviour and premature failure of the LiftlogTMXL electronics.
3.3.2.1 Using an AC Power Source
To connect an AC source from 24-240VAC wire active and neutral as follows.

24-240VAC (Active)

LiftlogXL

24-240VAC Power Supply

0V (Neutral)

25: 0VAC # 26: 24-240VAC

Notes: # All pins marked as `GND' are connected internally to pin 25, 0VAC.
Figure 3: Connecting an AC Power Source

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3.3.2.2 Using a DC Power Source To connect a DC source from 12-24VDC wire active and neutral as follows.
LiftlogXL

12-24V DC Power Supply

12-24VDC 0V (Neutral)

9,36: 24V 25,27: 0VAC #

Notes:
# All pins marked as `GND' are connected internally to pin 25, 0VAC.
Figure 4: Connecting a DC Power Source

It is important to remember that when powering the LiftlogTMXL from a DC source, that it may not be possible to use the load limiting functions of the LiftlogTMXL as the outputs only switch AC.

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3.3.3 Connecting Motion Inputs
Motion input pins (Aux1, Aux2, Aux3, E-W Fast, West, East, N-S Fast, South and North) must be connected to GND or 0VAC (pins 1, 25, 27, 33) by a set of voltage independent contacts. Where spare or auxiliary contacts are not available on the MAIN contactors, small relays must be employed.
For example, the DOWN and UP inputs on the Auxiliary hoist would be connected as follows:

To existing control circuitry

LiftlogXL

DU 0V

20: Aux DOWN 21: Aux UP
25, 1, 27, 33: GND

Figure 5: Connecting Motion Inputs

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3.3.4 Connecting Limit Inputs
There are two input pins for each limit input (e.g. Pins 45 and 46 for the Main hoist SidePull limit). Each input pair should be connected across the limit switch, or chain of limit switches, to be monitored. All limit inputs are voltage independent and typically configured to be normally closed (i.e. any voltage across these terminals keep the limit from activating). For example, the Main Hoist SidePull limit would be connected as follows:
LiftlogXL

45: MAIN SidePull 46: MAIN SidePull

MAIN hoist SidePull Sensor

Figure 6: Connecting Limit Inputs

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3.3.5 Connecting Load Sensor Inputs
The LiftlogTMXL supports two load sensor inputs (marked MAIN and AUX) of various types:
a) Strain gauge input (e.g. CASWA rope clamp load cell); b) 4-20mA input; c) 0-10V input; d) ABUS LIS Q, F1 or F2 inputs.
The load sensor for the MAIN hoist is connected to pins 1-7, the load sensor for the auxiliary hoist connects to pins 28-34.
It can also accept wireless inputs for both the MAIN and AUX hooks via HoistNet.
3.3.5.1 Strain gauge input
When using a strain gauge load cell to measure the load on either the MAIN or the AUX hooks, all four wires from the strain gauge need to be connected. For the MAIN hook, these should be connected as follows:

Red Green White Black

LiftlogXL 4: +XCite 3: + 2: -
1: GND

Notes: Colour codes are for CASWA supplied rope clamp load cells.
Figure 7: Connecting a Strain Gauge Input

The AUX hook can be connected in the same way using pins 30 to 33.

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3.3.5.2 4-20mA load sensor input
When using a 4-20mA signal to monitor the load, connect the load sensor between pins 5 and 9 for the MAIN hoist and pins 29 and 36 for the AUX hoist.

4-20mA Load Sensor on MAIN hook

LiftlogXL 9: 24V
5: 4-20mA

Figure 8: Connecting a 4-20mA Input

3.3.5.3 0-10V Load Sensor
When using a 0-10V signal to monitor the load (e.g. from a Konecranes ControlPro), connect the load sensor between pins 1 (or any other pin marked GND) and 6 for the MAIN hoist and pins 33 and 28 for the AUX hoist.

LiftlogXL

0-10V Signal for MAIN hook (External device, Amp etc)

6: 0-10V 1: GND

Figure 9: Connecting a 0-10V Load Input

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3.3.5.4 ABUS LIS Q or Frequency Input

LiftlogTMXL will also accept a load signal from either the Q, F1 or F2 terminals of an ABUS LIS. This has the advantage of not requiring a separate calibration of the load signal.
In this scenario the load signal from the ABUS LIS (marked as Q, F1 or F2) is connected into the `QLink +' terminal on the LiflogXL (pin marked 7 or 35 for the MAIN and AUX hoists respectively), whilst the ABUS LIS ground is connected into the `Q-Link-' terminal (pin marked 8 or 34 for the MAIN and AUX hoists respectively).
Connecting a signal for the MAIN hoist is depicted as follows:

ABUS LIS Q, F1, F2

LiftlogXL 7: Q-Link + 8: Q-Link -

GND

Figure 10: Connecting a Q-Link Input
3.3.6 Connecting the Fault Output
The two fault outputs (marked Fault1 and Fault2) are normally closed relays which open when an overload is detected. They are typically wired in series with the UP contactor coil. On a dual hoist crane an interposing relay may be required if both hoists are to be inhibited. For example, connecting up the Fault2 output:
LiftlogXL

49: Fault2 50: Fault2

Kx UP

Figure 11: Connecting the Fault Output

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4 COMMISSIONING DETAILS
LiftlogTMXL is designed to be commissioned using a laptop computer. You will need a CASWA LINK-2 Bluetooth Modem and the Field Service Utility (FSU) software application loaded on a laptop.

4.1 Installing and Launching the FSU Application
4.1.1 FSU Program Installation
Ensure that your computer is switched on, connected to the internet and that the minimum required software versions are installed (see Appendix B: for minimum system requirements). Ensure that the LINK-2 modem is installed and that the drivers have loaded.

4.1.2 Installing the FSU application
The latest LINK-2 FSU software (Link-2_FSU) can be downloaded from http://www.soledigital.com.au/Link2.html.
You should check this location regularly for updates.

4.1.3 Launching the application

Double click on the FSU program icon:

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4.2 Connecting to the Device
The FSU will scan for Bluetooth enabled devices. This process takes approximately 10 seconds; when complete a list of all CASWA devices within range will be displayed.

If a particular LiftlogTMXL unit is not found, ensure it is powered up and press <Look again> to repeat the search. Version 2 LiftlogTMXL devices are differentiated from version 1 devices by a 'II' superimposed over the device icons. NB: The Bluetooth link between the Laptop using a Link-2 and a LiftlogTMXL has a range of approximately 200m. Double-Click on the LiftlogTMXL you wish to configure.
4.3 Checking for Firmware
After you have selected your desired LiftlogTMXL, a connection will be made and the software will check if the device has the current firmware. If a new firmware version is available the following window will pop up:

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Press <Update> to update the LiftlogTMXL to the latest available firmware version (recommended). The new firmware will be installed on the device. DO NOT switch off the computer or remove the LINK2 modem until this is complete doing so may leave the LiftlogTMXL in an unrecoverable state.
Alternatively, press <Not now> to update firmware at a later time.
NB: If you did not see this window, then your device already has the most current firmware.
4.4 Checking the Date/Time
After checking for firmware the FSU application verifies whether the LiftlogTMXL has the same date/time as your computer.
If the times are not the same, the following pop up window will display on the screen:

Press <Yes> to update the devices date/time or press <No> to leave the date/time on the device as it is.
NB: If you did not see this window, then your device has the same date/time as your computer.

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4.5 General Tab
4.5.1 Setting Equipment Name
The only configurable item on the General page is the Equipment ID. This text can be up to 18 characters long and it is used to identify the crane in the reporting system. Whilst any name may be used, it is highly recommended that the XL be named according to the registration details provided at the time of purchase.
4.5.2 Upload Data to the Computer
Clicking the <Upload> button brings up a dialog asking where to save the data.
Enter the required file name (usually the crane name or serial number). Make sure the Location entry is set to "Storage card" and press <Save>.
Progress is indicated on the MAIN screen. Time to download depends on the number of lifts and can be up to 20 minutes.
4.6 Main and Aux Hoist Configuration

If your LiftlogTMXL device has been preconfigured (only available with Abus inputs) or you are using a HoistNet load signal (which must be calibrated) then you will not need to calibrate the LiftlogTMXL.
All other types of LiftlogTMXL inputs must be calibrated. Unless you are connecting the device to a Konecranes ControlPro (and elect to use the already calibrated ControlPro settings), this process will require test weights.
The process to configure the Main and Aux hoists is identical, as are the configuration screens.
Click on the Main or Aux tabs to bring up the load settings screens.

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4.6.1 Input Selection
Select the button that corresponds to the input you have connected to the LiftlogTMXL . For connection details see section 3.3.5.
Hint: If the Auxiliary input is not used, it is strongly recommended that its input selection be set to 420mA as this input is relatively insensitive to electrical noise. If this is not done, motion data for this crane will often appear to be erroneous (as the sum of both hoists is displayed).
By default the input type for the Main Hoist is set to mV, whilst the Aux is set to 4-20mA.
4.6.2 Using/Removing a HoistNet Input
LiftlogTMXL devices are now compatible with CASWA HoistNet. This means that they can obtain their load signal wirelessly from any other HoistNet enabled device, eliminating the need for long cable runs between the load cell and data logger.
NB: HoistNet was first enabled in FSU version 10.7. If you do not see the HoistNet option, then you are running an old FSU version. Download and reinstall the lastest version of CASWA FSU. You may also need to update the firmware on your LiftlogTMXL.
To receive a load signal via HoistNet, select the HoistNet input and then press the <Bind> button:

A box will appear asking you which HoistNet enabled device you want to connect to: Select the device that has the load signal to be used and press <OK>. The popup box will close.
© CASWA Pty Ltd 2013

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The name of the bound HoistNet device will be shown on the Main/Aux screen. The connection status will also be shown:
NB: You will need to ensure that the originating HoistNet device's load signal has been calibrated correctly. To unbind a LiftlogTMXL from a HoistNet device, or to change the bound device, press the <Bind> button on the Load screen and then select <Unbind> on the popup box.
4.6.3 Using the LiftlogXL with a ControlPro
If your LiftlogXL device is connected to a Konecranes ControlPro and you want to use the calibration settings stored on the ControlPro (rather than calibrating with test weights) press the <Control Pro> button. A dialog box will appear asking you to confirm this action:
Press <OK> to confirm. Another dialog box will appear.

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Enter the capacity of the hoist in tonnes and press <OK>. Your device is now calibrated and you will not need to zero or calibrate this hoist in order to use this Liftlog.
NB: You need to have selected the <0-10V> input type on the LiftlogXL and also check that the ControlPRO is set to output load on its analog output pins.
4.6.4 Checking the Gain
Irrespective of the indicated load (which is determined from the calibration), the signal indicator (bar below the load display) shows the absolute magnitude of the input signal.
Before undertaking a calibration, check the magnitude of the signal at near full load. It should be approximately 70-80% of the full scale reading.
If the signal is too large, the signal indicator will turn red and you should reduce the amplification applied to the signal by moving the gain slider to the left.
If the signal is less than half of full scale, then increase the amplification by moving the gain slider to the right.
4.6.5 Calibrating the Logger
With no load on the hook, press the <Zero> button.
After a brief pause the indicated load will show zero. Do not be concerned if the indicated load changes or is slightly higher than zero; in this state the indicated load is very sensitive to both electrical noise and very small changes in applied load.
Next, lift a known load with the crane. Ideally this load should be >80% of the crane's lifting capacity.
Note: In practice, it is often not possible to arrange test weights for every install. Provided the input amplification has been set correctly (5.2.2), then an acceptable calibration may be performed with 30-50% of the cranes capacity. However, if this is done, the LiftlogTMXL should then be recalibrated when the crane is next subject to a full load test.
With this known load lifted, press the <Cal> button. The FSU application will prompt you to enter the load. Do so and press <OK>.
After a brief pause the indicated load will match the load on the hook.

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4.6.6 Resetting the Calibration
Under some circumstances, it may be necessary to erase the calibration of a hoist. Warning: IF YOU ERASE THE CALIBRATION THEN YOU WILL NEED A TEST WEIGHT TO SET IT AGAIN! To reset the calibration for a hoist, tap the <!> button. NB: Resetting the calibration of one hoist (MAIN or aux) does not affect the calibration of the other.

4.7 Comms Tab

4.7.1 3G configuration
This tab allows the configuration of the 3G connection used to send data.

The values for APN UserID and Password are usually provided by the company supplying the SIM card.

If the SIM card is provided by CASWA, then the settings are:

APN: UserID: Password:

telstra.m2m <blank> <blank>

4.7.2 Link Status
Text at the bottom of the window will read either "Powering Up","Searching","Logging in", "Connected", or "Sending Data" depending on the state of the 3G connection. After power on, the LiftlogTMXL will take up to two minutes to establish a connection to the 3G network. Once connected, any motion of the crane will cause the status to change to "Sending Data".

On the right of the window is a signal strength meter. NB: This meter is only updated when the LiftlogTMXL status is "Connected".

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4.8 Inputs and Limits
These two tabs show the status of each of the LiftlogTMXL's input signals. They are intended to be used to confirm the correct wiring of the unit.
When a signal is detected, the respective box will be checked.
4.8.1 Using XL devices with a HVDC IO Expander
If you have been supplied a Sole Digital HVDC10 module for installing a LiftlogXL on your 80-270VDC crane, check the <Use HVDC IO Expander> box. Otherwise leave it blank (default). For more information on this option, contact CASWA for a detailed application note.

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4.8.2 Tuning Sensitivity and Noise Immunity
Very short duration events are often caused by noise; these may appear as very short duration input events. To remove these from the logged data set, adjust the value in the <Ignore inputs shorter than> dropdown box. The default output is 200mS (shortest option). Selecting a longer time period, will reduce the likelihood of recording spurious noise events, but also increases the risk that legitimate inputs will be erroneously ignored. Therefore it is recommended that this value only be increased when the current value is known to be insufficient at removing known noise events.
4.9 Overloads
The Overloads tab contains configuration settings for the behaviour of both Main, Aux and Combined overloads.
4.9.1 Main, Aux and Combined
In each of these boxes, enter the required overload in tonnes.
If only one load input is connected, it is recommended that the Aux and Combined overload be left at their default values.
4.9.2 Overload Sensitivity
Moving this slider changes the period of time that the hoist must be in an overload state before an overload event is triggered. It should always be set as far to the left as practical. Where electrical noise (K1 contactor closures are important to test), a rough runway or high vibrations are triggering false overload events, move the slider to the right to decrease the sensitivity.
4.9.3 Lockout
When an overload occurs, the fault output of the LiftlogTMXL opens. When the load is reduced to a safe level, there is a delay of 3 seconds after which the fault output closes and allows lifting to continue.

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If the Lockout control is set to a non-zero value, when the indicated load exceeds <Overload>+Lockout% a special alert will be sent and the fault output will not close. This effectively disables the crane until it can be inspected and put back into service.
NB: The locked state can only be cleared by unchecking the "Locked" checkbox.
An Example:
Crane capacity: 10t Overload set to: 11t Lockout set to: 20%

Indicated load >=11t and < 13.3t
>=13.3t

LiftlogTMXL behaviour An overload alert is sent, and lifting is disabled until the indicated load drops below 11t An additional locked out alert is sent and lifting is disabled until a technician re-enables it by clearing the "Locked" checkbox.

4.10 SD Card Management
Select the SD Card tab to bring up the following screen:

4.10.1 Test SD Card
To test the card and verify that the LiftlogXL device it is correctly writing data to, and reading data from, its internal SD card, press the <Test Card> button.
A popup box will appear informing you of whether the Test Passed or Failed.
If the test fails, it is recommended that the SD card be removed and replaced to ensure it is seated securely. The test process should then be repeated. If the card fails again, then a reformat may be necessary.

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4.10.2 Reformat SD Card
If necessary, it is possible to delete all loading history from the LiftlogXL device by formatting the SD card. A typical example of where this is useful is when the test process has not been successful, or if the data logger is moved from one crane to another and prior data on the device is no longer applicable.
Configuration and load calibration settings are not affected by reformatting the card. To delete/change these settings, go to sections 4.5 through 0 of this manual.
Hint: Prior to reformatting, it is recommended that data be downloaded from the device as detailed in section 4.5.2.
To erase the onboard memory card, press the <Reformat Card> button. You will be asked to confirm the action.
4.11 Running CheckIt Diagnostics
To confirm whether critical settings and parameters have been set sensibly, after completing the setup and commissioning of the LiftlogTMXL device, it is strongly recommended that you run CheckIt diagnostics (first introduced in version 11.9 of the FSU application).
To initiate CheckIt Diagnostics, go to the General Tab and click on the check box in the lower left corner of the tab:

A new window will appear and CheckIt Diagnostics will be initiated.
During this process you may be asked to enter parameters (e.g. rated capacity of the hoist) to verify that critical settings have been entered and have saved correctly.
Any potential issues or irregularities will be described in the CheckIt Diagnostics window. A summary of these will also be sent to the server for future reference.
Press <Close> to return to the main FSU screen.

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4.12 Recording a Service
LiftlogTMXL data logs can now incorporate a history of maintenance performed on the crane.
To record that a service has been conducted, select the Service tab on the FSU Application. (Hint: You may need to scroll through the tabs to see it.)
Enter the relevant reference number for the work (e.g. from your maintenance management system or job sheet) in the Reference/Job No field.
Press the <Record Service> button to record the date/time that this particular work was conducted. This maintenance history is then accessed via the online interface.

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5 ROUTINE MAINTENANCE
There is no routine maintenance required for this device.

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6 OPERATING LIFTLOGTMXL

6.1 Operating Status

The LiftlogTMXL is fitted with 3 LEDs labelled Power, Connected and Overload. These are visible from the front of the unit.

Power LED :

Illuminates whenever power is applied to the unit.

Connected LED:

Flashes quickly while a GPRS/3G connection is being established. Flashes every 3 seconds once connected.

Overload LED:

Illuminates for a couple of seconds on start-up. Flashes briefly once a second at other times to indicate normal operation. Illuminates continuously when either hoist exceeds it overload limit.

6.2 Accessing Your Data
Open a web browser (e.g. Internet Explorer) and type in the URL you have been given into the address box. If you have not received a URL (web address) that can be used to connect to your data, please contact tech@caswa.com.
A screen similar to the following will appear, that reflects all cranes with LiftlogTMXL devices installed, for which you have access rights. If the individual pieces of equipment are not visible, click on the icons on the left hand side to show the equipment belonging to that group (site, equipment class etc).

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Select the name of the crane/hook you wish to interrogate.
A variety of information is available via this screen to extract data, present data via charts/graphs and further configure the device's reporting features.
Events data: This shows the date/time (mm/dd/yyyy format), type of event and if an AccessPack is also installed on the equipment, the name of the responsible person using the crane at the time of the event.
Logs: This shows the full list of all logged events recorded by this LiftlogXL. Data includes date/time, hook (1 or 2), tons lifted, sec (duration of event), direction of motion and if an AccessPack is also installed on the equipment, the name of the responsible person using the crane at the time of the event.
Settings: This allows the user to set what type of events will trigger an automatic email. These settings do not affect what data is recorded.
Service History: This shows a list of all service date/times and their respective job numbers that have been logged via LiftlogTMXL devices using the CASWA FSU interface.
Graphs: A number of automated summary graphs are accessible via this interface, including graphs showing Load Spectrum, Remaining Life, Moves Per Month and Average Move Duration. To request a new graph, please contact tech@caswa.com or your local LiftlogTMXL supplier.
6.2.1 Downloading Data
To download any data, select the desired token (e.g. Logs, Events, Service History etc).
Press the Excel icon that is located just under the table on the right hand side.
Another window will then pop-up for you to select desired date range for your data. Select the start and end dates using the calendars.
Press the <Save> button. You will be asked for a location to save the data.
The format of the downloaded Log data is provided in Appendix D.

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8 TROUBLESHOOTING

Fault Intermittent connection between XL and Link2 during commissioning Blue LED not flashing / No data being sent
Erratic load readings Inputs on all the time Inputs flickering
No load indicated
No Bluetooth connection between XL and Link2
Connection between XL and Link2 lost when E-Stop is pressed Red LED not flickering during service but Green Power LED is on No data visible on website but all LEDs indicating correct operation No email notifications of crane events

Cause Intermittent power supply
Incorrect APN
No GPS signal
SIM Card expired Noise on input signals Noise on unused channels Active and neutral reversed Ground on LiftlogXL not at 0V
Noise on cables (typically when the cable runs are long or there is a noisy VSD) Wrong input selected Load input wired wrong Insufficient gain XL is not powered up
Insufficient range XL in confused state Faulty Link2 (very rare)
Incorrectly connected power supply (after E-Stop relay)
System failure probably due to stopping a firmware update midstream (Very rare) Incorrect name or serial number on LiftlogTMXL or in database
No events set to trigger an email
Incorrect email settings

Fix
Ensure power has not been supplied after the K1 or E-Stop relay. If so, rewire to supply constant power. Failure to do so will cause the electronics to fail very quickly. Connect with FSU and verify the information contained under the `Comms' tab Check if mobile phone coverage is available at specific location (inside cabinet). Check antenna is connected securely but not overtightened. If antenna has been over-tightened, the internal wiring may need to resoldered. Open case to check. Check account Check shielding on load cell and VSD cabling Set Aux load type as 4-20mA Check the power wiring Measure between the chassis and one for the LiftlogXL GND terminals, correct active and neutral wiring , ground control voltage transformer secondary, or ground LiftlogXL Fit 1Kohm, 1W termination resistors between the input terminal and GND.
Refer to section 4.6.5 to calibrate the input Refer to section 4.6.5 to calibrate the input Refer to section 4.6.5 to calibrate the input Check that the Green Power LED is illuminated. If not, check power is connected correctly as per section 3.3.2. Move laptop closer to the LiftlogXL. Power cycle the LiftlogXL. Check if possible to connect to another CASWA device. If not, then replace Link2. Ensure power has not been supplied after the K1 or E-Stop relay. If so, rewire to supply constant power. Failure to do so will cause the electronics to fail very quickly. Return to manufacturer for repair.
Check that Serial Number matches that on the outer case. If problem persists, contact tech@caswa.com and supply details of device's Equipment name and Serial Number. Check settings on website (settings tab)
Check settings on website (settings tab)

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Appendix A: COMMUNICATION PROTOCOL
The host sends single character commands to the device to write or query parameters.
Each command must be followed by a carriage return <CR>(ASCII 13).
Where the command is a query command, no arguments are sent and the device will respond with a single line (except for the "u" and "E" commands) the requested value in ASCI text followed by a <CR>. Where the command is a set command, an argument may be included between the command and the <CR> .
Where numbers are sent or received, they are sent as clear text; eg "1234"
Where a number represents a load (eg the "o" and "O" commands, and the logged data returned by the "u" command), it is expressed in 100Kg units. Eg 3.5mt would be sent and received as 35.
Where a number represents an elapsed time (eg in the logged data returned by the "u" command) it is expressed in 0.1second units. Eg. 35.4 seconds would be sent as 354.
Where dates-time values are sent or received, they are sent in the format dd/mm/yy hh:mm . Hours are in 24 hour clock format. Leading zeros must be used. Eg 3/8/07 13:30 is an invalid datetime and should be sent as 03/08/07 13:30

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Communication commands:

Command v ? h
H r i I z Z c C
on
On wn Wn *

R/W Read Read Read
Write Read Read Write Read Write Read Write
Read
Write Read Write Write

Description Query the firmware version number.
Display a summary of all settings Query the input mode: 0=Analog 1=Q-Link 2=Frequency Set the input mode Query the raw loadpin reading. The lifted load may be computed from this value as (RawZero)/Cal. See the "C" command. Query the device ID.
Set the device ID. Device ID's are limited to 18 characters Query the zero parameter The zero value is used to calculate the actual load. See the "C", and "r" commands/ Set the zero parameter. Query the cal parameter. The cal parameter is used to calculate the actual load. See the "C" and "r" commands Set the cal parameter. In normal operation, the cal parameter would be set as follows:
Send the "r" command to get the raw reading from the load pin in it's unloaded state.
Send the "Z" command to set the zero parameter
Apply a known load to the pin. Send the "r" command to get the raw
reading from the load pin. Sent the "C" command to set the
calibration value to (Rawunloadedzero)*Known_Load (in 100Kg units) Query the overload (setpoint) parameter. This parameter is stored in 100Kg units, eg 3.5mt is expressed as 35. It is used by the device to determine when an overload occurs. Set the overload parameter.

Example Send:v<CR> Rcv:1.02b<CR> Send:h<CR> Rcv:2<CR>
Send:H0<CR> Send:r<CR> Rcv: 354<CR> Send: i<CR> Rcv: crane34<CR> Send: Icrane45<CR> Send: z<CR> Rcv: 34<CR> Send: Z23<CR> Send: c<CR> Rcv: 11<CR> Send: C9<CR>
Send: o1<CR> Rcv: 35<CR>
Send: O140<CR>

Query the inverted status of a setpoint output. A return value of 1 means the output is normally open. Set the inverted status of a setpoint output.

Send: w2<CR> Rcv: 1<CR>
Send: W20<CR>

Reboot the device. This command is usually only used to load new firmware onto the device

Send: *<CR>

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Appendix B: COMMUNICATION OPTIONS
When purchasing a SIM card for use with the LiftlogTMXL system please ensure:
1. The pre or postpaid plan includes data access. Voice only SIM cards will not work with the Liftlog XL.
2. That you obtain the network name, User ID, and Password required for connection to the carriers network.
Many carriers do not require a User ID or Password. However, at a minimum, most require that you configure the LiftlogTMXL with the network name. Details on how to do this are provided in this User Guide.
B.1 How Much Data?
When choosing a mobile service plan for use with LiftlogTMXL, select the one with the lowest available monthly data limit. A VERY busy crane will generate around 1 megabyte of data per month. Some carriers offer low cost options for telemetry applications. It is worth investigating these.
B.2 Australian Carriers
A list of Australian mobile network service providers and some suggested network name, user ID and Password combinations are provided below. Blank entries in the table mean that the entry should be left blank.

Carrier Telstra prepaid Optus Business Telstra 3G (as supplied by CASWA)

APN telstra.internet yesbusiness telstra.m2m

USERNAME

PASSWORD

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Appendix C: FSU SYSTEM REQUIREMENTS
The minimum requirements for operating CASWA's Field Service Utility (FSU) and Link-2 Bluetooth modem are:
Laptop computer running Windows XP SP3 or later; One Spare USB port; Microsoft .NET framework 3.5.

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Appendix D: DATA FILE FORMAT

Data is recorded each time a motion is detected (a contactor closes). Each datum set contains:
1. Date/Time (based on the logger's internal clock when a user connects to the logger via Bluetooth using the FSU software, the time is compared to the time on the laptop and can be reset)
2. Operator (only used if a logger is bound to an AccessPack) 3. Hook (1 = main, 2 = Aux, 3 = Both hooks) 4. Load from load cell/other input in tenths of a tonne 5. Duration of motion in tenths of a second 6. Motion code type of motion as shown in the following table.

Motion Code 0 1 2 4 8 16 32 64 128 256 512 1024 2048 4096 8192

Motion
No move Move Up Move Down Move Fast Move East Move West Move North Move South Move Up Fast Move Aux1 / Aux Move Aux2 / Magnet Move Aux3/Override Move Aux1 Off Move Aux2/Magnet Off Move Aux3/Override Off

Note: If a combined motion is detected, then the sum of the individual motions is recorded (e.g. Move Up and Move Fast = 1+4=5).

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