LS425 - Two Lines Display With Capacity Charts Universal User Manual

LSI Load Systems International
LS425 – Two lines Display With Capacity Charts
Universal User Manual
GENERAL:
The LS425 is a wireless capable display programmed with crane specific capacity
charts which shows load limits, radius and measurements taken by up to seven sensors
linked in a local radio frequency network that can include any combination of load cells,
angle sensors, anti-two-block switches and a wind sensor. This unit is compatible with
the LSI sensor product line allowing full expansion: new LSI sensors may be added and
existing LSI sensors may remain in use when upgrading to a future display generation.
1 UM-LS425-2004-04-13 Universal User Manual V4.5.doc
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Table of Contents
System Description and Features ............................................................... 4

Important Note on System Operation and Start-up: .................................... 5
Contact Information: .................................................................................... 5
Notes For CSA Class 1, Division 2 Rated Equipment ................................. 5
Chapter 1: LS425 Front Panel..................................................................... 6
1.1 LS425 Indicator Lights .........................................................................................................6
1.2 LS425 Display Screen Abbreviations ..................................................................................6
1.3 LS425 Buttons .....................................................................................................................7
1.4 LS425 Display Options ........................................................................................................9
Chapter 2: Installation................................................................................ 10
2.1 Display Unit Installation .....................................................................................................10
2.2 Load Cell Installation V1.2 ...................................................Error! Bookmark not defined.
2.3 Angle Sensor Installation ...................................................................................................15
2.4 Anti-two-block switch installation V2.0 ...............................................................................17
2.5 Installation of a length sensor cable reel ...........................................................................20
2.6 Installation of radius calculation V1.0 ................................................................................21
2.7 Load Pin Adjustment..........................................................................................................25
Chapter 3: Changing Batteries .................................................................. 26
3.1 Changing Load Sensor Batteries V1.4 ..............................................................................26
3.2 Changing Angle Sensor Batteries V1.4 .............................................................................29
3.3 Changing Anti-two-block Batteries V1.5 ............................................................................32
Chapter 4: Replacing Antennas................................................................. 34
4.1 Replacing Load, Angle and Two-block Sensor Antennae V2.1 .........................................34
Chapter 5: Adding and Removing Sensors ............................................... 36
5.1 How To Add A Sensor to the LS425. .................................................................................36
5.2 How to Remove A Sensor from the LS425 ........................................................................37
5.3 Changing Sensor Configuration of the LS425 ...................................................................37
Chapter 6: Troubleshooting 1.0 ................................................................. 39
6.1 The Display Unit Does Not Light Up ..................................................................................40
6.2 The Lock-out Doesn't Engage ...........................................................................................41
6.3 The Display Unit Is Always In Alarm Mode, The "2 Block" warning light is on...................42
6.4 The Display Unit Is Always In Alarm Mode, the main hoist green light is flashing.............42
6.5 The Display Unit Is Always In Alarm Mode, the Load warning light is on ..........................43
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6.6 The Display Unit Is Always In Alarm Mode, the Limit+ or Limit- warning light is flashing ..44
6.7 The Display Unit Is Always In Alarm Mode, the wind speed alarm message is flashing ...45
6.8 Radio Communication Problem .........................................................................................46
Chapter 7: Purchasing and Customer Service .......................................... 47
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System Description and Features
The LS425 system detects and displays load and capacity related information and can
warn the operator when a limit is exceeded or a two-block event is pending. This system
is an operator aid and should not be solely relied upon for safe hoist operation. The
operator must at all times be fully aware of the approach of the hook block to the head
sheave, the length and angle of the boom and jib, the hoist and crane configuration and
rigging (including parts of lines, counter-weights, outriggers, rotation etc.) and the
appropriate capacity charts. This system is designed as a backup to the operator in the
event that he has exceeded the safe limits of the crane.
• Displays load limit, radius and other information calculated from preprogrammed
capacity charts and up to seven wireless sensors including load cells, angle sensors,
wind speed sensors and anti-two-block switches.
• Pre-programmed capacity charts based on slew, outrigger and jib conguration
• Overload warning for hoists.
• Adjustable boom and luffing jib maximum and minimum angle limits with warning.
• Anti-two-block alarm and bypass.
• Waterproof.
• Multi-position mounting bracket.
• All sensors pre-calibrated.
• Parts of lines setting.
• Tare function.
• Bar graph display of percentage of load limit on load cells.
• Sensor battery status display and low battery warning.
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Important Note on System Operation and Start-up:
For proper operation of the LS425 display unit it must be calibrated for the configuration
of installed sensors. The display unit powers up with several green lights flashing, this
indicates that a radio communication link is being created with all load sensors, angle
sensors, wind sensors and anti-two-block switches. Once a reliable radio communication
link is established, all green lights will remain lit without flashing.
This process takes about two minutes for sensors in sleep mode. The delay is created by
the battery management function and does not affect system security. If an anti-two-
block switch detects a pending two-block event, if a load cell detects a change in load, or
if an angle sensor detects a change in angle, the appropriate radio link will be
established in less than 1/10th of a second. To immediately wake-up a load cell, lift the
hook with a load; to immediately wake up an angle sensor, change the boom angle.
In special conditions of lockout created by a missing sensor, you may bypass that
sensor until the next display power up by pressing bypass for 10 seconds. That sensor
green light should stop flashing and then turn off.
Contact Information:
Corporate Office: Toll Free Ph.: (888) 819-4355 Toll Free Fax: (888) 238-4099
Load Systems International Dir. Ph.: (360) 666-5028 Dir. Fax: (360) 258-4093
P.O. Box 820486 sales@loadsystems.com
Vancouver, WA 98682 For any information visit our website www.loadsystems.com
U.S. Western Regional Office: Central/Gulf Regional Office: North Central Regional Office:
Scott Colberg Randall Perrin Terry Petzold
Toll Free Ph.: (877) 287-7011 Toll Free Ph.: (877) 278-7340 Toll Free Ph.: (877) 256-1674
Dir. Ph.: (360) 575-9518 Phone (337) 893-2322 Phone (920) 894-2785
Fax: (360) 575-8532 Fax (337) 893-0026 Fax (920) 894-4934
scolberg@loadsystems.com rperrin@loadsystems.com tpetzold@loadsystems.com
Notes For CSA Class 1, Division 2 Rated Equipment

WARNING: Understand manual before operation.
WARNING: Replace batteries only in area known to be non-hazardous. Use only Varta
UNIVERSAL Alkaline batteries model number 4014 or Duracell Procell model number PC1400
batteries.
WARNING: SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY
WARNING: SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I,

DIVISION 2
Warning: DO NOT remove power cable from display when on.
For sensors: Use "T4" temperature code, and for LS420 use "T4A".
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Chapter 1: LS425 Front Panel
1.1 LS425 Indicator Lights
WARNING! “Two-Block” light

indicates two-block condition
“M” = main, “A” = auxiliary.

Steady green indicates a2b
sensor online and functioning
Load indicated in pounds

WARNING! “Load” light
indicates that a load limit
has been exceeded.
“M” = main, “A” = auxiliary.

Steady green indicates load
cell online and functioning
WARNING! “Low Batt” light

indicates that one or more
sensors need new batteries.
WARNING! “Limit –” light flashes WARNING! “Limit +” light flashes

when minimum angle limit is passed. when maximum angle limit is passed.
1.2 LS425 Display Screen Abbreviations
"A" = angle
"AH" = auxiliary hoist
“F/R” = front/rear
"L" = length
"MA" = maximum or minimum angle, whichever actual angle is closest to
"MH" = main hoist
"MN" = minimum
"MX" = maximum
"R" = radius
"W" = wind speed
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1.3 LS425 Buttons
Bypass Button
1) The basic function of the bypass button is to bypass anti-two block lockout for
emergency purposes. The alarm will remain silent until the next two-block event;
lockout will re-engage as soon as the button is released.
2) When one of the operation screens is displayed, press the bypass button to return to the
load operation screen. When elsewhere in the system, press the bypass button to return the
most recent operation screen.
Hoist Selection Button
1) Press the hoist button to scroll between the following operation screens:
i) The radius operation screen, showing load (with parts of line and tare),
hook radius, boom length and boom angle.
ii) The slew selection screen.
iii) The outrigger selection screen.
iv) The jib selection screen.
v) The advanced options entry screen. Press the bypass button to return to the load
operation screen or the test button to verify the radius calibration parameters.
Note: the precise order and aspect of operation screens depends on system configuration.
2) When adjusting limits (after pushing either the limit+ or limit- buttons) the hoist button
allows the operator to scroll the display between the adjustable limits of the system. For
example: the main and auxiliary hoists' maximum load, the boom and luffing jibs' maximum and
minimum angles, maximum boom length, maximum hook radius and the wind maximum speed.
3) When adjusting the parts of lines (after pushing the parts button) or using the tare function
(after pushing the tare button) the hoist button allows the operator to scroll between the main
and auxiliary hoists.
Parts Of Lines Button
1) The parts button allows the operator to adjust the parts of lines displayed for
the main and auxiliary hoists. Use the limit+ and limit- buttons to adjust the parts
of lines and the hoist button to scroll the display between the main and auxiliary
hoists. Precise concordance between crane configuration and parts of lines
indicated by the LS425 is necessary for accurate load display.
2) When a wireless sensor battery status is displayed in the test function, press the parts
button to select and hold the radio reception diagnostic screen.
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Tare Button
1) The tare function enables the operator to zero the hook and rigging weight.
The operating screen will show the net weight. Pushing the tare button accesses
the tare function. The tare can now be enabled, or disabled, by again pushing the
tare button. When the tare function is enabled the tare light will light. The hoist
button allows the operator to scroll between the main and the auxiliary hoists.
When the tare function is not in use, the load displayed is preceded by the hook and ball
symbol: . With the tare function enabled, the tared load is displayed preceded by the hook
symbol: .
2) When a wireless sensor battery status is displayed in the test function, press the tare button
to select and hold the radio power diagnostic screen.
Limit+ And Limit- Buttons
Pushing the limit+ or limit- button allows the operator to adjust the
limits coherent with the system configuration. For example: the main
and auxiliary hoist load limits, the boom and luffing jib maximum and
minimum angle limits and the wind speed maximum limit. The hoist
button allows the operator to scroll between these limits. Further use of the limit+ and limit-
buttons will adjust the limit chosen accordingly. While adjusting a limit, if both limit buttons are
pressed simultaneously, that limit will return to a factory default value.
Test Button
Press the test button to engage the battery test function of the LS425. The display
screen successively shows the crane battery status then the battery status of each
sensor. The operator can advance to the battery status of the next sensor with
the test button.
"Batt: 40%": 40% (typically several months) of battery life remains.
"NoSignYet": communication not yet established with the sensor indicated.
"NoBattYet": communication established with the sensor but battery status not yet measured.
Battery status will usually be known within 5 minutes. When less than 10% of battery life
remains for any sensor the low batt indicator will light; use the test function to determine which
sensor. Batteries do not need to be replaced before the low batt warning: usually, several
days or weeks of operation remain from the moment the low batt warning first lights
(Use the limit+ and limit- buttons to make the following adjustments successively during the
first 30 seconds of the test function: indicator light intensity, display screen contrast, back-light
control.)
(When the battery status of a wireless sensor is displayed, press the parts button to select and
hold the radio reception diagnostic or the tare button to select and hold the radio power
diagnostic.)
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1.4 LS425 Display Options
1.4.1 Weight units
To change from pounds (lbs.) to kilograms (kg) or vice versa:

Step 1) Press the bypass and tare buttons simultaneously to enter the calibration menu.
Step 2) Press the hoist button to advance to the weight units selection screen.
Step 3) Press either the limit+ or limit- button to change from pounds to kilograms.
Step 4) Turn the display off, then on again. Adjust all load limits to conform to the new units.
1.4.2 Lock limits
To prevent the operator from changing the set limits.

Step 1) Press the bypass and tare buttons simultaneously to enter the calibration menu.
Step 2) Press the hoist button to advance to the limit locked selection screen.
Step 3) Press either the limit+ or limit- button to lock or unlock the set limits.
1.4.3 Indicator light intensity
To adjust indicator light intensity,

Step 1) Press the test button to enter the test function.
Step 2) Press the limit+ or limit- button to raise or lower indicator light intensity.
1.4.4 Display screen contrast
To adjust display screen contrast,

Step 2) Press the hoist button to select the display screen contrast control screen.
Step 3) Press the limit+ or limit- button to increase or decrease display screen contrast.
1.4.5 Display Screen Back-light
There are two different control systems that regulate the display screen back-light.
1) The back-light generates heat: the temperature control system permits the LS425 display to
turn the back-light on or off in reaction to extremes in internal temperature. This allows the
system to better maintain its optimum working temperature. To override the temperature
control system (i.e. when operating the display unit from a battery pack in low temperatures
or when conditions are both hot and poorly lit):
Step 2) Press the hoist button to select the back-light control screen.
Step 3) Press the limit+ or limit- button to select the temperature control system or the
back-light always on override.
2) When the display is operated from a battery pack, using the 4-second standby mode can
double battery life. In this mode the back-light will turn off after four seconds and turn on
immediately when a display button is pressed. To engage the standby mode:
Step 1) Press bypass and tare simultaneously to enter the calibration menu.
Step 2) Press the hoist button to advance to the back-light control screen.
Step 3) Press either the limit+ or limit- button to select the 4-second standby mode or
the normal back-light always on mode.
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Chapter 2: Installation
Important: The LS420/425 display is splash proof and rainproof. Waterproofing depends in
part on the integrity of the lexan fascia; the lexan must not be cracked nor punctured. The
LS420/425 display is not designed to withstand high-pressure washing devices that can
erode the lexan fascia seal or create fissures in the lexan fascia. Power washing the display
voids warranty coverage.
2.1 Display Unit Installation

To ensure reliable radio communication between the display unit and the installed
sensors), the display unit antenna must not be in contact with metal and must have a
direct, clear line of sight to the antennae of all sensors.
2.1.1 Mounting the display
The display box may be installed either inside or outside the cab: though water can penetrate
the display box, the interior is fully potted and will function properly in up to 1 ft (30 cm) of water.
The mounting bracket is designed with three pivoting axes so that it can be mounted on the
dash, on either sidewall or on the ceiling of the cab.
One 3/8'' bolt hole must be drilled to mount the display. The 3/8'' stainless bolt, washers and
stainless lock nut are supplied with the display. Choose a flat surface of at least 1-1/2'' in
diameter on both sides and where the back of the surface is accessible in order to tighten the
nut. Drill the hole with a 3/8'' bit. Place the display with the bolt through the hole. Mount the 2
large washers and the lock nut behind and tighten sufficiently. If the nut is on the outside of the
cab, caulk with silicone between the large washer and the cab to prevent water entry. Orient the
display to face the operator. Make sure the display antenna is not close to any metal surface
and has a direct line of sight to the antennae of all sensors.
For a boom truck with two operator stations, weld or bolt a pivoting arm in the center of the
column facing the rear. The bracket should be above the rear ledge in order to pivot easily. Bolt
the display in place. Use a wing nut instead of the mounting nut in order to make the display
more easily removable.
2.1.2 Yellow Power Cable Wiring:
The connector of the yellow power cable is waterproof and well rated for external environments.
Simply connect the cable to the display and gently tighten the nut. Do not put a kink in the
yellow cable where it enters the connector; any bend in the cable at the base of the
connector must not be so severe as to break the internal connections where the cable
meets the connector.
The display can be connected to a power source between 10 and 30V positive. The display will
automatically detect the voltage level and adjust itself; it is almost impossible to damage the unit
when connecting.
• Black wire: ground. The ground connection must be bolted to the body of the machine.
Use a 1/4'' or 5/16'' bolt. The ground connection must be strong enough to sustain 3 Amp.
• Red Wire: +12 or +24 volts. The red wire terminal must be connected to an accessory
source rated at least 10 Amps if the display is to be connected to a lockout system. The red
wire terminal must be connected to an accessory source rated at least 2 Amps if the display is
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not to be connected to a lockout system. An accessory source is a terminal, a fuse or wire
providing fused voltage only when the crane or the ignition is on.
• White Wire: optional lockout. If optional lockout is to be connected, the red wire must be
connected to an accessory source rated at least 10 Amps. Ideally, the white wire should be
connected to a Bosch relay coil and the other lead of the relay solenoid connected to the
ground. Alternately, the white wire may be connected directly to the valve or valves solenoid
lead and the other lead of solenoid connected to the ground. When operating properly, the
white wire will be energizing at the battery positive level. If no voltage is present, try to remove
the load connected on the lockout. An internal auto-re-settable fuse limits the current to 1
Amp. If a current higher than 1.5 Amp appears on the white wire, the fuse will trigger, cutting
the current on this circuit. The fuse will permit the normal current flow to resume a few
seconds after short-circuit removal. Fuse model #60R075 from www.littlefuse.com.
• Green Wire: Normally Not Used. For optional second lockout, only when ordered.
• Orange Wire: Do Not Connect. Display units made before July 2001 (s/n lower than
22545) were powered with the orange wire instead of the red. This was changed to conform to
industry standard. Now for optional cabled A2B, only when ordered.
Black wire: negative (ground)
Red wire: +12 or 24 volts (crane power supply)
White wire: standard lockout
Green wire: Second lockout, where required
Orange wire: do not connect. For

optional cabled A2B, only when
Wiring example without lockout
Yellow cable
Red wire
Black
wire
Battery +12V
or +24V
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Wiring example with lockout and recommended Bosch Relay
To valve coil if
Yellow cable Bosch relay n.c. is required.
White wire
n.c.
Red wire
Black
wire n.o.
co
Battery +12V
or +24V
To valve coil if
n.o. is required.
Wiring example with lockout for valve requiring less

than 0.75 Amp, without recommended Bosch Relay
Yellow cable
White wire Valve coil
Black Red wire

wire
Battery +12V Diode

or +24V
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2.1.3 LS425 Display Unit Datasheet
Dimensions :
Weight: 1.5 pounds
Hardware Electronics:
) Antenna length: 3.25"
• Voltage: 10Vdc to 30Vdc
• Radio Frequency: 925.43 MHz
• Temperature: 0°F to 140°F (-20°C to +60°C)
) Height: 4.45"
• Power requirement: 0.3 Amp
• Output: 1 Amp mosfet relay (for lock out relay)
• Antenna: 3.25" semi-rigid, replaceable
Hardware Housing:
• Rugged aluminum box. Electronic circuit com-
partment completely filled with neutral gel.
) Thickness: 2.30"
) Width: 4.45"
) Bracket length: 4.5"

The yellow cable should have this
4.5" room to protect the connector.
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2.2 Load Cell Installation
The load cell antenna must not be in contact with metal.
The load cell antenna must have a clear line of sight to the display unit.
The load cell antenna must point to the left or to the right of the boom; it must not point
directly to, or away from, the display unit.
Step 1) The load cell may have two different pin and bushing sizes to fit different dead end and
hook assembly requirements. 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 brass bushings must be used
where possible to adapt the holes in the load
cell to the pins. Bushings must be secured
with the hex screws provided, one on each
side of the load cell.
Step 2) A washer must be placed between

adapter plate and cotter pin on each end of
the pin that links the adapter plates to the
load cell. Additional washers should be added
as required to inhibit excessive lateral
movement of load cell and adapter plates
along the pin.
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. Note: on the smaller
of the two pins, space between the link and
the plates should not exceed ¼” either side of
the centred link regardless of washer
placement.
In all cases the washers must be placed

symmetrically such that the load cell is
centred on the pins.
Step 3) Once the pins are correctly placed

and spaced, they must be secured with the
cotter pins provided.
Step 4) Every lift assembly must be verified

by a qualified person before first use and
periodically thereafter, including before any
new, difficult or otherwise different lift.
WARNING! Capacity and safety factor for load cells and adapter plate assemblies are
calculated for load 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 hangs free
and not be subjected to side loading.
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2.3 Angle Sensor Installation
The angle sensor antenna must not be in contact with metal.
The angle sensor antenna must have a clear line of sight to the display unit.
Warning! When welding the metal lugs to the boom the angle sensor must be kept well
away from the weld site and any touching metal objects.
The angle sensor is pre-calibrated at the factory; for correct installation it must be positioned
carefully, then zeroed. The bracket has two bolt holes, one of which is a curved slot for fine
adjustment. See the diagrams below for correct orientation. The angle sensor should be
mounted on the left side of the boom (as viewed from the cab) with the indicator light pointing
towards the boom tip.
Left side Front
Cabin
Cabin
Boom
The angle sensor is
mounted with its The angle sensor is mounted
Boom Boom
horizontal axis with its top/bottom axis within
centerline.
parallel to the boom 15 degrees of vertical.
Front Front
Cabin
Cabin
The angle sensor must

not be mounted with its A wedge can be used to mount the
Boom Boom angle sensor with its top/bottom
top/bottom axis more than
15 degrees from vertical. axis within 15 degrees of vertical.
Indicator light
Towards The angle sensor is mounted with its Towards

boom tip horizontal axis parallel to the boom boom base
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Manual zeroing: the easiest method for two people
Mount the angle sensor with the indicator light pointing towards the boom tip. Set the boom
at a known angle such as forty-five degrees. Finely adjust the position of the bolt in the
curved slot until the angle sensor displays the correct value; allow the sensor a few seconds
to ensure it has the most accurate reading. The system should then show the correct angle
from zero to ninety degrees.
Angle sensor assisted zeroing: the easiest method for a single person
Step 1) Place the boom at zero degrees.
Step 2) Mount the angle sensor with a bolt in the fixed position hole and tighten loosely.
Step 3) Rotate the angle sensor to vertical and hold steady until the indicator light stops
flashing for ten seconds. Rotate the angle sensor to horizontal with the indicator light
pointing towards the boom tip. The indicator light will flash while changing from green to
red depending on slight changes in the angle: this indicates that the angle sensor is in
installation mode. The angle sensor should stay in installation mode for one or two minutes.
Step 4) The colour of the light will help to place the angle sensor at zero degrees from
horizontal. The goal is to position the angle sensor such that the indicator light is green
without flashing: this indicates that zero has been obtained (the angle sensor is placed at 0
to 1 degrees above horizontal). Then place the second bolt in the curved slot and tighten
both bolts securely. When the sensor angle is between 1 and 5 degrees, the light will flash
green. Below 0 degrees, the light will flash red. Around zero, if the indicator light flashes red
the curved slot side of the angle sensor must be raised and if it flashes green the curved slot
side of the angle sensor must be lowered. If the indicator light goes out before zero has
been obtained, repeat step 3. Zero could be hard to obtain; this is normal.
Indicator light in 'installation mode'
Angle Sensor at 30 degrees
Angle Sensor at 90 degrees
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2.4 Anti-two-block switch installation V2.0
The anti-two-block switch antenna must not be in contact with metal.
The anti-two-block switch antenna must point to the left or to the right of the boom; it
must not point directly to, or away from, the display unit.
The anti-two-block switch antenna must have a clear line of sight to the display unit; in
most cases this means mounting the sensor on the same side of the boom as the
operator's cab
Before mounting any anti-two-block switch, verify that it is calibrated to the display unit. All
switches shipped with display units are pre-calibrated in the factory. The display unit should go
into alarm when the wire rope of a calibrated switch is pulled and released. Please note that the
black travel clip must be removed to permit the switch to function. If a switch does not appear
correctly calibrated to the display unit please follow the instructions in the calibration section
(chapter 5) of this manual.
Step 1) Remove the black travel clip.
Depress the small button to …slide the locking ring back.

release the locking mechanism The clip can now be opened
and simultaneously… to release the wire rope.
• Leave the black travel clip

attached to the sensor by the thin
wire: it will be useful if the sensor is
to be removed and stored in the
future.
• Releasing the wire rope will

cause the alarm buzzer of the
display to which it is calibrated to
sound. Pressing the bypass button
of the display will silence the buzzer
until the next two-block event or
simulation.
Step 2) Position the sensor mounting bracket.

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

diameter
Mount bracket below and
behind sheave center (see
shaded region of diagram).
Reference Only
b) A2B switch placement on a lattice crane.
On sheaves between 8” and 16” in diameter two mounting brackets are necessary to
permit both live end and dead end mounting.
For live end mounting: For dead end mounting:
8” to 16” diameter
8” to 16”
diameter
Dead end pin
Mount bracket 4” (10 cm) Mount bracket 4”

below sheave center (see (10cm) forwards of
shaded region of diagram). dead end pin.
For live end mounting on multiple sheave blocks with sheaves greater than 16” in
diameter, consult your service representative.
c) A2B switch placement when used on one part of line only (jib, rooster et.c.)
Mount bracket 2” to 4” below sheave

center (see shaded region of diagram).
d) Fast line weight installation
Place the sensor mounting bracket directly below the sheave center as low or as close
to the edge of the sheave as possible. Place the auxiliary chain mounting bracket on the
opposite side of the sheave such that the chain hole is lined up opposite the pivot of the
sensor mounting bracket and such that the chain hole points down.
Auxiliary chain A2B switch
Sheave center mounting mounting
bracket. bracket.
A2B switch mounting

bracket directly below Chain hole.
sheave center and as low
as possible.
Fast line
weight.
Reference Only
Step 3) Test chain length.
i) At minimum boom angle, with no additional weight on the hook block and one part of line
only, lift the boom just enough to have the hook block suspend and clear the sensor chain
and weight.
ii) Hoist slowly until the red two-block warning lights up and the buzzer sounds. Note the
hoisting distance remaining; this distance must be great enough to allow the operator or the
lockout system, if installed, to prevent a two-block event. If necessary, add lightweight chain
between the sensor and weight to increase warning distance. If still insufficient, contact your
service representative.
Hook block stops

Boom at rising, two-block
minimum prevented with
angle, two- safety margin.
block alarm
triggered.
iii) Raise the boom to the maximum angle and repeat the procedure detailed in Step 2 very
carefully. It will help to have a second person standing off to the side of the crane to closely
monitor the hoisting distance from the hook block to the head sheave block. Verify that the
warning distance is equal to or greater than that determined at the minimum boom angle.
Hook block stops

Boom at rising, two-block
maximum prevented with
angle, two- safety margin.
block alarm
triggered.
iv) Lower the boom until the weight height becomes visually clear to the operator.
Repeatedly create two-block, progressively hoisting faster to ensure that the warning and
lockout (if installed) work within acceptable amount of time and distance. Increase the length
of the small chain if needed.
Reference Only
2.5 Installation of a length sensor cable reel
Step 1) The reel must be installed on its solder tab on the main boom. The cable reel is
usually installed on the main boom’s lower section on a clear area. Guides should be placed
along the boom sections and a cable anchor near the boom head.
Step 2) Feed the cable through the cable guides and pull on it to attach it to the cable anchor.
There should be minimal tension on the cable reel spring when the boom is fully retracted.
Verify the boom length as shown on the main operation screen of the display unit. This should
represent the actual total boom length from the boom pin to the head sheave center, however,
depending on the exact placement of the cable reel and cable anchor the displayed length may
differ from the actual length. Note the difference in feet.
Step 3) To adjust the length displayed, press the hoist button repeatedly until the display
shows the advanced options entry screen. Press the test button to enter the advanced options,
then press the hoist button until the display shows “Trim Length” (or “Offset AD1”). Use the
limit+ and limit– buttons to enter the difference noted above, in feet. E.g. i) if the length
displayed is 10 feet too short, the trim length factor must be set to 10 feet; ii) if the length
displayed is 6.5 feet too long, the trim length factor must be set to –6.5. When finished, press
bypass to return to the main operation screen. For help with the buttons of the display please
refer to the quick reference guide or section 1.3 of the user manual.
IMPORTANT! Step 4) Test: verify that the display correctly shows boom length when
completely retracted and when fully extended. It is safer to have someone helping to ensure that
the reel has enough cable to reach full crane extension.
Cable anchor
Cable guide Boom base pin
Cable reel
Boom length: distance

from boom base pin to
head sheave center.
Reference Only
2.6 Installation of radius calculation V1.0
Before proceeding with radius calibration:

• Install the display unit (see section 2.1 of this manual).
• Install the angle sensor (see section 2.3 of this manual). If a pendulum type angle
sensor is to be used it must be properly calibrated. (see section 2.6.5 of this manual)
• Install the length sensor (hydraulic cranes only) (see section 2.5 of this manual)
2.6.1 Radius calibration
The LS425 radius display must be calibrated for several crane specific angle and length
parameters for accurate radius calculation. Default values may have been programmed at the
factory before shipping. On system installation these parameters must be confirmed and
accurate radius calibration verified.
Step 1) Take the following measurements: slew offset, sheave head length, sheave radius
(to within a tenth of a foot e.g. slew offset = - 3.2 feet) and jib angle offset (in degrees).
These measurements are described in sections 2.6.2 (lattice cranes) and 2.6.3 (hydraulic
cranes).
Step 2) Confirm the parameters entered in the advanced options of the LS425 display.
Press the hoist button until the advanced options entry screen is displayed. Press the test
button to proceed to the advanced options. Verify that the appropriate values have been set
for the radius parameters, the values may be adjusted with the limit + and limit - buttons.
Press the hoist button to proceed from one parameter to the next.
Step 3) Test radius display. Compare the radius displayed with the actual radius at
different lengths of boom extension and different boom angles. If the radius displayed by the
LS425 corresponds to the actual radius in all cases, the radius function is correctly
calibrated. Be sure that all radius parameters have been carefully noted to facilitate re-
calibration in the event of component or system upgrade, change, or re-installation. If there
is a difference between displayed radius and actual radius that remains constant during
changes in boom length and angle the slew offset can be adjusted to compensate (see step
2 above). E.g. if the radius displayed is always 2.3 feet longer than the actual radius subtract
2.3 from slew offset. If the radius displayed is still different from the actual radius proceed to
section 2.6.4 of this manual (radius display trouble shooting).
Reference Only
2.6.2 Radius parameters for a lattice crane.
The radius calculation parameters highlighted in green must be measured

on the crane and set into the advanced menu of the LS425 display unit. Jib offset angle.
Jib mounting point. Head sheave.
Distance from head

sheave center to jib
mounting point.
(Your measurement)
Head sheave radius.
Jib
(Your measurement) length.
Sheave head length:

distance from head
sheave center to
boom centerline.
(Your measurement)
The radius equation is roughly:

slew offset
+ boom length x cos(angle)
+ sheave length x sin(angle)
+ sheave radius Boom Boom length: distance
= radius base from boom base pin to
pin. head sheave center.
Slew offset: distance from boom base

pin to crane center of rotation. If the
boom base pin is behind the crane center
of rotation this value must be negative.
Crane center of rotation.

(Your measurement)
Reference Only
2.6.3 Radius parameters for a hydraulique crane.
The radius calculation parameters in green must be measured on the crane and set into the
advanced menu in the LS425 display.
The radius equation is roughly:

slew offset
+ boom length x cos(angle)
+ sheave length x sin(angle)
+ sheave radius
= radius
The sheave head length is the distance

between the boom centerline and the
center of the lower sheave.
(Your measurement)
Crane center of rotation
Boom length: distance

from boom base pin to
head sheave center.
Boom base pin
Sheave radius.
(Your measurement)
The slew offset is the distance between

the boom pin and the center of rotation.
If the boom pin is behind the center of
rotation, the value must be negative.
(Your measurement)
Reference Only
2.6.4 Radius display troubleshooting
For accurate radius display radius parameters described in section 2.6.1 must be correctly
measured and entered in the advanced options of the LS425 display. Before proceeding with
troubleshooting confirm that the radius calibration procedure described in section 2.6.1 has
been followed correctly. The most common problem is caused by inaccurate slew offset
compensation. If the difference between radius displayed and actual radius remains constant
through all boom angles and boom lengths the slew offset should be adjusted accordingly.
The flexibility of some booms may allow them to bend under certain conditions, reducing
effective radius. Boom deflection can be verified if the displayed radius is equal to the actual
radius with the boom at 0° and at 90° but greater at a boom angle of 45° (boom deflection is
greatest at 45°). Furthermore, the effect of boom deflection is greater when the boom is longer.
To compensate for boom deflection adjust the boom deflection value in the advanced options of
the LS425 display. Follow the steps below to determine the appropriate boom deflection
compensation value.
Step 1) with a known load on the hoist; raise the boom to 45°.
Step 2) compare the radius displayed with the actual radius. Change the boom deflection
compensation value and again compare the radius displayed with the actual radius.
Continue adjusting the boom deflection compensation value until the radius displayed
equals the actual radius.
Tip: with the boom at 45° and the maximum load on the hoist, the boom deflection
compensation value should equal the difference in feet between the radius displayed
and the actual radius. And with the boom at 45° and half the maximum load on the
hoist, the boom deflection compensation value should equal twice the difference in
feet between the radius displayed and the actual radius. Etc.
The "No Ld Defl" (no load deflection) value permits compensation for booms that deflect
significantly under their own weight, even with no load on the hoist. This value should only be
adjusted in consultation with LSI. For any information contact LSI: see contact information on
page 3 of this manual.
2.6.5 Calibration of angle display with non-LSI angle sensors.
LS425 requires accurate boom angle information to display radius correctly. If a non-LSI
pendulum type angle sensor is to be used it must be correctly calibrated before
proceeding with radius calibration.
Step 1) Place the boom at a known angle.
Step 2) Compare the angle displayed with the actual angle. Adjust the angle offset (or offset
AD2) in the advanced options of the LS425 display to compensate, e.g. if the angle displayed is
1.5° greater than the actual angle, subtract 1.5 from the angle offset value.
Step 3) Verify that the boom angle displayed equals the actual boom angle.
The "scale ADC2" value should only be adjusted in consultation with LSI. For any information
contact LSI: see contact information on page 3 of this manual.
Reference Only
2.7 Load Pin Adjustment
This section applies to LS420 V1.6.1.5 (March 2003) or later.
The following procedure should be followed at installation and every time thereafter either the
load pin, or the LS420 is changed.
To access this function, a load pin must be calibrated to the LS420 (see chapter 5 to add a
sensor in the LS420 calibration menu).
To adjust load indication by a load pin, two known weights are required, one relatively small
(about 10% of pin capacity) and one more significant (over 50% of pin capacity).
Hold the bypass button and press the hoist button once to access the load pin calibration
pages; use the hoist button to advance from one page to the next.
a. “Trim load pin”.
b. “Scale load pin”.
c. “Recalibration Are You Sure?” Press bypass to exit or press test to start load pin
recalibration. When load pin recalibration is started, trim is reset to zero and
scale is reset to 1024. Note: press the bypass button at any time during the load
pin recalibration procedure to abort and return to the factory default trim and
scale values.
i. Recalibration Step 1) Load Point 1. Lift a
relatively small known weight (about 10% Load Pt1: ------
of pin capacity). The load transmitted per Press Test to Set
part of line will be displayed. Use the limit+
and limit– buttons to set load displayed to the actual load on the pin.
Note divide the weight lifted by the parts of line to find the load on the pin.
Press the test button to record load point one and advance to load point
two.
ii. Recalibration Step 2) Load Point 2. Lift a Load Pt2: ------
relatively large known weight (at least 50% Press Test to Set
of pin capacity); the recalibration procedure
will give a better result if the second lift is close to pin capacity. Use the
limit+ and limit– buttons to set load displayed to the actual load on the
pin. Note divide the weight lifted by the parts of line to find the load on the
pin. Press the test button to record the second load point and complete
the procedure.
Tip: following recalibration, return to load pin recalibration pages and record new “Trim load pin”
and “Scale load pin” values for future reference.
Reference Only
Chapter 3: Changing Batteries
3.1 Changing Load Sensor Batteries V1.4
DO NOT change load sensor batteries without first reading these instructions.
Many operators of LS401 and LS420 systems damage their load sensors with incorrect
battery changing procedures.
ALWAYS replace all three batteries of a load sensor at the same time. Replacing just
one or two batteries will cause the unchanged batteries to reverse polarity,
dramatically reducing the efficiency and life of the new batteries. This means all
batteries will need to be changed again within the next couple of days or even
hours…
ONLY use an RTV non-corrosive silicone (available where auto-parts are sold) to
reseal the box after batteries have been changed. Many silicones give off corrosive
gasses that destroy the battery contacts; this renders the sensor useless.
ALWAYS remove the battery closest to the indicator light first, by applying pressure
to the NEGATIVE pole ( – ) only. When metal (i.e. a screwdriver) touches the steel box
and any battery pole other than the negative pole of the battery closest to the
indicator light, a short is caused which may burn the sensor's internal circuits.
FOLLOW all the instructions detailed below. Carefully following every step described
below is the quickest, easiest way to successfully change batteries without damaging
the load sensor.
• Batteries should be changed when reduced to 10 – 20 % of full charge.

• The following items are necessary to successfully change the batteries of the load sensor:
a) Three new, high quality, alkaline “C” cell batteries (e.g. Duracell Ultra or Energizer E2).
b) A Phillips head screwdriver
c) A small knife
d) A flat head screwdriver
e) Optionally, a very small flat head screwdriver
f) An RTV non-corrosive silicone (available where auto parts are sold)

WARNING: Replace batteries only in area known to be non-hazardous. Use only Varta UNIVERSAL
Alkaline batteries model number 4014 or Duracell Procell model number PC1400 batteries.
WARNING: SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2
Step 1. Remove the load sensor from the crane
Step 2. Clean off dust and grime.
During the following operations the interior of the battery box must be protected from dirt and
humidity at all times.
Reference Only
Do not unscrew the white nylon hex bolt of the antenna.
Do not unscrew the four round topped hex bolts
Do not cut any wires
Step 3. Unscrew the two Phillips head screws about ¼ inch. Do

not fully unscrew or remove these screws to avoid destroying
the seal in which they are set.
Step 4. Carefully cut the silicone seal all around the base of the
box where it meets the link.
Step 5. Carefully separate the box from the link by inserting a

flat head screwdriver in the notch where the box meets the link Notch
and turning. Do not damage the wires that run between the link
and the box.
Step 6. Gently pull

on the connecting
wires to disconnect
the plug in the
battery box.
Avoid all contact with

the tiny white
interrupter switches.
Step 7. To remove the batteries, always remove the

battery closest to the indicator light first, the
middle battery second, and the battery furthest from
the indicator LED last. The batteries can easily be
removed by hand. Gently apply pressure in the
direction of the negative pole while lifting out the
positive pole.
Tip: Alternative method: use a very small, flat head

screwdriver. Gently place the tip of the screwdriver
against the top of the negative pole of the battery closest to the indicator light and, using the
side of the box for support, lift the battery up until it can be grasped and removed by hand.
+ The screwdriver
The battery closest to
is applied to the
the indicator light is
negative contact
removed first.
+ + only.
Indicator light
Reference Only
Step 8. To install the three fresh, top quality, alkaline “C”
cells the positive/negative alignment of the batteries as
indicated on the interior walls of the box must be
respected. Insert the negative pole first. Once the
negative pole is halfway in, gentle pressure in the
direction of the negative pole will allow the positive end of
the battery to be pushed in. Do not force more than is
necessary. Upon installation of the third battery, the
indicator LED will light briefly, indicating correct placement
of the batteries
Step 9. Clean the leading edges of the box and

the surface of the load cell where contact is to be
made.
Step 10.Apply the RTV non-corrosive silicone to the link to create a joint of 1/8th inch.
Step 11.Reconnect the wire connector. Only one orientation is possible. When correct
orientation is achieved, press down to mate securely.
Once again the small flat

head screwdriver may help:
use extreme caution!
Step 12.Reposition the box over the link. Avoid pinching the connecting wire between the
box and the link or between the batteries and the link. Verify that the silicone forms an
effective seal all around the joint between box and link.
Step 13.Secure the box to the link by tightening the two Phillips head screws.
Step 14.Clean off excess silicone.
Step 15.If battery replacement has been successful, the “Low Batt” icon of the cabin-mounted
display will no longer be lit. Use of the test function will confirm new battery status.
Step 16.Reinstall load sensor.
Reference Only
3.2 Changing Angle Sensor Batteries V1.4
DO NOT change angle or wind sensor batteries without first reading these
instructions.
Many operators of LS401, 420, 425 and 2002 systems damage their angle and wind sensors
with incorrect battery changing procedures.
ALWAYS replace all three batteries of an angle or wind sensor at the same time.
Replacing just one or two batteries will cause the unchanged batteries to reverse
polarity. This means that all batteries will need to be changed again within the next
couple of days or even hours…
ONLY use an RTV non-corrosive silicone (available where auto parts are sold) to
reseal the box after batteries have been changed. Many silicones give off corrosive
gasses that destroy the battery contacts; this renders the sensor useless.
ALWAYS remove the battery closest to the indicator light first, by applying pressure
to the NEGATIVE pole ( – ) only. When metal (i.e. a screwdriver) touches the steel box
and any battery pole other than the negative pole of the battery closest to the
indicator light, a short is caused which may burn the sensor's internal circuits.
FOLLOW all the instructions detailed below. Carefully following every step described
below is the quickest, easiest way to successfully change batteries without damaging
the angle or wind sensor.
• An angle sensor must be re-calibrated after this procedure. Follow instructions in the angle
sensor installation chapter of this manual.
• The following items are necessary to successfully change angle or wind sensor batteries:
a) Three new, high quality, alkaline “C” cell batteries (e.g. Duracell Ultra or
Energizer E2).
b) A Phillips head screwdriver
c) A small knife
d) A flat head screwdriver
e) Optionally, a very small flat head screwdriver
f) An RTV non-corrosive silicone (available where auto parts are sold)

Step 1. Remove the angle or wind sensor from the crane.
Step 2. Clean off dust and grime.
Reference Only
During the following operations the interior of the angle or wind sensor box must be protected
from dirt and humidity at all times.
Do not unscrew the four round topped hex bolts
Step 3. Unscrew the two Phillips head screws about ¼ inch. Do not fully unscrew or remove
these screws to avoid destroying the seal in which they are set.
Step 4. Carefully cut the silicone seal all around the base of the box where it meets the
mounting plate.
Step 5. Carefully separate the box from the mounting plate by inserting a flat head
screwdriver in the notch where the box meets the link and turning.
Notch
Avoid all contact with the tiny white interrupter switches.
Step 6. Remove the battery closest to the indicator

light first, the middle battery second, and the battery
furthest from the indicator LED last. The batteries can
easily be removed by hand. Gently apply pressure
in the direction of the negative pole while lifting out
the positive pole.
Tip: Alternative method: use a very small, flat head

screwdriver. Gently place the tip of the screwdriver
against the top of the negative pole of the battery closest
to the indicator light and, using the side of the box for support, lift the battery up until it can be
grasped and removed by hand.
+ The screwdriver
The battery closest
is applied to the
to the indicator light
negative contact
is removed first.
+ + only.
Indicator light
Reference Only
Step 7. Install the three fresh, top quality, alkaline “C” cells;
the positive/negative alignment of the batteries must be
respected as indicated on the interior walls of the box.
Insert the negative pole first, keeping the battery as parallel
to its final position as possible. Once the negative pole is
halfway in, gentle pressure in the direction of the negative
pole will allow the positive end of the battery to be pushed
in. Do not force more than is necessary. Upon installation
of the third battery, the indicator light will flash briefly,
indicating correct battery placement.
Step 8. Clean the leading edges of the sensor box and the surface of the mounting plate
where contact is to be made.
Step 9. Apply the RTV non-corrosive silicone to the mounting plate to create a 1/8th inch
joint.
Step 10.Reposition the sensor box over the mounting plate. Verify that the silicone forms an
effective seal all around the joint between box and plate.
Step 11.Secure the box to the mounting plate by tightening the two Phillips head screws.
Step 12.Clean off excess silicone.
Step 13.If battery replacement has been successful, the “Low Batt” icon of the cabin-mounted
display will no longer be lit. Use of the test function will confirm new battery status.
Step 14.Reinstall the angle or wind sensor; calibrate an angle sensor following the installation
procedure outlined in the angle sensor installation chapter of this manual.
Reference Only
3.3 Changing Anti-two-block Batteries V1.5
ALWAYS replace all four batteries of a two-block sensor at the

same time. Replacing just one, two or three batteries will cause the
unchanged batteries to reverse polarity. This means that all batteries will need
to be changed again within the next couple of days or even hours…
• The following items are necessary to successfully change the batteries of the anti-two-block:
a) A monkey wrench.
b) Four new, high-quality, alkaline “C”-cell batteries (Duracell Ultra or Energizer E2
recommended).

Step 1) Remove the anti-two-block from the crane and clean off dust and grime.
During the following operations the interior of the anti-two-block

must be protected from dirt and humidity at all times.
Do not unscrew the small screw to the left of the antenna.
Do not remove the small black plastic plug on the bottom of the anti-two-block.
Step 2) Place the anti-two-block on the edge of flat surface. Using a monkey wrench, partly
unscrew (about a half-inch) the large white nylon hex bolt through which the wire rope passes.
Step 3) Carefully remove the plunger assembly, without

separating it from the cover, and place it on a clean and dry
surface.
Step 4) The four batteries will easily slide out.
Step 5) Insert the four fresh, clean, top quality, alkaline “C”
cells according to +/- schema printed on the back of the sensor.
Reference Only
Step 6) Replace the plunger assembly. Correctly align the
bot-tom cover before screwing in the white nylon hex bolt through
which the wire rope passes. This hex bolt should be well
tightened with the monkey wrench.
If battery replacement has been successful the LED on the

bottom of the sensor will flash red when the wire rope is pulled
and the “Low Batt” icon of the cabin-mounted display will no
longer be lit. Use the test function of the cabin-mounted display
unit to confirm new battery status.
Step 7) Reinstall the anti-two-block.
Reference Only
Chapter 4: Replacing Antennas
4.1 Replacing Load, Angle and Two-block Sensor Antennae V2.1
• There are two types of sensor antennae:
1. Two-block sensor antennae: a blue tape identifies Load/
those made in the spring of 2002 and thereafter, they angle/
are replaceable. The antennae of two-block sensors wind
made before February 16th, 2002 are not replaceable in antenna
the field: please contact your service representative. with
2. Load/angle/wind sensor antennae: a green tape identifying
identifies those made in the spring of 2002 and green strip
thereafter. All load/angle/wind sensor antennae are
replaceable. Anti-two-
Note: two-block sensor antennae are not compatible with block
load, angle or wind sensors. Only a two-block antenna is antenna
compatible with a two-block sensor. with
identifying
• Slightly damaged antennae (bent, sheathing scratched, blue strip
plastic head cap missing etc.) should not be replaced
unless otherwise identified as preventing proper sensor
function. Heavily damaged antennae (ripped out, sheared
off, wire exposed and fraying etc.) should be replaced to ensure communication between
the sensor and the cabin mounted display unit.
• The following items are necessary to successfully replace the antenna of a load or angle
sensor:
a) a new antenna, of the appropriate type (load/angle/wind sensor or two-block sensor),
with white nylon hex bolt
b) a small pair of pliers
c) an electrical insulating compound
Step 1. Place the crane, boom, jib or ball hook such that the sensor is safely accessible.
This procedure may be followed without removing the sensor from the crane only if it is safe to
do so; avoiding removal and reinstallation procedures may save time. If removed, an angle
sensor must be re-calibrated during reinstallation for correct angle display (see the angle sensor
installation section of the user manual).
During this procedure the interior of the sensor must be protected from dust, grime and water at
all times. If it rains during the procedure an umbrella or other suitable means of protection
should be used.
Step 2. Clean dust, grime and water from the sensor.
Step 3. Identify the short black whip antenna and the

white hex bolt securing it.
Step 4. Inspect the antenna for signs of obvious

physical damage.
Step 5. Carefully unscrew the white nylon hex bolt

completely and slide it up the antenna.
Reference Only
Step 6. Grip the antenna by the base of the black
plastic sheathing and pull it straight out of the hole in
which it is seated. Place the old antenna aside.
Step 7. Slide the white nylon hex bolt to the middle of

the length of the new antenna.
Step 8. Coat the exposed metal foot of the new

antenna with an electrical insulating compound by
carefully inserting it in the mouth of the compound
tube.
White nylon hex bolt
Antenna
Sensor box
Step 9. Hold the new antenna by the black

plastic sheathing and guide it through the
hole in the sensor box. Carefully seat the
antenna in its mating connector. When
the antenna is correctly seated, pulling on
it will be met with light resistance. Antenna receptacle
Step 10.Carefully re-thread, screw-in and

tighten the white nylon hex bolt to secure the antenna in place.
Step 11.Reinstall the sensor if necessary (if removed from the boom or jib, an angle sensor
will require re-calibration during the installation procedure, see the angle sensor installation
section of the user manual).
Step 12.Verify that the sensor functions properly.
Reference Only
Chapter 5: Adding and Removing Sensors
• If in difficulty, disconnect and reconnect the yellow cable of the LS425, then press the test
button to verify all calibrated sensors. If in serious difficulty, simply start over by erasing all
sensors from the system (section 5.2), then re-entering them one by one (section 5.1).
• Correctly set the parts of line, tare and all applicable limits for any newly added sensor. The
buzzer will usually sound when a sensor is added until the appropriate limits have been set;
this is to ensure that the limits will be verified. While adjusting limits or parts of line, press
the limit + and the limit - buttons simultaneously to set a default value.
5.1 How To Add A Sensor to the LS425.
5.1.1 The Manual Calibration Mode
Step 1) Determine the ID (a number between 0 and 60000) of the sensor to be added; the ID
is engraved on the sensor. The LS425 uses the ID to identify the sensor.
Sensors should be installed on the crane before engaging in the calibration procedure. Sensors
must transmit to be identified by the LS425; lifting a load with a load cell or changing the angle
of an angle sensor will ensure immediate transmission.
Step 2) To enter the manual calibration mode, hold the bypass button down continuously and
press the tare button once. Release the bypass button when the screen displays
"Calibration Mode".
Step 3) Press the hoist button until the second line of the screen displays “No Sensor”. Use
the parts button to select the type of sensor to be added. Use the limit + and limit - buttons to
set the ID number of the sensor to be added. Use the parts button to set the sensor type. Press
the bypass button to exit the manual calibration mode at any time.
5.1.2 The Automatic Calibration Mode (An Alternative Method for Adding Sensors)
In the automatic calibration mode the LS425 detects and identifies all functioning LSI sensors
not calibrated to the LS425 and within radio transmission distance. This facilitates adding a
sensor that’s ID is not easily determined (e.g.: an a2b at the end of a 300’ boom). Care must be
taken not to add the wrong sensor to the system (e.g.: an a2b on a neighboring crane).
Step 1) To enter the automatic calibration mode hold the bypass button down continuously and
press the limit - button once. Release the bypass button when the screen displays "Auto Calibr
Mode". Press the hoist button twice. The buzzer may make small noises depending on
surrounding radio signals.
Step 2) Press the hoist button until the LS425 shows the sensor to be added with the correct
ID. Press the test button to add the sensor to the system. Press the bypass button to exit the
automatic calibration mode at any time.
Reference Only
5.2 How to Remove A Sensor from the LS425
Step 1) To enter the manual calibration mode, hold the bypass button down continuously and
press the tare button once. Release the bypass button when the screen displays "Calibration
Mode".
Step 2) Press the hoist button until the sensor to be removed is shown with the correct ID and
sensor type (Load, Angle etc.). Press the tare button to remove the sensor. The display will
show "ID = 0" on the first line and "No Sensor" on the second line. Press the bypass button to
exit the manual calibration mode at any time.
5.3 Changing Sensor Configuration of the LS425

When a sensor is added or removed, the system configuration number is automatically
adjusted. Use the table below to determine the appropriate configuration number by cross-
referencing the appropriate combination of sensors. If necessary the configuration number can
be adjusted manually. To enter the manual calibration mode, hold the bypass button down
continuously and press the tare button once. Release the bypass button when the screen
displays "Calibration Mode". Press the hoist button until the screen displays "Select Configur."
Use the limit + and limit - buttons to select the appropriate configuration number. Press the
bypass button to exit the manual calibration mode at any time.
x64 x32 x16 x8 x4

Configuration Custom Length Radius Wind Angle Load Comment
number
0 0 0 0 0 0 0
1 0 0 0 0 0 1 1 load sensor
2 0 0 0 0 0 2 2 load sensors
3 0 0 0 0 0 3
4 0 0 0 0 1 0 1 angle sensor
5 0 0 0 0 1 1 1 load, 1 angle
6 0 0 0 0 1 2 2 load, 1 angle
7 0 0 0 0 1 3
8 0 0 0 1 0 0 1 wind sensor
9 0 0 0 1 0 1
10 0 0 0 1 0 2
11 0 0 0 1 0 3
12 0 0 0 1 1 0 1 angle, 1 wind
13 0 0 0 1 1 1 1 load, 1 angle, 1 wind
14 0 0 0 1 1 2 2 load, 1 angle, 1 wind
15 0 0 0 1 1 3
16 0 0 0 2 0 0 2 wind speed sensors
17 0 0 1 0 0 1
18 0 0 1 0 0 2
19 0 0 1 0 0 3
20 0 0 1 0 1 0
21 0 0 1 0 1 1 1 load, 1 angle, 1 radius
22 0 0 1 0 1 2 2 load, 1 angle, 1 radius
23 0 0 1 0 1 3
24 0 0 1 1 0 0
25 0 0 1 1 0 1
Reference Only
26 0 0 1 1 0 2
27 0 0 1 1 0 3
28 0 0 1 1 1 0
29 0 0 1 1 1 1 1 load, 1 angle, 1 wind, 1 radius
30 0 0 1 1 1 2 2 load, 1 angle, 1 wind, 1 radius
31 0 0 1 1 1 3
32 l load, 2 angle, 1 wind
33 For systems with only a2bs
34 1 load, 1 angle, 1 radius, 1 length
35 LS2002 configuration
36
37 2 load with sum
38 2 load with sum, 1 angle
39 2 load, 2 angle, 1 wind, 1 radius
40 LS425
41 5 load
42 load and a2b with dual lock-out outputs
43
44
45
46
47
48 0 1 1 0 0 0
49 0 1 1 0 0 1
50 0 1 1 0 0 2
51 0 1 1 0 0 3
52 0 1 1 0 1 0 1 angle, 1 radius, 1 length
53 0 1 1 0 1 1 1 load, 1 angle, 1 radius, 1 length
54 0 1 1 0 1 2 2 load, 1 angle, 1 radius, 1 length
55 0 1 1 0 1 3
56 0 1 1 1 0 0
57 0 1 1 1 0 1
58 0 1 1 1 0 2
59 0 1 1 1 0 3
60 0 1 1 1 1 0
61 0 1 1 1 1 1
62 0 1 1 1 1 2
63 0 1 1 1 1 3
x64 x32 x16 x8 x4
Configuration Custom Length Radius Wind Angle Load Comment
number
Reference Only
Chapter 6: Troubleshooting 1.0
Troubleshooting Index
6.1 The Display Doesn't Light Up
6.2 The Lock-out Doesn't Engage
6.3 The Display Unit Is Always In 2 Block Alarm Mode
6.4 The Display Unit Is Always In Alarm Mode, the main hoist green light is flashing
6.5 The Display Unit Is Always In Overload Alarm Mode
6.6 The Display Unit Is Always In Limit Alarm Mode
6.7 The Display Unit Is Always In Wind Speed Alarm Mode
6.8 Radio Communication Problem
Reference Only
6.1 The Display Unit Does Not Light Up
The display won't light up
Press "Test" button
Is there
Please call your service
a change in the Yes
representative
display?
No
Verify the connections of the black wire,

the orange wire and, if appropriate, the red
wire of the yellow cable as described in
section 2.3 of the Universal User Manual.
Is there a bad
Yes reconnect properly
connection?
No
Press "Test" button to
Verify the voltage on the black wire, the Is there a change verify communication and
Yes
orange wire and, if appropriate according in the display? battery status of all
to the specifications in the user manual, sensors.
the red wire of the yellow cable.
No
Disconnect the yellow cable

from the display unit and re-
Yes connect it carefully
Is the voltage on the wires
equal to that of the crane
battery?
Is there a change
Yes
in the display?
No Press "Test" button to

verify communication and
Verify the crane battery. Verify the No battery status of all
crane fuse. Verify the crane sensors.
accessory switch if applicable. Please call your service
representative
Reference Only
6.2 The Lock-out Doesn't Engage
Carefully create a lock-out using an A2B switch. If there is
The lock-out doesn't engage no A2B switch in communication with the display lock-out
may be created by temporarily adjusting a load or angle limit.
Verify the connection of the

white wire of the yellow cable Measure the voltage on the white wire of the yellow cable.
Is there a bad connection? Is the voltage

Yes
on the white wire Yes
No equal to zero?
reconnect the
No white wire
carefully Everything seems
Disconnect the white wire fine, return any limits
from the lock-out circuit you may have changed
Is the
Yes display in lock-out or to their appropriate
alarm mode? Yes values and verify
Place the crane Wait 30 seconds and
lock-out function
in non-lock-out measure the voltage on
condition the white wire.
No
Lock-out coils
Verify the voltage on the white wire of the yellow cable.
Is the voltage may be connected to
on the white wire the positive battery Yes
equal to zero? Yes voltage of the crane
instead of the negative
Is the voltage on the
ground. Verify and
white wire equal to that of the
No refer to the lock-out
crane battery?
section of the user
manual.
Call customer service
No
Disconnect the white wire from the lock-out circuit

Reconnect the white wire to the lock-out circuit
Wait 30 seconds and measure the voltage on the white wire.

No
Measure the voltage
on the white wire.
Measure current
drawn on white
Is the voltage on the Does lock-out system
wire by lock-out
white wire equal to that of the Yes draw more than 1A on the
system. Refer to
crane battery? white wire?
lock-out section in
the user manual.
Is the
No
voltage on the
white wire equal to that
The display should be Yes
Disconnect the yellow of the crane
cable from the display
Yes fine, verify lock-out battery?
unit and reconnect it function Install a relay as
carefully. explained in the
lock-out section of
the user manual.
Is the voltage on the
Wait 30 seconds white wire equal to that
and measure the of the crane battery?
voltage on the No
Please call your
white wire. No
service representative
Reference Only
6.3 The Display Unit Is Always In Alarm Mode, The "2 Block" warning
light is on
6.4 The Display Unit Is Always In Alarm Mode, the main hoist green
light is flashing
The display is always in alarm mode, The display is always in alarm mode,
the "2 Block" warning light is on? the main hoist green light is on?
Yes
Yes
The load cell failsafe

Place all A2B warning is on. On
switches in startup this is normal as
safe condition. the load cell may take up
to fifteen minutes to
communicate its battery
status to the display unit,
until which time the
Is the The anti-two-block switch failsafe warning will
"2 Block"
appears to be working properly, sound.
warning No
light still please refer to the lockout
on? section of the user manual.
Press the "Test" button to verify battery status.
Yes
Are load cell batteries low?
Press the "Test" button.
Yes
Take the A2B
switch off the
Are A2B Verify battery installation or
No cable. Pull
batteries low? change batteries if necessary,
on the wire
rope. see the changing load cell No
batteries of the user manual.
Yes
The batteries Reinstall the batteries, carefully inspect

Does the red
the battery and plunger cavities for
need changing. light on the A2B switch
No infiltration of water or dirt. Refer to the
Refer to the flash after pulling on the
changing batteries section of the user
changing anti-two- wire rope?
manual. Verify
block batteries communication
section of the between the load
user manual. Yes Pull on the wire rope. cell and the display
unit (follow the
procedure).
There
Does the red light on
appears to be a the A2B switch flash after pulling on No
communication the wire rope?
problem, see
Please call your
diagnostic
mode p. ? Yes
Reinstall the A2B

switch on the cable.
Verify A2B function.
Reference Only
6.5 The Display Unit Is Always In Alarm Mode, the Load warning light
is on
Remove weight If "Hoist" button green light is on press the "Hoist" button until it goes off.
from load cell.
The display is
always in alarm Press the "Parts" button to verify that the parts of lines is consistent with actual
mode: the "Load" cable configuration. Refer to the "Parts" button section in the user manual.
warning light
is on.
If the "Tare" button light is on, press the "Tare" button once to disable the tare function
Press either the "Limit +" or the "Limit -" button to see the limit programmed for the hoist.Verify that
the limit programmed is consistent with the crane capacity in its present configuration.
If there is an auxilliary load cell press the "Hoist" button until the "Hoist" button light is on. Repeat
the previous three steps to verify the parts of lines, tare and laod limit for the auxilliary hoist.
Verify
Does the
communication
load displayed now
between load cell and Verify overload
correspond with the No
display unit (follow alarm function.
weight on the
procedure on page x)
load cell?
then return here.
Does
Yes the overload Press "Test" to verify
No
alarm now function loadcell batteries.
properly?
Is the
Everything seems to be Verify battery installation. Please pay special
overload alarm No Yes
still on? functioning normally. attention to avoid infiltration of water or dirt and to
ensure that the load cell wires are properly connecte
and not severed. Change the batteries if necessar
Yes
Verify proper load

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

Reference Only
6.6 The Display Unit Is Always In Alarm Mode, the Limit+ or Limit-
warning light is flashing
The display is always The display is always

in alarm mode: the in alarm mode: the
"Limit +" warning "Limit -" warning light
light is flashing. is flashing.
Press the "Hoist" button until Press the "Hoist" button until
the boom angle is displayed. the boom angle is displayed.
Verify the angle sensor

Does the angle installation. Reinstall or Does the angle
shown correspond to No recalibrate if necessary, see No shown correspond to
actual boom angle. the angle sensor installation actual boom angle.
section of the user manual.
Yes Yes
Press the "Test" button to
verify battery status.
The maximum angle limit The minimum angle limit

appears to be reached: press appears to be reached: press
the "Limit +" button to verify the "Limit -" button to verify
that this limit has been Are angle that this limit has been
correctly set, refer to the sensor batteries No correctly set, refer to the
adjusting angle limit section of low? adjusting angle limit section
the user manual. of the user manual.
Yes
Press the "Bypass" button to Press the "Bypass" button to
return to the main operating Verify battery installation
Verify return to the main operating
screen. Press the "Hoist" or change batteries if communication screen. Press the "Hoist"
button until the boom angle is necessary, see the between angle button until the boom angle
shown. changing angle sensor sensor and display is shown.
batteries of the user
manual.
unit (Section 6.4).
Is the Is the
boom angle boom angle
shown less than the No shown greater than the
No
maximum angle maximum angle
limit set? limit set?
The maximum
angle limit warning
Yes
Yes appears to be
functioning normally:
refer to the user
No The minimum
Is the manual for a Is the
"Limit +" warning light angle limit warning "Limit -" warning light still
description of this
still flashing? appears to be No flashing?
warning.
functioning normally:
refer to the user
Yes Yes
manual for a
description of this
Please contact your warning. Please contact your
service representative. service representative.
Reference Only
6.7 The Display Unit Is Always In Alarm Mode, the wind speed alarm
message is flashing
The wind
speed alarm
message is always
flashing
Does the
wind speed shown
No
correspond to actual
wind speed?
Yes
Visually inspect the wind

Is wind speed sensor for
speed greater than physical damage. Verify
No
set wind speed proper installation, refer
limit? to wind speed sensor
installation instructions.
Yes
Press the "Test" button
to verify battery status.
The maximum
wind speed warning
appears to be Verify
functioning normally: communication
Are wind
refer to the user between wind
speed sensor No
manual for a batteries low? speed sensor and
description of this display unit
warning. (Section 6.4).
Yes
Verify battery installation

or change batteries if
necessary, see the
changing wind speed
sensor batteries of the
user manual.
Reference Only
6.8 Radio Communication Problem
Radio communication between sensor(s) and cabin mounted display unit faulty.
Press the "Test" button and verify the sensor ID #. The ID # for each sensor can be found on the sensor itself or on any invoice
or shipping document for that sensor. Note that the ID # of older A2B switches is indicated on the A2B switch body in binary
form. The binary to decimel conversion procedure is detailed in the A2B calibration mode section of the distributor manual.
If either the sensor or the display unit has

recently been installed or replaced, the display
Does the Does the unit may require recalibration. If display unit's
display unit indicate display unit indicate
the correct ID # for
No
"0" or "5535" as the
No memory has been affected by a lightning strike or
the sensor? sensor ID #? other electrical event it may need reprogramming.
Refer to the technical manual or contact your
service representative.
Yes
Yes
Visually inspect the antennas of the sensor
and the cabin mounted display unit. The sensor chip's memory has been erased, please refer to
the technical manual or contact your service representative.
Is there a clear and Reinstall either the display unit, the

direct line of sight between the sensor antenna and the sensor or both such that there is a clear
No
antenna of the display unit? and direct line of sight between the two
antennas at all times.
Yes
Reinstall either the display unit or

Are both the sensor and the sensor such that both antennas are
the display unit antennas clear of all contact with any metal
object at all times?
No clear of all contact with any metal
including cables, chains, the boom,
or the cabin itself.
Yes
Are both the sensor A damaged antenna may need replacing.

and the display unit antennas complete and To replace the antenna of a load cell, an angle
undamaged? No sensor or a wind speed sensor please see the
appropriate section of the user manual. If an
Yes A2B switch antenna needs to be replaced please
contact your service representative.
If it is safe to do so, verify that the sensor is operational by observing its red LED during a change
in condition (change the boom angle for an angle sensor, pull the wire whip for an A2B switch,
change the load for a load cell, change the apparent wind speed for a wind sensor).
Verify sensor batteries,

Does the reinstall or replace if
sensor appear No necessary, see the
operational? appropriate section of
the user manual.
There appears to be a
Does the
problem with the sensor,
sensor appear No
operational? please contact your service
representative.
Reference Only
Chapter 7: Purchasing and Customer Service
Always call your service representative first, as he or she already knows the details of the sale
and applications. They may also supply lockout and be able to provide the required service for
that application.
If not available please contact:
LSI Corporate Offices: Western Regional Office: Central Regional Office:

Dave Smith Scott Colberg Randall Perrin
PO Box 820486 Phone (877) 287-7011 Phone (337) 893-2322
Vancouver, WA 98682 Fax (360) 575-8532 Fax (337) 893-0026
Phone (888) 819-4355 scolberg@loadsystems.com rperrin@loadsystems.com
Fax (360) 256-3344
sales@loadsystems.com
Our service personnel will do their best to help customers as quickly as possible and in the most
courteous manner.
Please be ready to give the following information:
i) Your name, company name, shipping address (no mail box), your phone number, fax
number and emergency phone number
ii) A credit card number - either Visa or MasterCard.
And for technical support, replacement, exchange or warranty:
iii) The part number of the defective or broken part

iv) The serial number of each display or sensor (If re-calibration is possible, it will be done)
In the event of exchange, replacement or warranty, a return tag will be in the box for
returning defective or broken parts. The customer can reuse the original box and the prepaid
return tag to return defective or broken parts.
Note: Some parts may not need to be returned.
Please note: although we design our products to fit the majority of cranes, there are exceptions
that will prevent the product from working or cause installation or operational problems. Our
technical staff will do their best to assist, help and advise any customer with such problems. We
strive to resolve problems as they may arise.
Reference Only

LS425 - Two Lines Display With Capacity Charts Universal User Manual

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LSI Load Systems International

LS425 – Two lines Display With Capacity Charts

Universal User Manual

1 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

System Description and Features ............................................................... 4

3 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

4 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

Notes For CSA Class 1, Division 2 Rated Equipment

WARNING: SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY

WARNING: SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I,

Warning: DO NOT remove power cable from display when on.

5 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

WARNING! “Two-Block” light

“M” = main, “A” = auxiliary.

Load indicated in pounds

“M” = main, “A” = auxiliary.

WARNING! “Low Batt” light

WARNING! “Limit –” light flashes WARNING! “Limit +” light flashes

1.2 LS425 Display Screen Abbreviations

6 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

Hoist Selection Button

Parts Of Lines Button

7 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

Limit+ And Limit- Buttons

8 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

1.4.1 Weight units

To change from pounds (lbs.) to kilograms (kg) or vice versa:

1.4.2 Lock limits

To prevent the operator from changing the set limits.

1.4.3 Indicator light intensity

To adjust indicator light intensity,

1.4.4 Display screen contrast

To adjust display screen contrast,

1.4.5 Display Screen Back-light

9 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

2.1 Display Unit Installation

2.1.1 Mounting the display

2.1.2 Yellow Power Cable Wiring:

10 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

Black wire: negative (ground)

Red wire: +12 or 24 volts (crane power supply)

White wire: standard lockout

Green wire: Second lockout, where required

Orange wire: do not connect. For

Wiring example without lockout

11 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

Wiring example with lockout for valve requiring less

Black Red wire

Battery +12V Diode

12 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

) Bracket length: 4.5"

13 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

Step 2) A washer must be placed between

If the dead end or hook to be connected to

In all cases the washers must be placed

Step 3) Once the pins are correctly placed

Step 4) Every lift assembly must be verified

14 UM-LS425-2004-04-13 Universal User Manual V4.5.doc

The angle sensor must