Conductix-Wampfler LASSTEC 0521 User manual

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
www.conductix.com translated document page 1 of 123
Order Number:
0521xx-….

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
www.conductix.com translated document page 2 of 123
Contents
1General Notes......................................................................................................................................................................................... 6
1.1 Information about this Document.......................................................................................................................................... 6
1.2 Limitation of Liability ............................................................................................................................................................. 6
1.3 Copyright .............................................................................................................................................................................. 6
1.4 Spare Parts........................................................................................................................................................................... 7
1.5 Material Defects.................................................................................................................................................................... 7
1.6 Technical Support................................................................................................................................................................. 7
2Safety Instructions................................................................................................................................................................................... 8
2.1 Explanation of the Symbols.................................................................................................................................................. 8
2.2 Personal Requisition............................................................................................................................................................. 9
2.2.1 Qualification.......................................................................................................................................................................... 9
2.2.2 Unauthorized Persons.......................................................................................................................................................... 9
2.3 Equipment Security ............................................................................................................................................................ 10
2.4 Safety Measures by the Operator....................................................................................................................................... 10
2.5 Behaviour in Case of Accidents and Disturbances............................................................................................................. 11
3Technical data....................................................................................................................................................................................... 11
3.1 General............................................................................................................................................................................... 11
3.2 Dimensions......................................................................................................................................................................... 11
3.2.1 Cabinet on Spreader .......................................................................................................................................................... 11
3.2.2 HMI in Crane Cabin............................................................................................................................................................ 13
3.2.3 Sensors glued in Twistlock................................................................................................................................................. 14
3.3 Standard Connection Diagram ........................................................................................................................................... 14
4Description of the functional Principle................................................................................................................................................... 15
5Configuration of the Interrogator ........................................................................................................................................................... 16
5.1 Required Software to be installed in advance .................................................................................................................... 16
5.1.1 LabView Runtime ............................................................................................................................................................... 16
5.1.1.1 Requirements for installation .............................................................................................................................................. 16
5.1.1.2 Installation instruction ......................................................................................................................................................... 16
5.1.2 NIVISA Communication Driver ........................................................................................................................................... 16
5.1.2.1 Requirements for Installation.............................................................................................................................................. 16
5.1.2.2 Installation Instruction......................................................................................................................................................... 17
5.2 LASSTEC Interrogator Configuration Software.................................................................................................................. 17
5.3 User Guide ......................................................................................................................................................................... 18
5.3.1 Connecting the Interrogator................................................................................................................................................ 18

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
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5.3.2 Program Start ..................................................................................................................................................................... 18
5.3.3 Interrogator Connection Manager....................................................................................................................................... 18
5.3.4 Communication Parameters............................................................................................................................................... 20
5.3.5 Password and Accessing restricted Sections..................................................................................................................... 22
5.3.5.1 The first Access/Password Change.................................................................................................................................... 22
5.3.5.2 Entering Password to access restricted Sections............................................................................................................... 24
5.3.6 Start Menu.......................................................................................................................................................................... 25
5.3.7 Display State of LASSTEC System.................................................................................................................................... 26
5.3.7.1 Recording Management ..................................................................................................................................................... 27
5.3.7.2 Advanced Parameters........................................................................................................................................................ 28
5.3.7.2.1 Sensor 1 (to 8) tab.............................................................................................................................................................. 28
5.3.7.2.2 Thresholds tab.................................................................................................................................................................... 29
5.3.7.2.2.1 Container Overload sub tab.............................................................................................................................29
5.3.7.2.2.2 Eccentricity Sub Tab........................................................................................................................................30
5.3.7.2.2.3 Twistlock Load & Overload Sub Tab ...............................................................................................................31
5.3.7.2.2.4 Dragging sub tab .............................................................................................................................................31
5.3.7.2.2.5 Snag load sub tab............................................................................................................................................31
5.3.7.2.2.6 Not carrying Sub Tab.......................................................................................................................................32
5.3.7.2.3 Interrogator Tab.................................................................................................................................................................. 32
5.3.7.2.3.1 Stabilized weight sub tab.................................................................................................................................32
5.3.7.2.3.2 Optical Sub Tab...............................................................................................................................................32
5.3.7.2.3.3 ADC Vref Tab ..................................................................................................................................................33
5.3.7.2.3.4 Functions Sub Tab ..........................................................................................................................................33
5.3.7.2.3.5 Communication Sub Tab ................................................................................................................................. 33
5.3.7.2.3.6 Identification Sub Tab......................................................................................................................................33
5.3.8 Configure the LASSTEC System Authorized Persons Only............................................................................................... 34
5.3.8.1 Communication................................................................................................................................................................... 35
5.3.8.2 Calibration .......................................................................................................................................................................... 36
5.3.8.2.1 Sensor Calibration .............................................................................................................................................................. 37
5.3.8.2.2 Advanced Calibration ......................................................................................................................................................... 39
5.3.8.2.3 Calibration per Twistlock .................................................................................................................................................... 40
5.3.8.2.3.1 Calibration per Twistlock – Step by Step Explanation .....................................................................................42
5.3.8.2.4 Container Adjustment ......................................................................................................................................................... 51
5.3.8.2.4.1 Step by Step Guide .........................................................................................................................................53
5.3.8.2.5 Temperature Calibration..................................................................................................................................................... 59
5.3.8.3 Thresholds Adjustment....................................................................................................................................................... 61
5.3.8.3.1 Load & Overload................................................................................................................................................................. 62
5.3.8.3.1.1 Single Tab .......................................................................................................................................................63

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
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5.3.8.3.1.2 Twistlock..........................................................................................................................................................63
5.3.8.3.1.3 Container counter ............................................................................................................................................64
5.3.8.3.2 Over-Eccentricities ............................................................................................................................................................. 65
5.3.8.3.2.1 X and Y over-eccentricity Thresholds..............................................................................................................65
5.3.8.3.3 Snag Load Detection.......................................................................................................................................................... 67
5.3.8.3.3.1 Global Threshold .............................................................................................................................................67
5.3.8.3.3.2 Start Threshold ................................................................................................................................................68
5.3.8.3.4 Dragging Detection............................................................................................................................................................. 68
5.3.8.3.5 Not carrying Detection ........................................................................................................................................................ 69
5.3.8.4 Date and Time setting ........................................................................................................................................................ 70
5.3.8.5 Advance Configuration ....................................................................................................................................................... 71
5.3.8.5.1 Stabilized Weight................................................................................................................................................................ 71
5.3.8.5.2 Time delays ........................................................................................................................................................................ 72
5.3.8.5.3 Interrogator......................................................................................................................................................................... 73
5.3.8.5.4 Pstab Measurement ........................................................................................................................................................... 73
5.3.8.5.5 Precision & Young Modul ................................................................................................................................................... 74
5.3.8.6 Save / Load Configuration.................................................................................................................................................. 74
5.3.8.7 Reset the Interrogator......................................................................................................................................................... 75
5.3.8.8 Download Data Logging ..................................................................................................................................................... 76
5.3.9 About the Lasstec System.................................................................................................................................................. 77
6Use of the Display................................................................................................................................................................................. 78
6.1 HMI overview...................................................................................................................................................................... 78
6.1.1 Glossary ............................................................................................................................................................................. 78
6.1.2 Hardware............................................................................................................................................................................ 78
6.2 Page description................................................................................................................................................................. 81
6.2.1 Loading............................................................................................................................................................................... 81
6.2.2 Home .................................................................................................................................................................................. 81
6.2.2.1 Single-Lift Mode.................................................................................................................................................................. 81
6.2.2.2 Twin-Lift Mode.................................................................................................................................................................... 85
6.2.3 Status of the Lasstec System ............................................................................................................................................. 88
6.2.4 Load Alarm ......................................................................................................................................................................... 90
6.2.5 System alarms of the Lasstec system................................................................................................................................ 94
6.2.6 Configuration of the load display ........................................................................................................................................ 96
6.2.7 Download Datalogging to USB Memory Stick .................................................................................................................... 98
6.2.8 User Configuration............................................................................................................................................................ 101
6.2.8.1 Set the date and time ....................................................................................................................................................... 105

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
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6.2.8.2 Counters........................................................................................................................................................................... 106
6.2.8.3 Reset counters ................................................................................................................................................................. 107
6.2.8.4 TCP/IP server configuration ............................................................................................................................................. 108
6.2.8.5 TCP/IP HMI configuration................................................................................................................................................. 109
6.2.9 Advanced configuration.................................................................................................................................................... 109
6.2.10 About ................................................................................................................................................................................ 110
6.2.11 Historical........................................................................................................................................................................... 111
6.2.12 Common visualisation elements....................................................................................................................................... 112
6.3 Procedures ....................................................................................................................................................................... 113
6.3.1 How to type a password ................................................................................................................................................... 113
6.3.2 How to set the date and time............................................................................................................................................ 113
6.3.3 How to type the IP-Address.............................................................................................................................................. 114
6.4 HMI / TOS Communication............................................................................................................................................... 114
6.4.1 TCP-IP communication protocol....................................................................................................................................... 114
6.4.2 Serial communication protocol ......................................................................................................................................... 117
6.4.3 Bluetooth communication protocol ................................................................................................................................... 118
7Status and Alarm description .............................................................................................................................................................. 119

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
www.conductix.com translated document page 6 of 123
1General Notes
1.1 Information about this Document
This operating instructions allow the safe and efficient handling of the equipment.
Moreover, you have to observe the local accident prevention guidelines and the general regulations for the application of the equipment.
Illustrations in this documentation are for basic comprehension and can deviate from the real design of the equipment.
The HMI description (see chapter 6) assist users of LASSTEC HMI V4.6 to use and configure the HMI screen. Description may differ in
minor parts depending on the actual software version. This also applies to the description of the configuration software V2.5.1 (see chapter
5).
1.2 Limitation of Liability
All specifications and advice of these Operating Instructions have been made up with regard to the existing standards and prescriptions,
the state-of-the-art and many years of technical expertise and experiences.
The manufacturer does not take over any liability for damage due to:
Non-observance of the mounting and operating instructions,
Application not in accordance with the regulations,
Employment of non-qualified staff,
Unauthorized reconstructions,
Technical modifications,
Application of unapproved replacement parts and accessories.
The effective volume of delivery may deviate from these explanations and descriptions in case of special design, the utilization of additional
order options or on account of to the latest technical modifications.
The commitments of the supply contract, the general terms and conditions as well as the manufacturer’s terms of delivery and the legal
regulations at the time of the contract conclusion have to be observed.
We reserve the right of technical modifications in the context of revision of useful properties and further developments.
1.3 Copyright
These operating instructions are copyrighted and intended for customer internal use only.
Surrender of the operating instructions to third party, any type of copying - even in extracts - as well as utilization and/or communication of
the contents are not permitted without written approval by the manufacturer, except for customer internal purposes.
Violations will cause indemnities. We reserve the right to further claims.

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
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1.4 Spare Parts
WARNING!
Safety risk due to faulty replacement parts!
Faulty or defective replacement parts might affect the security and cause damage, malfunction or
complete failure.
Therefore:
Use only original replacement parts of the manufacturer!
1.5 Material Defects
The regulations about material defects are listed in the general terms and conditions of business.
1.6 Technical Support
For technical support please contact our staff from the Customer Support Department.
Conductix-Wampfler GmbH
Rheinstrasse 27 + 33
79576 Weil am Rhein - Maerkt
Germany
Phone: +49 ( 0) 7621 662-0
Fax: +49 ( 0) 7621 662-144
[email protected]
www.conductix.com
Moreover, our staff is constantly interested in new information and experiences, which will arise from the application and which might be
valuable for the improvement of our products.

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
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2Safety Instructions
2.1 Explanation of the Symbols
DANGER!
Refers to an imminent danger, which might cause deathly or serious injuries if not avoided.
WARNING!
Refers to a possibly dangerous situation, which might cause deathly or serious injuries if not avoided.
CAUTION!
Indicates a possibly hazardous situation, which if not avoided, may result in moderate or minor
injury and property damage.
ADVICE!
Advice and recommendations:
Gives advice and recommendations as well as information for an efficient and undisturbed
operation.

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
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2.2 Personal Requisition
2.2.1 Qualification
WARNING!
Risk of injury in case of insufficient qualification!
Incorrect handling can cause serious injuries to persons and heavy damage to property.
Therefore:
All activities must be carried out by qualified staff!
The operating conditions indicate the following qualifications for the various fields of activity:
Instructed personnel/operators
have been instructed by the operator about the tasks assigned to them and the possible dangers due to improper behaviour.
Specialized staff
is able to carry out the works assigned to them and realize and avoid any dangers in this regard, based on their training,
knowledge, experiences and knowledge of the respective regulations.
Only those persons are authorized for these works, who are expected to do their work properly. Persons with restricted
responsiveness, e.g. due to drugs, alcohol or medication are not permitted.
For the selection of personnel observe the age-specific and job-related prescriptions effective at the place of installation.
2.2.2 Unauthorized Persons
WARNING!
Danger caused by unauthorized personnel!
Unauthorized personnel, who do not comply with the requirements described hereunder, are not
familiar with the dangers that might occur within the working area.
Therefore:
Keep unauthorized personnel away from the working area.
In case of doubt talk to those people and dismiss them from the working area.
Interrupt the works as long as there are unauthorized persons within the working area.

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
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2.3 Equipment Security
The equipment has been exclusively designed and constructed for the intended purpose.
WARNING!
Danger caused by application not in accordance with regulations!
Each application of the equipment not in accordance with and/or different from the regulations can
result in dangerous situations.
Therefore:
Only use the equipment in accordance with the regulations.
All details of these mounting and operating instructions must be strictly observed.
The following applications of the equipment are prohibited. Applications not in
accordance with regulations are as follows:
Application of the equipment with accessories not permitted or authorized by the manufacturer.
Operation of the equipment by not instructed personnel.
Exceeding / be lower than projected supply voltages.
Changing of the delivered software modules.
Changing, bridging and/or deactivation of control circuits or interlocking.
Bridging and/or deactivating electrical sensors or switches.
Use of non-approved protective devices.
Re-adjustment of protective devices.
2.4 Safety Measures by the Operator
The equipment is used in the commercial sector. The operator is therefore responsible for occupational safety. Besides the safety advice
of these mounting and operating instructions he must observe the safety, accident prevention and environmental protection regulations
effective for the range of application of this equipment. Please note in particular:
The operator must read the valid work safety regulations and determine any additional dangers in a risk assessment, dangers that
might arise from special working conditions at the place of installation of the equipment. He then must work out the operating
instructions for handling the equipment.
During the complete operating time the operator must check if his operating instructions are in accordance with the state of technology
of rules and standards and adapt them if required.
The operator must clearly regulate and establish the responsibilities for installation, handling, fault repair and maintenance.
The operator must ensure that all employees who are handling the equipment, have read and understood these mounting and
operating instructions. Moreover he must instruct the personnel at regular intervals and inform them about any dangers.
The operator must have checked all safety devices regularly for their operational capability and completeness.

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
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2.5 Behaviour in Case of Accidents and Disturbances
Measures to be taken in case of accidents:
Start with first aid measures.
Bring the people out of the danger zone.
Inform responsible persons on the site of operation.
Call the emergency medical services.
Clear access routes for rescue vehicles.
Measures to be taken in case of faults:
Analysis of fault.
Fixing of fault cause.
Check of correct functions after fault fixing.
3Technical data
3.1 General
LASSTEC™ is a container weighing system installed on a container spreader to determine the Verified Gross Mass (VGM). It is based on
Fiber Optic (FO) technology and measures the elongation of each Twistlock to calculate the applied weight on each Twistlock and from
this the mass of the container.
To enable the weight measurement with the Twistlocks, the original ones are replaced by Twistlocks equipped with a fibre-bragg-gratin
(FBG) sensor. The Sensors are connected to an evaluation unit called interrogator which it mounted in a cabinet on the spreader and
analyses the FBG signals, calculates the weights and sends them to a display (e.g.: in the driver cabin of a crane) where they are displayed
to the driver. They can also be sent to secondary devices (e.g.: to a Terminal Operating System) via several communication protocols.
3.2 Dimensions
3.2.1 Cabinet on Spreader
Side view:

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
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Bottom view:
Connection
plate:

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BAL0521-0001-EN
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3.2.2 HMI in Crane Cabin
Display mount set
Image source: IFM electronic (CR1081)
Display
Image source: IFM electronic (CR1081)

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LASSTEC
Weighing System 0521
BAL0521-0001-EN
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3.2.3 Sensors glued in Twistlock
Depending on the Twistlock and spreader manufacturer, the form and dimensions of the Twistlock may change. The pictures shown here
are for illustrative purposes only and do not reflect the parts installed in your system.
The Length L of the Sensor can, depending on the Twistlock type vary between 208 mm and 270 mm.
3.3 Standard Connection Diagram

Operating Instructions
LASSTEC
Weighing System 0521
BAL0521-0001-EN
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4Description of the functional Principle
Lasstec uses Fibre Bragg Grating (FBG) sensors. These sensors consist of an optical fibre in which two FBG are integrated. When Light
is sent through the optical fibre a certain wavelength is always reflected by the FBGs and is detected by the interrogator. When bonded
into a Twistlock, one of the FBGs changes it length according to the elongation of the cylindrical part of the Twistlock. As a consequence
of this, the reflected wavelength also changes. The second FBG is only sensitive to temperature changes and is located at the tip of the
sensor (bottom of the sensor hole in the Twistlock). It is essential that the load sensing FBG is located in a cylindrical part of the Twistlock.
The interrogator then extracts the extension of the steel due to strain only.
P
l
Incident light spectrum
P
l
Transmitted light spectrum
Fibre optic cable with Fibre Bragg Grating
P
l
Reflected light spectrum without
strain
P
l
Reflected light spectrum with strain
The difference between λ and λ´ is used to calculate
the weight applied on each Twistlock.
λ: Bragg wavelength without strain, λ´: Bragg wavelength with strain, P: Power, l: Wavelength
λ
λ
λ´

Operating Instructions
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Weighing System 0521
BAL0521-0001-EN
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It should be emphasized that the full scale (or the span) of the sensor output signal does not begin at zero. LASSTEC fibre-optic sensors
always indicate a value for the reflected wavelength.
A weighing cycle begins with the applied “lock” signal, the interrogator measures the Bragg wavelength off all connected Twistlocks and
stores them as reference. During the lifting of the container the Bragg wavelength are measured continuously and the interrogator
processes the difference between the reference Bragg wavelength and the Bragg wavelength with load into the actual weight. Once the
Twistlocks are unlocked again the load cycle is finished.
In case the lock signal is temporarily lost during a load cycle or the power of the crane or machine is switched off, the system continues
to weigh when the power is back again. The system only ends the weighing cycle when it receives the unlock signal. The LASSTEC
system always requires these signals to function.
5Configuration of the Interrogator
5.1 Required Software to be installed in advance
5.1.1 LabView Runtime
LabVIEW runtime is a free of charge software, and can be downloaded from the official National Instrument website.
The LabVIEW runtime version required for the LASSTEC configuration software V2.5.1 is:
LVRTE2010sp1std.exe.
5.1.1.1 Requirements for installation
The LabVIEW runtime installation file.
A compatible computer (see the National Instrument website for the PC requirements).
5.1.1.2 Installation instruction
The following instructions are based on the LabVIEW runtime xxx.
1. Download the appropriate installation file (if not already done) from the official National Instruments website.
2. Execute the installation file.
3. Follow the instructions until the installation is complete
5.1.2 NIVISA Communication Driver
NVISA runtime is a free of charge software, and can be downloaded from the official National Instrument website.
The NVISA runtime version required for the LASSTEC configuration software Vx.x is:
NIVISA runtime.msi, version 3.0.
5.1.2.1 Requirements for Installation
The NVISA runtime installation file.
A compatible computer (see the National Instrument website for the PC requirements).

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5.1.2.2 Installation Instruction
The following instructions are based on the NVISA runtime xxx.
1. Download the appropriate installation file (if not already done) from the official National Instruments website.
2. Execute the installation file.
3. Follow the instructions until the installation is complete.
5.2 LASSTEC Interrogator Configuration Software
The LASSTEC Configuration Software does not require an installation to work but there are a few instructions to follow.
After extracting the provided folder to your chosen path, the content should look like this:
The execution file “LASSTEC interrogator configuration software v 2.5.1” must always remain in this folder structure as the software
refers to the other files in it.
To create a shortcut on the desktop, right click on the execution file, select “Send to” and click on “Desktop”. A shortcut is then
created on the desktop. This shortcut can then be moved to any desired folder.

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5.3 User Guide
5.3.1 Connecting the Interrogator
To configure an interrogator with the LASSTEC Configuration Software, the interrogator must be connected to a computer equipped with
the software by an RS-232 to USB adapter.
5.3.2 Program Start
To start the program, perform a double right click on its icon.
5.3.3 Interrogator Connection Manager
The first window which appears is the “Interrogator connection manager”. It allows you to connect or disconnect the connection between
the interrogator and the computer and to access the communication parameters. You will always come back to this view when clicking on
“OFF LINE” or “ON LINE”.

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①Go On LINE:
Clicking “Go ON LINE” establishes the communication between the interrogator and the computer. “Communication
Parameters” have to be defined first.
②Go OFF LINE:
Clicking “Go OFF LINE” closes down the communication if it has been established before.
③Communication Parameter:
Clicking on “Communication Parameter” leads you to the “Communication Parameters” window.
④OK:
Clicking “OK” leads you to the “Start Menu” window or simply to the previously accessed window.
⑤OFF LINE / ON LINE:
This shows the communication status between interrogator and computer.
ON LINE: Communication between interrogator and computer is established.
OFF LINE: Communication between interrogator and computer is NOT established.

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5.3.4 Communication Parameters
In the “Communication Parameters” window, you can define the settings for the communication between the software and the
interrogator.
①Computer Used Com port:
Shows the selected serial port of your computer which will be used by the software for communicating with the interrogator. All
available ports are listed here. You have to define the port via which the communication to the interrogator is going to be
established and to which the interrogator is connected. If no serial ports are listed here, exit the software and check the installation
of the NVISA driver.
②Baud Rate [Bit/s]:
This shows the speed at which information is exchanged between this software and the connected interrogator. When using the
RS-232 protocol (④) for communication the baud rate is automatically set at 9600 [Bit/s]