Gigasense LKV User manual

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 1 / 12
LKV/LKVX
Mechanical Overload Protection
Mechanical Slack Rope detection

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 2 / 12
SYMBOLS USED
The following symbols are used throughout this documentation, and/or marked on the product:
CAUTION. This symbol on the equipment indicates that the manual must be consulted.
In this manual it appears before instructions, which if not followed, may result in
product damage or improper function.
CE-mark. Indicates that we as a manufacturer declare that this product is in conformity
with all relevant CE-marking Directives.
Caution, risk of electric shock.
Protective Conductor Terminal
Alternating current.
Direct current.
Follow local regulations regarding recycling at disposal of this product. This product
must be disposed of separately, and not with normal household waste. See separate
section in this manual.
To ensure safe operation, this manual, together with applicable local user industry’s safety rules
and regulations must be followed.
Gigasense product warranty is not valid if other modifications than those described in this manual
are made.
Gigasense AB will not be responsible for any other use of this product than the intended use,
which is specified in this manual.
The buyer of this product is responsible for giving only adequately trained people access to
installation, commissioning, maintenance and usage of this product. The users and installation
personnel must have read and understood this manual, before using or installing this product.
The instructions in this manual must be followed in installation, usage and maintenance
procedures.
Gigasense AB will not accept any responsibility for failure due to misuse, improper installation or
improper maintenance.
Apart from the above, there may be local laws, safety regulations and directives from public
authorities, relevant for the use of this product.

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 3 / 12
Revision history:
Rev 000_2018-10-03
First edition
Rev 001_2018-10-17
Type errors fixed.
Rev 002_2019-01-17
Page 4, 7, 8: add info about secured seal. Added accuracy + cable info page 4.
GENERAL –INTENDED USE...................................................................................................................... 4
CONSTRUCTION....................................................................................................................................... 4
SAFETY INFORMATION AND WARNINGS ................................................................................................ 4
SPECIFICATIONS....................................................................................................................................... 5
FUNCTION................................................................................................................................................ 5
INSTALLATION ......................................................................................................................................... 5
INSTALLATION –with switch value preset from factory......................................................................... 5
INSTALLATION –with NO switch value preset from factory................................................................... 7
MAINTENANCE ........................................................................................................................................ 9
TROUBLESHOOTING .............................................................................................................................. 10
IDENTIFICATION AND SPARE PARTS...................................................................................................... 10
REPLACEMENT OF PARTS AND DISPOSAL ............................................................................................. 11
RECOMMENDED SPARE PARTS ............................................................................................................. 11
CE-CERTIFICATION................................................................................................................................. 11
CONTACT ............................................................................................................................................... 11

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 4 / 12
GENERAL – INTENDED USE
Intended use for LKV/LKVX mechanical overload protection is to be used in lifting
equipment, to detect and protect for overload or slack rope. One model series, is used as
overload protection and one model series is used to detect slack rope. The LKV/LKVX is
manufactured for one type of function, and cannot be used for both functions at the same
time. The LKV/LKVX can only operate on a stationary part of the wire rope. The LKV/LKVX
can be used indoor or outdoor.
An explosive approved version of the LKVX is intended to use in environments with potential
explosive atmospheres.
Ex PROTECTION TYPE
For Zone 1 and 2 (Gas): Ex II 2G Ex d IIC T6 Gb
For Zone 21 and 22 (Dust): Ex II 2D Ex tD A21 IP66 T80°C
CONSTRUCTION
The LKV/LKVX is constructed in high quality steel, plates and special spring washers.
The protection class for LKV is IP67 according to IEC60529. Standard length of the cable is 4
m (weather- and oil resistant cable RDO 4x1.5mm²).
SAFETY INFORMATION AND WARNINGS
Pay attention to turn off all external power to the LKV/LKVX when all types of work
shall be done on the LKV/LKVX.
Safety mechanisms must not be bypassed without evaluation of the risk assessment.
Supplementary protective measures may be required on the basis of risk
assessments for the application.
If the system is operated in conjunction with other components, the corresponding
user information must be followed.
Max. contact load to the micro switch is 250VAC, 500VA, 3A or 15W @ 220VDC or
50W @ 24VDC.
The installation of the system must be performed by authorized technical personnel.
The system must be taken out of operation in the event of damage.
The personnel who work, install and operate the system are responsible for
understanding the function and installation prescriptions described in this manual. If
any questions or uncertainties occur, Gigasense AB must be informed before the
system is put in operation.
A correct assembly and electrical connection of the system is essential for the correct
operation of the system.
A correct function must be verified before the system is put in normal operation.
If this equipment is used in a manner not specified in this manual, or by Gigasense AB
personnel, protection or function normally provided by this equipment may be
reduced.
The switch value is set by Gigasense, if the secured seal has the label with Gigasense
printed. One extra secure seal is delivered without the label (Gigasense print), which

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 5 / 12
can be assembled when the switch value is changed by customer. The heat resistant
version uses a padlock with a key.
SPECIFICATIONS
Type designation: LKV-1, LKV-2, LKV-4, LKV-8, LKV-12, LKV-16, LKV 01 and LKV 08
EX versions: LKVX-1, LKVX-2, LKVX-4, LKVX-8, LKVX-12, LKVX-16, LKVX 01 and LKVX 08
Permitted ambient temperature: -25°C … + 60°C (special version up to 200°C)
Degree of protection: IP67
Accuracy (repeatability): set switch value ± 1,5 % of rated capacity (R.C.).
FUNCTION
The LKV/LKVX has a mechanical micro switch, which is connected to the lifting equipment via
the cable. The LKV/LKVX is attached to a stationary rope part. The LKV/LKVX can be installed
in a rope below the equalizer sheeve, if the rope is not moving too much. The rope is
deflected by a small angle between the two wheels and the clamping jaw. When loaded, the
rope tends to straighten. This applies force to the clamping jaw and to the pull rod. When
the set switch value is reached, the pull rod operates a micro switch and a close/open
circuit is made. The spring element of the load cell is preloaded, reducing pull rod movement
to the last 25% of full load. For the best possible accuracy, the LKV/LKVX is equipped with
case-hardened wheels with carefully designed rope grooves. To ensure correct
fitting on the rope diameter, the wheels and the clamping jaws are provided with
rope tracks at intervals of 4 mm. The wheels should not be regarded as wheels but
rather as moving support points, as the peripheral movement on the wheels at full
line load is only about 0.6 mm, including the extension of the rope.
INSTALLATION
Before installation: check the LKV/LKVX with cable for any damage. In case of any
damaged parts, do not install the LKV. Consult Gigasense AB or dealer.
INSTALLATION – with switch value preset from factory
1. Check that the LKV has the correct switch value engraved on the plate. The plate is
located on the side of the LKV/LKVX, in the secured seal. Check that the rope
diameter is correct.
2. Dismantle the outer clamping jaw.
3. Apply the LKV LKV/LKVX to the intended position on the rope (A). Make sure the
cable is pointing downwards. The provided chain can be used for easier assembly by
means of discharge the weight of the LKV/LKVX.

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 6 / 12
4. Install the outer clamping jaw and tighten the hexagon
headed bolts by hand using the spanner provided (B).
Max. contact load to the micro switch of the LKV/LKVX is 250VAC, 500VA, 3A or 15W @
220VDC or 50W @ 24VDC.
Notice, the LKV/LKVX is ordered, as either overload protection or slack rope detection.
The function cannot be set afterwards.
5a. Electrical connection to the lifting equipment for overload protection:
Connect the LKV/LKVX to the operating circuit of the lifting equipment so that the lifting
motion will be interrupted on overload of the LKV/LKVX, leaving it possible to lowering the
load.
Figure D shows the micro switch status in no alarm state, a connection between the grey and
brown wire. When the switch value is reached (the overload protection value), the micro
switch opens and make open circuit between the grey and the brown wire.
Use a closed circuit that opens at overload status, for safety purposes. If the cable is
damaged, the system will indicate overload.
5b. Electrical connection to the lifting equipment for slack rope detection:
Connect the LKV/LKVX to the operating circuit of the lifting equipment, so that the lowering
motion will be interrupted at slack rope detection of the LKV/LKVX.
Figure D shows the micro switch status in no alarm state, a connection between the grey and
brown wire. When the switch value is reached (the slack rope detection value), the micro
switch opens and make open circuit between the grey and the brown wire.
Always connect the protective earth wire, when an AC control circuit is used.
6. Connect the protective earth wire, yellow/green, to the protective earth of the lifting
equipment, if AC control circuit is used.

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 7 / 12
7. Check that the LKV/LKVX cable is hanging clear and does not stretch when the hook is
swinging. If the LKV/LKVX is installed below an equalizer sheeve, check so the movement
does not interfere with the installed LKV/LKVX.
8. Adjust the limit switch of the lifting equipment if necessary.
INSTALLATION – with NO switch value preset from factory
This LKV/LKVX is supplied by Gigasense AB or the dealer without a preset switch value. To
set the correct switch value, the instructions below must be followed. Gigasense AB does not
accept any responsibility or liability for switch values set by the user who should ensure for
himself that the equipment is operating correctly and safely.
1. Dismantle the secured seal and the outer clamping jaw. The secured seal must be cut off
with a bolt cutter and cannot be reassembled again. At delivery of the LKV/LKVX, one extra
secure seal is delivered, which can be assembled after the switch value is set. The heat
resistant version uses a padlock with key.
2. Apply the LKV/LKVX to the intended position on the rope (A).
3. Install the outer clamping jaw and tighten up the two hexagon-headed bolts manually
with the spanner provided for this purpose (B).

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 8 / 12
4. Setting of switch value
Apply a load to the lifting equipment equal to the intended switch value.
Use a crane scale or similar device with high accuracy, on the hook to
verify the load.
NOTE: The machinery of the lifting equipment must not be used.
Connect a buzzer or meter according to the wiring diagram (D).
If the LKV/LKVX is to be used as an overload guard, the normally closed function should
always be used. Turn the adjustment nut (C) according to the inscription on the badge plate
with the spanner provided for this purpose. If a higher switch value is desired, turn the
adjustment nut to the right (+). For a lower switch value, turn the adjustment nut to the left
(-). To eliminate the hysteresis of the LKV/LKVX, the switch setting should be approached by
rising load, but if a weight on the hook is used, equivalent to the overload setting and the
LKV/LKVX switch does not operate, adjust the nut to the left (-) until it does. If the adjusted
value is too low, turn the nut to the right (+) well past the switch value and then down again
just enough for it to switch off. 1/6 turn of the
adjustment nut corresponds to a change of the
switch value with about:
- 75 kg for type LKV/LKVX 1
- 150 kg for type LKV/LKVX 2
- 300 kg for type LKV/LKVX 4
- 950 kg for type LKV/LKVX 8
- 1400 kg for type LKV/LKVX 12
5. Unload the lifting equipment and test load it
once more to check the switch setting values.
6. After setting of the switch value, for safety
reasons, the protective clamp should be assembled and locked with a new secure seal or
padlock. If LKV/LKVX is delivered without a switch value, an unlocked seal is included to be
mounted after setting. Mount the protective clamp, lock pin and lock the secure seal by
pressing it together by hand until it cannot be disassembled.
Max. contact load to the micro switch of the LKV/LKVX is 250VAC, 500VA, 3A or 15W @
220VDC or 50W @ 24VDC.
Notice, the LKV/LKVX is ordered, as either overload protection or slack rope detection.
The function cannot be set afterwards.
7a. Electrical connection to the lifting equipment for overload protection:
Connect the LKV/LKVX to the operating circuit of the lifting equipment so that the lifting
motion will be interrupted on overload of the LKV/LKVX, leaving it possible to lowering the
load.

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 9 / 12
Figure D shows the micro switch status in no alarm state, a connection between the grey and
brown wire. When the switch value is reached (the overload protection value), the micro
switch opens and make open circuit between the grey and the brown wire.
Use a closed circuit that opens at overload status, for safety purposes. If the cable is
damaged, the system will indicate overload.
7b. Electrical connection to the lifting equipment for slack rope detection:
Connect the LKV/LKVX to the operating circuit of the lifting equipment, so that the lowering
motion will be interrupted at slack rope detection of the LKV/LKVX.
Figure D shows the micro switch status in no alarm state, a connection between the grey and
brown wire. When the switch value is reached (the slack rope detection value), the micro
switch opens and make open circuit between the grey and the brown wire.
Always connect the protective earth wire, when an AC control circuit is used.
8. Connect the protective earth wire, yellow/green, to the protective earth of the lifting
equipment, if AC control circuit is used.
9. Check that the LKV/LKVX cable is hanging clear and does not stretch when the hook is
swinging. If the LKV/LKVX is installed below an equalizer sheeve, check so the movement
does not interfere with the installed LKV/LKVX.
10. Adjust the limit switch of the lifting equipment if necessary.
11. Check that the LKV/LKVX cable is hanging free and is not stretched when the hook
swings. Test load the LKV/LKVX once more to check the functions.
12. Put the shackle, the cotter and the secured seal. The set switch value is now locked in
position and interference with the adjustment screw is prevented.
MAINTENANCE
The LKV/LKVX is designed to be maintenance free. However, according to local regulations, a
proof lift shall be carried out on a regular basis, to check function

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 10 / 12
In case of cleaning the equipment, this should be done, by gently wiping it off with a dry or
damp cloth.
TROUBLESHOOTING
1. The lifting equipment cannot lift (or, lowering - slack rope versions)
- The cable to the LKV/LKVX is damaged
Solution: Check the cable for repair/ reconnection
- The LKV/LKVX is mechanically damaged
Solution: replace the unit or send for repair
2. The overload / slack rope switch value does not interrupt the lifting/lowering circuit
- The Switch value is changed by unknown reason
Solution: Check the switch value in a controlled environment, or send to Gigasense AB or
Dealer.
- The LKV/LKVX is mechanically damaged
Solution: replace the unit or send for repair
3. The LKV/LKVX does not switch/close after set value. No defects on the cable.
-The micro switch is damaged
Solution: replace the unit or send for repair
IDENTIFICATION AND SPARE PARTS
Identification:LKV-1, LKV-2, LKV-4, LKV-8, LKV-12, LKV-16, LKV 01 and LKV 08
EX versions: LKVX-1, LKVX-2, LKVX-4, LKVX-8, LKVX-12, LKVX-16, LKVX 01 and LKVX 08
Spare part no. LKV:
Heat resistant versions, contact Gigasense AB or the Dealer.

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 11 / 12
Spare part no. LKVX:
REPLACEMENT OF PARTS AND DISPOSAL
If a failure should occur, it is recommended to send back the unit to the manufacturer for
repair.
Risk of electric shock! Make sure that connections to the LKV/LKVX is isolated before it is
disconnected from the lifting equipment.
After repair/service, and reconnection to the crane system, perform the steps in chapter
"INSTALLATION" to verify proper function of the complete system. When proper function is
verified, the system can be used again.
Replaced and disposed parts can be sent to Gigasense AB for destruction.
RECOMMENDED SPARE PARTS
The LKV/LKVX overload protection system does not require any spare parts.
In a sensitive application, where downtime is not acceptable, we recommend to keep one
unit in stock for quick replacement if needed.
CE-CERTIFICATION
Hereby, Gigasense AB, declares that this equipment is in compliance with the essential
requirements.
CONTACT
Sales and service
Gigasense AB
Stationsvägen 16,
184 50 Åkersberga
SWEDEN
Phone [phone], fax [phone]
E-mail [email protected]
www.gigasense.se

Manual LKV/LKVX –Mechanical Overload Protection
Manual LKV_LKVX_EN_002_1901017 © Gigasense AB Page 12 / 12