Gigasense GII User manual

ManualGIIAntiCollisionSystem
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GIGASENSE®II
IntelligentMicrowaveAntiCollisionSystem
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ManualGIIAntiCollisionSystem
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SYMBOLSUSED
Thefollowingsymbolsareusedthroughoutthisdocumentation,and/ormarkedontheproduct:
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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.
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CE‐mark.Indicatesthatweasamanufacturerdeclarethatthisproductisinconformity
withallrelevantCE‐markingDirectives.
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Class2alertsign.Radioequipmentissubjecttorestrictionsofuse.
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Caution,riskofelectricshock.
Directcurrent.
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Class3equipment.
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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.
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Toensuresafeoperation,thismanual,togetherwithapplicablelocaluserindustry’ssafetyrulesand
regulationsmustbefollowed.Itisalsoessentialtofollowtheapplicablecountrylawandsafety
regulationsanddirectivesrelevantfortheuseofthisproduct.
Warrantyisnotvalidifanysealedscrewsareadjusted,orifanyothermodificationsnotdescribedin
thismanualaremade.
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Revisionhistory:
Rev001_2016‐05‐20:Firstedition
Rev002_2017‐05‐30:Addrevisionhistory
Rev002_2017‐05‐30:ChapterCEmarking
‐ChangedtoREDdirective
Rev002_2017‐05‐30:ChapterTroubleshooting
‐Added(lastpointinTroubleshooting)”Displayinrelayboxshowvalues…”
Rev002_2017‐05‐30:ChapterInstallation
‐Addedtextandfigurewithclarificationofmetalof1m²behindantennas.
‐Addedfigureof1,5mradiusfreespace.Changedtextfrom3mdiameterto
1,5mradius.
Rev002_2017‐05‐30:ChapterSpecifications
‐Speeddependance:changedto600%
‐Antennadimensios:changeto(HxBxD)443x359x294mm
‐Grossweight/dimensions:Added”1”intext”1systemincl.packing..”
Rev002_2017‐05‐30:ChapterMenustructure
‐AddedtextinmenudbFI:”ThefilterisinactiveifMode2isselected”(3rdmeny
fromtheend).
‐newmeny”MSR”addedwithtext(secondmenufromtheend).
‐clarificationtextforMSraddedinchapter”Controloftherelayfunctions´
outputformodulatedsignalreflection”underMode1.
‐menuSPD1andSPD2addedintext”Range:0–600%(stepof10%)”
‐changedintextdescriptionofSPD”…range0–600%tobesetbytheuser”
(was0–200%inrev001)
‐ChangedfirstmenutoA26(wasA23)
‐Mode2addedtext:”(L1rSandL2rSareinactive)”underchapter
“Controloftherelayfunctions´outputformodulatedsignalreflection”
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Rev002_2017‐05‐30:ChapterFunction
Under”PrincipleoftheunmodulatedsignalreflectionintheGigasenseIIsystem:”
‐Addedclarificationtextintheendofthetext
‐figure3A/3Bchanged
Rev002_2017‐05‐30:ChapterPushbuttons
‐Changedtolargerfonts(Calibri16)of“warningifthemiddlepushbuttonisnot
pressed”
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GENERAL–INTENDEDUSE......................................................................................................................5
CONSTRUCTION.......................................................................................................................................6
SAFETYINFORMATIONANDWARNINGS................................................................................................6
SPECIFICATIONS.......................................................................................................................................7
SAFETY&ENVIRONMENT.......................................................................................................................8
FUNCTION–twomovingcranes.............................................................................................................9
FUNCTION–onemovingcrane.............................................................................................................11
INSTALLATION.......................................................................................................................................12
INSTALLATION‐ALIGNMENTPROCEDURE...........................................................................................15
INSTALLATON‐WIRING.........................................................................................................................19
INSTALLATON‐CONNECTIONSOFTHEANTENNABOX........................................................................21
INSTALLATON‐CONNECTIONSOFTHERELAYBOX..............................................................................22
INSTALLATON‐SEALINGOFTHEANTENNABOXLID............................................................................23
PUSHBUTTONS.....................................................................................................................................24
MENUSTRUCTURE................................................................................................................................24
ADJUSTMENTS&TESTOFPERFORMANCE...........................................................................................30
MAINTENANCE......................................................................................................................................30
TROUBLESHOOTING..............................................................................................................................31
IDENTIFICATION&SPAREPARTS..........................................................................................................34
REPLACEMENTOFPARTS&DISPOSAL..................................................................................................36
RECOMMENDEDSPAREPARTS.............................................................................................................36
CE‐CERTIFICATION.................................................................................................................................36
CONTACT...............................................................................................................................................36
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Appendix1:Frequencydataandworkingrange‐Countries
Appendix2:WARNING‐MAINSSYPPLY
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GENERAL–INTENDEDUSE
GIGASENSEIIisanAntiCollisionprotectionSystemdesignedforOverheadTravelling(EOT)
cranesorothermachineryrunningonacommonsetofrails.
Inthemostcommoncase,wheretwoEOT‐cranesonthesametrackbothneedtobe
protectedfromcollision,twounitsareneeded.Whenthecraneshouldbeprotectedfrom
runningintoawallortrackend,onecompleteunit(antennaandrelaybox)incombination
withoneunitconsistingofonlytheantennaandpowersupply(norelayboxisneeded)is
required.
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Theantennaismountedwiththecentreaxisinthedirectionofmovement,alwayspointing
towardstheoppositeantenna.Therelayboxismountedapartfromtheantenna,normally
nearbythecranecontrolfunctions.
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EachunitworksaccordingtotheSFCW(SteppedFrequencyContinuousWave)radar
principle,sensingtherelativespeedanddistancetothereflectingtransponderinthe
oppositeantenna.Byusingamodulated“fingerprint”reflectionintheoppositeantenna,the
systemisnotdisturbedbyundesiredechoesfromsurfacesonthecraneandothermetal
parts.
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Theantennaispoweredbytherelayboxanddatafromtheantennaiscontinuously
received,every128ms.Therelayboxhasthreepotentialfreerelaycontactoutputswhich
arecontrolledbyLimit1andLimit2forbrakingandstoppingthecranemovement.One
outputrelayisusedforinternalfaultmonitoring.Therelaysareheldactivebythe
electronicsandanyexceededlimitoralarmofthefunctionwillmakethemtrigger.Settings
andreadoutofparameters,areeasilyaccessibleviaadisplayandpushbuttonsintherelay
box.
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Internalfaultmonitoringiscarriedoutcontinuously.Iftheoppositeunitfailsoriftheunit
cannotdetectitbecausethepowerwasswitchedoff,themodulatedreflectionisstillactive
thankstoeachantennahavingabackupsupercapacitorforthemodulating“fingerprint”
reflection,andwillcontinuetoworkforapproximately6‐12hours(dependingon
temperature).Whenthebackupsupercapacitorrunsoutofpowerinoneunit,theopposite
unitstillsensesasignalfromthegirderorothermetalpartsofthecrane,whichwilltrigger
analarmtostopthecranemovement.
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GIGASENSEIIcontainsaMicrowavetransmitter.Althoughithasverylowoutputpower,this
systemmustconformtothelocalregulationssetupbytheTelecomAuthorityintheuser
country.Thisequipmentoperatesinthe9.4‐10.6GHzfrequencybands.Seeappendix1for
detailedinformation.
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CONSTRUCTION
Theantennaismadeofcast,stove‐enameledAluminumwhichcanbeseparated
intotwoparts,theReflectorandtheAntennabox(IP56).
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Therelayboxcontainsamicrocontroller,outputrelays,terminalconnections,displayand
pushbuttons.ThehousingisanIP66/67standardpolycarbonateenclosure.Theterminal
blockshaveeasyaccessbypushingascrewdrivertoconnectthewires.
SAFETYINFORMATIONANDWARNINGS
VERYIMPORTANT:
THEANTICOLLISIONSYSTEMGIIUNITAANDUNITBMUSTALWAYSHAVETHEPOWERTURNED
ON,EVENIFTHECRANEPOWERISSHUTOFF.
LIMIT1ANDLIMIT2WILLONLYWORKIFTHEUNITAANDUNITBAREPOWEREDON,THEBACKUP
SUPERCAPACITORISONLYINTENDEDTOWORKFORSHORTPOWERFAILURES.
CONNECTMAINSSUPPLYOFTHEANTICOLLISIONSYSTEMGIIBEFORETHEMAINCONTACTONTHE
CRANE.
Important:OneAntennaA‐unitmustalwaysworkwithanAntennaB‐unit.
TherelayboxescanbeusedwitheitherA‐unitsorB‐units.
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Payattentiontoturnoffallpowerbeforeopeningtheantennaandrelayunit.
Insomecertaincasesdescribedinthismanual,itisallowedtohavethelidopen
whilethesystemisworking,butconnectionstotherelaysMUSTbeisolatedor
disconnectedfromhazardousvoltage!
Itisonlyallowedtoopentheunitsinacontrolledenvironment,forexampleduring
installationandmaintenance.Acontrolledenvironmentiswhentemperatureis
between5°and40°C,andmax.relativehumidityis80%(upto31°C,decreasing
linearlyto50%at40°C).
Turnoffallpowerifanyworkistobedoneonthesystem.TheGIGASENSEIIis
poweredwith24VDC.
ReflectorRelayboxAntennabox

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Electrostaticdischarge(ESD)‐becarefulwhenopeningthelidsoftheantennabox
andtherelaybox
Microwaveradiation.Within5cmoftheantennaoutput,thepowerdensityofthe
microwaveradiationmayexceed10W/m2,butisnevermorethan20W/m2.
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.
AllexternalconnectionsfromthissystemmustonlybemadetoClassIII.
equipment/circuits.Onlytherelaysareallowedforconnectionsupto250VAC.
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alignment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.
Thelidsoftheantennaboxandtherelayboxmustnotbeopenedduringoperation.
Duringalignmentoftheantenna,itisallowedtohavethelidopen,ifthe0–5VDC
signalstrengthoutputisused.Whenadjusting,testingperformanceorloggingdata
fromtheRS232output,itisallowedtorunthesystemwithoutthelidoftherelay
box.NohazardousVoltageconnectionstotherelaysareallowed!
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.
SPECIFICATIONS
Typedesignation:GII.
Alarmlimits'distance:2‐50m,themaximumworkingrangevariesfordifferent
frequenciesfrom20mto50mbecauseofrestrictedoutputpower(EIRP),see
appendix1.
Accuracyoflimits:+/‐0,5m.
SamplefrequencyoftheSFCWradarmeasurement:128mS.
Speedrange:0.05‐10m/srelativespeedbetweenthecranes.
Speeddependence:Thealarmlimitscanbecompensated(0‐600%)accordingto
differentspeeds.
Relayoutputs:3switchingpotentialfreerelaycontacts(max.load250VAC/8A).
TheRelayoutputsareusedforbrakingandstoppingthecranemovementand
correspondtothealarmlimits,Limit1andLimit2.Onerelayoutputisusedforthe
failurealarm.
TheLimit1outputrelaycanbegivenapulsingfunctionsuitableforawarninglamp.

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Analogueoutput4‐20mA:forexamplearemotedisplay,correspondingtothe
distancebetweentheunits.4mA=2mand20mA=40m(maximumrange,see
appendix1).
SupplyVoltagecompletesystem:24VDC.
SupplyVoltageantennabox(shouldbepoweredviarelayunit):12VDC.
SupplyVoltageTransponderunit:12VDC.
PowerconsumptionAntenna/Transponderunit:200mA.
PowerconsumptionRelaybox:100mA.
Permittedambienttemperature:‐25...+70°C.
Degreeofprotection:IP66/67(Relayunit),IP56(Antennaunit).
Relativehumidity:10to80%(nocondensation).
Max.altitude:2000m.
Transmitterfrequency:Within9.4...10.6GHzbandwidth,seeappendix1.
RadiatedpowerdefinedasEIRP,seeappendix1.
SFCW(SteppedFrequencyContinuousWave)sweeprange,seeappendix1.
Dimensionsantenna(HxWxD)443x359x294mm&weight4.0kg.
Relaybox(HxWxD)175x125x75mm0.8kg.
GROSSWEIGHT/DIMENSION:1systemincl.packing(UnitA+UnitB)=
12.5kg/370x370x330mm.

Options:
Parametersettingprogram,tosetparametersanddownload/uploadparametersvia
aPC.CablewithMolexRS232connectionrequired.
Powersupplybox100‐240VAC(orotherrequiredvoltages).
TransponderUnitAorUnitB(cranetobeprotectedfromtrackendorwall).
TheTransponderUnitworksagainstanactiveunitwithrelaybox.


SAFETY&ENVIRONMENT
Avoidscraneaccidentsandprotectsproperty,productionandpeople.
DesignedtoworkinthetoughestconditionssuchasinSteelworks,Harbours,Mines
etc.
FailSafeoperationthankstosupervisionoffunction,bothinantennaboxandrelay
box.Theantennaunitissupervisedbyawatchdog.Therelayboxautomaticallyputs
thesysteminfailuremode(allthreerelaysinalarmposition)ifdataisnotreceived
fromtheantennabox.
Thesignalisveryhardtodisturb,theA‐andB‐unitsusedifferentfrequencies,
differentpolarizationoftheMicrowavesanda"fingerprint"radarreflection.The
"fingerprint"radarreflectionfunctionhasabackupsupercapacitorincaseofshort
powerfailures.
TheAntiCollisionSystemisnotdisturbedbyrain,dust/metalparticles,fogor
sunlight.
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FUNCTION–twomovingcranes
ByusingSFCW(SteppedFrequencyContinuousWave)radartechnique,thedistanceand
relativespeedarecalculated.

NOTICE!Themaximumworkingrangeisstatedas40minthefiguresbelow.Themaximum
workingrangevariesfordifferentfrequenciesfrom20mto50mbecauseofrestricted
outputpower(EIRP),seeappendix1.

Principleofthemodulatedsignal(fingerprint)reflectionintheGigasenseIIsystem:


Figure1A.UnitAtransmitsanunmodulatedMicrowavesignaltoUnitB.
Figure1B.UnitBmodulatestheMicrowavesignalandUnitAreceivesthemodulated
reflection.


Figure2A.UnitBtransmitsanunmodulatedMicrowavesignaltoUnitA.
Figure2B.UnitAmodulatestheMicrowavesignalandUnitBreceivesthemodulated
reflection.

TheUnitAandUnitBworkindependentlyofeachotherandcontinuouslytransmittheir
respectivesignals.Whentheunitsareinrangeforthemodulatedreflection,theLimit1and
Limit2willactivateatpresetalarmlimits.

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PrincipleoftheunmodulatedsignalreflectionintheGigasenseIIsystem:

Figure3A.UnitA(orUnitB)transmitsanunmodulatedMicrowavesignaltowardsthe
unidentifiedobject.
Figure3B.TheMicrowavesignalisreflectedunmodulatedbytheunidentifiedobjectand
receivedintheUnitA(orUnitB)whereittriggersanalarm.
Unmodulatedsignalreflectioncanoccurswhenanidentifiedobjectissuddenlydetectedin
frontoftheantenna,ifoneunit(AorB)malfunctionsorifunit(AorB)haspowerfailure
(thesupercapacitorisdischargedafterapprox.12hours)


DISTANCESOVER40METERS
(seeappendix1forworkingrangedetails)
Figure4.IfthedistancebetweenunitAandunitBisover40metersandnounidentified
objectispresent,unitAandunitBisinNOalarmstate.

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FUNCTION–onemovingcrane

Ifthereisonlyonemovingcranetobeprotectedfromrunningintoawalloratrackend,the
configurationwithonecompleteunitAandonetransponderunitBcanbeused.


Figure5A.UnitAisacompletesystemwithrelaybox.UnitAtransmitsanunmodulated
MicrowavesignaltoTransponderUnitB(norelayboxneeded).
Figure5B.TransponderUnitB(withoutrelaybox)modulatestheMicrowavesignal,UnitA
receivesthemodulatedreflection.
WhenunitAisintherangeforthemodulatedreflection,Limit1andLimit2willactivateat
presetlimits.


AntennaboxTransponderbox

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INSTALLATION

Thelocationandalignmentoftheantennasisimportant,thelocationoftheRelayboxesis
notcritical.Theantennasmustbeplacedoppositeofeachother.Thereflectorhasthree
fittingholessuitedfor8mmbolts(notincludedindelivery).

Agoodlocationisoftenthebarrierofaplatformoraladder,thebarrierofthegirderetc.
providedthattheyarerigidandnotresonantwhenthecranemoves.

Forcorrectdetectionoftheunmodulatedsignalreflection(incaseoferrorinoneunit),it
isnecessarytohaveasurfaceofmetalwithminimum1m²behindtheantennas.Aplateof
1m²orlargercanbeinstalledbehindtheantennas,ifthelocationoftheinstallationdo
nothaveenoughsurfaceofmetalbehindtheantennas.Seefigurebelow.

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Tohaveeasyaccesstotheantennaboxisalsorecommended.
Theantennasaretobemountedwiththeirmain‐beamaxisparalleltothecranetravelling
directionandfreefromotherfixedormovingobjectswithinaradiusof1,5mfromthemain‐
beamaxiscentre.
Themovingtrolleyortrolleycablesmustnotcrosstheantennabeam.


1,5mfreespacearoundtheantennasisnecessary,bothatthelocationforinstallationand
alongthecranetravellingtrack,togetcorrecttransmitting/receivingofthemicrowaves.
Seefigurebelow.





Itissuitabletohavethecranesclosetoeachotherwheninstallingtheantennas.Toadjust
thealignmentoftheantennas,washersornutscanbeusedonthebacksideofthereflector
(mountedonthethree8mmbolts).Alaserwaterlevelpointerisagoodtooltohelpupthe
alignment.
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
Toolsforthealignmentprocedure:
‐Alaserwaterlevelpointer
‐Aquickgriptool







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




Dimensionsoftheantenna:
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INSTALLATION‐ALIGNMENTPROCEDURE


REFLECTORno.1:



Step1(reflectorno.1)

Fitthereflectorno.1onthecranewiththree8mm
bolts.Useawaterlevelindicatortoalignthe
reflector(seefigure1).








Step2(reflectorno.1)

Usetwooftheassemblyhexscrews(intendedfortheantennabox)mountedonthe
reflectorno.1tosupportandalignthelaserwaterlevelpointer(seefigure2).

Checkthealignmentofthereflectorno.1.Usewashersoradjustthenutsifneededtoalign
correctly(seefigure3).

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

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Figure1
Figure3
Figure2

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Step3(reflectorno.1)
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FitapieceofwhiteA4papersheetontheothercrane(oronthewallifatransponderunitis
used),indicatingthelaserpointfromthelaserwaterlevelpointerinthemiddle.

RunthecranesapartfromeachotherandcheckthatthelaserpointstayswithintheA4
papersheet.Add/removewashersoradjustthenutstoalignreflectorno.1ifneeded.

Donotremovethelaserwaterlevelpointerfromreflectorno.1yet!
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REFLECTORno.2:
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Step4(reflectorno.2)
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Runtheoppositecraneclosetothecranewith
theinstalledreflectorno.1.

Installthereflectorno.2intheposition
indicatedfromthelaserwaterlevelpointer
(fittedonreflectorno.1).seefigure4.
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Step5(reflectorno.2)

Usethewaterlevelindicatortoalignreflectorno.2
(seefigure5).
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
Figure4
Figure5

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Step6(reflectorno.2)
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Usetwooftheassemblyhexscrews(intendedfortheantennabox)mountedonthe
reflectorno.2tosupportandalignthelaserwaterlevelpointer(seefigure6).

Checkthealignmentofthereflectorno.2.Usewashersoradjustthenutsifneededtoalign
correctly(seefigure7).
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Step7(reflectorno.2)

Runthecranesapartfromeachotherandcheckthatthelaserpointstaysintheareaofthe
oppositereflectorno1.

Add/removewashersoradjustthenutstoalignthereflectorno.2ifneeded.

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Step8Finalalignmentofthereflectorstoachievethestrongestpossiblesignal
ThisisaVERYIMPORTANTstep!

Applyawasher(thickness1mm)ontheleftassemblypointofreflectorno.1andreflector
no.2,alternativelyadjustthenutontheleftassemblypoint1mm.(seefigure8)

TheMicrowavespreadisslightlytotheleftwhenthe
reflectorsarepointedstraightinlinetoeachother.
Toachievethestrongestpossiblesignalandtomaintainthe
signalifthecranesareturningslightlyalongtherails,the
reflectorsshouldbealignedabout1,5degreestotheright.

Seefigure9and10,showingtheMicrowavespread.

Figure7
Figure8
Figure6

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MicrowavetransmittingspreadfromA‐unittoB‐UnitandfromB‐UnittoA‐Unitwitha1mm
washerassembled(seefigure9).

MicrowavetransmittingspreadfromA‐unittoB‐UnitandfromB‐UnittoA‐Unitwithout
a1mmwasherassembled(seefigure10).
Figure9
Figure10

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INSTALLATON‐WIRING

TURNOFFTHEPOWERSUPPLY(MAINSSUPPLY)BEFOREWIRING.
WIRINGISONLYALLOWEDTOBEPERFORMEDINACONTROLLEDENVIRONMENTANDBY
AUTHORIZEDPERSONNEL.

Connectionofthecablebetweentheantennaunitandtherelaybox
Usea4wirecable0,5mm2(striplength8‐9mm),outerØ5‐9mmmax.length30meters.
Minimumratedtemperatureshouldbe80°C.(CableisnotsuppliedbyGigasenseAB).
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The4wirecableisroutedviaametalcableglandthroughthesideoftheantennabox.
Connectthe4‐wireshieldedcabletotheterminalsinsidetheantennabox(seechapter
"Connectionsoftheantennabox").Thecableshieldmustbeconnectedtothecableglandin
theantennaboxinordertofollowtheEMC(ElectroMagneticCompatibility)regulations.

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Cable gland with shield connection
Mountandsecurethecabletotherelayboxandconnectittoterminalsintherelaybox(see
chapter"Connectionsoftherelaybox").
Thecableshieldmustbeconnectedtothecableglandintheantennabox.
TherelayoutputscanbeconnectedinNormallyOpen(NO)contactsorNormallyClosed
(NC),contactsdependingontypeofcrane,seenoteintheconnectionsfortherelaybox.

INSTALLATON‐POWERSUPPLY

VERYIMPORTANT:
THEANTICOLLISIONSYSTEMGIIUNITAANDUNITBMUSTALWAYSHAVETHEPOWERTURNED
ON,EVENIFTHECRANEPOWERISSHUTOFF.
LIMIT1ANDLIMIT2WILLONLYWORKIFTHEUNITAANDUNITBAREPOWEREDON,THEBACKUP
SUPERCAPACITORISONLYINTENDEDTOWORKFORSHORTPOWERFAILURES.
CONNECTMAINSSUPPLYOFTHEANTICOLLISIONSYSTEMGIIBEFORETHEMAINCONTACTONTHE
CRANE.
Thepowersupplyshouldincludeanall‐poleswitchaccordingtolocalregulationsfor
disconnectionofthepowersupply.Itmustbesuitablylocatedandeasilyreached.Markitas
"Disconnectingdevice"forthisequipment.
Mainssupplycordshallbea2X0,75mm2cablewithouterdiameterØ5‐9mmanditmust
meettherequirementsofIEC60227orIEC60245.Minimumratedtemperatureshallbe
80°C.Green/Yellowcoloursshouldnotbeused.

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