Safeaid TS7000 User manual

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I Page 1
TS7000
MATERIAL HANDLER OPERATORS MANUAL
VERSION I
7/20/2020

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I
Page 2
THE PURPOSE OF THIS MANUAL IS TO PROVIDE THE CUSTOMER WITH THE OPERATING
PROCEDURES ESSENTIAL FOR THE PROMOTION OF PROPER MACHINE OPERATION FOR
ITS INTENDED USE. THE IMPORTANCE OF PROPER USAGE CANNOT BE OVERSTRESSED.
ALL INFORMATION IN THIS MANUAL SHOULD BE READ AND UNDERSTOOD BEFORE ANY
ATTEMPT IS MADE TO OPERATE THE MACHINE.
SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION
AND OPERATION, CONFORMANCE WITH GOOD SAFETY PRACTICE IN THIS AREA IS THE
RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL.
ALL PROCEDURES ARE BASED ON THE USE OF THE SYSTEM UNDER PROPER OPERATING
CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND
OR MODIFICATION OF THE EQUIPMENT IS STRICTLY FORBIDDEN WITHOUT PRIOR
WRITTEN APPROVAL FROM ELEC-MECH (PTY) LTD.
THE SAFE-AID TS7000 (RATED CAPACITY INDICATOR (RCI)/LOAD MOMENT INDICATOR
(LMI)) IS ONLY TO BE REGARDED AS AN AID TO THE OPERATOR. WHEN THE
PARAMETERS ARE SET CORRECTLY, THE INDICATOR WILL WARN THE MACHINE
OPERATOR OF AN APPROACHING OVERLOAD CONDITION OR A CONDITION THAT COULD
CAUSE DAMAGE TO EQUIPMENT, PROPERTY, AND/OR INJURY TO THE OPERATOR OR
THE SITE WORKERS IN THE VICINITY OF THE MACHINE AND ITS LOAD.
THIS SYSTEM UNDER NO CIRCUMSTANCES MUST BE USED AS A SUBSTITUTE FOR THE
GOOD JUDGEMENT OF A MACHINE OPERATOR WHEN CARRYING OUT APPROVED
MACHINE-OPERATING PROCEDURES, THEREFORE THE RESPONSIBILITY FOR THE SAFE
OPERATION OF THE MACHINE LIES WITH THE MACHINE OPERATOR. THE SYSTEM WILL
NOT NECESSARILY PREVENT DAMAGE DUE TO OVERLOADING AND RELATED CAUSES,
IF NOT SET PROPERLY.
BEFORE OPERATING A MACHINE EQUIPPED WITH A SAFE-AID TS7000 RCI, THE
OPERATOR MUST READ THE INFORMATION IN THIS MANUAL CAREFULLY. CORRECT
FUCTIONING OF THE SYSTEM DEPENDS UPON ROUTINE DAILY INSPECTION AND ANY
SUSPECTED FAULTS OR APPARENT DAMAGE SHOULD BE IMMEDIATELY REPORTED TO
THE RESPONSIBLE PERSON BEFORE USING THE MACHINE.

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I Page 3
Contents
SYSTEM USE ....................................................................................................................................... 4
SYSTEM STARTUP – FIGURE 2 & 3 ................................................................................................ 5
MACHINE CONFIGURATION SELECTION .................................................................................... 6
OPERATING SCREENS – FIGURE 4 & 5 .......................................................................................... 6
ERROR MESSAGES - FIGURE 6 AND TABLE 1 ............................................................................. 9
SAFE-AID TS7000 SYSTEM ERROR TABLE – TABLE #1 ........................................................... 10
WORKING OPERATIONS – FIGURE 7 ........................................................................................... 12
INDICATING STATUS LIGHTS AND DUMP OUTPUT (LEVER CUT-OFF) – TABLE # 2....... 14
TOUCH SCREEN CALIBRATION – FIGURES 8, 9 & 10............................................................... 16
SCREEN BRIGHTNESS – FIGURES 11 & 12 .................................................................................. 18
SET DATE & TIME – FIGURES 13 & 14 ......................................................................................... 19
KEYSWITCH OVERRIDE – FIGURE 15 ......................................................................................... 20
FUSES – FIGURE 16 .......................................................................................................................... 20
INSTALLATION DETAILS ............................................................................................................... 21

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I Page 4
SYSTEM USE
The TS7000 unit is designed with ease of operation in mind. The machine setup is automatic
or selected and confirmed by the operator before the system goes into its normal
operating/monitoring screen, requiring no further input from the operator unless the machine
configuration is changed, and a manual setup is required. Before this is done the machine
will remain in safe mode, i.e. the dump circuit (cut-off) will be operational (if the machine has
a dump system fitted). All inputs to the system are done by the operator via the touch screen
including the buzzer override function and momentary bypass. The touch screen is sensitive
to touch therefore it is not necessary to push hard on the screen (if touch screen does not
work or selects incorrectly see Touch Screen Calibration).
Figure 1

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I
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SYSTEM STARTUP – FIGURE 2 & 3
The TS7000 display (LMI) will automatically come on when you switch the machine on, and
the buzzer will sound once. The system will run a CRC (cyclic redundancy check) to make
sure that all raw data is correct.
Once the system has completed the CRC the buzzer will sound again and a set of internal
diagnostics (watchdogs) will be utilised to verify that all inputs and outputs are working
correctly.
Figure 2 Figure 3

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I Page 6
MACHINE CONFIGURATION SELECTION
The system will now run through a series of selections to establish the current machine
configuration. These selections are setup by the machine manufacturer and correspond to
the relevant load chart and are not necessarily displayed in the same order as laid out in this
manual. These checks can be automatic or user selectable if automatic no input is required
by the operator as the system users machine inputs and logic to determine the correct
configuration.
If operator selectable use the back button to start the complete selection from
the beginning at any time.
OPERATING SCREENS – FIGURE 4 & 5
All the machine and system information can be viewed from here including all the parameters
selected from power up. On manual setup if a different configuration is required, press the
machine graphic on the screen, the system will go back to the beginning as on system start
up. Repeat the selection steps.
Figure 4 Figure 5
In operating mode, you can see all the current parameters of the machine.

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Under Carriage: This is the current under carriage and can be represented by the following:
 outrigger picture with the outrigger length
 or picture of a tyre with the crane travel speed or description
 Tracks with extended or retracted measurement
Radius: This is the measurement from the centre
line of rotation to the end of the stick.
Radius: This is measurement from the ground to the end of the stick.
Lifted Load: This is the load on the hook at the present time, if the green
light and the load are flashing it is a tare load (the tare has been pressed).
Rated Capacity: This is the load allowed to be picked up with the selected
configuration at the current radius and height as specified by the manufacturer.
Boom Angle: This displays the boom angle.
Stick Angle: This displays the stick angle.
Utilisation: Percentage utilisation is the percentage of rated load used by
the current lifted load.
Date & Time: This is the current date and time.

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I Page 8
Utilisation Bar: The percentage utilisation is also displayed graphically by a bar graph,
going from green (0% - 89%), then amber (90% - 99%) and finally red (100% and above)
increasing incrementally with the percentage utilisation.
Area Selection: This is not user selectable and shows the current area the crane is working
in:
360 Degrees Over Side & Rear Direct over front
Direct Over Rear Direct Over Front & Rear Over Side
Over Front and Side Over Front Outrigger to Outrigger Over Rear Outrigger to
Outrigger
Level/Tilt: The cross through the area selection represents the X & Y axis
while the two lines in the axis are the positioning of the crane (see Tilt or Level setup).
Area Selection Potentiometer: The black dot in the perimeter circle
represents the position of the boom relative to the carrier.

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ERROR MESSAGES - FIGURE 6 AND TABLE 1
The TS7000 will sound a buzzer and the green block will be replaced by an orange or red
block at the top of the screen if any error occurs on the system. These errors are displayed
at the bottom of the screen as either an error code only or the error description with the error
code e.g. Anti-2-Block E002 where program selection is normally displayed. If more than one
error occurs the errors will scroll on the bottom until rectified.
Figure 6
For all the errors, we have given an indication of the problem and the common
solution to the problem. These can be done by the operator or an individual who
has some basic crane knowledge. If the given solution does not work, please
contact the original installer or someone from our service network where we can
try and help telephonically or send a technician to repair the system.

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I Page 10
SAFE-AID TS7000 SYSTEM ERROR TABLE – TABLE #1
CODE SCREEN DISPLAY INDICATION OPERATOR SOLUTION
E001 Slew Error Boom is not over an area covered by the current
configuration selected.
Slew the boom into a safe working area.
E004 90% Overload The lifted load is greater than or equal to 90% of the
rated capacity
Move load into safe working position -
winch down, boom up or retract boom.
E005 Overload The lifted load is greater than or equal to 100% of the
rated capacity
Move load into safe working position -
winch down, boom up or retract boom.
E008 Low Angle The angle of the boom is below the crane manufacturer's
minimum specification. Raise boom.
E027 Main A400 No Coms No communication between main angle board and
motherboard/display. Call installer or service technician.
E028 Aux A400 No Coms No communication between auxiliary angle board and
motherboard/display. Call installer or service technician.
E029 M400 No Coms
No communication between mother board and display.
Call installer or service technician.
E033 R400 No Coms No communication between relay board and
motherboard/display. Call installer or service technician.
E034 No Load Chart Data You are working out of the manufactures specified
working range – incorrect working radius
Lower Boom to within the manufacturers
specified working range.
E035 No Moment Value Pressure Error No empty and loaded moment data at
specific length and angle.
E036 Tilt Error X Axis Crane has tilted over maximum allowed tilt on the X axis
(Left & right of carrier) Level crane to within specified tilt range.
E037 Tilt Error Y Axis Crane has tilted over maximum allowed tilt on the Y axis
(Front & rear of carrier) Level crane to within specified tilt range.
E040 A400 Tilt No Coms No communication between A400 Tilt board and
motherboard/display. Call installer or service technician.
E045 Main Dump Short Circuit Short circuit on the Main Dump Output. Call installer or service technician.

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I Page 11
CODE SCREEN DISPLAY INDICATION OPERATOR SOLUTION
E046 Main Dump Open Circuit Open circuit on the Main Dump Output. Call installer or service technician.
E053 No Dump Supply No supply (power or ground) on the selected dump
supply. Check 5A dump fuse.
E054 Keyswitch Override –
High Side
Override Key has been turned to the override position -
key cannot be removed from the switch
Turn override key to position where key can
be removed.
E055 Keyswitch Override –
Low side
Override Key has been turned to the override position -
key cannot be removed from the switch
Turn override key to position where key can
be removed.
E064 Slew Disabled Slew function disabled – No slewing allowed in the
selected program
Select correct program either manually or
for automatic make sure machine is setup
correct
E065 P/Tdx Bottom Error Bottom pressure transducer reading below 3.75mA –
5400 - 5410 counts. Call installer or service technician.
E066 P/Tdx Top Error Top pressure transducer reading below 3.75mA – 5400 -
5410 counts. Call installer or service technician

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I Page 12
WORKING OPERATIONS – FIGURE 7
There are SEVEN different areas/places on the operating screen which can be pressed
to initiate a function.
1. Configuration selection is the machine graphic on the screen. If at any given
time, the current configuration needs to be changed, press on the graphic and this will
return to the first selection as if powering up for the first time. This option is disabled
if automatic selection is configured.
2. The buzzer override which is in the bottom centre of the screen; buzzer
override will only be displayed 5 seconds after an error condition occurs. When the
buzzer override is pressed, a red cross will be placed through the picture of the buzzer
and the buzzer will shut off.
The buzzer override is needed for each alarm condition i.e. if one error has
been overridden and another error occurs the buzzer will sound again.
3. The Tare which is activated by pressing directly on the lifted load
when a load is displaying on the hook. The Lifted Load will be zeroed allowing for a
reading excluding the original weight. The original weight is still considered when
calculating the percentage of utilisation therefore the TS7000 will still give the correct
90% and 100% warnings. Once pressed, the numbers under the lifted load will flash
showing no value, only 0,0t and the GREEN LED will flash intermittently. Thereafter,
if a weight is lifted, only the weight lifted will be displayed and not the weight together
with hook block or any other additional weight. To return to the actual load, press the
lifted load again, it will stop flashing showing the actual load on the hook.
4. The momentary override which is the utilisation bar graph on the screen. By
holding your finger anywhere in this area, the dump solenoids (lever cut-off) can be
overridden momentarily (while pushing on the screen in that area).
5. Password Access - This is accessed by pressing the top left-hand corner. Once
pressed a password screen will be displayed, enter the relevant password to access
the required menu. To exit and return to the operator’s screen press Enter button.
Screen Brightness & Set Date & Time access is accessed from this menu.

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6. Wind Speed – Press on the wind speed block to enter the wind speed
setup (see Optional Wind Speed Setup).
7. Press on the level the following option is to determine the machine level
along the X & Y axis. Press the button to return to main working screen.
Figure 7
Note: Function 1, 4, 6 & 7 can only be used activated by the
programmer/installer.

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I Page 14
INDICATING STATUS LIGHTS AND DUMP OUTPUT (LEVER CUT-OFF) –
TABLE # 2
There are Three BLOCKS (RED, YELLOW & GREEN) that are illuminated like a traffic robot
situated on the top of the display screen.
These BLOCKS are illuminated depending on the working state and error conditions. These
BLOCKS are a basic way of checking the LMI.
The following chart gives you the BLOCK status, buzzer status as well as the status of the
DUMP (Lever Cut-off). DUMP the crane will cut-out and NO DUMP you are able to work. To
rectify or check the error, please check the error message chart (Table 1).
The GREEN BLOCK will be permanently on when the system is in the correct working
condition i.e. no errors
CODE SCREEN DISPLAY BLOCK
STATUS
DUMP
STATUS
BUZZER
STATUS
E001 Slew Error RED ON ON
E004 90% Overload YELLOW OFF INTERMITTENT
E005 Overload RED ON ON
E008 Low Angle RED ON ON
E027 Main A400 No Coms RED ON ON
E028 Aux A400 No Coms RED ON ON
E029 M400 No Coms RED ON ON
E033 R400 No Coms RED ON ON
E034 No Load Chart Data RED OFF ON
E035 No Moment Value RED ON ON
E036 Tilt Error X Axis RED ON ON
E037 Tilt Error Y Axis RED ON ON
E040 A400 Tilt No Coms RED ON ON
E045 Main Dump Short Circuit RED ON ON

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I Page 15
CODE SCREEN DISPLAY BLOCK
STATUS
DUMP
STATUS
BUZZER
STATUS
E046 Main Dump Open Circuit RED ON ON
E053 No Dump Supply RED ON ON
E054 Keyswitch Override – High
Side RED ON ON
E055 Keyswitch Override – Low
side RED ON ON
E064 Slew Disabled GREEN SLEW NONE
E065 P/Tdx Bottom Error RED ON ON
E066 P/Tdx Top Error RED ON ON
NOTES:
 The GREEN BLOCK will flash when TARE function is used, and the machine is within
the limits specified by the manufacturer.
 Errors will only be displayed if the equipment is installed e.g. no A-2-B error can occur
if no winch is fitted

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TOUCH SCREEN CALIBRATION – FIGURES 8, 9 & 10
If the touch screen is not responding correctly to touch, the touch screen may need to
be calibrated.
Switch the TS7000 system power off then power up the TS7000 and wait for the splash
screen (Figure 8) to appear.
Figure 8
While the splash screen is on, press and hold the screen for five full seconds in the centre
until the touch calibration is activated and loaded (Figure 9). Lift finger when prompted.

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Figure 9 Figure 10
If the calibration screen has been entered by accident and touch calibration is not necessary,
press the Exit button without pushing anywhere else on the screen. This process exits the
touch screen calibration and continues with the standard start up procedure.
If touch calibration is required, follow the below procedures:
Press and hold finger where the two lines meet inside the small box (Figure 10 bottom left
hand corner). Calibration works fine when using a finger but for better results use a pen taking
care not to press too hard or the screen will be damaged.
Hold finger/pen in this area until prompted to lift (Figure 9). The software will then prompt for
three more touch zones resulting in co-ordinates for all four corners of the screen.
Once calibration is complete the software automatically begins the standard start up
procedure.

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SCREEN BRIGHTNESS – FIGURES 11 & 12
The screen backlight can be set as required.
Use the following steps to adjust the screen brightness:
1. Press the top left-hand corner and the Password screen will be displayed (figure 11).
2. Press the and the Brightness adjust screen (figure 12) will be displayed. Use
the slider bar to adjust the screen to the required brightness.
3. Once the brightness has been adjusted press the button to return to the
operating screen.
Figure 11 Figure 12

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I
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SET DATE & TIME – FIGURES 13 & 14
The date and time can be adjusted as required, if the date and time does not save the battery
for the real time clock is no longer working (see Real Time Clock battery replacement).
Use the following steps to adjust the date & time:
1. Press the top left-hand corner and the Password screen will be displayed (figure 13).
Figure 13 Figure 14
2. Press the and the Set Date & Time screen (figure 14) will be displayed.
Select the data to be adjusted and set the correct time and date.
3. Time format is 24 Hour Clock hh : mm : ss
4. Date format is dd / mm / yyyy
5. Once the time & date have been adjusted press the button to return to the
operating screen.

TS7000 MATERIAL HANDLER OPERATORS MANUAL - VERSION I
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KEYSWITCH OVERRIDE – FIGURE 15
Figure 15
The Override Keyswitch is located on the right side of the M400 Motherboard box. The key
can be removed when the override is not engaged once the override is engaged the key
cannot be removed and the display will show Keyswitch Override E05 or E055
This switch is used to override the cut out so should only be done under supervision
as a last resort.
FUSES – FIGURE 16
All the outputs and the voltage in are protected by standard blade fuses.
Figure 16
1. 2 Amp Main System Fuse
2. 5 Amp Keyswitch Override Fuse
3. 5 Amp Dump Fuse
4. 5 Amp Relay #2 Fuse
5. 5 Amp Relay #3 Fuse
6. 5 Amp Relay #4 Fuse