LMS Edgevision – V 2.2.

LOAD MANAGEMENT SYSTEM

EDGEVISION

Versione 2.2.x
3004.964511

OPERATOR MANUAL

CS7.5 STACKERS

Index
1. Introduction.......................................................................................................................2
2. Front panel description ..................................................................................................2
3. Front panel keys use .......................................................................................................3
4. Basic sensor and system test ........................................................................................4
5. Safeties ...............................................................................................................................5
6. Inserting bypass codes ...................................................................................................5
7. Operator Messages ..........................................................................................................6
8. Warning lights panel ......................................................................................................7

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 LMS Edgevision – V 2.2.x

1. Introduction
LMS (Load Management System) Edgevision – has following features:

• Measurement and visualization of operator’s most important machine parameters for normal
machine handling.

• Boom movements interlock in case of overload or other dangerous conditions.

• Malfunction black box: all sensors malfunctions, overloads and bypass use are stored in a
permanent memory

• Operative black box: all information of containers moved is stored into a permanent memory

• Test of all signals connected to the system.

2. Front panel description

1. Weight lifted, in tons

2. Weight maximum allowed, in tons
3. Load center distance (from front wheel to spreader center) in meters
4. Twist Lock height to ground, in meters
5. Boom length, in meters
6. Boom angle, in degrees
7. Twist Lock status (locked, unlocked, seated)
8. Machine stability histogram (full means overload)
9. Date and time
10. Alarm and warning messages to operator

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3. Front panel keys use

Information regarding the software installed and system type (exit with F4)

Sensors test page (see paragraph 4). Exit with F4

It shows the total container number ever lifted by the machine. Exit with F4

Increases LCD contrast

Decreases LCD contrast

Bypass entering codes page. It is like the BYPASS key in the external keyboard

“Enter” key: used to confirm bypass code inserted by operator

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4. Basic sensors and system test

1) Angle sensor value, expressed in milliampere (mA) and degrees.

2) Boom length sensor value, in mA and meters.
3) Load cell left value, in mA and quintals.
4) Load cell right value, in mA and quintals.
5) Twist lock sensors status (unlocked, locked, seated). 0 means open, 1 means closed.
6) from left to right:
Overload safety: 1 movements enabled, 0 movements locked (except retraction)
Minimum distance safety: 1 boom up-in locked, 0 movements enabled
Stabilizers safety: 1 stabilizers lifting locked, 0 stabilizers free
7) from left to right:
High boom speed: 1 high speed enabled, 0 normal speed enabled
Engine RPM
High angle safety: 1 lifting locked, 0 lifting enabled.

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5. Safeties

Safety Active when Effect Bypass with

Actual weight is All boom movements Key on the lower
Overload control bigger than maximum except retraction are panel or bypass code
allowed locked
Minimum distance Distance is lower Boom lifting and Key on the lower
than limit (usually 0 retraction are locked panel or bypass code
mt)
High Angle Boom angle is over Boom lifting is locked Bypass code
the limit set.
Stabilizers control Machine is not safe Stabilizers lifting is Key on the lower
without stabilizers locked panel

In case of alarms, LMS will sound a buzzer with a frequency depending on the alarm number (each
alarm corresponds to a “beep” per second).
It is possible to bypass alarm sound with the bypass code 4444. The bypass use will be stored in the
black box.

6. Inserting bypass codes

Pressing the key on the panel the system shoes this screen:

Pressing the keys from F1 to F4 each digit increases by one unit, from 0 to 9, in order to compose a
4 digits number.

Confirm the final code with the key

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7. Operator Messages

Cod. Message Meaning

1 overload Overload control active

2 bypass key The key on the panel has been activated to bypass safeties

3 bypass min dist The bypass code to override minimum distance safety has
been inserted
4 bypass max angle The bypass code to override high angle safety has been
inserted
5 bypass overload The bypass code to override overload control has been
inserted
6 bypass buzzer The bypass code to override alarms buzzer has been inserted

7 Invalid calibration Memory reported a fault in the calibration. Restart the

system and, if not solved, reset the system and repeat all
calibrations.
9 angle fault The inclinometer sensor is fault or not connected

10 length fault The cable reel sensor is fault or not connected

11 load cell left fault Load cell left sensor is fault or not connected

12 load cell right fault Load cell right sensor is fault or not connected

14 minimum distance Minimum distance safety is active

15 angle over limit High angle safety is active

16 load not calibrated The load is not calibrated or the calibration is lost. Follow
instructions on assistance manual.
17 approaching overload Actual weight is close to the maximum allowed (pre-alarm)

18 high speed disabled There are not the right conditions for high boom speed.

19 angle not calibrated The boom angle calibration is lost. Follow instructions on
assistance manual.
20 length not calibrated The boom length calibration is lost. Follow instructions on
assistance manual.

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8. Warning lights panel

Red lights indicate an alarm condition, the others are for normal operations.

1) High beam lights on

2) Side lights on
3) Direction lights on
4) Low battery recharging by alternator
5) Parking brake inserted
6) Preheating diesel engine
7) Transmission in neutral position
8) Hydraulic oil filter clogged
9) Low engine oil pressure
10) Air filter clogged
11) Connectors for serial ports and external keypad
12) Key for safeties override

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ASSISTANCE MANUAL

ATTENTION

This manual part is reserved to technical assistance, and it is important for LMS calibrations and
troubleshooting.
An incorrect calibration affects seriously machine safety.
In order to increase the safety, all calibrations procedure can be done only using and external and
removable keyboard, that allows to access to system’s menu.

This keyboard must never be left in the operator cab.

The operator is the sole responsible for machine handling.

Bypass codes diffusion is exclusive responsibility of maintenance supervisors.

An improper use of bypass codes makes possible the machine use under unsafe conditions.
The manufacturer will not be responsible for that.
Every safety override will be stored in the system black box.

CODES:

Overload safety bypass: 1234

Minimum distance safety bypass: 2468
High angle safety bypass: 3579
Buzzer alarm bypass: 4444
Black box erasing: 6666
System reset: 9090

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Index

1. External keyboard .......................................................................................................................... 10

2. Menu navigation ............................................................................................................................. 11
3. Angle calibration............................................................................................................................. 12
4. Length calibration ........................................................................................................................... 13
5. Load calibration .............................................................................................................................. 13
6. Reference loads ............................................................................................................................. 14
7. RPM Calibration ............................................................................................................................. 14
8. Machine Geometry ......................................................................................................................... 15
8.1 Set min/max angle.......................................................................................................................... 15
8.2 Set min/max length......................................................................................................................... 15
8.3 Distance, top boom and height ...................................................................................................... 16
8.4 Set RPM ......................................................................................................................................... 16
9. Safeties........................................................................................................................................... 17
10. Alarms ............................................................................................................................................ 17
11. Parameters ..................................................................................................................................... 17
12. Date-Time....................................................................................................................................... 18
13. Data Transmission ......................................................................................................................... 18
13.1 Print calibrations ............................................................................................................................. 18
13.2 Receive calibrations ....................................................................................................................... 19
13.3 Transmit calibrations ...................................................................................................................... 19
13.4 Receive capacity charts ................................................................................................................. 19
14. System Reset ................................................................................................................................. 19
15. System Test ................................................................................................................................... 20
15.1 Analog inputs test........................................................................................................................... 20
15.2 Test digital inputs ........................................................................................................................... 21
15.3 Set digital outputs........................................................................................................................... 21
15.4 Test digital outputs ......................................................................................................................... 22
15.5 Test rpm inputs............................................................................................................................... 22
16. Operative Black Box....................................................................................................................... 22
16.1 View operative black box................................................................................................................ 22
16.2 Erase operative black box .............................................................................................................. 23
16.3 Print operative black box ................................................................................................................ 23
17. Alarms Black Box ........................................................................................................................... 23
17.1 View alarms black box.................................................................................................................... 23
17.2 Erase alarms black box .................................................................................................................. 23
17.3 Print alarms black box .................................................................................................................... 23
18. Language ....................................................................................................................................... 24
19. Information ..................................................................................................................................... 24
APPENDIX 1: Null-Modem Cable Schematic ............................................................................................. 25
APPENDIX 2: LMS System Installation ...................................................................................................... 25
APPENDIX 3: Pin-out connectors ............................................................................................................... 26

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1. External keyboard

These are most common functions:

• Arrows are used to scroll through menu items and to select the fields where to insert
numerical values.
• ENTER key confirms new insertions
• F1-F2-F3-F4 have the same functions of the front panel keys.
Inside menus and editing forms, they can assume different meaning, that is always explained
graphically on the screen. F4 is also used to exit from menus.

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2. Menu navigation
This the menu tree under the MENU key:

0. calibrations
0. sensor calibration
0. angle calibration
1. length calibration
2. load calibration
3. reference loads
4. rpm calibration
0. machine geometry
0. set angle min/max
1. set length min/max
2. distance, top boom, height
3. set rpm
2. safeties
3. alarms
4. parameters
5. date - time
6. data transmission
0. print calibrations
1. receive calibrations
2. send calibrations
3. receive capacity chart
7. system reset
1. system test
0. analog inputs test
1. digital inputs test
2. set digital outputs
3. digital outputs test
4. rpm inputs test
2. operative black box
0. view operative black box
1. erase operative black box
2. print operative black box
3. alarms black box
0. view alarms black box
1. erase alarms black box
2. print alarms black box
4. language
5. about

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To access to the different items it is possible:

• using the arrows keys and selecting the right item. Confirm with ENTER key
• using the numbers of the item (for example selecting the option “set angle min/max” can be
done pressing the keys: MENU-0-1-0)

DEL key goes back one menu level, F4 goes back to the main screen directly.

3. Angle calibration
From main screen: MENU - 0 - 0 - 0.

Min and max sensor value at 0 deg and 60.8

deg as stored in the last calibration.
Inclinometer sensor current value in real time

angle calibration 12,9 mA

min angle: 5.08 mA 0 deg

max angle: 14.56 mA 60,8 deg

Real minimum and maximum machine boom

It is done as follows: angles as stated in the menu “Machine
• Move boom at minimum and press F1 Geometry”
• Move boom at 60.8° (maximum possible) and press F2
• Press F3 to store the new calibration

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4. Length calibration
From main screen: MENU - 0 - 0 – 1.

Length calibration 11,9 mA

Length min: 18,40 mA 8.66 mt

Length max: 4.16 mA 15.37 mt

See “angle calibration” for an explanation of the different items.

Procedure:
• Move boom at minimum length and press F1
• Move boom at maximum possible length and press F2
• Press F3 to store the new calibration
NOTE:
On CS7.5 machine boom can’t be extended completely for low angles even if empty. During
calibration, no boom control is made, so keep angle high during this calibration.

5. Load calibration
From main screen: MENU - 0 – 0 - 2.
The weight is calculated measuring the sum of the currents supplied by the two load cells.
So, it is necessary to calibrate these sensors with the spreader empty and with one reference load,
whose weight must be known.
For a good calibration, the selected weight must be closest possible to the machine maximum
capacity.
The real container weight must be set in the screen “reference loads” (see next paragraph), before
this calibration.

load cells: 10.4 12.5 mA

min: 30.2 0.00
max: 14.7 8.00

F1 min F2 max F3 OK F4 Exit

Procedure:
• With empty and centered spreader, check the load cells currents: they must be about the same.
If not, adjust the trimmer in the load cell amplifiers (located close to the load cell pin).
• Once currents are set, press F1 to store the value.
• Lock and lift the reference container (8 tons in the example) up to 20-30 degrees; wait for
currents stabilization (side shift the spreader to center the weight if necessary) and press F2 to
store the value.
• Then, press F3 per store the final calibration.

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6. Reference loads
From main screen: MENU - 0 – 0 - 3.
Use this option to insert the reference loads necessary for the load calibration.
Usually, the minimum load is set to 0 (spreader empty); the maximum weight should be close to the
machine real maximum capacity.
NOTE:
This maximum reference inserted here load has nothing to do with the real machine capacity:
it is only a reference for the calibration
Reference loads

min load: 0.00

max load: 9.00

7. RPM Calibration
From main screen: MENU - 0 – 0- 4.
This option allows to calibrate the real engine according to a frequency signal, that can come from
alternator or magnetic pick up. References can be changed in the option “set rpm”.
Signal from RPM sensor

Max value stored in the previous

calibration rpm 150 Hz calibration (Hz)

freq max 876

Procedure:
• Accelerate the engine at maximum RPM and press F1.
• Press F3 to calibrate or F4 to exit without calibrating.

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8. Machine Geometry
This option allows to set all geometrical parameters typical o a generic stacker machine. The
examples below use the real data of a CS7.5 machine.

8.1 Set min/max angle

From main screen: MENU - 0 – 1- 0.

These values are the references in the angle calibration screen.

Setting angles

min angle: 0.0

max angle: 66.6

8.2 Set min/max length

From main screen: MENU - 0 – 1- 1.

These values are the references in the boom length calibration screen.

Setting boom

min length: 9.00

max length: 15.80

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8.3 Distance, top boom and height

From main screen: MENU - 0 – 1- 2.

These values are for a CS7.5 machine:

Setting geometric factor

distance: 5.90
top: 0.60
height: 1.30

The meaning of the terms are indicate in this figure:

Distance: A
Top: B
Height: C

8.4 Set RPM

From main screen: MENU - 0 – 1- 4.

This is to set up references for engine RPM calibration.

Set RPM

rpm max: 2300

rpm for high speed: 1500

rpm max: real maximum engine rpm.

rpm for high speed: if weight is lower than 25 tons and engine rpm is over this limit, high boom
speed is enabled (output 5 of LMS system)

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9. Safeties
From main screen: MENU - 0 – 2.

Safeties

min distance: 0.00

max safety angle: 65.0

min.distance: minimum distance safety threshold (in meters)

max.safety angle: high angle safety threshold ( in degrees)

10. Alarms
From main screen: MENU - 0 – 3.

overload: 100
pre-alarm: 90
lock delay: 1
unlock delay: 5

Overload: % of maximum capacity to activate overload alarm condition.

Prealarm: % of maximum capacity to activate approaching overload alarm condition
Lock Delay: Delay in ms between the overload alarm activation and the movements interlock.
Unlock Delay: Delay in ms between the overload alarm end and the movements enabled.

11. Parameters
From main screen: MENU - 0 – 4.

Parameters

usa standard: 0

Value 1 indicates that all the measures are expressed in the USA standard: feet instead of meters
and pounds instead of tons.
Value 0 indicates the standard metric system.
Even with USA standard, all calibrations references must be expressed in the metric system.

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12. Date-Time
From main screen: MENU - 0 – 5.

date: 12 / 3 / 2
time: 18 : 20

It is possible to adjust date and system time (they are used in the black boxes).

13. Data Transmission

From main screen: MENU - 0 – 6.
This menu allows data communication between an external PC and LMS Edgevision.
It is always necessary to connect a serial cable (null-modem standard, see appendix) between the
RS232_1 connector of LMS and the PC serial port (COM1 or COM2). Then, configure the PC
serial port or the serial printer as follows:

• Baud rate: 19.200 bps

• Data bits: 8
• Parity: No parity
• Stop bit: 1

For all following options (except “Print calibrations”) it is necessary to get the proper
communication software, developed by FRED (SuperLoaderTM), that allows the complete
management of the LMS information. This software is not part of the standard supply, and it is sold
only to sub-dealers that manage big machines parks.
See help file in the SuperLoader program to get more details.

13.1 Print calibrations

From main screen: MENU - 0 – 6 - 0.

This option allows to download or print all machine calibrations regarding a particular machine. It
can be very useful as remind of the calibration status, also in case of spare parts replacement.
On the PC there must be any serial terminal software, like, for example, Hyperterminal, always
present in any Windows operating system.

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13.2 Receive calibrations

From main screen: MENU - 0 – 6 - 1.

This option allows to receive from a PC a binary file (not readable) that contains all machine
calibrations.
This file can be used if it is necessary to set up a LMS without repeating all calibrations procedures.
This is very useful in case of spare part setup “ready to use”.

13.3 Transmit calibrations

From main screen: MENU - 0 – 6 - 2.

With this option it is possible to send to a PC all machine present calibrations. The PC will be able
to store that information in a binary file.
This file can be used to prepare other LMS boxes that can be installed in the same machine without
repeating any calibration.

13.4 Receive capacity charts

From main screen: MENU - 0 – 6 - 3.

This option allows to update machine capacity charts. The manufacturer has to produce tha capacity
chart in a Microsoft Excel (XLS) file format, and this can be send to the LMS.

14. System Reset

From main screen: MENU - 0 – 7.
This sets all calibrations value into a standard, erasing any existing calibration.

NOTE:
This options erases all boom angle, length and weight calibration.
All default values will be restored. A code is request for this operation.
After that, all these calibrations will have to be repeated manually or
downloading from external PC.

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15. System Test

From main screen: MENU – 0 – 1
This menu allows a troubleshooting of all LMS inputs/outputs signls, in order to find out any
problem can arise.

15.1 Analog inputs test

From main screen: MENU – 0 – 1 – 0.

AN1: 12.4 AN5: 0

AN2: 7.1 AN6: 0
AN3: 5.67 AN7: 0
AN4: 3.80 AN8: 0

This is the list of analog sensors present in the system. Each signal is expressed in mA (milli-
ampere):

AN1: inclinometer (boom angle sensor).

AN2: cable reel (boom length sensor).
AN3: load cell left sensor.
AN4: load cell right sensor.
AN5 – AN8: non connected

The above values must be always in the range as indicated in following table. Out of that range, the
sensor has to be considered fault or not connected.

signal min (mA) max (mA)

AN1 2 19,8
AN2 2 19,8
AN3 1 20
AN4 1 20

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15.2 Test digital inputs

From main screen: MENU – 0 – 1- -1.

DIG1: 1 DIG5: 0
DIG2: 0 DIG6: 0
DIG3: 0 DIG7: 0
DIG4: 0 DIG8: 0

Correspondences:

DIG1: sensor “spreader locked”: 1 locked, 0 no signal

DIG2: sensor “spreader unlocked”: 1 unlocked, 0 no signal
DIG3: sensor “spreader seated”: 1 seated, 0 no signal
DIG4: sensor “stabilizers lowered”, 1 stabilizers lowered, 0 no signal
DIG5 – DIG7: non connected
DIG8: bypass key on warning lights panel: 1 key activated, 0 no signal

15.3 Set digital outputs

From main screen: MENU – 0 – 1- -2.

1.DIG1: 1 5.DIG5: 0
2.DIG2: 0 6.DIG6: 0
3.DIG3: 0 7.DIG7: 0
4.DIG4: 0 8.DIG8: 0
F4 – exit 1 ..8 on/off

This option allows to force the output activation in oder to check the system and cabling.
For example, pressing 1 the status of DIG1 is forced to high (1, 24V), and pressing 1 again DIG1 is
resetted (0, 0V).
Once exited from the test, outputs will be automatically set by the control program.

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15.4 Test digital outputs

From main screen: MENU – 0 – 1- -3.

1.DIG1: 1 5.DIG5: 0
2.DIG2: 0 6.DIG6: 0
3.DIG3: 0 7.DIG7: 0
4.DIG4: 0 8.DIG8: 0

It shows the digital outputs status in real time:

DIG1: overload safety: 1 (24 V) no overload, 0 overload
DIG2: minimum distance safety: 1 (24 V) activated, 0 not activated
DIG3: stabilizers safety: 1 (24 V) activated, 0 not activated
DIG4: high angle safety: 1 (24 V) activated, 0 not activated
DIG5: high boom speed solenoid: 1 (24 V) activated, 0 not activated

15.5 Test rpm inputs

From main screen: MENU – 0 – 1- -4.

RPM1: 569
RPM2: 0

RPM1: engine rpm signal (expressed in hertz)

RPM2: not used

16. Operative Black Box

From main screen: MENU – 0 – 2.
Operative black box contains information regarding the total number of containers ever lifted and
the data of the last 6.500 containers.

Date and time container handling

16.1 View operative black box

Handling time (sec) time: 15/03/02 15:10:37

and container number weight: 20.1
(it restarts from 1 every hand.time: 15 34/45
time the system is
turned off)
counter: 1

Message number and total messages

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16.2 Erase operative black box

From main screen: MENU – 0 – 2 - 1.

It deletes permanently all operative black box information. A code is required.

16.3 Print operative black box

It transmits all black box messages through the serial port RS232_1. See the paragraph “print
calibrations” for the serial port settings.
In the PC it is necessary a software like Hyperterminal of Windows.

17. Alarms Black Box

From main screen: MENU – 0 – 3.
Alarms black box contains all sensor malfunction, overloads and bypass use messages.
It is possible to store about 4.500 messages.

Date and time start and end alarm. “-“ means

17.1 View alarms black box that the alarm is not finished.

start: 15/03/02 15:08:09

end: -
Max weight and max value: 24.5
distance of the distance: 3.85 12 / 24
container at the Overload
overload moment.
Not used for other
alarms Message Number of message and
total number.

17.2 Erase alarms black box

From main screen: MENU – 0 – 3 - 1.

It deletes permanently all alarms black box information. A code is required.

17.3 Print alarms black box

It transmits all black box messages through the serial port RS232_1. See the paragraph “print
calibrations” for the serial port settings.
In the PC it is necessary a software like Hyperterminal of Windows.

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18. Language
From main screen: MENU – 0 – 4.

It is possible to select one of 5 different languages for all messages and menu of LMS. The
language selected will be stored.
Select the language with the appropriate numerical key in the screen below:

0: English
1: Italian
2: French
3: Spanish
4: German

19. Information
From main screen: MENU – 0 – 5.
It shows a screen with the system type and software version. Press F4 to exit.

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APPENDIX 1: Null-Modem Cable Schematic

DB9 Female
DB9 Female

DCD 1
DCD 1
RD 2
RD 2
TD 3
TD 3
DTR 4
DTR 4
GND 5
GND 5
DSR 6
DSR 6
RTS 7
RTS 7
CTS 8
CTS 8
RI 9
RI 9

APPENDIX 2: LMS System Installation

BACK EDGEVISION BOX BACK WARNING LIGTHS
PANEL

2
1

4
3
1 2
6 7
5

BYPASS KEY:
A: OUT
B: +24VDC
C: OUT

OUTPUT - DB25 M POWER SUPPLY

WARNING LIGHTS
DB25 F
INPUT - DB25 F

1. Input (DB25 M) 5. CAN/Programming (DB9 M)

2. Serial RS232_1 (DB9 M) 6. External keypad (DB15 F)
3. Serial RS_232_2 (DB9 M) 7. Power supply (DB9 F)
4. Output (DB25 F)

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APPENDIX 3: Pin-out connectors

Input connector (DB25 M)

PIN Signal Notes

1 Locked Digital input
2 Unlocked Digital input
3 Seated Digital input
4 Stabilizers lowered Digital input
5 Digital input
6 Digital input
7 Digital input
8 Bypass key Digital input
9 Not used
10 Input RPM
11 Input RPM
12-13 Not Used
14 Angle (0-20 mA) Analog - 0-20 mA
15 Length (0-20 mA) Analog - 0-20 mA
16 Load cell left (1-20 mA) Analog - 0-20 mA
17 Load cell right (1-20 mA) Analog - 0-20 mA
18 Analog - 0-20 mA
19 Analog - 0-20 mA
20 Analog - 0-20 mA
21 Analog - 0-20 mA
22-25 Not used

Output Connector (DB25 F)

PIN Signal Note

1 Overload safety 3A, 24 VDC
2 Min. Distance safety 3A, 24 VDC
3 Stabilizers lift lock 3A, 24 VDC
4 Lifting lock (high angle) 3A, 24 VDC
5 3A, 24 VDC
6 3A, 24 VDC
7 3A, 24 VDC
8 3A, 24 VDC
9-25 Not used

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Power supply Connector (DB9 F)

PIN Signal Note

1 +24 VDC
2 +24 VDC
3 +24 VDC
4 GND
5 GND
6 +24 VDC
7 +24 VDC
8 +24 VDC
9 GND

CAN/Programming Connector (DB9 M)

PIN Signal Note

1 Not used
2 CAN Low
3-6 Not Used
7 CAN High
8-9 Not used

NOTE: in LMS boxes with serial number from 01/02 to 05/02 connections are:
• CAN H: pin 1
• CAN L: pin 3

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