WINDCRANE Mini 2G/LTE-M Small Compact and Tough Wind Monitoring System Installation Guide
- June 12, 2024
- WINDCRANE
Table of Contents
WINDCRANE
Hardware Installation Guide
17 Jan 2023
Hardware Version 1.12 (2G/LTE-M)
for 12/24V
Hardware Overview
WINDCRANE is a remote monitoring wind measurement and reporting system. It
consists of a web data/management portal and mobile app, and a
logger/telemetry device housed in a compact weatherproof enclosure that
contains sensor interface circuitry, processor and cellular communications
module.
The device uses GSM/LTE-M cellular networks to communicate with the WINDCRANE
web portal, where system setup and data analysis/download is handled (see
separate documentation for the portal and app). The GSM/LTE-M antenna is built
into the enclosure. There are internal slots for microSD card and SIM cards
which are typically supplied pre-installed.
Standard screw clamp terminals are used for power and input signals. Two cable
glands are provided for sensor and power cabling. One gland is fitted with a
sealing plug in case only one gland is used.
1.1 Enclosure
The enclosure is a weatherproof box with latching hinged lid designed to
meet IP67 rating. It is supplied fitted with 2 IP68 metal cable glands for
power and sensor cables. If one gland is unused, it must be sealed using the
supplied blanking plug.
The enclosure should only be opened in dry, clean conditions. It is generally
only necessary to open the enclosure during installation to complete the
wiring, or to change the SIM card or update firmware.
1.2 Power
WINDCRANE requires 12 or 24 VDC +/-25% from a regulated DC supply rated for at
least 10 W, or from a 12 or 24 V battery system. The average consumption is
very low, but during GSM/LTE transmit the consumption peaks can be higher.
Also allow power for accessories and sensors (AUX+ output).
1.2.1 Permanent device installation
The unit is supplied with a cable terminated with a M12 connector for fast
disconnection from the power supply. If supplied cable is not used and the
unit is permanently wired to the vehicle, a fuse rated at 500mAshould be used
in series of the positive supply (for example Littelfuse 218.500MXP) . In
addition to a protection fuse, means to be able to disconnect the power from
the unit using a ‘all poles’ switch / circuit breaker or cable plug. Any
device used as the disconnection device must be suitable rated for the voltage
and power. A switch must be approved to IEC 60947-3; a circuit breaker must be
approved to IEC 60947-2. Any external cables should have a temperature rating
of +60°C The protection of the equipment may be impaired if the equipment is
not used as specified.
1.3 Inputs
The WINDCRANE logger is typically used with a single wind speed sensor but
provides inputs for up to 4 digital pulse signals and up to 6 analogue
signals.
Inputs A1-A4 are pulse frequency counter inputs for anemometers.
Inputs B1-B2 are isolated pulse inputs for 12-24 V anemometer pulse signals,
and internally drive the A1-A2 inputs respectively.
Input channels D1-D3 are sampled from on-board sensors. D1 provides barometric
pressure, D2 provides internal temperature, and D3 provides internal relative
humidity.
Input channel D4 is a resetting counter that is triggered by the A4 input. The
count is reported, and the counter is reset at the end of each data interval.
Inputs D5-D10 are general-purpose analogue inputs and can be configured for
0-3.3V, 0-10V or 0-20mA (420mA) signals.
Input channel D11 samples the supply voltage at the PWR+ terminal.
1.4 Antenna
WINDCRANE has an internal multi-band GSM/LTE antenna built into the front/lid
of the enclosure. This gives good performance for most areas with cellular
network coverage.
Take care not to ob struc t the central part of the f ront o f the encl osure
(un der the WI N DC RA NE l og o) wi th metallic objects and do not mount the
WINDCRANE in a metal cabinet, otherwise the cellular signal may be affected.
1.5 Status Indicator LED
The WINDCRANE circuit board includes a green activity/status LED which
indicates microSD card access, logging activity and communications status.
This is only visible with the enclosure lid open. However, there is provision
for adding an externally visible LED via PCB solder pads.
| Activity LED Indication | Meaning |
|---|---|
| Rapid flashing at power up | SD card missing or unreadable |
| Single short flash every 1 or 3 secs | Normal logging/sampling, data transmit |
OK
Double short flash every 1 or 3 secs| Normal logging, transmit failed at last
attempt
On solid for approx 10 secs during comms| Data transmit completed OK
Flashing for approx 10 secs during comms| Data transmit failed (possible
network/SIM problem)
On solid for more than 10 secs| Data bulk upload in progress. Do not switch
off.
On solid at power up| Firmware update in progress. Do not switch off.
1.6 Micro SIM Card
The microSIM card provides cellular network access, and slides into a socket
next to the antenna connector.
The SIM orientation is printed onto the board next to the SIM socket. To
insert a SIM, hold the SIM at the end opposite the cut off corner, with the
gold-coloured contacts facing down, and gently slide the SIM into the socket
and under the metal top until it stops.
If you use your own SIM, its APN parameters must be specified in the
configuration file on the microSD card.
1.7 Micro SD Card
The microSD card is used for initial configuration, firmware updates, and data
log files. The card socket is a push-to-eject type. To insert the card, simply
slide it into the socket, with contacts facing down, until it latches into
place. To remove the card, push it into to the socket slightly to unlatch it,
then pull it all the way out. Be careful not to drop the card or get cards
mixed up.
The microSD card holds backup log files and the SIM configuration file. See
the reference section for SIM configuration details.
WINDCRANE is compatible with standard microSD cards up to 2GB capacity,
formatted as FAT or FAT32. Do not use 4GB or larger SDHC cards.
1.8 Input Port Mode Jumpers
Input port jumpers are used to select the operating mode for each input by
shorting together pairs of pins on the circuit board. There is a set of
jumpers for each input, located near the respective input terminal. The
jumpers are normally pre-set to the appropriate positions for the supplied or
specified sensors.
Always power off the device before changing jumpers. Use fingers or needle
nose pliers to lift off and reposition the plastic jumper caps.
Do not lose or discard any jumper caps. Unused jumpers can be “parked” by
fitting them on to one pin only instead of bridging two pins.
Default jumper settings are shown in the table and photo below.
| A1 – A4 anemometer inputs | Position 1-2 (Volt-free contact) |
|---|---|
| D5 – D6 wind vane inputs | Not fitted, or “parked” on single pin (0 – 3.3 V) |
| D7-D10 analogue inputs | Not fitted, or “parked” on single pin (0 – 3.3 V) |
1.8.1 Input Mode Jumper Positions
The table below lists the input mode jumper positions for the supported signal
types and ranges.
| Input Port | Mode | Jumper Position |
|---|---|---|
| Pulse Inputs | Al — A4 Anemometers or Meters / Pulses | Volt-Free (Dry Contact) |
| Pulse (Default position) | ||
| Low AC (sine wave) frequency * | ||
| Analogue Inputs | D5 – D10 | 0 — 3.3 V DC (Default position) |
| D5-D8: 0 —10 V DC |
D9-D10: 0 — 3.3 VDC with 10k pullup to SPW (3.3 V sensor supply) **
0 — 20 mA (or 4 — 20 mA)|
Installation
2.1 Mounting
For mobile or crawler cranes, WINDCRANE may be mounted at the jib end close to
the sensor position, or elsewhere on the crane that allows cabling to the
sensor and a power source.
Find a suitable mounting position that is protected against impacts and will
not obstruct the operation of or access to other equipment. Orient the
enclosure with glands vertically downwards if possible, and with enough space
to open the enclosure lid for access to the wiring.
The WINDCRANE may be mounted to a structural member or plate using stainless
steel or plastic straps through the loops/slots in the enclosure, or in a
suitable cradle (not supplied). This prevents access into the enclosure, so
complete any wiring first.
Take care to no t ob struc t the front of the enclosure under the WINDCRANE
logo, as the antenna is located inside the lid. See Section 1.4 (page 4) for
details.
Ensure the cable glands are tightened onto the cables after wiring. Check the
lid sealing gasket is in place and not damaged, before closing the lid with
the “claw” latch.
2.2 Power Wiring
For mobile or crawler cranes, the WINDCRANE should be powered from a 12-24 VDC
auxiliary circuit that can provide power while the crane is operating or
erected, or permanent power via a dedicated switch/breaker. The typical
consumption is low enough that the WINDCRANE can be left running continuously
while the crane is on site.
NOTE: The supply circuit must be fused for safety with a 500 mA T (time-
delay / slow-blow) fuse.
Run a supply cable of at least 0.34 mm 2 (22 AWG) through the gland nearest
the enclosure hinge and to the supply terminals and wire up as follows:
| Supply negative / 0 V | GND terminal (next to PWR+ terminal) |
|---|---|
| Supply positive / 12 – 24V | PWR+ terminal |
2.3 Sensor Wiring
Sensor wiring depends on the specific sensors being used. For a single
anemometer with a volt-free contact type output (e.g. reed switch sensor),
wire as follows:
| Sensor return / common / negative | GND terminal (next to A1 terminal) |
|---|---|
| Sensor output signal | A1 terminal (or A2 for secondary sensor) |
| Cable shield / screen | GND terminal (any adjacent GND) |
For two sensors, connect the secondary sensor signal to A2 terminal. Connect
the common/ground and cable shield to adjacent GND terminals.
For switch type sensors (reed switch or open collector NPN), the input mode
jumpers must be set to the “Volt-Free Contact” position.
Some sensors have a low-voltage AC sine wave output. These are wired in the
same way as above, but the corresponding input mode jumpers must be set to the
“Low-voltage AC Sine Wave” mode.
Refer to Section 1.8.1 on page 6 for jumper positions.
Specifications
3.1 Power Supply
Supply voltage range| 12 – 24 VDC ±25%
Input protection by TVS diodes and resettable fuses.
---|---
Power consumption| 5 mA at 24 V average typical (depends on data amountsand
cellular network conditions, excluding AUX+)
3.2 Auxiliary Supply Outputs
| Sensor excitation supply (SPW terminals) | 3.3 VDC, max 20 mA total load |
|---|---|
| Aux supply output | 350 mA max load, supplied from PWR+ supply terminal via |
resettable fuse.
3.3 Input Ports
3.3.1 A1-A4 Anemometer Inputs
Volt-free contact input mode (jumpers in position 1-2)
Maximum open-circuit voltage| 3.3 V (from WINDCRANE via 10k Ohm pull-up
resistor)
---|---
Maximum closed-circuit current to GND| 500 uA
Maximum closed-circuit voltage| 1.0 V
Measurable frequency range| 1 Hz to 3 kHz (minimum 100 us pulse width)
Low-voltage AC Sine Wave input mode (jumpers in position 2-3)
| AC voltage range (symmetrical about GND) | 100 mV to 12 V (peak) sine wave |
|---|---|
| Measurable frequency range | 1 Hz to 200 Hz |
3.3.2 B1-B2 Anemometer Inputs
Opto-isolated passive pulse inputs, which are internally mapped to the A1-A2
anemometer inputs respectively. These inputs can be driven from a digital
pulse output sensor or PLC digital output.
| ON input voltage (between B1+ and B1-) | 8 V (1.25 mA min) to 32 V (5.5 mA max) |
|---|---|
| OFF input voltage (between B1+ and B1-) | 0 V to 5 V (0.8 mA max) |
| Isolation voltage (to GND terminals) | 300 V peak |
| Measurable frequency range | 1 Hz to 3 kHz (minimum 100 us pulse width) |
3.3.3 D5-D6 Wind Vane Inputs
2 inputs for potentiometer wind vanes. Inputs are sampled at 1 Hz. Data is
reported as unit vector average over the preceding data interval, in degrees
heading (0 to 359.9). Input signal configurable as:
0 to 3.3 V mode (using SPW sensor power)| Mode jumper not fitted, or “parked”
on single pin
---|---
0 to 10 V mode (15 k Ohm input resistance)| Mode jumper in position 1-2
0 to 20 mA (165 Ohm burden resistance)| Mode jumper in position 2-3
3.3.4 D7-D8 Analogue Inputs
2 general-purpose analogue inputs. Inputs are sampled at 1 Hz. Data is
reported as linear average of samples over the preceding data interval.
0 to 3.3 V mode (high impedance input)| Mode jumper not fitted, or “parked” on
single pin
---|---
0 to 10 V mode (15 k Ohm input resistance)| Mode jumper in position 1-2
0 to 20 mA (165 Ohm burden resistance)| Mode jumper in position 2-3
3.3.5 D9-D10 Analogue Inputs
2 general-purpose analogue inputs with optional 10k Ohm bridge resistor for
thermistor or volt-free contact. Inputs are sampled at 1 Hz. Data is reported
as linear average of samples over the preceding datainterval.
0 to 3.3 V mode (high impedance input)| Mode jumper not fitted, or “parked” on
single pin
---|---
0 to 3.3 V range, with 10k Ohm pullup to SPW (3.3 V) to suit 10k NTC
thermistor, or volt-free status contact.| Mode jumper in position 1-2
0 to 20 mA (165 Ohm burden resistance)| Mode jumper in position 2-3
3.3.6 D1 Barometric Pressure Sensor
The barometric pressure sensor is mounted internally on the WINDCRANE circuit
board. The enclosure has a waterproof pressure vent to equalise atmospheric
pressure. However, there may be a small pressure differential inside the
enclosure. The pressure is sampled at 1 Hz and reported as the average over
the preceding data interval.
| Measurement range | 500 hPa to 1100 hPa (500 to 1100 mBar) |
|---|---|
| Pressure resolution | 1 Pa (0.01 mB) |
| Accuracy | ±4 hPa (over -10 to +50 °C) |
3.3.7 D2 Temperature and D3 Humidity
The temperature and humidity sensors are mounted internally on the circuit
board. They are intended onlyfor information and will not accurately reflect
ambient atmospheric conditions due to the sealed enclosure.
The temperature and humidity are sampled at 1 Hz and reported as the average
over the preceding data interval.
Tem perature m easurem ent range| -40°C to +85°C (-30°C to +60°C operating
range)
---|---
Tem perature resol uti on| 0.1°C
Tem perature accuracy| ±1°C
Humidity measurement range| 0% to 100% RH non-condensing
Humidity resolution| 1% RH
Humidity accuracy| ±3% RH (over 20% to 80% range)
3.3.8 D11 Supply Voltage Monitor
The D11 input channel is connected to the power supply input terminal PWR+. It
is sampled at 1 Hz and reported as the average over the preceding data
interval.
| Voltage measurement range | 0 V to 33 V (9 V to 30 V operating range) |
|---|---|
| Voltage accuracy | Approx 2% of full scale |
3.4 Cellular Connectivity
Integrated certified cellular modem module provides global 2G/GSM and 4G/LTE-M
(Cat-M) connectivity.
4G / LTE Cat-M Bands (MHz)| FDD B1(2100), B2(1900), B3(1800), B4(AWS1700),
B5(850), B8(900), B12(700), B13(700), B18(800), B19(800), B20(800), B26(850),
B28(700)
---|---
2G / GSM / GPRS Bands (MHz)| B2(PCS1900), B3(DCS1800), B5(GSM850), B8(GSM900)
Regulatory approvals| PTCRB, GCF, RED, FCC/IC, RCM FCC ID: RI7ME910C1WW IC:
5131A-ME910C1WW
Network approvals| Jate, Telec, CCC, AT&T, Verizon, NTT DoCoMo, Deutsche Tel
ekom , A natel, Tel stra, I fetel, Rogers, Tel us, U S C el l ular
Max transmit power| LTE-M/FDD: 23 dBm (200 mW) GSM/GPRS/EDGE: 33 dBm (2 W)
3.5 Data Handling
Anemometer input sampling| A1-A4 inputs act as pulse frequency counters with 1
sec gate/sampling period. Data reported as max gust, average speed, and
standard deviation of speed.
A4 pulse count is reported as channel D4. Counter is reset after end of each
data interval.
---|---
Analogue input sampling| Analogue inputs sampled at 1Hz. Data reported as
linear average of samples over data interval (D5/D6
wind vane inputs reported as unit vector average).
Data interval/reporting| Data interval is typically 10 minutes, synchronised
to midnight UTC (data points are calculated/reported at
00:00, 00:10 etc.
Data sets are automatically transmitted to WINDCRANE data portal at end of
each interval and logged to internal memory card as local backup.
WINDCRANE logger configuration| Cellular network configuration via SD card
setup file. Data/sensor setup via WINDCRANE web portal.
3.6 Mechanical
| Enclosure dimensions | 215 x 130 x 65 mm (HxWxD), excl cables |
|---|---|
| Weight | 650 g (excluding cables) |
| Enclosure materials/ratings | PC/ABS shell with TPE bumpers and gasket 304 |
Stainless steel fixings
Designed to meet IP67 rating, -29°C to +60°C operating
Cable entry glands| 2no M16 nickel-plated brass cable glands, IP68, 4.5 mm to
10.0 mm cable diameter Designed to operate with typical anemometers
Environmental Operating temperatureEquipment environment Maximum operating
relative humidity Designed to work at altitudes up to Designed for pollution
degree Enclosure| All components RoHS compliant -29°C to +60°C Wet
environment Outside enclosure 100% Inside enclosure 95% non-condensing
11,700 meters 2 Designed to meet IP67 rating
3.7 Regulatory Approvals and User Information
This equipment complies with FCC 47 CFR Parts 2, 15B, 22, 24, 27
FCC ID: 2A9L4WINDCRANE
Contains FCC ID: RI7ME910C1WW (Cellular modem module)
This equipment complies with:
EN 61326-1: 2021
ETSI EN 301 489-1: V2.2.3 (2019-11), EN 301 489-52 V1.2.1 (2021-11), EN 301
511: V12.5.1 (2017-03), EN 301 908-1: V15.1.1 (2021-09)
ICES-003: Issue 7: 2020
ISED RSS-132: Issue 3 (2013-01), RSS-133: Issue 6 (2013-01) + A1 (2018-01),
RSS-GEN: Issue 3 (2015-07),
RSS-130: Issue 2 (2019-02), RSS-139: Issue 3 (2015-07)
This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions:
- This device may not cause harmful interference, and
- this device must accept any interference received, including interference that may cause undesired operation.
Modification statement
Logic Energy Ltd has not approved any changes or modifications to this device
by the user. Any changes or modifications could void the user’s authority to
operate the equipment.
FCC Part 15 Class A Digital Device
NOTE: This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to part 15 of the FCC Rules. These
limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in
which case the user will be required to correct the interference at his own
expense.
Exposure to radio frequency energy:
The radiated output power of this device meets the limits of FCC/IC radio
frequency exposure limits. This device should be operated with a minimum
separation distance of 50 cm (20 inches) between the equipment and a person’s
body.
Note:
This document applies to WINDCRANE Mini 2G/LTE-M hardware versions 1.12r3 or
later, and firmware version 1.12.088 or later. Other hardware/firmware
versions may have differences in features and specifications. Refer to
original installation manual supplied with the hardware for full details.
Contact:
WINDCRANE
Logic Energy Ltd.
PO Box 26237
KILMARNOCK
KA1 9GE
Scotland, UK
Website: www.windcrane.com
Email: [email protected]
Support: [email protected]