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55M3500MNE rev. E 

Telescopic cranes with derrick pressure sensors                                   Calibration Manual i3500 

Audible alarms: an intermittent buzzer sounds if the percentage of the safe working load 
is between 85%-99% and a continuous buzzer sounds when the % of the safe working 
load  is  in  the  range  of  100%  to  120%.    Visual  alarms:  A  yellow  led  illuminates  for  an 
approach  to  an  overload  between  85%-99%  of  the  safe  working  load.  A  red  led 
illuminates  for  an  overload  between  100%-119%  of  the  safe  working  load  and  an 
additional  red  led  illuminates  for  a  cut  out  >  120%  of  the  safe  working  load.  If  the 
additional  sensors  are  fitted,  then  some  information  about  the  current  slew  angle  and 
the  hook  height  will  also  be  available.    The  required  crane  duty  charts  are  stored  in  a 
non-volatile  memory  and  can  only  be  modified  with  the  approval  of  the  crane 
manufacturer.    The  calculated  crane  parameters  and  calibration  data  are  stored  in  an 
additional  non-volatile memory.  The  calibration  of  the  crane  is  performed  only  with  the 
use of known loads, boom angles, and other pre-determined data.  
 
 

2.0  THE I3500 SYSTEM 

 
2.1 

Troubleshooting 

 
This  section  provides  technical  troubleshooting  support.  It  will  answer  most  questions 
that repair personnel may have when installing, repairing or performing maintenance on 
the i3500 system.   
 
2.1.1  Diagnostic Menu 
 
 
A  diagnostic  menu  provides  information  on  the  systems  status  and  the  state  of  all 
connected sensors.  To access the diagnostic menu, press #1 “mode”, and use ”

” or 

” to highlight “diagnostic”, then press “

” to enter the diagnostic menu. 

 
The  information  is  divided  into  several  pages  with  each  page  applying  to  only  one 
sensor or one type of information.  The different pages available are: angle/length, load, 
relay, general info for a specific type of calibration (e.g. telescopic multi-point), rotation 
and also the addresses of sensors detected by the i3500 system. 

 

Depending on the system configuration, a minimum of three pages are always provided: 
angle/length,  general  info  and  detected  addresses.    Other  pages  are  optional  and  are 
only  shown  if  one  or  more  sensors  are  activated  by  the  system  (refer  to  the  option 
activate/deactivate I/O’ in calibration). 
 

Summary of Contents for i3500

Page 1: ...ing that the material is for internal use only Ref MP December 2007 RaycoWylie Systems RaycoWylie Systems RaycoWylie System Drury Lane 1020 9th Avenue SW 2440 Ave Dalton St Leonards on Sea Suite 124 S...

Page 2: ...ion data 18 2 2 4 Entering fixed data values dimensions 20 2 2 5 Relays configuration relays configuration 26 2 2 4 Digital inputs configuration dig inputs config 27 2 2 7 Angle Calibration 28 2 2 8 L...

Page 3: ...garded only as an aid to the operator When the parameters are set correctly the indicator will warn the crane operator of an approaching overload condition that could cause damage to equipment propert...

Page 4: ...s safe or critical conditions while performing an authorized lift of loads Optional sensors may also be fitted to monitor the slew angle and the rotation of the hoist drum to provide some extra inform...

Page 5: ...performed only with the use of known loads boom angles and other pre determined data 2 0 THE I3500 SYSTEM 2 1 Troubleshooting This section provides technical troubleshooting support It will answer mos...

Page 6: ...ow The first angle sensor to be listed is the one installed closest to the main boom base Referring to the example above for the angle 1 sensor values ain1 and ain2 vary depending on the inclinometers...

Page 7: ...ro of the angle has been calibrated on the machine To view the software version of the length sensor or it s calibration state press when length 1 is highlighted The displayed Information will look si...

Page 8: ...xt two lines indicate if a sensor has been calibrated or if the calibration is valid The scale value must be smaller than 1 0 Relay The displayed Information will look similar to this relay inputs rel...

Page 9: ...nstalled for line tension measurements larq cable arm lever and lah cylinder arm lever are values used by engineering to verify certain calculations l corr is the real load including correction factor...

Page 10: ...ference point Angle of rotation is on Zero prox value when the proximity switch is detecting the target prox detect shows proximity switch state The 0 indicates that the proximity switch is detecting...

Page 11: ...d write verification of bank C EEPROM chip It is used as a backup for the system s operation parameters Ex winch number of strands duty 1 There is a problem with EEPROM memory U45 Clock error Logger o...

Page 12: ...two flash memories Recorder low batt Logger System detected that Lithium battery is low This may cause clock to stop or lose precision 1 Logger card s plastic cap must be replaced It contains the bat...

Page 13: ...Accelerometer or converter 12 bits are defective Length out of range A 0xFFFF code is sent by angle length card to indicate that length sensor is not present 1 Length sensor is not installed 2 A wire...

Page 14: ...rors The i3500 system can support up to 4 relay cards Activation of every relay card is done in the calibration menu section ent sor activate deactivate Error message Execution process Cause of error...

Page 15: ...n encoder and rotation card Encoder ratio No ratio has been entered 1 Put a different value than 0 Encoder position prox Proximity is not detected in configured position by i3500 system 1 Proximity is...

Page 16: ...u enable disable i o Press to confirm this choice Use or to highlight one of the sensor inputs then press to change the sensor state Repeat this procedure for each sensor Press 5 ESC to return to the...

Page 17: ...activated if there is at least one limit programmed when starting the I3500 system a message will appear on the screen informing the operator He will then be able to judge whether this limit should b...

Page 18: ...represents all the parameters used for the system based on the client s recommendations 2 2 3 1 Rope limit Main Aux Rope limit main This is the maximum line pull permitted per part of line on the main...

Page 19: ...w radii beyond the maximum radius given by the load charts The OD OUT of DUTY on RADIUS will allow the SWL to decay evenly from the last point on the chart to zero over the distance set by this variab...

Page 20: ...are the same value cl3 p2blh the horizontal distance between the boom pivot pin and lift cylinder base pin cl4 p2blv the vertical distance between the boom pivot pin and lift cylinder base pin cl7 p2b...

Page 21: ...ahh the horizontal distance between the center of the auxiliary hoist drum and boom pivot pin If the drum is mounted on the boom this dimension is zero cl6a p2ahv the vertical distance between center...

Page 22: ...if main boom pivot is placed behind rotation center 2 PIVOT 3These dimensions are not available for editing 3 3 3 Note on the sign convention Every dimension is positive except cf If the rotation cent...

Page 23: ...h derrick pressure sensors Calibration Manual i3500 23 Diagram 2 2 4 2 Crane dimensions cnt d CH1 CL1 CH2 CH1 0 1m CL2MR CL2 Slew Ground level Fully retracted Fully extended excluding manual section F...

Page 24: ...Hoist Drum s on superstructure with boom mounted guide sheave s CL28A CL28M CL29A CL29M CR22A CR22M 1 1 1 V2582 V3335 CL6M V3346 V3505 CL5A CL6A V3993 V3999 CR2M CL5M CR2A Alternative location of hoi...

Page 25: ...Telescopic cranes with derrick pressure sensors Calibration Manual i3500 25 Diagram 2 2 4 4 Jib dimensions CR A8 CLF Fly CLF Lattice CL12 Lattice CL12 Fly CL13 Diagram 2 2 4 5 Rooster dimensions CL12...

Page 26: ...nctions TABLE 2 Digitals outputs configuration Relays Relay 1 ATB Lockout ATB Disable Relay 2 Lockout Disable Relay 3 Swing Left Disable Relay 4 Swing Right Disable Relay 5 External Alarm For overload...

Page 27: ...t can be detected using a magnetic or mechanical proximity switch The External Bypass is required for the EN13000 compliance When this function is used the bypass key on the i3500 display is disabled...

Page 28: ...alibration menu 2 2 7 2 Span Angle This step is not required for the angle sensor The importance of displaying the sensor signal in bits is to verify that it changes through the entire working area of...

Page 29: ...zero calibration To zero the pressure sensors open the hydraulic lines of both sensors in order to remove any residual pressure Make sure the boom is resting at its lowest point to prevent sudden fall...

Page 30: ...3200 and not exceed 3850 c Press to enter the value engraved on the pressure sensor below the label A typical value will read CAL 285 6 BAR d Enter the value engraved on the pressure sensor If there...

Page 31: ...out then derrick up in slightly before recording the calibration point When telescoping in or out it is not necessary to derrick up in unless the crane has had to be derricked down out during telescop...

Page 32: ...y Telescopic band to be calibrated Minimum of points None 2 min Up to 20 feet 3 20 to 30 feet 4 30 to 45 feet 5 45 to 60 feet 6 Over 60 feet 7 max When the proper number of length steps is entered pre...

Page 33: ...length 1 then press to accept Enter the number of angle calibration points for each length step in turn as prompted 2 2 10 3 Hook Block Weight After the last number of angle points is entered the dis...

Page 34: ...rrect the display will change to Calibration point 1 Press pd1 aa a pd2 bb b Boom length cc c is ok Angle ee e ff f Plus asking a message to boom up or down to the required angle When the boom angle i...

Page 35: ...sed to compensate for lifting on tires if relevant see section 2 2 9 8 For rooster configurations the unloaded deflection characteristics of the main boom will be inherited and a separate calibration...

Page 36: ...he displayed radius equals the measured radius note that the indicated radius can only be increased not decreased and that the value of x x must be less than the equivalent value entered with the boom...

Page 37: ...r machine configurations on outriggers or on crawlers For rooster configurations the deflection characteristics of the main boom will be inherited and a separate calibration is not required and should...

Page 38: ...nge the system will automatically return to the main calibration menu Carefully replace the test load on the ground 2 2 10 10 Load adjustment This procedure is optional one calibration is available pe...

Page 39: ...this change The system will automatically go back to the main calibration menu Carefully place the test load back to the ground 2 2 10 11 Load offset This procedure is optional one calibration is ava...

Page 40: ...m pres med bar 1 1 100 100 100 0 0 sup lim pres med bar 0 0 Boom down friction compensation should only be done once the no load calibration and various deflection calibrations have been completed Onl...

Page 41: ...tion These two points cannot have a common angle or boom length A load correction factor will be applied to all boom positions whose angle and length are greater than point 1 and also whose angle and...

Page 42: ...load equals the calculated test load Press to accept the change the system will automatically return to the main calibration menu Carefully put the test load back on the ground Repeat this procedure...

Page 43: ...Case 4 limited CF zones 1 2 1 2 3 4 6 7 8 10 11 12 3 7 4 8 6 10 6 11 7 12 1 5 1 1 9 2 2 6 3 5 4 4 8 5 10 6 3 7 9 Case 3 suggested sequence for better results 7 12 7 8 6 10 6 11 12 10 11 No CF applied...

Page 44: ...istance on the CANBus network This resistance can be activated when putting a jumper on the connector header identified as END Note that only the last card on the CANbus requires a termination resista...

Page 45: ...be turned ON If the ATB is not linked to the systems ignore this section Multiple ATBs can be installed on a crane and they will be supported by the display as long as they are enabled The ATB signal...

Page 46: ...h 1 pressure transducer input and another with 2 pressure transducer input It should be noted that the dual transducer interface will always have an even physical address on the CAN BUS network See la...

Page 47: ...Data Sheets Rotation center CL7 CL8 AD RD CL5M CL5A CF CL6M CL6A CR2A CR2M CL9 CL3 CL4 CL11 CL10 CR1 1 1 2 Boom Crane dimensions Boom Foot Pin 1 2Negative if boom foot pin is behind slew centerline N...

Page 48: ...th derrick pressure sensors Calibration Manual i3500 48 Ground level CH1 CL1 Rotation center CH2 CH1 0 1m Fully retracted Fully extended excluding manual section Fully extended including manual sectio...

Page 49: ...sure sensors Calibration Manual i3500 49 Main boom pivot CL28A CL28M CL29A CL29M CR22A CR22M 1 1 1This size will be negative Alternative hoist placement using a guide sheave on main boom V1011 V2494 V...

Page 50: ...55M3500MNE rev E Telescopic cranes with derrick pressure sensors Calibration Manual i3500 50 CLF CL13A CR3 CLF1 CL12A CL12B A8 CLF Fly CLF Lattice CL12 Lattice CL12 Fly CL13 Jib dimensions...

Page 51: ...55M3500MNE rev E Telescopic cranes with derrick pressure sensors Calibration Manual i3500 51 CL12 CL13 CLF 0 A8 0 Rooster dimensions...

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