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55M3500MNE rev. E 

Telescopic cranes with derrick pressure sensors                                   Calibration Manual i3500 

The use of the up/down arrows (

 and 

) will allow the user to scroll in the menu. 

When  pressing  simultaneously  on  an  “arrow”  key  and  the  “?”  key,  the  display  will 
move  from  one  page  to  the  other.  Pressing  

  will  show  calibration  details  and  also 

the original software version of the underlined sensor, this is not available for all sensors 

 

Notes: 

  Pressing  #5  “ESC”  takes  you  to  the  previous  menu  or  exits  from  the 

diagnostic mode. 

 
Angle/length sensor: 
 
In the diagnostic menu, this is the typical displayed information: 
 

sensor 

ain1 

ain2 

dr+ 

a2b 

------------------------------------------------------------------------------------------------------------ 

angle 1 

1428 

1503 

4.99 

length 1 

203 

N/A 

4.99 

 
Some  applications  have  more  than  one  angle  or  length  sensor.  In  this  case,  all  of  the 
angle sensors are listed first then length sensors will follow. 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  in  the  X  and  in  Y  axes  that  are  used  to  calculate  the 
angle.    These  values  are  normally  between  1200  and  2900  bits.  DR+  represents  the 
D.C voltage level of excitation on the angle/length card and must be close to 5.00V. 
 
When  the  multiple  reel  option  is  required  every  angle/length  card  has  an  ATB  option 
that can be activated by dipswitch #4. For the angle/length card, which is not monitoring 
the ATB, N/A is shown under a2b instead of 0 or 1, indicating it is not available on this 
card.  0 is a safe condition and 1 will show a two-block condition. 
 
For the “length 1” sensor, the value “ain1” represents the boom extension value in bits.  
It  may  vary  between  around  50  and  975  bits.    The  “length  1”  sensor  “ain2”  value  is 
reserved for future expansion.   
 
Note:  “angle 1” sensor and “length 1” are physically located on the same card.     
 

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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