RaycoWylie i3500 Instruction Manual Download Page 9

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6- INSPECTION TESTING & MAINTENANCE

6.1- Frequent Inspections

page 63

6.2- Periodical Inspections

page 63

6.3- Rated Load test

page 64

6.4- Maintenance

page 65

6.5- Maintenance Procedure

page 66

6.6- Adjustements & Repairs

page 67

i3500 Introduction

Telescopic Cranes Pressure Sensing

Instruction Manual

Summary of Contents for i3500

Page 1: ...venue SW Suite 124 Bessemer AL USA 35022 Tel 205 481 2080 Fax 205 481 2081 Rayco Electronic Systems Rayco Technology Group 2440 Dalton Avenue Ste Foy Qc CANADA G1P 3X1 Tel 418 266 6600 Fax 418 266 6610 Wylie Systems Rayco Technology Group Drury Lane St Leonards on Sea East Sussex ENGLAND TN38 9BA Tel 44 1 424 421235 Fax 44 1 424 433760 55M3500JBE00 Rev B Crane Warning Systems Atlanta 770 888 8083 ...

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Page 4: ... Safety limiting and indicating devices EN 954 1 Safety and related parts of control systems Category 2 EN 60204 32 Safety of machinery Electrical equipment of machine Requirement for hoisting machine EN 61000 6 2 Electromagnetic compatibility immunity EN 61000 6 4 Electromagnetic compatibility emission For and on behalf of Wylie Systems a division of RaycoWylie Systems Luc Patry RaycoWylie Qualit...

Page 5: ...or will warn the crane operator of an approaching overload condition that could cause damage to equipment property and or injury to the operator or site workers in the vicinity of the crane and its load This system must never be used under any circumstances as a substitute for the good judgment of a crane operator when carrying out approved crane operating procedures Responsibility for the safe op...

Page 6: ...take time to read and understand these definitions NOTE PROVIDES INFORMATION THAT MAY BE OF SPECIAL INTEREST DANGER INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES IMPORTANT IND...

Page 7: ...reen page 12 2 2 Display Buttons Location and Purpose page 13 2 3 Warning Lights and Indicators Location page 15 2 4 Warning Lights and Indicators Detailed Description page 16 3 INSTALLATION CALIBRATION 4 OPERATING INSTRUCTIONS 4 1 Safety Instructions page 19 4 2 Residual Risks page 20 4 3 Power On page 21 4 3 System configuration page 21 4 4 1 Duty Number Selection page 22 4 4 2 Hoist Selection p...

Page 8: ... 5 2 Limit value Adjustments page 40 4 5 3 Enable Disable a limit page 41 4 6 Range Limiting Option page 42 4 6 1 Accessing Range Limiting Mode page 44 4 6 2 Limit high page 45 4 6 3 Free Zone page 46 4 6 4 Variable Limit Height page 47 4 6 5 Variable Limit Radius page 48 5 DIAGNOSTIC TROUBLESHOOTING 5 1 Diagnostic Menu page 50 5 2 Angle Lenght Sensor page 51 5 3 Pressure Sensor page 53 5 4 Relays...

Page 9: ...Inspections page 63 6 2 Periodical Inspections page 63 6 3 Rated Load test page 64 6 4 Maintenance page 65 6 5 Maintenance Procedure page 66 6 6 Adjustements Repairs page 67 i3500 Introduction 3 Telescopic Cranes Pressure Sensing Instruction Manual ...

Page 10: ...eted all operator trainee qualification requirements and have read and fully understood the instructions in this manual Operator requirements shall include demonstrating the ability to read write and comprehend and use arithmetics and read and understand the load capacity charts in the language of the crane manufacturer s operating instruction materials Maintenance of the system is intended only f...

Page 11: ... related to the maximum permissible crane loading The actual load is expressed as a percentage of the permitted load SWL If this percentage exceeds a preset value alarms and safety functions are activated The values of the hook load the permissible load the main boom angle and the radius are displayed in a digital form on a graphic liquid crystal display LCD If the additional sensors are fitted th...

Page 12: ...city 100 A red light will illuminate when the rated capacity has been reached or exceeded An additional red light will also turn on when the rated capacity limiter is activated Cut Off External visual alarms are also provided with the external audible alarm to warn the personnel in the danger zone so that they can be aware of the danger when the rated capacity limiter is activated or overridden No...

Page 13: ...ton activated within working range deadlock 100 110 override X X X X On Off On On Boom up override X X X X On Off Off On Bridging Key X X X X On Off Off On A2B operating mode X X On Continuous Off On Off Off A2B Calibration or Rigging mode X X X Off Off Off On Off Setup button activated in Erection Rigging to override the A2B Off Off Off Off Off Off On On Calibration mode Off Off Off Off Off Off O...

Page 14: ...librated On On On Continous On On Setup button activated within working range deadlock 100 110 override X X X X On On Boom up override X X X X On On Bridging Key X X X X On On A2B X X X X Off Off Setup button activated in Erection Rigging to override the A2B Off Off Off Off On On Calibration mode Off Off Off Off Off Off Range Limiting approach On Off Off Intermittent Off Off Range limiting limit r...

Page 15: ...Pressure sensors Highly sensitive built for precise lifting and weighing in harsh environments 4 Cable reel with angle and length sensor A solid state angle sensor is used to monitor the angle of the boom A potentiometer is used to monitor the boom length 5 Anti two block the anti two block switch is normally closed with weight hanging spring loaded switch option 6 Wind speed sensor Shows wind spe...

Page 16: ...1 6 Block Diagram Block Diagram of the i3500 CANbus Communication Link Network i3500 Introduction 10 Telescopic Cranes Pressure Sensing Instruction Manual ...

Page 17: ...x 3 15cm x 21cm x 7 5cm Display sealing IP65 Memory capacity 10 000 load radius curves CANbus sensors interface Default quantity Maximal quantity Load or pressure sensor 2 6 Angle Length sensor 1 5 Relay output 5 32 Digital input 4 16 Provision for other sensors Peripheral communication port RS 232 i3500 Introduction 11 Telescopic Cranes Pressure Sensing Instruction Manual ...

Page 18: ...D BOOM TIP HEIGHT BOOM ANGLE 2 Detailed description of the display unit The display should be used only as a guide NOT as an indication that the crane would or would not pass under a structure of an accurately known height The slew angle indicator upper left corner of the screen is only present when the range limiting option is installed in the machine i3500 Introduction 12 Telescopic Cranes Press...

Page 19: ...t Up mode Diagnostic mode Calibration mode password protected HOIST SCROLL UP BUTTON Shows hoist menu for selection of the hoist currently in use Also used to scroll up through options or to increase adjustable values PARTS SCROLL DOWN BUTTON Shows parts of line falls menu for selection of the number of parts currently in use Also used to scroll down through options or to decrease adjustable value...

Page 20: ...gging mode See sections 4 4 7 4 4 7 1 for complete details TARE BUTTON Toggles the load display between the actual load and the tared load SELECT BUTTON Used to select a highlighted item in a menu In normal mode use this button to select the infor mation displayed in one of the pull down menus If no menu is opened used to scroll through the configuration at the bottom line of the display ESCAPE BU...

Page 21: ...RESET LIMIT S REACHED TWO BLOCK CONDITION DETECTED RATED CAPACITY LIMITED BY THE HOIST ROPE MOTION CUT RED LIGHT OVERLOAD WARNING RED LIGHT APPROACH WARNING YELLOW LIGHT i3500 Introduction 15 Telescopic Cranes Pressure Sensing Instruction Manual ...

Page 22: ...capacity This is usually associated with for example booming down telescoping out or hoisting up The exact operation is specific to the crane model The overload warning light red in color illuminates at or above 100 of the rated capacity This light will also turn on if you are reaching a predetermined limit set in the limits setting mode Operate with caution The crane is working near its maximum o...

Page 23: ... This indicates that the maximum load is limited by the rated strength and the number of parts of line of the hoist rope Increasing the number of falls parts of line reeved and set in the display is normally required to reduce a rope limit One of these indicators appear on the screen when a preset Maximum or Minimum Angle Limit has been reached or is about to be reached If you are approaching a pr...

Page 24: ... be reached If you are approaching a predetermined maximum radius limit this indicator will appear on the screen the approach warning light will blink and the internal buzzer will turn sound on and off If you have reached a predetermined maximum radius limit the overload warning light will light up and the buzzer will sound continuously This indicator appears on the screen when a preset Maximum He...

Page 25: ...ot been included in this instruction manual 19 Telescopic Cranes Pressure Sensing Instruction Manual i3500 Operation 4 Operating Instructions 4 1 Safety Instructions When operating the i3500 system always observe the safety rules and regulations applicable in the country of operation to reduce the risk of personal injury or damage to the equipment Read the following safety instructions before atte...

Page 26: ...lead to serious injury or death 7 The operator must verify the crane configurations and number of parts of line for each available hoist every time he she enters the crane and every time the crane is rigged Note each hoist has its own configuration set up kept in memory and simply by changing the hoist from main to auxiliary the configuration and number of parts of line will change to suit 4 2 Res...

Page 27: ...could result in injury or death System gives no indication of poor ground stability causing risk of machine breakage or tipping that could result in injury or death Switch on the electric power i e crane key switch to the i3500 system The indicator will perform a Self test during which time approx 10 sec the audible alarm will sound the approach overload and motion cut lights will illuminate and t...

Page 28: ...nderstand these instructions before selecting a duty number Selecting the wrong duty number can result in overloading of the crane risking machine breakage or tipping that could result in serious injury or death Never select a duty number if you have any doubts instead seek the advice of a qualified technician Make sure that the duty number displayed in the normal mode screen matches the current c...

Page 29: ...h your system for more details This document is a plasticized sheet of paper and it must be stored in the operator s cab for duty selection purpose In case of need of assistance contact RaycoWylie with the serial number of your system for technical advice The current duty number is displayed in the upper right corner of the normal display and additional configuration information can be seen by pre...

Page 30: ...o display the duty menu Note the duty number should be already highlighted 2 Press Select button 4 to enter the duty number menu 3 Press Scroll Up or Down button to highlight the desired number for the first digit see fig 1 a 4 Push Select button 4 to confirm your choice 5 Scroll Up or Down to highlight the desired number for the second digit 6 Press Select button 4 to confirm your choice 7 Repeat...

Page 31: ...overloading of the crane risking machine breakage or tipping that could result in serious injury or death Make sure that the hoist displayed in the normal mode screen matches the current configuration of the machine In some software versions the hoist selection must be made by using the Duty button 7 In that case please note that the direct selection is not possible using the procedure described h...

Page 32: ...of line selection menu 2 Scroll up or down with buttons 2 3 to highlight the desired number of parts of line 3 Push Select button 4 to confirm your choice Carefully read and understand these instructions before selecting the Parts of line used Selecting the wrong Parts of line can result in overloading the rope risking breakage that could result in serious injury or death Make sure that the Parts ...

Page 33: ... Scroll down 3 buttons to select the function to test 3 Press Select 4 button to run the desired test If the button test function is selected press a button to see its corresponding number appear on the screen To exit the button test do not press any buttons and the system will automatically return to the test menu screen 4 Press Escape 5 button to exit the test menu Caution The crane must not be ...

Page 34: ... system should be configured correctly Chart Info Screen Once your system is properly configured the i3500 Rated Capacity Indicator is ready to use 4 4 5 System Configuration Information Screen The chart info screen is different for each crane model The representation depicted above may not be identical to the chart info screen shown on your system Press the Info 8 button repeatedly to display the...

Page 35: ... steps to modify any of the system setup options you must first access the system set up mode 1 Press the Mode 1 button 2 Scroll down with the Parts Scroll down 3 button to highlight the system set up line 3 Press the Select 4 button to confirm your choice and enter the desired menu Operating Mode Selection Menu Choose the System Set Up mode 29 Telescopic Cranes Pressure Sensing Instruction Manual...

Page 36: ...epeat steps 1 to 3 of the preceding section system setup options section Select language 2 The language line should be highlighted on the display by now If not scroll up or down with the Hoist Scroll up 2 or Parts Scroll down 3 buttons to highlight the desired language 3 Press Select 4 button to confirm your choice or 30 Telescopic Cranes Pressure Sensing Instruction Manual i3500 Operation ...

Page 37: ...3 of the system setup options sec tion see page 29 of this manual Select units 2 The Units line should be highlighted on the display by now If not scroll up or down with the Hoist Scroll up 2 or Parts Scroll down 3 button to highlight he desired unit combination 3 Press the Select 4 button to confirm your choice or Display unit menu 31 Telescopic Cranes Pressure Sensing Instruction Manual i3500 Op...

Page 38: ...ll up or down with the Hoist Scroll up 2 or Parts Scroll down 3 button to highlight the desired choice 3 Press the Select 4 to invert the colors accor ding to your choice or Normal display Inverted display 4 4 7 Bypass Rigging Warning When in Rigging mode the cutoff and overload alarms are disable In this condition the crane is not fully protected by the i3500 so it s absolutely essential to obey ...

Page 39: ...ollowing points when in rigging mode There are No lock outs except for the ATB The ATB switch is still monitored No audible alarms The Amber Light is on The speeds of the movement are not limited A flashing rigging message is shown on the display The rigging mode can be accessed when the SWL is zero The rigging mode is automatically exited when The system is powered off or The SWL is greater than ...

Page 40: ...valid duty is selected and the capacity is greater than 0 and There are no faulty sensors The override is automatically cancelled when The load exceeds 110 SWL or The load is below 100 SWL or The bypass button is pressed a second time or The control levers are in neutral position for more than 10s or There is a faulty sensor or At engine stop or An ATB condition occurs or The RCI LMI resets An ATB...

Page 41: ... 8 Bridging and Range Limiting Box 4 4 8 1 Bridging device When the bridging device is activated the crane is no longer protected by the i3500 system Therefore it is absolutely essential to obey the crane manufacturer s advice regarding crane operations 35 Telescopic Cranes Pressure Sensing Instruction Manual i3500 Operation RANGE LIMITING KEY SWITCH OPTION RESET OVERRIDE KEY SWITCH ...

Page 42: ...tivation of the bridging device the speed of all movements increasing the loading condition is fixed at 15 max 25 in some machines of the permissible working speed for the corresponding load case Furthermore when the bridging device is enabled the external alarm and the external warning red light are activated An override message flashes on the system display The bridging is activated when The mom...

Page 43: ...ndicator will be activated Range Limiting Key Switch Normal Run position Normal mode The system works without a programmed limit Slew Range Set position This switch position allows access to the Range limiting mode refer to section 4 6 of this manual Tracks stopped position This switch position locks the machine tracks in place to stop it from moving when one or several limits have been pro gramme...

Page 44: ...um Operating Radius Limit Carefully read and understand these instructions before setting the Operational Limits Setting the wrong Operational Limits can result in accidentally running into obstacles which could lead to serious injury or death Important Please note that if your machine is equipped with the Range limiting key switch option the Operational Limits setting mode will Not be available f...

Page 45: ... 3 Press Select 4 button to enter the limits setting menu Limits setting Menu Please note that limits are not active when power is first applied to the i3500 system and they are automatically disabled if power is removed Depending on software version in some systems the limits will be kept active even if power is cut 39 Telescopic Cranes Pressure Sensing Instruction Manual i3500 Operation ...

Page 46: ...light the limit you want to edit 3 Press Select 4 button to confirm your choice 4 Press the Hoist Scroll up 2 and Down 3 button to select the desired value for this particular limit 5 Press Select 4 button to confirm the selected value 6 Press Escape 5 button to return to the normal operating mode or or 40 Telescopic Cranes Pressure Sensing Instruction Manual i3500 Operation ...

Page 47: ...3 button until the highlighted area moves to the first line of the column indicated above 3 Use the Hoist Scroll up 2 and Parts Scroll down 3 buttons to highlight the current state ON or OFF of the limit you want to activate or deactivate 4 Press Select 4 button to toggle between the ON and OFF state of the limit 5 Press Escape 5 button to return to the normal operating mode or Limit Status 41 Tel...

Page 48: ...crane outside the minimum clearances allowed in such a way that there is no possibility of the crane load line or load becoming a conductive path to avoid the risk of being electrocuted The crane shall not be used to handle material stored under electrical power lines unless any combination of boom load load line or machine cannot enter the prohibited zone The range limiting option provided by the...

Page 49: ...ALL Menu options When the system is equipped with the Range Limiting key switch option the system automatically selects the Range Limiting mode as the only possible choice In that case the following menu options are offered High Limit Free Zone Variable Limit Height Variable Limit Radius In most systems only one menu option can be chosen at the time however this may vary depending on software vers...

Page 50: ...ition see fig on section 4 4 8 2 Scroll down with Parts Scroll down 3 button to highlight the range limiting option of your choice 3 Press the Select 4 button to select one of the following menu options High Limit Free Zone Variable Limit Height Variable Limit Radius Menu screen 44 Telescopic Cranes Pressure Sensing Instruction Manual i3500 Operation ...

Page 51: ...n to confirm the maximum boom tip height position As you release Select 4 button an 8 second countdown will allow you to boom down before your programmed height limit becomes active 4 To go back to Normal mode turn the Range limiting key switch to the Normal run position or Tracks stopped option if available 45 Telescopic Cranes Pressure Sensing Instruction Manual i3500 Operation ...

Page 52: ...sition of the first wall 4 Rotate the crane to the second limit position second wall Press Select 4 button to confirm that this will be the position of the second wall As you release Select 4 button an 8 second countdown will allow you to rotate the crane between the two walls before your programmed free zone limit becomes active 5 To go back to Normal mode turn the Range limiting key switch to th...

Page 53: ...e the crane toward the second limit position second wall with the boom tip always at the maximum height per mitted by the surrounding environment Press Select 4 button to confirm the position of the second wall As you release Select 4 button an 8 second countdown will allow you to return between the two walls and boom down below the height limit before your programmed variable height limit becomes...

Page 54: ...he boom tip always at the maximum radius per mitted by the surrounding environment Press Select 4 button to confirm the position of the second wall As you release Select 4 button an 8 second countdown will allow you to return between the two walls and boom up within the allowed radius limit before your programmed variable radius limit becomes active 6 To go back to Normal mode turn the Range limit...

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Page 56: ...telescopic multi point rotation as well as the addresses of all sensors detected by the i3500 system Regardless of system configuration a minimum of three menu pages are always provided angle length general info and detected addresses Additional pages are optional and are only shown if one or more sensors are enabled refer to the option enable disable I O in the calibration menu The use of the Scr...

Page 57: ...d has an ATB option that can be activated by dip switch 4 For the angle length card which is not monitoring the ATB N A is shown under a2b instead of 0 or 1 indicating that it s not available on this card Value 0 represents a safe condition while value 1 will represent a two block condition As shown on the above table for the length 1 sensor the value ain1 represents the boom extension value in bi...

Page 58: ...ey when Length 1 is highlighted The displayed information will look similar to this The line beginning with Ver indicates the software version of the angle length sensor and also its creation date The next two lines indicate if a sensor has been calibrated or if the calibration is valid The scale value must be smaller than 1 0 Lenght 1 Ver 1 01 07 jun 07 Offset 57 Scale 0 149661 Press button when ...

Page 59: ... energized whereas 1 indicates that it s not energized The Inputs block represents the state of the 4 DIN inputs Value 0 represents an active input A maximum of 4 relay cards can be installed The line beginning with Ver indicates the software version of the pressure sensor and its creation date The next two lines indicate if a sensor has been calibratedorifthecalibrationisvalid Thescalevaluemustbe...

Page 60: ... to this Press when Relay board 1 is highlighted The Ver line indicates the software version of the relay card and its creation date fig below The displayed Information will look similar to this Relay Board 1 Ver 1 01 07 jun 07 Relay 1 2 3 4 5 6 7 8 1 2 3 4 Board 1 1 1 1 1 0 1 1 1 1 1 1 1 Relay Inputs 54 Telescopic Cranes Pressure Sensing Instruction Manual i3500 Troubleshooting ...

Page 61: ...e encoder type Represents the type of sensor This menu page provides the sensor addresses on the CAN network detected by the i3500 system Addresses remain in memory as long as the system is powered even if a sensor stops communicating The displayed information will look similar to this Note The informa tion depicted here may differ depen ding on the rota tion sensor used Consult the i3500 Calibrat...

Page 62: ...ive soldering or is broken 3 There is a problem with the logger card Rld flash Test failed When starting system there is a verification writing reading of the flash chip of the limit programmed range limiting device 1 There is a problem with flash memory U52 Chart Test failed Upon startup the system does a read verification of the load chart flash memory chip 1 The Load chart chip is not installed...

Page 63: ...pon startup the system does a read write verification of RAM chip This is a volatile memory 1 There is a problem with RAM memory U3 With Logger option the cause is RAM memory U5 if system is behaving strangely if system initializes often during operation mode if system never starts Not calibrated There is no calibration for the selected duty 1 The calibration must be done General failure or CANbus...

Page 64: ...rt corresponds to the crane to be calibrated 2 Does load chart depend on rotation 3 Does load chart depend on DIN inputs No Parameter The Crane dimensions must be entered in the system The Load value will be null or wrong 1 CL3 CL4 and CL7 values should Not be at zero No 2nd duty found The Comparison angle radius option must be activated Thus a jib capacity is evaluated by its angle offset against...

Page 65: ... bits of the accelerometer is valid Angle length Comm The i3500 system does not receivedatafromanglesensor If time out delay is reached then a communication error is displayed 1 The angle length circuit board is defective 2 The Can bus network cable is broken Length x Not calibrated Length sensor is not calibrated Angle Not calibrated Angle sensor is not calibrated Angle length x Dr The 5 volts re...

Page 66: ...a from relay card If time out delay is reached then a commu nication error is displayed 1 The Relay card is defective 2 The Can Bus network cable is broken The i3500 system can support up to 4 load circuit boards Activation of every load sensor is done in the calibration menu section Enable Disable I O The i3500 system can support up to 4 relay cards Activation of every relay card is done in the c...

Page 67: ...ute rotation and another one for analogical output Activation of every generic card is done in the calibration menu section Enable Disable I O D Generic interface board errors Relative rotation The i3500 system can support only one 1 rotation card There are two differ ent kinds a relative one and an absolute one Activation of rotation card is done in the calibration menu section Enable Disable I O...

Page 68: ... from the rotation card If the timeout delay is reached then a communication error is displayed 1 The Rotation card is defective 2 The Can Bus network cable is broken Error message Execution process Cause of error Encoder ratio Ratio is not programmed 1 The Encoder is defective Encoder Works with serial link RS 422 Encoder communication i3500 system does not receive anything from rotation card If ...

Page 69: ...tem has been properly configured Verify the accuracy of the clock Verify that no error has been detected by the system Verify the weight of the hook block must be consistent with last check Verify the radius according to the boom selection The displayed radius must be between 0 and 10 greater than the actual radius or in accordance with current regulations Verify that the capacity displayed confor...

Page 70: ...acy of load indication Rig with enough parts of line to lift a large weight Measure and record the radius and the hook weight Note the displayed radius length hook weight parts of line and capacity on the i3500 display unit Lift the large weight Record the actual weight with the hook and rigging attachment Note the average the low and the high value Perform a hoist up and stop and note the same da...

Page 71: ...ent parts must be obtained from RaycoWylie as original parts unless approved and authorized as an equivalent by a Service technician of RaycoWylie To keep the waterproofness of the i3500 s display the back cover must be tighten following an X pattern Your i3500 system requires no additional lubrication Important If condensation appears in the screen of the display unit open the cover in a dry plac...

Page 72: ...ng or removing hydraulic components Warning or Out of Order signs shall be placed on the crane controls and be removed only by authorized personnel After adjustments and repair have been made the crane shall not be re turned to service until all guards have been reinstalled trapped air removed from the hydraulic system and safety devices reactivated The instructions shall be provided by the crane ...

Page 73: ...lie Any hazardous conditions disclosed by the inspection requirements shall be corrected before operation of the crane is resumed Important Adjustments and repairs shall be done only by qualified personnel If you have any questions or need technical assistance please contact our Technical Service Department at RaycoWylie quoting the infor mation found on the serial number label of your i3500 syste...

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Page 75: ... Notes 69 Telescopic Cranes Pressure Sensing Instruction Manual i3500 Maintenance ...

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