RaycoWylie i4300 Calibration Instructions Manual Download

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55M4300CCE00 Rev A

TABLE OF CONTENTS

INTRODUCTION .................................................................................................. 7

Personnel qualification and scope of this manual .................................................... 7

Using this manual ......................................................................................................... 7

CONFIGURATION ............................................................................................... 9

Step #1: Accessing the calibration menu .................................................................. 9

Step #2: “Enable/Disable i/o” Setting

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Step #3: “Calibration units” setting

...............................................................................

Step #4: “Calibration data” Entry

....................................................................................

Step #5: “Dimensions” Data entry

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Step #6: “Block capacities and block weights” setting

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Step #7: “System options” setting

.................................................................................

Step #8:

“Picture”

..............................................................................................................

Step #9: Set the clock .................................................................................................21

CALIBRATION ....................................................................................................23

Step #10: “Zero sensor/Side of boom angle” angle sensor calibration

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Step #11: “Zero sensor/Span sensor” length sensor calibration ...........................25

Step #12: “Zero pressure/Span pressure” press. sensor calibration

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Step #13: Main boom “No Load calibration”

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Step #14: Main boom “Unloaded boom deflection”

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Step #15: Main boom “Loaded boom deflection”

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Step #16: Main boom

“Load adjustment”

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Step #17: Main boom

“Load offset”

...............................................................................

Step #18: Attachment “Jib deflection”

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Step #19: Attachment

“Load adjustment”

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Step #20: Attachment

“Load offset”

..............................................................................

Step #21:

“Friction Cylinder”

...........................................................................................

Step #22: “Transfer” Calibration backup

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“Transfer” restoring calibration and load chart files

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“Memory”

..............................................................................................................................

OPTIONS ............................................................................................................54

Summary of Contents for i4300

Page 1: ...mentation Copyright 2017 Rayco Wylie Systems All rights reserved Any part of this document may not be reproduced or transmitted in any form or by any means including photocopy or any other information storage and retrieval system without the permission from RaycoWylie Systems which will not normally be withheld assuming that the material is for internal use only ...

Page 2: ...55M4300CCE00 Rev A ...

Page 3: ...on and or modification of the equipment are strictly forbidden without written approval from RaycoWylie Systems The i4300 RaycoWylie Systems Rated Capacity Indicator RCI is to be regarded 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 property and or injury to ...

Page 4: ...anual and the crane manufacturer operator s manual He must also be aware of all the federal state and local safety standard and regulations applicable to his job Correct functioning of the system depends upon routine daily inspection Any suspected faults or apparent damage should be immediately reported to the responsible authority before using the crane ...

Page 5: ...RATION 23 Step 10 Zero sensor Side of boom angle angle sensor calibration 23 Step 11 Zero sensor Span sensor length sensor calibration 25 Step 12 Zero pressure Span pressure press sensor calibration 27 Step 13 Main boom No Load calibration 29 Step 14 Main boom Unloaded boom deflection 37 Step 15 Main boom Loaded boom deflection 39 Step 16 Main boom Load adjustment 42 Step 17 Main boom Load offset ...

Page 6: ...00 Rev A Limits setting parameters 54 Users ID Setting user pass codes 54 5 AUTOMATIC LOGS 56 Fault log 56 Event recorder 56 6 ANNEX 1 Calibration of Main boom Load correction 58 7 ANNEX 2 Menu cross reference 63 ...

Page 7: ...bration Personnel qualification and scope of this manual Installation of the i4300 system shall be performed by a qualified technician Furthermore calibration of the i4300 system must be performed by a RaycoWylie trained technician The RaycoWylie technician will perform a complete and structured verification of the whole system before beginning the system s calibration Failure to calibrate the sys...

Page 8: ... relevant text for detailed use SAVE button Press to save all recent changes into memory DELETE button Press to delete a stage of some calibrations CLEAR button Press to clear the fault log or the event log CHANGE SIGN button Press to set a variable to negative or back to positive ...

Page 9: ...er confirming the 5th digit the system will enter the calibration menu provided the password is correct If the password is not correct the system will return to the normal working screen 5 If a mistake is made while entering the password press to return to the previous digit Some systems are installed with dual level password access this manual includes information on all features accessible from ...

Page 10: ...ue then Press to confirm 5 Any change made must be permanently registered by pressing the save button 6 Press at any time to abandon any changes not saved or to exit the menu when done As a guide the minimum requirements for a basic systemare Angle 1 ON Length 1 ON Load 1 ON Load 2 ON Relay board 1 ON All remaining items in the list are optional and set to OFF if not used Refer to the wiring diagr...

Page 11: ...e the use of the HDIN HDOUT connections Scroll to GPio Hdins configuration and press to enter the screen will show options to set each GPio that has HDIN HDOUT set to ON Select the pair of inputs required press to highlight the option currently set use or to scroll through the available options and then press save when the required option is displayed Refer to the wiring drawing supplied for the n...

Page 12: ...libration units setting 1 In the calibration menu scroll up or down to the item Calibration units 2 Press to toggle between metric and imperial imperial use x1000lbs and feet metric use metric tons and metres 1 metric ton 1000 kg ...

Page 13: ...e and the hook capacity the lowest of these figures will be used as the current SWL for alarm purposes Rope limit Aux This is the maximum tension that the cable is rated for per fall or part of line rope SWL for the auxiliary rope Note that this value will be monitored simultaneously with the relevant load table and the hook capacity the lowest of these figures will be used as the current SWL for ...

Page 14: ...th This variable represents an upper tolerance on the automatic selection of the relevant load capacity chart for the actual boom length measuredby the system length sensor Inside duty length This variable represents a lower tolerance on the automatic selection of the relevant load capacity chart for the actual boom length measuredby the system length sensor Number of hoists Set to the number of h...

Page 15: ...s eg mode A with top section pinned closed and mode B with top section included in telescoping set CL2 to max boom length with top section closed CL2MR full extend w o extension length of the boom fully extended but with any manual or power pinned extension retracted Note For full power booms without a manual section CL2 and CL2MR are the same value Special case for booms with two telescoping rang...

Page 16: ...o CR22M radius of the boom base mounted main hoist guide sheave see note 1 CL28M vertical distance between the boom base mounted main hoist guidesheave and the boom foot pin measured when the boom is horizontal see note 1 CL29M horizontal distance between the boom base mounted main hoist guide sheave and the boom foot pin measured when the boom is horizontal see note1 CR2A a h radius radius of the...

Page 17: ...th the missing dimensions and weights The load chart file will be updated with the verified information and returned via email Before calling please take note of the technical file reference TF xxxxx and serial number located on the serial number label of the display alternatively go to the diagnostics screen select system and note the full name of the load chart file given there This will enable ...

Page 18: ...55M4300CCE00 Rev A Boom hoist cylinder geometry Winch geometry Winches or guide sheaves on superstructure ...

Page 19: ...used by the i4300 system to determine whether the current SWL for the configuration and position of the machine is limited by the load curve the parts of line or the hook capacity The weight of the selected hook will be used in the calculation of the load if set as an unused hook in the duty wizard refer to operation manual After selecting block capacities and block weights from the main calibrati...

Page 20: ...art to determine if the charts should be interpolated or stepped Crane ID This is a unique identifier for the crane It is used as an identifier for files once downloaded and removed from the machine Enter a unique reference for the machine eg crane serial number or fleet number etc Password protection When set to ON will set the system to ask for a pass code number to be entered each time the syst...

Page 21: ...that looks similar to the machine to which the system is fitted It can be set to any of the available choices at any time without changing the performance of the system Step 9 Set the clock The clock must be set to the correct local time and date to ensure any event recorded by the i4300 is simple to analyze It is not necessary to be in the calibration mode of the i4300 for this setting see also S...

Page 22: ...ch highlighted field in turn using the or buttons to select the value and the button to save each setting and move to the next field The screen will return to the main screen after the minutes have been set Press at any time to exit to the main screen ...

Page 23: ... the address dip switch setting for the angle sensor interface Angle Sensor Side of Boom 1 Use or to choose select sensors and press 2 Use or to choose the relevant angle sensor and press the 3 Use or to choose span sensor or side of boom angle and press 4 Press to highlight the value to edit and use or to edit the location of the angle sensor normally integrated into the length sensor reel press ...

Page 24: ...angle measure to accurately establish the true angle of the base boom section The angle is displayed in degrees and the sensor value is in bits This value must be above 100 bits If smaller turn the sensor to increase the value 3 Press to edit the angle value using or 4 Press again to confirm the zero 5 Press to return to the main calibration menu The boom angle need not be zero but it s true value...

Page 25: ... the boom completely The sensor s value must be approximately 100bits 0 50 volts adjust the potentiometer inside the cable reel if necessary 5 Edit the zero value when the boom is completely retracted the value must be set to zero 6 Press to confirm the value Note the indicated value will return to it s earlier state temporarily the new zero value will be stored after the next step 7 Press to retu...

Page 26: ...een the extended length and the fully retracted main boom length using the units shown at the bottom of the screen For example A fully extended boom of 30m minus a fully retracted boom of 10m 20m Enter 20 0 for the span extension 3 Press to edit the span value 4 Edit the span value then press to confirm the value 5 Press to return to the main calibration menu ...

Page 27: ...r and press 2 Use or to choose the Load 1 Bore or Load 2 Rod sensor and press Zero pressure calibration 1 Use or to choose Zero pressure and press WARNING Make sure the boom is mechanically supported by the cylinder stops to prevent a sudden fall when the residual hydraulic pressure is released To zero the pressure sensors open the hydraulic lines of both sensors in order to remove any residual pr...

Page 28: ...nd white wires of the relevant pressure sensor together As above the reading on the bottom line represents the current bits value of the sensor for the span setting the reading should be above 3200 and not exceed 3850 If the reading is outside of these values then adjust the gain setting jumpers in the transducer interface unit to achieve the closest possible setting refer to the label inside the ...

Page 29: ...ons are done the system will continue to monitor the temporarily non telescoping section s to ensure it is not moved If a change is detected then the calibration will be suspended until the situation is corrected For all other configurations using the same main Boom Mode but with an attachment fitted i e main boom jib stowed main boom jib erected lifting over jib etc no other no load calibration i...

Page 30: ...Ensure that the crane chassis is level for all no load boom deflection and load correction calibrations Start this procedure with the boom fullyretracted Use or to choose No load calibration and press to enter If the selected configuration has been calibrated previously the system will prompt for a new calibration or give the option to escape Warning if you press X the previous calibration will be...

Page 31: ...than the default use or to edit this number to the required value Once the last number is entered press save to confirm the value and move to the next step Setting the number of length steps The display now shows The number of length steps represents the number of different boom lengths that will be used during this calibration process the number of points selected will directly affect the calibra...

Page 32: ...s will default to evenly distributed lengths calculated by the system Use or to change the default value of length 2 if required then press save to confirm the value and move to the next step Specified lengths should coincide with rated boom lengths where possible although not all rated boom lengths need to be specified Specified lengths must include lengths at which the boom telescoping sequence ...

Page 33: ... that points at 5 degree intervals will give an acceptable result Hence for example if the maximum angle is 80 degrees and minimum is 20 degrees then 13 points should be used Use or to set xx to the required number of angle steps for calibration length 1 then press save to accept Enter the number of angle calibration points for each length step in turn as prompted Setting the maximum boom angle Th...

Page 34: ...xx xx Where xx xx is the lowest working angle in degrees for length 1 Check the load chart and determine the lowest rated angle for each of the boom lengths you have previously entered i e length 1 length 2 etc and enter separate minimum working angles for each calibration length as prompted When complete the display will show ...

Page 35: ...he current bore side pressure pd2 is the current rod side pressure Boom length will show the current length followed by the target length for this calibration point or ok if at the correct length Angle will show the current angle followed by the target angle for this calibration point or ok if at the correct angle If one or both values needs to be adjusted a message will be displayed suggesting th...

Page 36: ...is point If the calibration is exited at this stage then the system will display the following screen when the no load calibration is reselected allowing the procedure to continue from the same point without the need to redo the completed section Note the incomplete calibration will be lost if the duty is changed before returning to the no load calibration procedure When the final calibration poin...

Page 37: ...wance into the calculation of the hook radius to compensate for main boom and or chassis deflection due to the self weight of the machine A separate calibration is available for each crane configuration that also has an individual no load calibration but is not used for configurations with boom attachments refer to Section 3 10 A no load calibration should be completed before continuing with this ...

Page 38: ...t the hook block does not foul the boom tip and that the boom is at a high enough angle to safely permit maximum extension 2 When the boom is at the desired extension press to accept the display will change to show the current boom angle followed by a target boom angle for calibration the default target of 60 is for guidance and can be ignored if necessary 3 Adjust the boom angle to the target ang...

Page 39: ...new correction value until the displayed radius equals the measured radius Press to accept 10 Press to return to the main calibration menu Step 15 Main boom Loaded boom deflection This procedure is used to add an allowance into the calculation of the hook radius to compensate for main boom and or chassis deflection due to a suspended load A separate calibration is available for each crane configur...

Page 40: ...th the hook block suspended telescope the boom out to fully extended for the boom mode and telescoping sequence selected for dual mode booms this will be longer than the target indicated when calibrating the larger telescoping range Warning Be sure to check that the hook block does not foul the boom tip and that the boom is at a high enough angle to safely permit maximum extension When the boom is...

Page 41: ... clear of the ground Accurately measure the actual radius of the suspended load from the centre line of slew of the machine 4 Use or to adjust the Corr x x value until the displayed radius equals the measured radius note that the indicated radius should normally be increased not decreased Press to accept the change the system will confirm the calibration is saved 5 Press to return to the main cali...

Page 42: ...whether load adjustment load offset or a combination of both should be used to improve performance Load adjustment should only be used if the load reading indicates a constant percentage of load error for the complete operating range it allows for a positive or negative percentage value adjustment to be applied to the displayed load If the error is variable then verify all data entries required in...

Page 43: ...oad offset This feature is optional and can be omitted if the displayed load is judged acceptable it is normally used in tandem with section 3 7 load adjust A separate calibration is available for each crane configuration that also has an individual no load calibration but is not used for configurations with boom attachments refer to Section 3 11 It is used to increase the accuracy of the load on ...

Page 44: ...esents the offset factor a value of 0 00 signifies that there is no applied offset The main boom must be completely retracted for the mode selected and with an angle of approximately 60 When positioning the machine remember to make the last derrick motion boom up Carefully lift the test load until it is just clear of the ground 2 Use or to modify the load offset factor until the displayed load is ...

Page 45: ...L for the configuration being calibrated and should be based on the SWL with the boom at the calibration angle chosen below this angle is normally approximately 60 but any value can be chosen if this proves unsuitable The calculated test load should normally include the weight of the hook block and any slings shackles etc that are used Ensure the current duty selection matches the actual crane con...

Page 46: ... for Corr will increase the indicated radius Press to accept the change and move to the second calibration screen 6 Carefully lift the test load until it is just clear of the ground Accurately measure the actual radius of the suspended load from the centreline of slew of the machine 7 Use or to adjust the Corr value until the displayed radius equals the measured radius Press to accept the change t...

Page 47: ...tive or negative percentage value adjustment to be applied to the displayed load If the error is variable then verify all data entries required in the dimensions area of the chart file are correct before proceeding It is recommended that this procedure is done with the machine on outriggers or crawlers A known test load is needed to perform this calibration and should be between 50 and 90 of SWL f...

Page 48: ...cks performed in section 3 10 to establish if a load offset is required Load offset should only be used if the load reading indicates a constant fixed load error for the complete operating range it allows for a positive or negative fixed value offset to be applied to the displayed load If the error is variable then verify all data entries required in the dimensions area of the chart file are corre...

Page 49: ...an angle of approximately 60 When positioning the machine remember to make the last derrick motion boom up Carefully lift the test load until it is just clear of the ground 2 Use or to modify the load offset factor until the displayed load is equal to the test load and press to accept the change the system the system will confirm the calibration is saved 3 Press to return to the main calibration m...

Page 50: ...rial and error 1 Use or to highlight friction compensation and press to enter 2 Scroll down to down friction and press to highlight the value for editing 0 00 indicates that no friction compensation is applied To begin with increase the default value from 0 00 to 0 10 and press to confirm 3 Press save to record the change 4 Press to exit the calibration mode and retest the boom down performance to...

Page 51: ...e is the date the calibration file is completed downloaded and tech is the initials of the calibrating technician For early operating systems prior to rev sc122 v0200 some configuration specific calibration data may be stored in the load chart file and for these versions only it is recommended to also make a backup copy of this second file Select load chart USB stick and press a copy of the load c...

Page 52: ...o the i4300 system at any time Note a USB memory stick must be connected to connector B of the i4300 display unit using a Deutsch to USB converter lead RaycoWylie part no 33V0414 before proceeding The USB memory stick must be formatted to FAT32 format Ensure the file required to be restored is saved in the root folder of the USB stick Navigate through the calibration menu using or to highlight tra...

Page 53: ...sented on start up Memory Warning Initialising memory A will delete all the information stored in the calibration memory be sure you have made a backup copy of the calibration file before using this option if in doubt don t initialize memories A and C Select this option to re initialize the system memory a warning screen will be displayed to ask for confirmation if confirmed all calibration data w...

Page 54: ... all the data is entered Users ID Setting user pass codes This feature is only used if password protection is set to ON It is a list of password numbers used to log into the i4300 on startup Where this feature is not used the default login number is 99999 Navigate through the calibration menu using or to highlight users id and press to enter Scroll down to the first 0 entry and press to highlight ...

Page 55: ...mmended that the default value of 99999 is retained and new entries made from position 2 onward but if the default value is changed remember to safely record the new value The i4300 system must have a valid number entered before it will go to the normal working screen if password protection is set to ON ...

Page 56: ...highlight fault log and press to enter Note the fault status press to return to the main calibration menu or press XX to reset all the counters to zero Event recorder The event recorder provides a summary of lifts performed in each 10 band of SWL it also provides a count of ATB and bypass activations Note the event recorder does not replace the data logger feature as no date and times are recorded...

Page 57: ...Rev A Note the event status these sample screens show 2 lifts performed between 50 and 60 SWL and also 2 ATB alarms recorded Press to return to the main calibration menu or press XX to reset all the counters to zero ...

Page 58: ...culation of the hook load to compensate for a potential build up of minor errors in either fixed data or previous calibration data It is recommended that this procedure is done with the machine on outriggers or crawlers Some inaccuracy of load indication with very small loads at high boom angles and short boom lengths is likely due to the small boom lift cylinder pressures encountered in this zone...

Page 59: ... than point 2 A load correction factor will not be applied to boom positions outside of this zone Case 2 This shows the influence of adding one additional calibration point to case 1 the pair of numbers in each sub zone show the calibration points used to determine the load correction factor calculated for various points in that sub zone Case 3 This shows a typical set of calibration points that w...

Page 60: ...tter results 4 8 4 3 7 3 6 2 6 2 1 5 5 10 5 9 1 9 1 12 7 12 8 7 11 6 11 10 6 10 Case 6 limited CF zones effect of omissions 4 8 No CF applied 6 No CF applied No CF applied 12 11 10 7 12 Case 4 limited CF zones 6 11 8 7 6 10 4 8 4 6 3 7 3 No CF applied No CF applied 11 No CF applied 10 Case 5 limited CF zones effect of omissions 3 11 8 7 3 10 4 8 4 3 7 3 No CF applied No CF applied 4 ...

Page 61: ...d reading and Corr 1 00 represents the adjustment factor a value of 1 00 signifies that there is no applied adjustment Angle and Length are the current values for the machine position The Point number will be 1 for the first calibration otherwise it will be the first available uncalibrated point Press to highlight the corr value for editing Position the boom to the required angle and length and ca...

Page 62: ...rom the calibration memory Press to accept the deletion the system will confirm this calibration point is deleted press to return to the main calibration menu To erase all load correction points for this configuration enter the load correction calibration screen and select any existing calibration point press XX to select all points for deletion from the calibration memory Press to accept the dele...

Page 63: ...ghts No load calibration Unloaded boom deflection Loaded boom deflection Jib deflection Load correction Load adjustment Load offset Memory Calibration data Dimensions Friction cylinder Limits setting if no slew encoder fitted Enable disable i o GPio Hdins configuration Calibration units System options Picture Transfer Fault log Event recorder Users ID Manual section 3 1 3 1 3 2 3 3 3 3 3 3 2 6 3 4...

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