55M4500CCE00 REV A
Calibration Instructions
i4500 Rated Capacity Limiter/Indicator
for
telescopic cranes, pressure sensing
Crane safety instrumentation
Page 1: ...55M4500CCE00 REV A Calibration Instructions i4500 Rated Capacity Limiter Indicator for telescopic cranes pressure sensing Crane safety instrumentation...
Page 2: ...55M4500CCE00 REV A...
Page 3: ...n and or modification of the equipment are strictly forbidden without written approval from RaycoWylie Systems The i4500 RaycoWylie Systems Rated Capacity Indicator RCI is to be regarded only as an ai...
Page 4: ...nual 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 depen...
Page 5: ...bridging bypass output 20 Step 10 picture 20 3 CALIBRATION 21 Step 11 Zero sensor Side of boom angle angle sensor calibration 21 Step 12 Zero sensor Span sensor length sensor calibration 22 Step 13 Ze...
Page 6: ...55M4500CCE00 REV A special calibration 47 Users ID Setting user pass codes for the data logger 47 rotation data 48 5 AUTOMATIC LOGS 50 Fault log 50 Event recorder 50...
Page 7: ...ration Personnel qualification and scope of this manual Installation of the i4500 system shall be performed by a qualified technician Furthermore calibration of the i4500 system must be performed by a...
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 even...
Page 9: ...on to the second digit Repeat this for all 5 digits after confirming the 5th digit the system will enter the calibration menu provided the password is correct If the password is not correct the system...
Page 10: ...e 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 m...
Page 11: ...55M4500CCE00 REV A For the Generic and GPio items there are various configuration options available once enabled refer to the system wiring drawing for details of which selection to set...
Page 12: ...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 t...
Page 13: ...main rope 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 Max parts of line This is the maximum number of parts of line...
Page 14: ...ON Outside duty angle This variable works in the same way as outside duty radius but is used for charts where the SWL is determined by boom angle and not radius Outside duty length This variable repre...
Page 15: ...ontal distance between the boom foot pin and lift cylinder base pin CL4 p2blv vertical distance between the boom foot pin and lift cylinder base pin CL7 p2buh distance between the boom foot pin and li...
Page 16: ...the boom base mounted main hoist guide sheave and the boom foot pin measured when the boom is horizontal see note 1 CR2A a h radius radius of the auxiliary hoist drum from the center to the middle of...
Page 17: ...e them with 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...
Page 18: ...acity of each hook will be used by the i4500 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 ca...
Page 19: ...o the crane manufacturer s load chart to determine if the charts should be interpolated or stepped Datalogger Allows the datalogger if fitted to be switched ON or OFF Crane ID This is only used if a d...
Page 20: ...ware installed When available it allows the selection of one or more crane models within a single manufacturer s range to allow for differences in required features It must be set to precisely match t...
Page 21: ...These switches are factory set prior to dispatch and will not normally require changing Please refer to the wiring diagram to see the address dip switch setting for each angle sensor interface Angle S...
Page 22: ...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 increa...
Page 23: ...o and including the section that the length sensor cable is attached to for single reel installations this is all boom sections including a manual section if fitted The sensor value should be a minimu...
Page 24: ...d 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 t...
Page 25: ...esents 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...
Page 26: ...econd will monitor the whole boom to section 5 One no load calibration procedure is done using sections 3 4 and 5 telescoping and with the section 2 fully retracted a second is done using sections 3 4...
Page 27: ...ic Boom Mode calibration it is highly recommended that all unnecessary stowed attachments are removed from the boom to ensure the best result Only the main block should be rigged during a no load cali...
Page 28: ...te X the previous calibration will be lost Press X to delete the existing calibration and go to the next screen or to escape If this is the first calibration for this duty the display will show Where...
Page 29: ...ctions 3 4 and 5 combined 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...
Page 30: ...nce changes Where no intermediate boom lengths are shown in the crane capacity chart use the default lengths chosen by the system Enter the remaining lengths as prompted ensuring that each new calibra...
Page 31: ...hoist cylinder almost fully extended just avoiding the maximum boom angle stops and press when done Setting the minimum boom angle for each calibration length The display will show Minimum angle for l...
Page 32: ...e 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...
Page 33: ...procedure When the final calibration point is accepted the i4500 will automatically save the data and display the following confirmation screen Press to return to the main calibration menu To exit the...
Page 34: ...or the configuration being calibrated and should be based on the SWL with a fully extended boom at approximately 60 boom angle The calculated test load should normally include the weight of the hook b...
Page 35: ...change to show Carefully lift the test load just 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...
Page 36: ...or is variable then verify all data entries required in the dimension and calibration data section It is recommended that this procedure is done with the machine on outriggers or crawlers A known test...
Page 37: ...constant fixed load error for the complete operating range If the error is variable then verify all data entries required in the dimension and calibration data section It is recommended that this proc...
Page 38: ...the test load just clear of the ground 2 Use or to modify the load adjustment factor until the displayed load is equal to the test load and press to accept the change the system will confirm the cali...
Page 39: ...must be calibrated is 2 the maximum that can be calibrated is 20 The following notes are intended to give general guidance only as each individual installation will be different The full working enve...
Page 40: ...ter 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...
Page 41: ...d load 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 n...
Page 42: ...from 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...
Page 43: ...tor is best established by trial 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 tha...
Page 44: ...ial number of the i4500 system the date is the date the calibration file is completed downloaded and tech is the initials of the calibrating technician Some configuration specific calibration data may...
Page 45: ...files can be restored to the i4500 system at any time Note a USB memory stick must be connected to connector B of the i4500 display unit using a Deutsch to USB converter lead RaycoWylie part no 33V04...
Page 46: ...ented 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 op...
Page 47: ...ction will contain calibration settings for special features if enabled and will be described in a separate addendum to this manual Users ID Setting user pass codes for the data logger This feature is...
Page 48: ...l go to the normal working screen if password protection is set to ON rotation data This feature is only available if the range limiting feature is fitted to the system or a sensor is used to monitor...
Page 49: ...ged It represents the type and manufacturer of the encoder that is fitted Ratio This value will only be available if a multi turn encoder is specified above and represents the number of turns that the...
Page 50: ...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...
