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55M4500EBE00A-A

i4500 Lattice Boom Crane

Instruction Manual

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. Note that depending

on system configuration, your system may be equipped with one or with

three external lights. See tables 1 and 2 for external visual alarm operation.

I4500 system with three warning lights

Internal alarms

External alarms

Event

Green

Light

Yellow

Light

Red

Light

External

Buzzer

No event

Off

Approach

to SWL

(Alarm 1)

Blinking

Off

Intermittent

Off

Overload

(Alarm 2)

Off

Continuous

Off

Motion Cut

(Alarm 3)

Continuous

Off

Duty not

calibrated

Continuous

Off

Bypass

Overload

Off

Continuous

Off

Bypass

ATB

Off

Bridging Switch

Activated

Off

A2B

(Normal Mode)

Off

Continuous

Off

A2B

(Calibration mode)

Continuous

Off

A2B

(Rigging Mode)

Off

Calibration mode

Off

Approach

(Range Limiting)

Off

Intermittent

Off

Limit reached

(Range limiting)

Off

Continuous

Off

Rigging Mode

Off

Table 1

Summary of Contents for i4500

Page 1: ...tronic 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 55M4500EBE00A Rev A Ref VH June 2013 Ref A A Crane Warning Systems Atlanta U S Distributor for Rayco Wylie Systems 6175 Hickory Flat Hwy Suite 110 ...

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Page 5: ...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 damage the equipment property and or cause injury to the operator or people working near 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 car...

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Page 7: ...ols appears in this manual personnel safety is a concern Please take the 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 MACHINE DAMAGE CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERAT...

Page 8: ...1 7 Technical Data page 20 2 detailled description of the display unit page 21 2 1 Main Display Default Screen page 21 2 2 Display Box Overview page 22 2 3 Operating Buttons Description page 23 2 4 Main Modes page 25 2 5 Warning Lights and Indicators Location page 26 2 6 Warning Lights and Indicators Description page 27 3 INSTALLATION AND CALIBRATION page 31 4 OPERATING INSTRUCTIONS page 31 4 1 Sa...

Page 9: ...t and Remove Tare page 55 4 4 7 Bypass Rigging Mode page 56 4 4 7 1 Rigging Mode Maintenance and Rigging page 56 4 4 7 2 Accessing Rigging Mode page 57 4 4 7 3 Bypass page 57 4 5 Operational Limits page 58 4 5 1 Accessing the Operational Limits Setting Mode page 59 4 5 2 Limit Value Adjustments page 60 4 5 3 Enable Disable a Limit page 61 4 6 Range Limiting Options page 62 4 6 1 Accessing Range Li...

Page 10: ...age 76 5 5 Slew Sensors Range Limiting Options page 77 5 6 Detected Addresses page 77 5 7 Error Messages page 78 5 7 1 Internal Peripherals page 78 5 7 2 External Peripherals page 80 6 INSPECTION AND MAINTENANCE page 84 6 1 Frequent Inspections page 84 6 2 Periodical Inspections page 84 6 3 Rated Load Test page 85 6 4 Maintenance page 86 6 5 Maintenance Procedure page 87 6 6 Adjustments and Repair...

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Page 13: ...fied and trained personnel 1 3 Intended Use The i4500 system is intended to provide a valuable aid to the crane operator by indicating all relevant parameters typically shown on the duty chart of the crane The i4500 system shall prevent the crane from supporting a load outside the loads shown and described on the rated capacity chart when set calibrated and operated correctly This manual contains ...

Page 14: ...k load The two block condition A2B The system takes this information to check overload conditions and to measure the operating radius and the crane capacity A slew sensor optional can also be installed to measure the boom position on 360 degrees and give extra information to the operator The display is located inside the operator s cab to provide an easy access to the information All the sensors a...

Page 15: ...approach alarm at 95 of the rated capacity A red light will illuminate when the rated capacity has been reached or exceeded WARNING LIGHT YELLOW red GREEN An intermittent buzzer located in the i4500 system display warns the crane operator to take specific course of actions at the approach of the rated capacity The threshold of the approach alarm has been fixed at 95 of the rated capacity The buzze...

Page 16: ... Off Off Off Off On Off Off Off Approach to SWL Alarm 1 Blinking Off Off Intermittent Off On Off Off Overload Alarm 2 On On Off Continuous Off Off On On Motion Cut Alarm 3 On On On Continuous Off Off On On Duty not calibrated On On On Continuous Off Off On On Bypass Overload On On Off Continuous Off On On On Bypass ATB Off Off Off Off Off On On On Bridging Switch Activated Off Off Off Off Off On O...

Page 17: ...t Alarme 3 On On On Continuous On On Duty Not calibrated On On On Continuous On On Bypass Overlaod On On Off Continuous On On Bypass A2B Off Off Off Off On On Bridging Switch Off Off Off Off Off Off A2B Normal Mode Off Off On Continuous On On A2B Calibration Mode X X X Continuous On On A2B Rigging Mode Off Off Off Off On On Calibration Mode X X X Off Off Off Approach Range Limiting Off Off Off Int...

Page 18: ...hical LCD screen 2 Central I O interface This relay interface module is connected to individual external I O devices to be controlled or monitored by the i4500 system 3 Load sensors The load sensor is used to calculate the load on hook It is a dynamometer installed on the hosting rope 4 Anti two block the anti two block is used make sure the block does not hit the tip of the boom optional 5 Wind s...

Page 19: ...RE SENSOR CAN I O CANbus LOAD CELL INTERFACE CAN I O CABLE REEL INTERFACE CAN I O EXTERNAL VISUAL AND AUDIBLE ALARM LOCKOUT RELAY RLD KEY SWITCH CAN 2 0B Keypad PRIMARY RCI SAFETY CRITICAL BUS ECU CAN SECONDARY BUS Hydraulic controller CAN CAN 2 0B CANbus INTERFACE CAN A2B SWITCHLENGTH Angle I O Slew Sensor CANbus INTERFACE CAN I O Anemometer Video IN TFT Display CAN 2 CAN 1 USB Optional Optional ...

Page 20: ...ltage 9 to 32 VDC maximum rating Display size Available in 4 3 LCD Screen 7 0 LCD Screen 10 4 LCD Screen Display sealing IP67 Memory capacity 10 000 load radius curves CANbus sensors interface Default quantity Maximal quantity Load or pressure sensors 2 6 Angle Length sensors 1 5 Relay output 5 32 Digital inputs 4 16 Provision for other sensors Peripheral communication port RS 232 ...

Page 21: ... machine The parameter showing the boom height should be used only as a guide NOT as an indication that the crane would or would not pass under a structure of which we precisely know the height 2 1 Main Display Default Screen operating radius slew angle boom angle duty number m main boom A aux boom boom length parts of line boom tip height warning alarms hook load max safe working load percentage ...

Page 22: ... 2 2 Display Box Overview multifunction keys multifunction keys bar graph GRAPHIC DISPLAY This menu driven communication interface allows access to the various menus and options to control the i4500 unit system MULTIFUNCTION BUTTONS Each of these buttons allows you to select and or execute the indicated function displayed on the screen in any given window This way the task performed by a given mul...

Page 23: ...menu or any programming window without saving any changes and to go back to the previous screen Select repeatedly to return to the main screen UP BUTTON Select this button to scroll up through menu options or to increase adjustable values DOWN BUTTON Select this button to scroll down through menu options or to decrease adjustable values MODE BUTTON Enables you to select the operation mode Select t...

Page 24: ...igging Mode option or to bypass See section 4 4 7 INFO BUTTON Select this button to access all the information regarding the current crane configuration Press it to access the operating system s information CLOSE WINDOW BUTTON Select the close window button to close a menu window and go to back to the main screen PARTS OF LINE BUTTON Select this button to quickly access the parts of line menu for ...

Page 25: ...ce Boom Crane Instruction Manual 55M4500EBE00A A 2 4 Main Modes Main mode config mode info mode Error mode diagnostic mode calibration mode night mode Limit Mode with rotation Limit Mode without rotation Or optional ...

Page 26: ...and Indicators Location SYSTEM ERROR INDICATOR TWO BLOCK CONDITION INDICATOR WARNING ALARM ICONS OVERLOAD WARNING RED LIGHT APPROACH WARNING YELLOW LIGHT lockout warning RED LIGHT WARNING LIGHT GREEN NORMAL YELLOW APPROACHING LIMIT OR OVERLOAD RED OVERLOAD CONDITION OR LIMIT REACHED ...

Page 27: ...grees of a predetermined limit set in the limits setting mode The crane maximum capacity has been reached or exceeded The overload warning light red turns on at or above 100 adjustable value of the rated capacity This light will also turn on if you are reaching a predetermined limit set in the limits setting menu The crane has exceeded safe operational ratings and is now in an unsafe condition Hoi...

Page 28: ...00 system to make this indicator disappear and to reduce a rope limit One of these indicators or many of them appear in the top left corner of the i4500 screen when at least one operational limit is active on the system This is not a warning It is just there to remind you that an angle radius or height limit has been set in the limits setting mode ANGLE RADIUS HEIGHT If you are approaching a prede...

Page 29: ...the yellow approach warning light will blink and the internal buzzer will sound on and off If you have reached a predetermined maximum radius limit this indicator will appear on the screen the overload warning light will turn on and the buzzer will sound continuously The zones where the system will warn the operator that a preset limit is being approached can be changed as required These values ar...

Page 30: ......

Page 31: ...t the installation and calibration instructions have intentionally not been included in this instruction manual 4 Operating Instructions 4 1 Safety Instructions When operating the i4500 system always respect the safety rules and regulations applicable in the country where you operate the crane to reduce the risk of injury or damage to the equipment Read the following safety instructions before att...

Page 32: ...ust 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 the configuration and number of parts of line will change simply by changing the hoist from main to auxiliary 4 2 Residual Risks In spite of the application of all relevant ...

Page 33: ...result in injury or death The crane operator must confirm that the duty given by the system is the one he really wants to use or he must choose another one among the duties shown Once his choice is made he must press the Select button and the system goes to the normal operating mode When the i4500 system is powered on it performs a self test during which it verifies with the installed sensors the ...

Page 34: ...matches the current configuration of the machine Use the Duty button to select all the crane configuration details such as the lenght of the main boom the lenght of the jib the counterweight the outriggers crawlers tires the hoists etc Afterwards this duty is associated to a corresponding duty number by the system If you need assistance contact RaycoWylie with the technical file number of your sys...

Page 35: ...that matches your crane configuration 1 Select the Duty button 2 Answer each question by selecting the right information and press the Select Enter button to accept new values into the system and go to the next question or or 1 Select the Duty button 2 Use the Up or Down buttons to select the lenght of the main boom among the choices on the list 3 Choose the Select button to accept new value into ...

Page 36: ...hoist H1 Hoist 1 main or H2 Hoist 2 auxiliairy Use the Up or Down buttons to select the right value among the choices on the list 7 Press the Select button to confirm your choice accept new value in the system and go to the next parameter or press on the Escape button to go back to the previous screen or or 4 4 2 Working with the Main Boom 1 ou 2 Hoists Cont d This menu only appears if the system ...

Page 37: ...d digit 10 Use the Up or Down button to select the required value 11 Use the Select button to enter the new value or press on the Escape button to go back to the previous screen 4 4 2 Working with the Main Boom 1 ou 2 Hoists Cont d or or 12 Use the Up or Down buttons to select the position of the outriggers among the list or If there is only one choice on this list this menu will not appear and th...

Page 38: ... Boom 1 ou 2 Hoists Cont d Once the duty selection is over the i4500 automatically returns to the main screen normal operating mode You can use the Info button to see at a glance the configuration of the crane Info button You might have to answer extra questions according to your crane and its load chart or for example if you have a counterweight that you need to configure Keep answering the quest...

Page 39: ... 1 Press the Select button 2 Use the Up or Down button to select the main boom length from the list 3 Press the Select button to confirm your choice or press the Escape button to go back to the main screen 4 Use the Up or Down button to select the jib configuration from the list 5 Press the Select button to confirm your choice or press the Escape button to go back to the main screen or or ...

Page 40: ...f the jib you chose at point 4 7 Press the Select button to accept new value in the system and to go to the next parameter or press the Escape button to go back to the main screen or or 8 Press the X button to answer NO to the following question Is a block rigged on the main boom This menu will not appear if your crane has only one hoist 4 4 3 Working with Jib One Hoist Cont d ...

Page 41: ...the list 10 Press the Select button to accept this new value in the system or press the Escape button to go back to the main screen o r or This menu will not appear if your crane has only one hoist 4 4 3 Working with Jib One Hoist Cont d or 11 Now enter the number of parts of line used between the jib block and the head sheave Use the Up or Down button to enter the first digit 12 Press the Select ...

Page 42: ...l go on to the next menu if there is only one choice on this list 16 Press the Select button to accept this new value in the system or press the Escape button to go back to the main screen or Once the selection of the configuration is over the system automatically goes back to the main screen normal operating mode You can use the Info button to see at a glance the configuration of the crane You ma...

Page 43: ... Press the Select button 2 Use the Up or Down button to select the main boom lenght from the list 3 Press the Select button to confirm your choice or press the Escape button to go back to the main screen 4 Use the Up or Down button to select the jib configuration from the list 5 Press the Select button to confirm your choice or press the Escape button to go back to the main screen or or ...

Page 44: ...new value in the system and to go to the next parameter or press the Escape button to go to the previous screen or or 8 Press the Select button the check mark to answer YES to the following question Is there a block rigged on the main boom This question will appear on the screen if you have decided to lift the load with the jib at step 6 If you have decided to lift the load with the main boom the ...

Page 45: ... on the list 10 Press Select button to accept the new value in the system or press the Escape button to go back to the previous screen o r or or 11 Now enter the number of parts of line used between the block of the jib and the head sheave Use the Up or Down button to enter the first digit 12 Press the Select button to highlight the second digit According to your choice at step 6 the system will e...

Page 46: ...button to go back to the previous screen 15 You now have to select the hoist used on the main boom usually H1 Use the Up or Down button to select the right value from the list 16 Press Select button to accept the new value in the system and go to the next parameter or press the Escape button to return to the previous screen or or or 17 Now enter the number of parts of line for the main block Use t...

Page 47: ...e choice on this list this menu will not appear and the system will go on to the next menu 22 Press the Select button to accept the new value in the system or press the Escape button to return to the previous screen or Once the selection of the configuration is over the system automatically goes back to the main screen normal operating mode You can use the Info button to see at a glance the config...

Page 48: ...00A A 48 i4500 Lattice Boom Crane Instruction Manual 4 4 4 Working with the Main Boom or Jib Cont d Quick Duty Change Button Press this button to choose to whether lift the load with the main boom or with the jib ...

Page 49: ...ce the settings for many parameters such as the outriggers state the boom selection the jib selection etc If all the data under the chart info screen is correct and if you had previously set the correct hoist and parts of line number then your system should be configured correctly You can also access the info mode by pressing the Mode button see steps below 4 4 5 System Configuration Information S...

Page 50: ...manual may not be identical to the chart info screen shown on your system 4 4 6 System Setup Configuration Mode Various display parameters can be configured by the operator These parameters are grouped in the system config mode menu and they include 1 Unit selection 2 Set tare 3 Language 4 Date and time 5 Backlight Config Mode Selection Menu Choose the Configuration Mode Config Mode 4 4 5 System C...

Page 51: ...ct the desired unit combination 4 4 6 1 Unit Selection 1 Press the Mode button 2 Scroll down with the Down button to highlight the config mode line 3 Press the Select button to confirm your choice and access the config mode menu Repeat these steps to modify any of the system setup options You must first access the system s configuration mode It is possible to choose among 6 measurement units combi...

Page 52: ... set the language proceed as follows 1 Repeat steps 1 to 3 of the system setup configuration mode section see section 4 4 6 on page 51 2 Select the Language menu 3 Use the Up or Down buttons to highlight the desired language 4 Press the Select button to confirm your choice 4 4 6 3 Date and time setting This sub menu allows you to adjust the date and time in the system This is an important step for...

Page 53: ... the Select button to accept this new value into the system 6 Repeat procedure to adjust the day and the year Press the Select button to confirm your choice 7 To adjust the clock scroll up or down with the Up or Down buttons to select the desired hour value Repeat procedure to enter the minutes 8 Choose the Select button to save changes and go back to main menu 4 4 6 4 Night Day light mode This me...

Page 54: ... screen brightness levels of the night mode to help you read the screen under various lighting conditions To adjust the display brightness proceed as follow 1 Repeat steps from 1 to 3 of the system setup option section see section 4 4 6 on page 51 of this manual 2 Select the backlight menu 3 The night level window should appear on the screen The day level is at 100 maximum brightness For the night...

Page 55: ... Down button to highlight the Set Tare line 5 Press the Select button to enable the Tare feature 6 Repeat these steps to remove tare and to go back to normal mode Select the Tare Mode option to display the actual load on hook during a lifting operation This mode is used to remove the weight of the block hook and hoisting rope This way it only shows on the screen the weight of the lifted load The t...

Page 56: ...ust be released and pushed again after 10 seconds It is often necessary to go outside the safety zone for which the crane manufacturer provides ratings when stowing or erecting the machine For example the boom stowed position may be outside the maximum load radius or minimum boom angle specified on any load chart For this reason the i4500 provides a Maintenance Erection mode where the boom may be ...

Page 57: ...stem resets At this point when pressing the Bypass Rigging button the system automatically enters in rigging mode and an override message flashes on the system display The rigging mode is automatically exited when The operator selects another mode The boom returns in the working zone capacity higher than zero The system is powered off When the boom is positioned outside the maximum radius of opera...

Page 58: ... machine is equipped with the range limiting option the operational limits setting mode will not be available for selection refer to section 4 6 of this manual for more details on the range limiting device In the operational limits setting mode the operator can set and activate deactivate the following four 4 operational limits in addition to those automatically provided by the i4500 system Here a...

Page 59: ...ational Limits Setting Mode 1 Press the Mode button 2 The line Limit Mode should be highlighted by default If it is not the case use the Up or Down buttons to highlight this line 3 Choose the Select button to confirm your choice and access the operational limits mode ou Limit setting menu ...

Page 60: ... 1 on page 59 2 Use the Up and Down buttons to highlight the limit setting you want to edit 3 Press Select button to confirm your choice The cursor will automatically go to the next column 4 Press the Up and Down buttons to select the desired value for this particular limit 5 Press Select button to confirm the selected value 6 Press Escape button to return to the norma operating mode or or ...

Page 61: ...e section see section 4 5 1 on page 59 2 Press many times the Down button until the first line of the limit state column column On Off is highlighted see picture at the bottom of the page 3 Use the Up or Down buttons to highlight the current state ON or OFF of the limit you want to activate or desactivate 4 Press Select button to toggle between the ON and OFF state of this limit 5 Press the Escape...

Page 62: ...an extremely hazardous practice that requires extra precautions To avoid the risk of being electrocuted it is therefore essential to operate the 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 electricity The crane shall not be used to handle material stored under electrical power lines unless any ...

Page 63: ...he crane the i4500 automatically selects the range limiting mode as the only possible choice In this case the following limit mode menu options are offered Height limit Free zone Variable height limit Variable radius limit Shows which zone is programmed Height Limit Varialbe height limit Variable radius limit Free Zone two walls A red icon indicates that a limit has been reached ...

Page 64: ...nge Limiting Mode Range Limiting Mode Screen 1 Press the Mode button 2 The Limit Mode line should be highlighted by default If it s not the case use the Up or Down button to or highlight the line 3 Press the Select button to confirm your choice and to access the range limiting mode ...

Page 65: ...3 Press the Select button to confirm your choice 4 Boom up to the desired boom tip height limit 5 Press Select button to confirm the maximum height of the boom tip As you release Select button a 10 second countdown will allow you to boom down before your programmed height limit becomes active The height limit is a limit on the maximum height of the tip of the boom or jib We can also say that it is...

Page 66: ...rst wall 4 Press the Select button to confirm the position of the first wall 5 Rotate the crane to the second limit position second wall 6 Press the Select button to confirm the position of the second wall 7 As you release select button a 10 seconds countdown will allow you to rotate the crane between the two walls before your programmed free zone limit becomes active 66 The free zone is a zone wi...

Page 67: ...on to confirm your choice 4 Rotate the crane towards the first limit position first wall 5 Press Select button to confirm the position of the first wall 4 6 3 Free Zone Cont d Programmed free zone Right wall reached Left wall reached A variable height limit is a height limit which varies according to the boom position on rotation variable height limit According to the obstacle we can need a limit ...

Page 68: ...m height permitted by the surrounding environment 7 Press Select button to confirm the position of the second wall 8 As you release Select button a 10 second countdown will allow you to return between the two walls and boom down below the height limit before your pro grammed variable height limit becomes active Variable height limit programmed Right wall reached Left wall reached Height limit reac...

Page 69: ... Press Select button to confirm that this will be the position of the first wall 6 Rotate the crane towards the second limit position second wall with the boom always at the maximum radius permitted by the surrounding environ ment Note that you can change the maximum radius during this operation 4 6 5 Variable Radius Limit Avariableradiuslimitisaradius limit which varies according to the boom posi...

Page 70: ... 8 As you release the Select button a 10 seconds countdown will allow you to return between the two walls and boom up below the allowed radius limit before your programmed variable radius limit becomes active Variable radius limit programmed Right wall reached Left wall reached Radius limit reached 4 6 5 Variable Radius Limit Cont d ...

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Page 72: ...iagnostic option Press the Select button to enter the diagnostic menu Warning Troubleshooting shall be performed by a qualified technician or by an operator assisted by a RaycoWylie Service technician Press the Escape button to return to the previous menu or to exit the diagnostic mode 5 Diagnostic Troubleshooting By pressing the Select button each line of the diagnostic menu gives access to anoth...

Page 73: ... the value of the parameter calculated by the interface connected to the CanBus network and the third column gives the state of the sensor connection to the CanBus network Concerning the A2B it is its activation status that is displayed If the interface is not a sensor such as the relay interface and therefore does not return a specific value no value is displayed in the second column however the ...

Page 74: ...re version of the angle length sensor and also its creation date The following values will allow the RaycoWylie technician to diagnose a problem coming fron the sensor If the angle sensor is not functionning properly note these values and give them to a RaycoWylie technician Press the Escape button to return to the main screen of the diagnostic mode 5 3 Load Sensor To see the software version of t...

Page 75: ...nformation will look similar to this The basic criteria for a proper fucntionning of the load sensor are the scale value must be smaller than 1 0 Dr must be close to 5 00 volts DC Press the Escape button to go back to the main screen of the diagnostic mode 5 3 Load Sensor Cont d ...

Page 76: ... Hdin and it indicates whether the input is active or not Up to 4 relay cards can be installed 5 4 Relays In the diagnostic menu press the Select button when Relay Board 1 is highlighted By pressing the Down button you get access to the Input block The displayed information will look like this Press the Escape button to go back to the main screen of the diagnostic mode The system shows the first s...

Page 77: ...municating addresses remain in memory as long as the system is on The displayed information will look similar to this The second line indicates the software version of the rotation interface and it s creation date ThesevalueswillallowtheRaycoWylie technician to diagnose a problem coming from the slew sensor In the diagnostic menu press the Select button when the line Rotation relative encoder is h...

Page 78: ...stem there is a verification writing reading of the whole flash memory on the engine board There is a problem with the flash memory on the engine board located in the i4500 display Contact the technical service department at RaycoWylie RAM memory is defective When starting system there is a verification writing reading of the RAM memory on the engine Board There is a problem with the RAM memory on...

Page 79: ...t corresponding to the crane has been calibrated 2 Does the load chart depend on rotation 3 Does the load chart depend on DIN inputs No 2nd duty found The load chart must be programmed in order to compare two charts One of them is based on the angle and the other one is based on the radius The smallest value will be selected The Angle Radius option must be activated during the compilation of the l...

Page 80: ...s in Pre calibration Indicates that angle card is in pre calibration mode 1 In normal operation mode the Cal jumper must be taken out from the circuit board 2 Verify that the calibration value of the accelerometer is valid Lost communication with angle X The i4500 system has not received data from angle interface If time out delay is reached then a communication error is displayed 1 The angle inte...

Page 81: ...em has not received a valid message from the load interface on time 1 The load interface is defective 2 The cable that links the interface to the canbus net work is broken Error Message Execution Process Cause of Error Lost communication with Relay board X i4500 system does not receive data from relay interface If time out delay is reached then a communication error is displayed 1 The relay interf...

Page 82: ... the interface to the canbus network is cut Cant Y on generic X Waiting for a valid value of the Cant Y from the interface 1 The generic interface is broken 2 A wire between the cable that links the interface to the canbus network is cut AIN 1 on generic X Waiting for a valid value of the AIN 1 input from the interface 1 The AIN 1 input of the generic interface is not calibrated 2 A wire is cut be...

Page 83: ...interface Rotation encoder s ratio No ratio has been detected No ratio has been entered or calibrated in the system Rotation encoder s prox switch Proximity sensor is not detected at the configured position 1 The proximity sensor is defective Lost communication with rotation encoder The i4500 system does not receive anything from the rotation interface If the timeout delay is reached then a commun...

Page 84: ...erly 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 the last time you checked Verify the radius according to the boom selection The displayed radius must be between 0 and 10 greater than the actual radius or it must be in accordance with current regulation Verify that the capacity displaye...

Page 85: ...l to the maximum capacity near minimum radius should be used to test the alarm and the accuracy of the load indicator Rig with enough parts of line to lift a large weight Measure and record the radius and the hook load Note the displayed radius length hook load parts of line and capacity showed on the i4500 display unit Lift the weight Record the actual weight with the hook and rigging attachment ...

Page 86: ...e plunger shows excessive corrosion 6 4 Maintenance Replacement parts and original parts must be obtained from RaycoWylie unless approved and authorized as an equivalent by a RaycoWylie technician To keep the i4500 s display waterproof make sure the back cover is tightened following an X pattern Your i4500 system requires no additional lubrication Important If condensation appears in the screen of...

Page 87: ...inst dropping Release hydraulic pressure from all hydraulic circuits before loosening 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 repairs have been made the crane shall not be used until all safety devices are reactivated and trapped air removed from the hydraulic system The i...

Page 88: ...fied personnel If you have any questions or need technical assistance please contact our Technical Service Department at RaycoWylie quoting the information found on the serial number label of your i4500 system Any adjustment shall meet RaycoWylie s specified tolerances in order to maintain the correct functioning of all components Please contact our service department at RaycoWylie if you need rep...

Page 89: ...89 i4500 Lattice Boom Crane Instruction Manual 55M4500EBE00A A Notes ...

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