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RaycoWylie i4507, Instruction Manual

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RaycoWylie i4507 Instruction Manual Download Page 11

11

i4507 Offshore Lattice Boom Crane

Instruction Manual

55M4507OBE00-B

6- 

INSPECTION 

AND 

MAINTENANCE 

     page 

71

 

6.1 

Frequent Inspections 

 

 

 

 

 

 

page 71

 6.2 

Periodical 

Inspections 

      page 

71

 6.3 

Rated 

Load 

Test 

       page 

72

 6.4 

Maintenance 

        page 

73

 6.5 

Maintenance 

Procedure 

      page 

74

 

6.6  Adjustments and Repairs   

 

 

 

 

 

page 75

TABLE OF CONTENTS

Summary of Contents for i4507

Page 1: ...ms 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 55M4507OBE00 Rev B Ref VH Sept 2014 Crane Warning Systems Atlanta U S Distributor for Rayco Wylie Systems 6175 Hickory Flat Hwy Suite 110 376 Canton GA 30115 8...

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Page 5: ...ded 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 carryi...

Page 6: ...55M4507OBE00 B 6 i4507 Offshore Lattice Boom Crane Instruction Manual ...

Page 7: ...symbols 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 MOD...

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Page 9: ...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 33 4 1 Safety Instructions page 33 4 2 Residual Risks page 34 4 3 Power On ...

Page 10: ...s Setting Mode page 47 4 5 2 Limit Value Adjustments page 48 4 5 3 Enable Disable a Limit page 49 4 6 Range Limiting Options page 50 4 6 1 Accessing Range Limiting Mode page 52 4 6 2 Height Limit page 53 4 6 3 Free Zone page 54 4 6 4 Variable Height Limit page 55 4 6 5 Variable Radius Limit page 57 5 DIAGNOSTIC TROUBLESHOOTING page 59 5 1 Diagnostic Menu page 59 5 2 Angle Sensor page 61 5 3 Load S...

Page 11: ...5M4507OBE00 B 6 INSPECTION AND MAINTENANCE page 71 6 1 Frequent Inspections page 71 6 2 Periodical Inspections page 71 6 3 Rated Load Test page 72 6 4 Maintenance page 73 6 5 Maintenance Procedure page 74 6 6 Adjustments and Repairs page 75 TABLE OF CONTENTS ...

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Page 13: ...ualified and trained personnel 1 3 Intended Use The i4507 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 i4507 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 conta...

Page 14: ...e hook 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 sens...

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 i4507 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 buzz...

Page 16: ...roach 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 A2B Off Off Off Off Off On On On Bridging Switch Activated Off Off Off Off Off On Off Off A2B Normal Mode Off Off On C...

Page 17: ...n Cut 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...

Page 18: ...he load on hook It can be a dynamometer or a dead end load link Others options available upon request Termination Unit This interface is connected to the various I O sensors installed on the crane It transmits the information to the i4507 display box using the CANbus network Optional explosion proof enclosure available Anti two Block optional The anti two block switch prevent the hook block to be ...

Page 19: ...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 YES Peripheral communication port RS 232 Wind speed sensor optional Shows wind speed value on the i4507 display Slew Encoder optional The slew encoder is used to display the position of rotation of the crane to select the duties...

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Page 21: ...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 BOOM ANGLE DUTY NUMBER MAIN BOOM AUX BOOM BOOM LENGTH PARTS OF LINE MEASUREMENT UNITS HOOK LOAD MAX SAFE WORKING LOAD PERCENTAGE OF SAFE WORKING LOAD WARNING ALARMS BOOM ...

Page 22: ... occurred 2 2 Display Box Overview MULTIFUNCTION KEYS MULTIFUNCTION KEYS GRAPHIC DISPLAY GRAPHIC DISPLAY This menu driven communication interface allows access to the various menus and options to control the i4507 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...

Page 23: ...ithout 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 this button to choose one of thes...

Page 24: ...exit any programming window menu without saving any changes and go back to the previous screen BYPASS RIGGING BUTTON Select this button to enable the Rigging 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 windo...

Page 25: ...Lattice Boom Crane Instruction Manual 55M4507OBE00 B 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: ...dicators 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 ROPE LIMIT INDICATOR ...

Page 27: ...r degrees 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...

Page 28: ... line on the i4507 system to make this indicator disappear and to reduce a rope limit One of these indicators or many of them appear in the i4507 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 predetermine...

Page 29: ...een 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 value...

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Page 31: ...ed verification of the whole system before beginning the calibration of the system Failure to properly calibrate the system can result in overloading the crane This can cause machine breakage or tipping that could result in serious injury or death Always refer to a RaycoWylie certified technician to calibrate your system Installation and calibration manuals are available upon request at RaycoWylie...

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Page 33: ...ane operator The i4507 system will not necessarily prevent crane damage due to overloading and or other related causes 3 Proper functioning of the equipment depends upon proper daily inspection and conformity to the operating instructions described in this manual 4 During normal operation the rated capacity of a crane should not be exceeded The overload indication should not be used as a normal op...

Page 34: ...It can cause machine breakage or tipping that could result in injury or death The system gives no indication of the crane level It can cause machine breakage or tipping that could result in injury or death The system gives no indication of poor ground stability It can cause machine breakage or tipping that could result in injury or death When the i4507 system is powered on it performs a self test ...

Page 35: ...ber 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 configuration of the machine If you need assistance contact RaycoWylie with the technical file number of your system The current duty number associated by the i4507 system figures in the normal mode screen and additional configuration i...

Page 36: ...s 1 Press the Duty button 2 Use the Up or Down buttons to select the desired crane configuration among the duty selection list 3 Press the Select button to accept new value into the system or The Duty Selection screen appears Duty Selection Screen Please note that this screen will be different on your system as it differs from crane to crane ...

Page 37: ...on of your crane You can check at a glance the settings associated with a specific duty number such as the boom mode the boom length the head type the outriggers state etc If all the data under the chart info screen is correct then your system should be configured correctly There are two ways to access the information mode 4 4 2 System Configuration Information Screen Press the Info button to disp...

Page 38: ...identical to the screen shown on your system 4 4 3 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 The Configuration Mode Config Mode 4 4 2 System Configuration Information Screen Cont...

Page 39: ...elect button to choose the desired unit combination 4 4 3 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 mea...

Page 40: ...on the software version To set the language proceed as follows 1 Enter de configuration mode see section 4 4 3 on page 38 2 Select the Language 3 Use the Up or Down buttons to highlight the desired language 4 Press the Select button to confirm your choice 4 4 3 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 the data recorder...

Page 41: ... 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 M o n t h D a y Y e a r 4 4 3 4 Night Day mode This menu allows acces...

Page 42: ... modify the 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 Enter de configuration mode see section 4 4 3 on page 38 2 Select the backlight line 3 The night level window should appear on the screen The day level is at 100 maximum brightness For the night level a 30 to 60 backlight is sugge...

Page 43: ... the 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 T...

Page 44: ...g button must 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 i4507 provides a Maintenance Erection mode where the bo...

Page 45: ...The system 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...

Page 46: ...your 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 i4507 system He...

Page 47: ...mits 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 or Limit setting menu Limit Mode Line Highlighted ...

Page 48: ...ee previous page 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 normal operating mode or or ...

Page 49: ... to access the operational limits setting mode see page 47 2 Press many times the Down button until the first line of the limit state column column On Off is highlighted 3 Use the Up or Down buttons to highlight the current state ON or OFF of the limit you want to activate or deactivate 4 Press Select button to toggle between the ON and OFF state of this limit 5 Press the Escape button to return t...

Page 50: ...t is 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...

Page 51: ...lly 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 4 6 Range Limiting Option Cont d 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 52: ...de button 2 The Limit Mode line should be highlighted by default 4 6 1 Accessing Range Limiting Mode Range Limiting Mode Screen or If it s not the case use the Up or Down button to highlight the line 3 Press the Select button to confirm your choice and to access the range limiting mode ...

Page 53: ...ess the Select button to confirm your choice 4 Boom up to the desired boom tip height limit 5 Press the Select button to confirm the maximum height of the boom tip As you release the 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 i...

Page 54: ...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 54 The free zone is a zone wi...

Page 55: ...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 56: ...imum 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 seconds 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 ...

Page 57: ...ss 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 A variable radius limit is a radius limit which varies according to the boom po...

Page 58: ...wall 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 ...

Page 59: ... Diagnostic Mode line 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 ...

Page 60: ... 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 state of connection to the CanBus network is given in t...

Page 61: ...ftware version of the angle length sensor and also its creation date The following values will allow the RaycoWylie technician to diagnose a problem coming from the sensor If the angle sensor is not functioning 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 o...

Page 62: ...yed information will look similar to this The basic criteria for a proper functioning 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 63: ...puts 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 fir...

Page 64: ... communicating 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 ...

Page 65: ...g system 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 i4507 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 memor...

Page 66: ...chart 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 t...

Page 67: ...e x is 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 i4507 system has not received data from angle interface If time out delay is reached then a communication error is displayed 1 The angle...

Page 68: ... system 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 i4507 system does not receive data from relay interface If time out delay is reached then a communication error is displayed 1 The relay i...

Page 69: ...inks 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 cu...

Page 70: ...ion 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 i4507 system does not receive anything from the rotation interface If the time out delay is reached then a c...

Page 71: ...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 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 disp...

Page 72: ...equal 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 i4507 display unit Lift the weight Record the actual weight with the hook and rigging attachm...

Page 73: ...f the 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 i4507 s display waterproof make sure the back cover is tightened following an X pattern Your i4507 system requires no additional lubrication Important If condensation appears in the scree...

Page 74: ... against 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 T...

Page 75: ...qualified 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 i4507 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 nee...

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