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Содержание RCI-1550 LM

Страница 1: ...1550 LM Telescopic Boom System Instruction Manual MAN 1078 Rev B LSI Robway Pty Limited 32 West Thebarton Road Thebarton South Australia 5031 Phone 61 0 8 8238 3500 Fax 61 0 8 8352 1684 www lsirobway com au ...

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Страница 3: ...sor DRURW43LAA 5 3 4 12 Pay out Cable 5 4 12 ANTI TWO BLOCK IF INSTALLED 5 4 1 12 Rectangular type Anti two Block switches 5 4 2 12 Tubular type Anti two Block switches 5 4 3 12 Multiple Anti two Block switches 5 4 4 12 Bob weight both types of switches 5 5 12 LOAD MOMENT BASED SYSTEMS 5 5 1 12 Overview 5 5 2 12 Pressure Transducers Luffing Cylinder 5 6 13 CABLING AND GLANDS 5 7 14 DISPLAY UNIT 5 ...

Страница 4: ...libration Item 7 2 2 29 View Main Load and View Aux Load items 7 2 3 30 View Boom Angle item 7 2 4 30 View Jib Angle item 7 2 5 30 View Length item 7 2 6 31 Set Gain Trans 1 item 7 2 7 31 Set Gain Trans 2 item 7 2 8 32 Set MUX Delay item 7 2 9 32 No of Samples item 7 2 10 32 Set Lift Value Threshold item 7 2 11 33 Set Rigging Load Threshold item 7 2 12 33 Correct Radius Unladen boom item 7 2 13 33...

Страница 5: ...nd of Transducer 2 7 9 46 PREPARATION BEFORE CALIBRATING LOAD 7 10 46 CALIBRATING ACTIVE SELECTED WINCH 7 11 47 BOOM STOP FRICTION COMPRESSION CORRECTION 7 11 1 47 Introduction 7 11 2 47 Boom Backstop Function Codes 7 11 3 47 How to Calibrate 8 48 MAINTENANCE 8 1 48 CHECK LIST 8 2 48 IN CABIN ITEMS 8 2 1 48 Additional detail 8 3 49 ELECTRICAL EQUIPMENT 8 4 49 RECOIL DRUM TELESCOPIC CRANES 8 4 1 49...

Страница 6: ...ience or safe crane operation At all times the driver is ultimately responsible for safe crane operation 2 SPECIAL NOTES 2 1 Brandnames Tradenames and Trade Marks All product brand or trade names used in this publication are the trademarks of their respective owners and they are only mentioned to provide more accurate information for the reader 2 2 Important Safety Notice Notes cautions and warnin...

Страница 7: ...ths from the original supply date to original purchaser from RSS 2 4 Glossary of some used terms Used in Manual Alternative Description RSS Robway Robway Safety Systems P L Length Sensor Boom Length Measures telescoping boom sections Pressure Transducer Measures hydraulic pressure Boom Angle sensor BAS Measures angle to horizon ATB Over hoist Over hoisting the hook into the boom tip RCI LMI same b...

Страница 8: ...tual overload and is designed to activate function motion cut if fitted connected 4 3 Capabilities The RCI 1550 display provides the following capabilities Suitable for mobile crawler and fixed type telescopic boom cranes load moment sensor based Multi hoisting winch operation Provides monitoring and display of Boom Length Boom Angle Luffing fly jib Angle as applicable Boom Tip Radius Boom Tip Hei...

Страница 9: ...ultiple switch analogue input output expansion engine management special alarms on site configurable user data data logging customer formats optional printing ROBWAY also cater for custom applications and special user requirements Please contact your nearest ROBWAY distributor or ROBWAY directly ...

Страница 10: ...AS is physically mounted within the recoil set for RHS boom mounting as standard Should the recoil drum be mounted to the LHS of the boom the BAS will need to be rotated to the LHS mount position Undo the 2 mount screws and rotate the BAS clockwise to the alternative mount position Refix the 2 mount screws 5 3 Length Sensors 5 3 1 General Fix the recoil drum and pay out cable to the RHS side of th...

Страница 11: ...ravel is at minimum Tie off cable to cable anchor securely Extend boom or travel machine slowly to the full extent of travel Before reaching the limit of travel haul off cable from the reel by hand to ensure that the reel will not bind up before full travel is reached Check that at full extension there is at least one turn available at the reel before binding up Whilst doing this keep on turning t...

Страница 12: ...ave an assistant hold the reel from turning and unwind sufficient cable to reach the cable anchor while boom or travel is at minimum Tie off cable to cable anchor securely Extend boom or travel machine slowly to the full extent of travel Before reaching the limit of travel haul off cable from the reel by hand to ensure that the reel will not bind up before full travel is reached Check that at full...

Страница 13: ...s working range Consult installation drawings at the rear of this manual 5 4 3 Multiple Anti two Block switches Additional switches for fly jibs can be added Connection is via plug and socket at the Junction box adjacent to the main boom head Consult installation drawings at the rear of this manual 5 4 4 Bob weight both types of switches Hang the bob weight assembly from the switch eye after cutti...

Страница 14: ...ection Failure to terminate the screens in the glands will void the Electro Magnetic Compatibility EMC compliance which the system carries and will put the unit at risk of malfunction due to EMI When armoured cable is used then the armour must be trapped in the gland body and the internal cable braid or screen must be terminated in the chassis terminals on the appropriate on board connectors The g...

Страница 15: ...he display and reach the push buttons comfortably Check bonding between enclosure and chassis If a good bond cannot be ensured through the mounting bracket then install earth strap It is a condition of installation that equipotential bonding must be ensured between the display enclosure and the Control Unit enclosure ...

Страница 16: ...lated power supply The input connector has three terminals for each of the supply positive V and supply negative V allowing for looping if required The V is switched to the output connector via a single pole 5A relay only when the PS is running The output connector contains two sets of power RS 485 connections one being for the display connection and the other for expansion modules The front panel...

Страница 17: ...cket may be damaged The high capacity Flash memory has been added to the 1550 to contain three main blocks of information being Load charts Load Moment LM calibration tables and Data logging The memory is contained in two plug in SIMM cards and depending on the application any number of these may be installed Refer to the relevant software configuration sheets for more details The SIMM cards can o...

Страница 18: ...te of 8 switch inputs and controlling 8 relay outputs Connection is via plug in Mini Combicon R screw terminals The DIO section is very versatile and reference should be made to the installation drawings for details The digital section features LED indicators for input and output status If the digital section detects an input signal voltage the corresponding LED will be illuminated If an output LE...

Страница 19: ...g DIP switch SW1 with the switch position number referring to the respective output When the switch is ON the corresponding output will be energised if the CPU fails or alternatively when the switch is OFF the corresponding output will be de energised if the CPU fails This fault state can be selected manually by the user by activating the disable input 5 8 4 6 Specifications Relay Outputs 5 ampere...

Страница 20: ...motion cut connections are made 2 POWER MUST BE DISCONNECTED before attempting connections 3 NEVER insert larger capacity fuses than those originally supplied 4 Obtain specialist assistance if you are unfamiliar with crane electrics 5 The Robw ay relay contact ampere rating must not be e xceeded when dire ctly operating hydraulic or mechanical solenoid devices or high capacity relays For s uch dev...

Страница 21: ...ndicator 12 Alpha numeric buttons refer manual 4 Approach to rated capacity LED 13 Up button when Menu selected see also 18 5 100 capacity exceeded LED 14 LCD Display refer manual 6 Motion Cut activated LED 15 Winch Select Button 7 Bar Graph of rated capacity 16 Tare on off button 8 Rigging mode button 17 OK or accept button 9 Function Buttons refer manual 18 MENU button also Down button when MENU...

Страница 22: ...nd 2 or 3 winch selected will show TOTAL BOOM length inclusive of the Upper Boom Point rooster sheave OR inclusive of the FLY JIB 6 1 4 Angle This is the current boom angle This angle will be either the MAIN BOOM OR the LUFFING FLY when selected and in use 6 1 5 Radius Shows the operating radius for the CURRENT CONFIGURATION and DUTY and WINCH selection The radius is calculated from the Boom Angle...

Страница 23: ...rpose keys that may be assigned a job specific use Any special functions use will be listed in the appendix 6 2 2 Soft Menu Keys These are similar to the Function keys in that each one does not have a specific use Their use can change depending on what state the display is in The function of each key if it is actually used at that time will be listed above it on the bottom line of the LCD Not all ...

Страница 24: ...is initiated the boom is raised more than 10 degrees this function will reset to normal crane operation This is necessary to ensure overall safe crane operation Temporary ATB Rigging mode which is essentially the same as normal rigging mode with the exception that it over rides motion cuts for only a limited period or time This mode is intended to allow the operator to over ride the display in spe...

Страница 25: ... with an Anti Two Block sensor to prevent two blocking of the main and aux winches When the A T B indicator on the front panel is lit a two blocking condition has occurred and further hoisting may be stopped by activation of the ATB motion cut relay if installed An audible alarm also sounds a warning If the Anti Two Block system is not required for the given application the two wires normally conn...

Страница 26: ...gnition key switch OR as installed Power to the RCI 1550 can be derived from the automotive alternator DC supply nominally 12V or 24V DC namely The crane electrical ignition circuit The crane electrical accessory circuit For either DC suppl y absolute voltage range is 10 40V DC As soon as power is applied to the RCI 1550 its display and other indicators should light up and the RCI 1550 should go t...

Страница 27: ... it is imperative to change the configuration even though a lift is being monitored it is possible to change the duty and or falls in calibration mode provided you have the correct access code When no lift is in progress it is possible to change any of the items that describe the crane configuration Selecting to change the duty will cause a series of screens to be displayed prompting the operator ...

Страница 28: ...ift 6 7 3 3 LCD Contrast This allows the operator to adjust the LCD for optimum contrast The contrast or ratio of black to white on the LCD depends on viewing angle and temperature Temperature compensation is provided in hardware but variations in the individual LCD circuits mean this may not compensate perfectly Hence the contrast may need to be adjust occasionally The setting is retained when th...

Страница 29: ...en the Function code item is selected from the main menu the password entry screen will be displayed A PIN is required to enter calibration mode View Press OK Change key P I N PIN _ Pressing the Cancel button returns the operator to the main menu If view mode is requested the message View access granted will be displayed If calibration mode is required the operator must enter a PIN and then press ...

Страница 30: ...or needs to press the button 0 before the button otherwise a will be displayed 7 2 Calibration Functions Breakdown 7 2 1 Exit Calibration Item Returns the operator to the main menu 7 2 2 View Main Load and View Aux Load items Displays the active winch load on LM systems VIEW MAIN LOAD F01 Load 100 12 hh mm 7 2 2 1 CAL ACTIVE WINCH item By using the numeric buttons calibration of the active winch t...

Страница 31: ... 7 2 3 2 CAL HIGH BOOM ANGLE item The graphical LCD will appear similar to CAL LOW BOOM ANGLE 7 2 4 View Jib Angle item This function code item is only available for Luffing fly systems The graphical LCD will appear similar to VIEW BOOM ANGLE 7 2 4 1 CAL LOW J ANGLE item This function code item is only available for Luffing fly systems The graphical LCD will appear similar to CAL LOW B ANGLE 7 2 4...

Страница 32: ... TRANS 1 F14 Uncal 555 Health 500 approx Cal 22 11 hh mm 7 2 6 2 CAL TRANS 1 LOW item The graphical LCD will appear similar to CAL LOW B ANGLE 7 2 6 3 CAL TRANS 1 HIGH item The graphical LCD will appear similar to CAL LOW B ANGLE 7 2 7 Set Gain Trans 2 item This function code is exactly the same as the Set Gain Trans 1 item except it of course operates on the transducer 2 gain 7 2 7 1 VIEW TRANS 2...

Страница 33: ...c buttons are used and the value entered is larger than then maximum allowed the message Max Sample will be displayed NO OF SAMPLES F22 Samples 8 hh mm 7 2 10 Set Lift Value Threshold item A lift of a load is said to have commenced when the load is greater than or equal to the lift value During a load lift it is not possible to change the crane configuration duty falls etc There is one lift value ...

Страница 34: ...or unladen boom deflection As such it should only be used when the displayed load radius is less than the true operating radius of the crane In such a case the installer should measure the physical load radius at a position where boom deflection is seen to have the maximum effect on the load radius Maximum boom deflection occurs when the boom is fully telescoped and is positioned at about 45 60 de...

Страница 35: ...splay can be placed in the rigging mode If rigging mode can t be entered because of the rigging length threshold a message is shown on the graphical LCD informing the operator Generally this is only used on telescopic cranes however in some cases it may also apply to lattice boom scenarios 7 2 15 View Directions item The Hoist directions for winch 1 2 and 3 can be viewed if installed and the Luff ...

Страница 36: ...diagram The date displayed is in the ISO format YYYY MM DD An invalid date will cause an error message to appear SET DATE F27 1998 11 24 YYYY MM DD hh mm 7 2 19 Set Time item When changing the time the graphical LCD will appear as shown in the following diagram The time displayed is in the format HH MM SS An invalid time will cause an error message to appear Note The seconds can t be edited and wi...

Страница 37: ... interest has been selected and OK is pressed the graphical display should be showing the following information VIEW CAL DATA F32 Raw Lo 123 0 Raw Hi 222 0 Cal Lo 222 23 Cal Hi 12 99 A 22 5 B 33 4 hh mm 7 2 21 1 ALTER CAL DATA item The Cal data item of interest needs to be selected before editing can occur This is achieved in a similar method to selecting main menu items When the OK button is pres...

Страница 38: ...e appropriate settings but only start the PC once the download function code has been activated on the RCI 1550 7 2 26 Receive Lm Data item This function code item is only available for Load Moment systems This function is of course the opposite of the above It allows load moment calibration that was previously saved to be restored to the RCI 1550 The communications settings are as shown above and...

Страница 39: ...o crane even if they are of the same model the RCI 1550 allows the installer to change crane information on site These user variables include dimensions such as slew offset maximum falls for main aux winches maximum line pulls sheave diameters etc refer to function code listing at the end of this manual The actual value of these variables are printed on a configuration sheet which is supplied with...

Страница 40: ...the RCI 1550 The range of possible numbers is 0 to 1023 when an 8 bit analogue to digital converter is used which is the most common type The RCI 1550 allows the user to view both the UNCALIBRATED or the CALIBRATED signal from a given sensor refer to function code listing at the back of this manual When viewing the UNCALIBRATED signal from a sensor make sure the number displayed is less than 999 a...

Страница 41: ...re all digital outputs switched are wired correctly Review all geometry Function code settings for correctness Check Set the following function codes No of Samples amount of averaging applied to sensor inputs Set Lift Value enter a weight slightly larger than the selected winch hook block Set Rigging Load enter the maximum allowable load allowed during rigging Set Rigging Length enter the maximum ...

Страница 42: ...red using the VIE W BOOM ANGLE function 7 6 Calibrating Jib Angle Luffing fly jibs only 7 6 1 Calibrating low Jib angle Ensure that the angle sensor is mounted on the luffing fly and the cable is connected Safely luff the jib down to a low angle eg 30 to the horizon Enter calibration mode and select the correct function code for calibrating low jib angle Accurately measure the actual jib angle usi...

Страница 43: ... Moment systems This method does not require test loads for calibrating the load instead it uses the un laden boom which is calibrated at two different boom angles The weight of the hook block and any wire rope betw een the hook block and boom jib sheaves must be known precisely 7 8 3 Testing calibrating Transducers Overview Load is measured using force transducers There may be one or two of these...

Страница 44: ...exit view mode and calibrate the transducers as described below If the numbers do not change or fall outside the valid range then check the wiring from the transducers to the ROBWAY display If the transducer signals check out then you need to calibrate them to force This is done using a ROBWAY transducer simulator and functions Alternatively you can just activate function code ALTER CAL DATA and e...

Страница 45: ...e required if using a load cell not supplied b y Robway w ith the initi al sy stem supply or a load cel l is has be en changed from original Make sure the simulator cable is plugged into Load 1 on the Controller Unit analog section Enter calibration mode if not already activated and select function CALIBRATE HIGH END OF TRANSDUCER 1 Dial up position 10 on the simulator switch Using the UP DOWN key...

Страница 46: ... if using a load cell not supplied by Robway with the initial system supply or a load cell is has been changed from original Make sure the simulator cable is plugged into the Load 2 transducer input on the Controller Unit analog section Enter calibration mode if not already activated and select function CALIBRATE HIGH END OF TRANSDUCER 2 Dial up position 10 on the simulator switch Using the UP DOW...

Страница 47: ...tor is available you can also calibrate the low and high of the transducers by simply activating function code Alter Cal Data and enter the low and high cal values of the amplifiers Please no te that the follow ing procedu res must be done for every duty selectable 7 10 Calibrating Active selected WINCH Make sure that the correct duty and falls are selected for the crane setup and that the correct...

Страница 48: ...which the boom is restricted from moving any higher by the boom back stop For most cranes this value should be known however it can be measured simply by luffing the boom to the highest possible angle and measuring the angle 7 11 2 3 Backstop Load Error This value represents the error in the load reading when the load is luffed from the Low Angle to the High Angle If a known 5t test weight was luf...

Страница 49: ...fied 8 2 In cabin items Ensure the display unit mounting is solid and vibration free and that the display cable connection is firmly connected Ensure the display cable is not pinched or caught or may become suspect to damage on route from the Display Unit to the Controller Unit outside the cabin A water dampened cloth is preferred for cleaning general dirt items from the display Wipe off any build...

Страница 50: ...aw compartment complete with cable The spring compartment is now exposed and the 4 nyloc nuts and the cover may be removed The rewind spring will now be visible and seen to be held in a captive band A broken spring normally occurs close to the arbor as this is at the point of maximum flexing If this is seen to be the case the spring may be lifted out BEING VERY CAREFUL TO ENSURE THAT THE COILS REM...

Страница 51: ...haft and withdraw compartment complete with cable The spring compartment is now exposed and the 4 nyloc nuts and the cover may be removed The rewind spring will now be visible and seen to be held in a captive band A broken spring normally occurs close to the arbor as this is at the point of maximum flexing If this is seen to be the case the spring may be lifted out BEING VERY CAREFUL TO ENSURE THA...

Страница 52: ...re that all of the coils remain within the captive band 8 5 INSPECTION AFTER MAINTENANCE Robway consider it essential by that a detailed Inspection is performed following any maintenance to ensure that the equipment and installation continue to comply with the documentation Any deviations to supplied documentation should be updated to inform any future service attendance 8 6 RECORDS Any details of...

Страница 53: ...a fault in a cable or sensor which was not identified prior to re calibration Re calibration must only be performed when all physical inputs have been verified for correct operation and in actual fact is rarely ever needed Do you have your simulator with you A simulator is a very quick way to verify if the fault is external to the display and will save you a lot of heartache A simulator is purely ...

Страница 54: ...sor 3 Sensor is open or short circuit 108 Angle Sensor 4 Sensor is open or short circuit 201 Load Sensor 1 Sensor is open or short circuit 202 Load Sensor 2 Sensor is open or short circuit 204 Load Sensor 3 Sensor is open or short circuit 208 Load Sensor 4 Sensor is open or short circuit 210 Digital Input Digital input error detected 220 ATB Crane is two blocking 240 Overload Current load exceeds ...

Страница 55: ...pped or the load cell has been installed upside down The load display is very erratic and displays massive changes in value Check the view UNCALIBRATED TRANSDUCER INPUT for that channel If the values are flickering by 2 3 counts while the display is changing by say a number of tonnes then the cause is most probably calibration One common cause of this is if different load values were entered for t...

Страница 56: ... the signal and each of the excitation wires varying between 0 and 1k or 5k ohms between any of the wires and chassis or shield high ohms or open circuit Electronic Angle Sensor Between any of the wires and chassis or shield high ohms or open circuit Length Sensor Across the excitation wires 500 ohms Between the signal and each of the excitation wires varying between 0 and 500 ohms Between any of ...

Страница 57: ...12 APPENDICES 12 1 Drawings Part A System Components 12 2 Drawings Part B General Arrangements and Wiring 12 3 Software Documents ...

Страница 58: ...Drawings Part A System Components ...

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Страница 63: ...APPROVED BY TOL 0 0 0 1 2 3 4 55 26 2 0 7 2 8 9 1 1 1 1 0 7 5 6 2 ...

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Страница 65: ...5031 PHONE 61 8 8238 3500 FAX 61 8 8352 1684 X X X X XX TOL 1 0 2 0 02 DRAFTING STANDARD AS1100 DO NOT SCALE DRAWING ALL DIMENSIONS ARE IN MILLIMETERS UNLESS OTHERWISE STATED johnh 19 04 2013 A 4807 A idw MOUNTING PLATE TO SUIT RW10 TO DRUKOR0413 PLAM4807 1 1 4807 A A B 316 0 296 0 102 5 270 0 250 0 138 0 85 0 6 0 3 0 BACK TO BE FLUSH n 12 0 16 0 M8x1 25 THREAD Material MILD STEEL Finish GOLD PASS...

Страница 66: ...APPROVED BY TOL 0 0 0 1 22 3 4 5 6 0 22 2 1 7 8 98 1 7 8 98 7 8 98 7 8 98 1 0 9 8 3 6 8 3 ...

Страница 67: ... APPROVED BY 0 1 2 22 3 3 3 TOL 4 4 23 4 232 22 5 0 42 4 2 3617 8 9 8 8 2 ...

Страница 68: ... APPROVED BY 0 1 2 22 3 3 3 TOL 4 4 23 4 232 22 3 242 4 2 32 2 3516 7 8 7 7 9 2 3 42 4 2 ...

Страница 69: ...BLE ONLY IF ATB NOT INSTALLED IF ATB IS INSTALLED LEAVE ENOUGH CABLE TO ATTACH TO THE ATB SWITCH ENSURE THAT ALL CABLE GUIDES ARE IN A STRAIGHT LINE OR EXCESS WEAR ON THE CABLE WILL OCCUR 3m MINIMUM STEP 3 STEP 4 STEP 5 FULLY EXTEND BOOM DRAWING No DESCRIPTION OF CHANGE REV DATE APPR D X X X XX DO NOT SCALE DRAWING ALL DIMENSIONS ARE IN MILLIMETERS UNLESS OTHERWISE STATED TOL X 1 AS STATED 0 2 PAR...

Страница 70: ...IS NOT SATISFIED THE CABLE MAY OVER SPILL SIDES OF THE DRUM FLANGE DRAWING No DESCRIPTION OF CHANGE REV DATE APPR D X X X XX DO NOT SCALE DRAWING ALL DIMENSIONS ARE IN MILLIMETERS UNLESS OTHERWISE STATED TOL X 1 AS STATED 0 2 PART OF ASSY APPROVED DRAWN PART NO TITLE DWG 3718 FILE No N A SHEET OF REV SCALE 1 0 2 4 PROJECT DRAFTING STANDARD AS1100 31 10 2007 S CHAMBERS 371801AA DWG INSTALLATION DET...

Страница 71: ...CHAIN LENGTH TO SUIT CRANE CABLE GUIDES DRAWING No DESCRIPTION OF CHANGE REV DATE APPR D X X X XX DO NOT SCALE DRAWING ALL DIMENSIONS ARE IN MILLIMETERS UNLESS OTHERWISE STATED TOL X 1 AS STATED 0 2 PART OF ASSY APPROVED DRAWN PART NO TITLE DWG 3718 FILE No N A SHEET OF REV SCALE 1 0 3 4 PROJECT DRAFTING STANDARD AS1100 31 10 2007 S CHAMBERS 371801AA DWG INSTALLATION DETAILS RECOIL DRUM J KOVAL 1 ...

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Страница 73: ...ustrate the sample tapping points for the pressure transducers Different machines have different geometries and the installer must determine correct tapping points of the transducers The BORE FORCE side pressure transducer must be connected to the full bore head side of the ram If Lock Valve is fitted to the bore side the transducer must be fitted to the live side of the valve If machine has two l...

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Страница 75: ...ALL DIMENSIONS ARE IN MILLIMETERS UNLESS OTHERWISE STATED N A S CHAMBERS 19 04 2005 1 3 293401AD idw ASSY BB5 DIMENSIONAL DETAIL SWIBB5 BB5 ATB SWITCH 1 2 2934 A CANLAS 19 04 2005 3RD ANGLE 1 1 16 07 10 EXPLORED VIEW ADDED REFER PCR 322 A A 1 2 14 01 2011 REFER TO PCR 366 A A 1 3 24 1 14 REFER TO ECN 543 J H Parts List ITEM QTY DESCRIPTION DWG No PART NUMBER 18 2 CABLE TIES TIE200BK 40 60 4 0 9 TH...

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Страница 80: ...Drawings Part B General Arrangement and Wiring ...

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Страница 96: ... Appendix 4 RCI System Crane Configuration Sheet Duty Listing XQFWLRQ RGHV ...

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