LSI-Robway RCI-1502 HRT User manual

RCI-1502 HRT Telescopic Boom System
Instruction Manual
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MAN-1073Rev G
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LSI-Robway Pty Limited, 32 West Thebarton Road, Thebarton, South Australia, 5031
Phone: [phone] Fax: [phone] www.lsirobway.com.au

RCI-1502 HRT Tele Boom Manual
Contents Page No.
1. Important Safety Notice................................................................................... 3
2. General Description......................................................................................... 4
3. Operating Instructions..................................................................................... 5
3.1. Turning On the RCI-1502................................................................... 5
3.2. Turning Off the RCI-1502 .................................................................. 5
3.3. Operating Screen............................................................................... 6
3.4. Display Functions.............................................................................. 7
3.5. Data Logging and Data Downloading.............................................. 9
4. Installation ........................................................................................................ 10
5. Calibration......................................................................................................... 17
5.1. Verifying Operation of Sensors........................................................ 20
5.2. Configuring User Variables .............................................................. 21
5.3. Calibrating Main Boom Angle........................................................... 28
5.3.1. Calibrating Low Boom Angle............................................. 28
5.3.2. Calibrating High Boom Angle............................................ 28
5.4. Calibrating Main Boom Length......................................................... 29
5.4.1. Calibrating Short Boom Length......................................... 29
5.4.2. Calibrating Long Boom Length ......................................... 29
5.5. Calibrating Load on the MAIN Winch............................................... 30
5.5.1. Calibrating Light Main Load............................................... 30
5.5.2. Calibrating Heavy Main Load............................................. 30
5.6. Calibrating Load on the AUX. Winch (Twin Winch)........................ 31
5.6.1. Calibrating Light Aux Load................................................ 31
5.6.2. Calibrating Heavy Aux Load .............................................. 31
5.7. Copying and Restoring Calibration Data Function ........................ 32
6. Troubleshooting............................................................................................... 38
7. Electrical Specifications.................................................................................. 45
8. Appendices....................................................................................................... 48

RCI-1502 HRT Tele Boom Manual
1. Important Safety Notice
The RCI-1502 S ystem is a cra ne device which warns the operato r of impending
overload conditions and of overhoist c onditions which could cause dama ge to
property, crane and personnel.
The system is not a substitute for good operator judgement, experience and safe
crane operation. The operator is solely responsible for the safe operation of the crane.
The operator must, prior to operation of the crane, read this manual carefully and
thoroughly and shall ensure that all operatio nal instructions an d warnings a re
understood and complied with.
Proper system operation requires the operator to correctly program the RCI System to
match the crane setup and working configuration.
The system is equipped with an override key which bypasses alarms and motion cut
function at which time the system can no longer warn of impending overload and must
only be operated strictly in accordance to the crane manu facturer’s setup and
operation procedures. Operation of this key is for authorised personnel only who shall
be solely responsible for its use.
SPECIAL NOTE FOR TENSIOMETER INSTALLATION AND USE
Please Note: Remove tensiometers during dragline and piling operations.
Tensiometers (dynamometers/line-riders) are NOT designed for use on wire ropes
performing Piling operations due to the high cycle and high speeds combined with high
linepulls.
Please ensure they are removed before commencing operations.
LSI-Robway and distributors will not accept responsibility for either rope or
tensiometer damage resulting from this type of use.

RCI-1502 HRT Tele Boom Manual
2. General Description
This Manual contains general information, installation, operation, calibration,
maintenance and parts information for the RCI-1502 Rated Capacity Indicator to suit
various Telescopic boom mobile cranes.
Refer to drawing DWG 2464 “RCI-1502 GENERAL ARRANGEMENT FOR TYPICAL
TELESCOPIC BOOM HRT SYSTEM” on Section 8.2. of the Manual for an overview of
the System.
Drawing (DWG) Numbers, where applicable in the following Sections, are also
provided for quick reference.
The RCI-1502 is a fully automatic Rated Capacity Indicator which provides a display of
the following functions:
• Boom Length,
• Boom Angle,
• Hook Radius,
•S.W.L. (Safe Working Load),
•Hoist Rope Falls,
• Duty (Configuration),
•Actual Load of Selected Winch (Main or Aux),
•Percentage of SWL (3 coloured lamps - green, amber, and red).
The RCI-1502 display also provides the following features:
•Visual and audible alarms on wa rning (approach to overloa d),
overload, motion-cut, two-blocking detection, and error detection,
•Self-diagnosis and error codes,
• Data-logging,
•Built-in calibration and fault-finding tools,
•Units conversion (imperial/metric) facility,
•Anti-two-block (overhoist limit) facility.

RCI-1502 HRT Tele Boom Manual
3. Operating Instructions
The following sections explain how to operate the RCI-1502 and make best use of its
capabilities.
3.1. Turning On the RCI-1502
Power to the unit is from the crane battery (nominal 12 or 24 volts dc) through
the start-up or ignitio n key . In some applications an additional switch may be
used to enable the operator to switch the unit on/off as required.
As soon as power is applied to the unit, its display and other ind icators should
light up and the unit should go through its self-test operation.
3.2. Turning OFF the Unit
The unit will stop working as soon as the power is removed from it by switching
off any of the switches indicated in Section 3.1 above.

RCI-1502 HRT Tele Boom Manual
3.3. Operating Screen
The following is the operating scr een of the RCI-1502 showing the general
display functions:
Multi-function
Select Button
(Length…Duty)
Multi-function
Display
(Length…Duty)
Green/Amber/Red LED
Indicator Lamps for
Percentage of SWL
LED Indicator
Lamps for
Multi-function
Select Button
(Length…Duty)
Actual Load for
Winch Selected
(Kips or Tonnes)
LED Indicator
Lamps for ATB
and Override
LED Indicator
Lamps for
Winch Select
Button
(Main or Aux)
Setup/Cancel
Button for Use
in Calibration
Mode
Winch Select
Button
(Main or Aux)
Test/Enter Button
(Pressing Test will Restart
the System; Enter is Used in
Calibration Mode)
UP/DOWN Buttons
for Changing Duty
& Falls, and for Use
in Calibration Mode
LED Indicator for
Units in Use
(OFF = Metric &
ON = Imperial)

RCI-1502 HRT Tele Boom Manual
3.4. Display Functions
The RCI-1502 has 2 LCD display windows and 6 front panel push buttons. The
display panel can also be grouped into four parts as follows:
3.4.1. “Approach to Rated Capacity” Indication Lamps
This is the uppermost part of the di splay which contains three coloured
lamps to indicate “ap proach to rated capacity ”. Factory settings are as
follows:
•Green: 50 to 84%, Amber: 85 to 99%, Red: 100 to 110%
•Amber lamp flashes when first trip point is rea ched (i.e. 8 5%
Rated Capacity) plus an intermittent audible alarm.
•Red lamp will flash at 100% of rated capacity plus a continuous
audible alarm.
•Red lamp will stop flashing and will stay ON when the lifted load
exceeds 110% of SWL plus a c ontinuous audible alarm. Crane
motion controls are also activated at this stage if fitted.
3.4.2. Numerical LCD for Various Functions
This is a numerica l LCD display , just below the indication lamps
mentioned abov e, which shows th e LENGTH, ANGLE, RADIUS,
S.W.L., FALLS, and DUTY status.
This window is also used to display ERROR codes when any errors are
detected. The error function cannot be manually selected but will be
displayed automatically if there are any errors. Please refer to Section
6. “Troubleshooting” for the meaning and description of the error codes.
The above functions are selected by pressing the SELECT button on
the front panel. The selected function is indicated by the lamp nex t to
the labels. The display functions are as follows:
LENGTH
The numerical display shows the BOOM length, in unit selected (feet or
metres), for the winch selected.
ANGLE
The numerical display shows the current working angle in degrees
which is read from the main boom angle sensor.
RADIUS
The numerical display shows the current working radius, in unit selected
(feet or metres), for the winch selected.
SWL
The numerical display shows the current maximum safe working load in
unit selected (kilopounds or tonnes). The S.W.L. will depend on the
current crane configuration (duty ), winch selected (if twin winch), the
maximum linepull and the falls selected.

RCI-1502 HRT Tele Boom Manual
FALLS
The numerical display shows the number of falls (parts of line) used for
the winch selected. To change the falls, press the UP/DOWN arrow
keys to ramp to the desired falls number while the FALLS indicator is
on, make sure the correct winch is selected.
DUTY
The numerical display shows the current duty (or configuration) number
selected. Each system manual is supplied with a DUTY LISTING for a
given application. Please refer to the DUTY LIS TING at the rear of the
manual for a description of the duties. A plastic encapsulated version is
also supplied with the system for the crane operator’s quick reference in
the cabin.
To change the Duty number, use the UP/DOWN key to ramp to the
desired value, while the DUTY LED indicator is on.
3.4.3. A.T.B. (Anti-Two-Block) and O/RIDE (Override) Indication LEDs
This part of the display has two red LED’s which shows the current
status of the following functions:
O/RIDE - LED ON when over-ride/bypass key is switched on.
A.T.B. - LED ON when on two-blocking condition.
The RCI-1502 is supplied with a standard Anti-Two-Block (ATB ) input
for connecting an optional ATB sensor to preve nt two-blocking. When
the ATB indicator on the front panel is lit, a two-b locking condition has
occurred and further hoisting is st opped by activating the motion cut
relay, if installed.
3.4.4. Numerical LCD for Current Load Readout
This part has a numerical LCD which shows the current load, in unit
selected (kilopounds or metric tonnes), on the winch selected.
There are three red LED’s on th e left side of t his window. The MAIN
and AUX LED’s indicat e which winch is selected. The LB S LED
indicates the units selected. LED O N means Imperial Un its (kips, feet)
and LED OFF means Metric Units (tonnes, metres).
Use the WINCH SELECT butt on to switch between MAIN and AUX
winches. For S ingle Winch cranes, onl y the MAIN winch is a ctive and
the AUX LED is disabled.
Although the RCI-1502 will always check safe operation for both
winches, you should make sure that the correct winch is selected as the
winch selection affects the values shown on the displays.
When the ACTUAL LO AD exceeds the SWL for the current crane
configuration the RCI-1502 will activate audible and visual alarms.

RCI-1502 HRT Tele Boom Manual
If the overload is higher than the SWL % for MOTION CUT OUTPUT,
set in ca libration mode, the instrument will also activate the motion cut
relay, if installed. This will then stop further over-loading of the crane.
To bypass or temporarily disable mo tion cut, the operator must use the
over-ride key which should be held by the site-supervisor. When the key
is inserted into the display and is turned on the O/RIDE indicator is
illuminated as a reminder.
LSI-Robway recommends that the over-ride key be switched OFF
at all times and the over-ride key be held by the site-supervisor.
3.5 Data Logging and Data Downloading
For downloading data to PC, connect th e Data-Logging Download Cable (Part
No. CABCOM 1261) between the RS -232 so cket at the back of the RCI-1502
display and the PC.
Please refer to Section 8.1. “DATA LOGGING ON RCI SYSTEMS” at the rear
of the manual for usage information and details.

RCI-1502 HRT Tele Boom Manual
4. Installation
SETTING UP THE CRANE
Lower the crane boom to a safe and convenient position.
INSTALLING BOOM PARTS
Recoil Drum
The recoil drum contains both the angle sensor a nd length sensor for
telescopic cranes. The payout cable of the drum is also used for wiring the ATB
switch/es if required. It is supplied for right hand side mounting unless
ordered specifically for left hand side mounting.
The recoil drum comes complete with mounting bolts, payout wire roller guides
and boom tip tie-off bracket.
First remove the recoil drum cover a nd set aside. Fix the recoil drum and
payout cable to the right hand sid e of the main boom by welding the mounting
bolts provided to a suitable location on the side of the boom. Mount the recoil
drum on the bolts ensu ring that the el ectrical connection socket is pointing
towards the cabin. Ensure the recoil drum is mounted 'squarely' to the boom
side panel, this is essential to avoid incorrect payout wire spooling problems.
When the recoil drum is m ounted to the left hand side of the boom , the
electronic angle sensor must also be adjusted to get it working to its full range.
Please refer to drawings DWG 1199 , 1239, & 2159 at the rear of this m anual
for the correct position of the angle sensor.
Select a convenient uninterrupted payout cable alignment along the side of the
boom and cut and weld the anch or post provided to a suita ble position on the
boom head, so that the cable can be clamped into the groove on the post to
obtain a temporary line. Select positions for the intermediate cable roller guides
provided, one for each telescoping section and one or more for the main boom
allowing 3-4m between the drum and the nearest cable roller guide. Measure
the distance f rom the cable to the sides of the boom sections, record lengths
and mark the positions for the roller guides. Cut and weld the brackets of the
guides to the sides of the boom sections after remov ing the cable. Refit the
cable through the guides and then anchor it to the p ost using the clamp
provided.
When the installation is complete, the recoil spring should be 'maximised' to
ensure that maximum available tension is applied to the payout wire to prevent
poor spooling onto the recoil drum. If possible, extend the boom fully at zero
degrees and pull the recoil drum payout wire fully out by hand until the spring
'locks up'. Allow 2 metres of payout wire to return back onto the drum and cut
off the exce ss. Remake the connection to the boom tip tie -off bracket.
Remember to leave sufficient cable l ength for connection to the anti-2-block
switch if one is being fitted.
If it is not possible to safely extend the boom at zero degrees, then simulate by
extending the payout by hand to a mark on the ground representing the full
telescopic extension.

RCI-1502 HRT Tele Boom Manual
Fully retract the boom. Extend the payout wire slightly and note the direction of
rotation of the large gear wheel for an extending boom. Relea se the payout
wire and allow it to retract to its' fu lly retracted positio n. Turn the large
aluminium gear, by hand, in the opposite direction to that noted fo r an
extending boom, until the gear sto ps. Turn the gear in the opposite direction
(i.e. as if for extending) for ¾ of a turn or three clicks of the clutch. Safely
extend the boom to full exten sion ensur ing continuous operation of the gear
wheel and potentiomete r. Fully retrac t the boom and again check operation.
Refit the recoil drum cover and ensure all mounting nuts are tight.
Route the cable carefully from the recoil drum back around the boom pivot to
the cabin. Fix the cable to the boom and turret using adequate fixings ensuring
that the cab le is n ot pinched or stretched as the boom moves through its full
luffing arc. Only connect the cable to the Display Unit when finished welding.
Notes:
The slip-rings in the LSI-Robway recoil drum are designed for use
with LSI-Robway Anti-2-block systems and are not for resistive or
inductive circuits such as lights or bells. If you have a particular
application that you feel may be applicable to the slip-ring facility,
please contact LSI-Robway for further advice.
Please note also that high tensile booms require proper welding
procedure specifications. Obtain specialist assistance in these cases.
Recoil drum and typical installation at the boom base section
Load Sensor (Dynamometer/Tensiometer Type)
Please Note:
Remove tensiometers during dragline and piling operations. Refer to Section 1.
“Important Safety Notice” – Special Note for Tensiometer Installation & Use.

RCI-1502 HRT Tele Boom Manual
The RCI-1502 System uses a dy namometer/tensiometer (also known as line-
rider) type load sensor which directly senses the line-pull generated when lifting
the load.
The dynamometer, or dyno for short, is a three-pulley arrangement load sensor
with a beam ty pe load cell (model RW5000) mounted within. The dyno
monitors the ho ist rope line-pull as the hoist rope passes t hrough the th ree
sheaves. The dyno sheaves must be suited to the diameter of the hoist rope.
The dynos are usually rigidly mounted on top of the boom base section towards
the outer end. Th ey are available in both single and twin winch versions. The
mounting base consists of a pair of angle irons complete with 4 off hi-tensile
black bolts, nuts and sprin g washers. It is usual to weld the bolt heads to the
boom top. Consult layout drawings at the rear of this manual for more details.
On some cranes where the angle bet ween the boom tip and the hoist rope
varies greatly as the boom luffs up and down, an articulated arm assembly (or
universal arm) may be used to fix the dyno to one end of the arm and the other
end of the arm bolted or fixed to the boom. This universal arm a llows the dyno
to follow the natural location/movement of the hoist rope relative to the boom
itself. It is available at LSI-Robway or can be fabricated on site to suit
application.
The load cell in the dyno will output an electrical signal proportional to the hoist
rope line-pull forces, the RCI-1 502 will then convert this into hook-load weight
in tonnes or kilopounds. Correctly foll owing the calibration procedures is
essential for accurately determining the hook load weight.
Drawing References:
DWG 1393 – “Overall Dimensions, HRT-3MM Micro-Mini Dyno”
DWG 0875 – “General Arrangement, HRT-3MM Dynamometer”
DWG 0422 (Sheets 1-2 of 2) – “General Arrangement, HRT-3 Dyno”
DWG 0104, 0786, 0787 – “Parts List for HRT-3 Dynamometer”
DWG 0353 – “Exploded View & Parts List for HRT3-2 Double Dyno”
DWG 0552 – “General Arrangement, HRT3-2 Double Dynamometer”
DWG 0370 – “General Arrangement, Std Articulated Arm for Dyno”
DWG 2468T – “Typical Installation of Dyno on Telescopic Crane”
Typical installation of dynamometers/tensiometers on telescopic cranes

RCI-1502 HRT Tele Boom Manual
Anti-Two-Block (Optional Item)
Fix the anti-two-block (ATB) switch mo unting bolt by welding it to the boom
head preferably so that the bob weight (when suspended from the switch) can
be fitted to the static hoist rope below the rope anchor. Check that the switch
works correctly as the boom luffs throughout its working range.
Additional switches (for fly-jibs) can be added. Connection is via the bullet-type
connectors from the cab le. When more th an one ATB switch is required (e.g.
main & fly), connect the ATB cables of the switches in series via the bullet-type
connectors.
Hang the bob weight assembly from the switch eye after cutting the chain to
length if desired to suit winch line speed. Repeat the procedure if required for
rooster or fly jib.
Drawing References:
DWG 2934 – “Dimensional Detail, BB5 Anti-Two-Block Switch”
DWG 0667 (Sheets 1-2 of 3) – “ATB Switch Installation Details, Telescopic
Crane”
Please note that high tensile booms require proper welding procedure
specifications. Obtain specialist assistance in these cases.
Model BB-5 anti-two-block (ATB) switch
Cabling (Boom Sensors)
Sensor ca bles should be fixed firmly to where they are installed and routed
along the boom chords through to t he crane cabin ensurin g freedom of
movement around the boom pivot pin.
The cables are normally quite robust. They should be treated with care,
however, as ev en a small amount of damage can be very costly due to down-
time or intermittent beha viour. Always support the cable in such a way that
there is no "excessive" strain applied, su ch as tension or flexing. The cable
should be strapped to a fixed member that it runs along, unless it is held within
a cable tray or trunking. Clip cables at approximately 600mm intervals or where
suitable to secure them firmly to the boom. Avoid sharp bends such as around
a sharp corner. Where there is to be flexing, the installer must ensure that the
bending is reduced to an absolute minimum to avoid fatigue breakage of the
conductors.
Drawing Reference:
DWG 1224 – “RCI Series Cable Connections”

RCI-1502 HRT Tele Boom Manual
Connectors
It is recommended that the installer applies a suitable silicone grease (e.g.,
Dow Corning 4 “Electrical Insulating Comp ound” or any similar compound) on
the plugs and sockets prior to connec ting the cab les. The silicone grease
should be smeared across the connecto r contact points to increase the wa ter
proofing of the connector.
INSTALLING CABIN PARTS
Display Unit and Key Switch Box
Fit the RCI-1502 Display Unit a nd Key S witch Box in a convenient position in
the crane cabin such that the operator can view the display s and reach the
push buttons comfortably.
Connect the Switch Box power supply lead to the key start switch or directly to
the battery via a relay that is energised by the key start switch. Ensure that the
polarity of the power supply is correctly connected.
Standard back plate bracket and kit comprising of bolts and nuts are provided.
Special bracket may need to be fabricated on site for suitable mounting in the
cabin.
Connect the load, angle, and anti-two-block ATB cables to the display unit.
Note: If a good earth connection between the mounting bracket and the
cabin cannot be guaranteed then the earthing wire attached to the base of
the display must be used to properly earth the display. Failure to do so
could result in a non-operational ATB signal and faults due to Radio
Frequency Interference.
Drawing References:
DWG 0279 – “Dimensional Drawing, RCI-1502 Display”
DWG 2459 – “Dimensional Detail, RCI-1502 Switchbox”
DWG 3336 – “RCI-1502 Switchbox V2 Wiring Diagram”
Display unit and typical installation inside the cabin

RCI-1502 HRT Tele Boom Manual
WIRING SLEW SWITCH/ES AND MOTION CUT OUTPUT
Slew/Proximity Switch/es (Optional Items)
The slew switch is used when the crane has different zones of SWL (e.g. over-
rear ratings, ove r-side ratings, etc.). The switch will convey a signal to the
display when the crane moves into a zone of different capacity rating. The RCI-
1502 system can interface with up to three switches maximum.
The switch is magnetically switched and requires a metal target to switch ON.
Fabricate, fix and secure a suitable mounting plate to the switch between the
two locknuts supplied. Mount the plate/switch assembly at a suitable location
on the revolving upperstructure preferably so that the switch moves and rotates
with the upperstructure. The metal target plate must be mounted at a safe and
suitable location on the carrier about which the upperstructure rotates.
Alternatively, fix the switch and target plate around the centre post of the crane
slew (refer to typical installation photo below).
The gap between the switch and target must not exceed 10mm. The switch
distance can be adjusted via the locknuts.
Connect the switch to the RCI-1502 S witchbox as per DWG 3336 (refer to
Section 8.2. “Drawings” for details).
Drawing References:
DWG 2461 – “Dimensional Details, Proximity Switch (SWIPROX02)”
DWG 2462 – “Dimensional Details, Proximity Switch (SWIPROX03)”
DWG 930050 – “RCI Slew Switch Mounting”
Typical installation of slew/proximity switch
Motion Cut Output
The standard RCI-1502 Switchbox has an in-built relay to output the motion-cut
signal. This allows connection of the crane’s lockout solenoids direct into the
Switchbox.
The Switchbox is fitted with a standard 24VDC (contact rating of 10A) relay
when supplied from the factory. A spare 12VDC (contact rating of 10A) relay is
also supplied with the installation kit supplied with the system. This is to replace
the 24VDC relay if the crane’s nominal supply is 12VDC.
To wire the crane’s lockout solenoi ds, open the RCI-1502 Switchbox a nd use
the following relay connections to match the solenoids: