LSI-Robway RCI-1502 LM User manual

RCI-1502 LM Telescopic Boom System
Instruction Manual


MAN-1074 Rev G

LSI-Robway Pty Limited, 32 West Thebarton Road, Thebarton, South Australia, 5031
Phone: [phone] Fax: [phone] www.lsirobway.com.au

Contents PageNo.
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 Low End & High End of Transducers........................... 30
5.5.1. Calibrating the Low End of Transducer 1 (Bore Side)..... 30
5.5.2. Calibrating the High End of Transducer 1 (Bore Side).... 30
5.5.3. Calibrating the Low End of Transducer 2 (Rod Side)...... 31
5.5.4. Calibrating the High End of Transducer 2 (Rod Side) ..... 31
5.6. Calibrating Load for Active Winch.................................................. 32
5.6.1. Calibrating a Duty ............................................................... 32
5.6.2. Calibrating a Boom Section............................................... 33
5.6.3. Examples on Section Number Selection .......................... 34
5.7. Copying and Restoring Calibration Data Function ........................ 36
6. Troubleshooting............................................................................................... 42
7. Electrical Specifications.................................................................................. 48
8. Appendices....................................................................................................... 51

1. Important Safety Notice
The RCI-1502 System is a crane device which warns the operator of impending
overload conditions and of overhoist conditions which could cause damage 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 operational instructions and warnings are
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 manufacturer’s setup and
operation procedures. Operation of this key is for authorised personnel only who shall
be solely responsible for its use.

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 3063 “RCI-1502 GENERAL ARRANGEMENT FOR TYPICAL
TELESCOPIC BOOM LM 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 warning (approach to overload),
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.

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 ignition 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 indicators 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.

3.3. Operating Screen
The following is the operating screen 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
Percenta
g
e 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 = Im
p
erial
)

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 display which contains three coloured
lamps to indicate “approach 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 reached (i.e. 85%
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 continuous audible alarm. Crane
motion controls are also activated at this stage if fitted.
3.4.2. Numerical LCD for Various Functions
This is a numerical LCD display, just below the indication lamps
mentioned above, which shows the 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 next 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.

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 LISTING 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 prevent two-blocking. When
the ATB indicator on the front panel is lit, a two-blocking condition has
occurred and further hoisting is stopped 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 the left side of this window. The MAIN
and AUX LED’s indicate which winch is selected. The LBS LED
indicates the units selected. LED ON means Imperial Units (kips, feet)
and LED OFF means Metric Units (tonnes, metres).
Use the WINCH SELECT button to switch between MAIN and AUX
winches. For Single Winch cranes, only the MAIN winch is active 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 LOAD exceeds the SWL for the current crane
configuration the RCI-1502 will activate audible and visual alarms.

If the overload is higher than the SWL % for MOTION CUT OUTPUT,
set in calibration 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 motion 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.
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 the Data-Logging Download Cable (Part
No. CABCOM 1261) between the RS-232 socket 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.