LSI-Robway RCI-1550 HRT User manual

RCI-1550 HRT Telescopic Boom System
Instruction Manual
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MAN-1077 Rev B
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LSI-Robway Pty Limited, 32 West Thebarton Road, Thebarton, South Australia, 5031
Phone: [phone] Fax: [phone] www.lsirobway.com.au

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Table of Contents
1 WELCOME TO ROBWAY PRODUCTS ................................................................................................ 4
2 SPECIAL NOTES....................................................................................................................................... 7
2.1 BRANDNAMES,TRADENAMES AND TRADE MARKS................................................................................... 7
2.2 IMPORTANT SAFETY NOTICE ..................................................................................................................... 7
2.3 LIMITED PRODUCT WARRANTY................................................................................................................. 8
2.4 GLOSSARY OF SOME USED TERMS.............................................................................................................. 8
3 INTRODUCTION....................................................................................................................................... 9
3.1 MANUAL CONTENTS.................................................................................................................................. 9
3.2 SCOPE OF MANUAL ................................................................................................................................... 9
3.3 INTENDED AUDIENCE ................................................................................................................................9
3.4 PERSONNEL QUALIFICATIONS ................................................................................................................... 9
4 SYSTEM DESCRIPTION........................................................................................................................ 10
4.1 APPLICATION........................................................................................................................................... 10
4.2 PURPOSE.................................................................................................................................................. 11
4.3 CAPABILITIES .......................................................................................................................................... 11
4.4 AVAILABLE OPTIONS............................................................................................................................... 12
5 OPERATING INSTRUCTIONS.............................................................................................................. 14
5.1 THE LCD DISPLAY.................................................................................................................................. 14
5.1.1 The Bar Graph .............................................................................................................................. 14
5.1.2 SWL............................................................................................................................................... 14
5.1.3 Length............................................................................................................................................ 14
5.1.4 Angle ............................................................................................................................................. 15
5.1.5 Radius............................................................................................................................................ 15
5.1.6 Load .............................................................................................................................................. 15
5.1.7 Error Codes................................................................................................................................... 16
5.2 THE DISPLAY KEYPAD ............................................................................................................................ 16
5.2.1 Function Key (F1, F2, F3)............................................................................................................ 16
5.2.2 Soft Menu Keys.............................................................................................................................. 16
5.2.3 Alpha-Numerical Keys .................................................................................................................. 16
5.2.4 Ok (
4 ) key...................................................................................................................................... 17
5.2.5 Cancel (
5 ) Key............................................................................................................................... 17
5.2.6 Tare Key........................................................................................................................................ 17
5.2.7 Rigging Key................................................................................................................................... 17
5.3 LED INDICATORS.................................................................................................................................... 18
5.3.1 Override LED................................................................................................................................ 18
5.3.2 Audible Alarm Disabled LED........................................................................................................ 19
5.3.3 A.T.B. Indicator (anti-two-block or over-hoist) ............................................................................ 19
5.3.4 Approach to Rated Capacity LED................................................................................................. 19
5.3.5 100% Capacity Exceeded LED ..................................................................................................... 19
5.3.6 Motion Cut LED............................................................................................................................ 19
5.4 OVER-RIDE KEY-SWITCH (IF FITTED)...................................................................................................... 20
5.5 DISABLE KEY SWITCH (IF FITTED).......................................................................................................... 20
5.6 TURNING ON THE RCI-1550 .................................................................................................................... 20
5.6.1 On Power Up................................................................................................................................. 21
5.7 MENU NAVIGATION................................................................................................................................. 21
5.7.1 Config Change Menu .................................................................................................................... 21
5.7.2 Function Codes ............................................................................................................................. 22
5.7.3 Display Options Menu................................................................................................................... 22
5.8 DATA LOGGING AND DATA DOWN-LOADING .......................................................................................... 23
6 INSTALLATION - GENERAL ............................................................................................................... 24
6.1 SETTING UP THE CRANE.......................................................................................................................... 24
6.2 ANGLE SENSOR (TELESCOPIC BOOM CRANES ) ....................................................................................... 24
6.2.1 Changing from RHS to LHS mounting.......................................................................................... 24
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6.3 LENGTH SENSORS.................................................................................................................................... 25
6.3.1 GENERAL..................................................................................................................................... 25
6.3.2 110’ Length Sensor – (DRURW33LAA)........................................................................................ 26
6.3.3 140’ Length Sensor– (DRURW43LAA)......................................................................................... 28
6.3.4 Pay-out Cable................................................................................................................................ 29
6.4 ANTI-TWO-BLOCK (IF INSTALLED ) ........................................................................................................ 29
6.4.1 Rectangular type Anti-two Block switches.................................................................................... 29
6.4.2 Tubular type Anti-two Block switches........................................................................................... 29
6.4.3 Multiple Anti-two Block switches.................................................................................................. 29
6.4.4 Bob-weight (both types of switches).............................................................................................. 30
6.5 LOAD-LINE (LINE-PULL)BASED SYSTEMS ................................................................................................ 30
6.5.1 Overview ....................................................................................................................................... 30
6.6 CABLING AND GLANDS............................................................................................................................ 30
6.7 DISPLAY UNIT ......................................................................................................................................... 31
6.8 CONTROL UNIT........................................................................................................................................ 32
6.8.1 Power Supply (PS) ........................................................................................................................ 32
6.8.2 CPU Section.................................................................................................................................. 34
6.8.3 Analog Input Section..................................................................................................................... 35
6.8.4 Digital IO Section ......................................................................................................................... 36
6.9 UPGRADING TO RCI-1550 FROM EARLIER ROBWAY MODEL DISPLAYS.................................................... 39
7 CALIBRATION ........................................................................................................................................ 41
7.1 CALIBRATION PURPOSE........................................................................................................................... 41
7.1.1 Entering Calibration Mode and Selecting calibration functions. ................................................. 41
7.1.2 Function codes menu item............................................................................................................. 41
7.1.3 General information regarding text editing.................................................................................. 42
7.2 CALIBRATION FUNCTIONS BREAKDOWN ................................................................................................. 42
7.2.1 EXIT CALIBRATION item ............................................................................................................ 42
7.2.2 VIEW MAIN LOAD and VIEW AUX LOAD items........................................................................ 43
7.2.3 VIEW BOOM ANGLE item........................................................................................................... 44
7.2.4 VIEW JIB ANGLE item................................................................................................................. 45
7.2.5 VIEW LENGTH item..................................................................................................................... 45
7.2.6 SET GAIN TRANS 1 item .............................................................................................................. 45
7.2.7 SET GAIN TRANS 2 item .............................................................................................................. 46
7.2.8 SET MUX. DELAY item ................................................................................................................ 46
7.2.9 NO. OF SAMPLES item................................................................................................................ 47
7.2.10 SET LIFT VALUE (Threshold) item.............................................................................................. 47
7.2.11 SET RIGGING LOAD Threshold item .......................................................................................... 48
7.2.12 SET RIGGING LENGTH Threshold item...................................................................................... 49
7.2.13 CORRECT RADIUS (Unladen boom) item................................................................................... 49
7.2.14 CORRECT RADIUS (laden boom) item........................................................................................ 49
7.2.15 VIEW DIRECTIONS item.............................................................................................................. 50
7.2.16 VIEW LOAD-CHART item............................................................................................................ 50
7.2.17 VIEW DIGITAL I/P item............................................................................................................... 51
7.2.18 SET DATE item............................................................................................................................. 51
7.2.19 SET TIME item.............................................................................................................................. 52
7.2.20 DOWNLOAD LOGGER item........................................................................................................ 52
7.2.21 VIEW CAL-DATA item.................................................................................................................. 52
7.2.22 CHANGE DUTY item.................................................................................................................... 54
7.2.23 CHANGE FALLS item................................................................................................................... 54
7.2.24 BACK UP CAL-TABLE item......................................................................................................... 54
7.2.25 RESTORE CAL-TABLE item......................................................................................................... 54
7.2.26 ERASE CAL-TABLE! item ............................................................................................................ 55
7.2.27 User Variables .............................................................................................................................. 55
7.2.28 Viewing Errors.............................................................................................................................. 56
7.2.29 Verifying Operation Of Sensors.................................................................................................... 57
7.3 TOOLS REQUIRED FOR CALIBRATION ...................................................................................................... 57
7.4 MAP OF CALIBRATION (SUGGESTED ORDER) ........................................................................................... 58
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7.5 CALIBRATING BOOM ANGLE.......................................................................................................... 59
7.5.1 Calibrating a low boom angle....................................................................................................... 59
7.5.2 Calibrating a high boom angle ..................................................................................................... 59
7.6 CALIBRATING JIB ANGLE (LUFFING FLY JIBS ONLY) ........................................................................ 60
7.6.1 Calibrating low Jib angle.............................................................................................................. 60
7.6.2 Calibrating high Jib angle ............................................................................................................ 60
7.7 CALIBRATING BOOM LENGTH........................................................................................................ 61
7.8 CALIBRATING TENSIOMETER BASED SYSTEMS ........................................................................ 62
7.8.1 Calibrate the Main Winch with light load..................................................................................... 62
7.8.2 Calibrate the Main Winch with heavy load................................................................................... 62
7.8.3 Calibrate the Aux winch with light load........................................................................................ 63
7.8.4 Calibrate the Aux winch with heavy load...................................................................................... 63
8 MAINTENANCE ...................................................................................................................................... 64
8.1 CHECK LIST ......................................................................................................................................... 64
8.2 IN-CABIN ITEMS....................................................................................................................................... 65
8.3 ELECTRICAL EQUIPMENT................................................................................................................ 65
8.4 RECOIL DRUM..................................................................................................................................... 66
8.4.1 110’ Recoil Drum – (DRURW33LAAX)........................................................................................ 66
8.4.2 140’ Recoil Drum – (DRURW43LAAX)........................................................................................ 67
8.5 INSPECTION AFTER MAINTENANCE.............................................................................................. 69
8.6 RECORDS.............................................................................................................................................. 69
9 ELECTRICAL SPECIFICATIONS........................................................................................................ 70
10 APPENDICES ........................................................................................................................................... 72
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1 WELCOME TO LSI-ROBWAY PRODUCTS
MADE IN AUSTRALIA
HEAD OFFICE
LSI-Robway Ltd
32 WestThebarton Road, Thebarton,
South Australia, 5031
Tele: [phone]
Fax: [phone]
E-mail: [e-mail]
Robway Crane Safety Systems are pleased to have been selected
to provide the RATED CAPACITY LIMITER fitted to this crane.
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The electronic load-charts in this system have been
provided to assist the operator to drive the crane safely
and productively. These load-charts have been provided to
Robway by either the crane manufacturer or crane owner
(or their representatives).
Robway dutifully re-represent these load-charts into
memory.
Motion Limiters may have been fitted to stop those
functions that will increase radius and hoist-up if the load-
chart is exceeded. This feature is provided as an aid to
safer crane operation.
In certain situations, such as crane setup, the crane
operator may need to ‘over-ride’ the motion limiters. At
these times, the system can no-longer warn of overload and
the crane must only be used in strict accordance to the
crane manufacturer’s setup and operation procedures.
Proper system operation requires the operator to correctly
program the Robway system to match crane setup and
working configuration.
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This Rated Capacity Indicator is fitted to assist the crane
operator.
This Rated Capacity Indicator is not a substitute for
operator judgement, experience or safe crane operation.
At all times the driver is ultimately responsible for safe
crane operation.
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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 warnings are presented to aid in understanding and operating the
equipment or to protect personnel and equipment. At all times, relevant codes applicable
to location of service must be adhered to.
Safe, reliable operation of Robway systems require the systems to be maintained in a
proper manner and serviced by technically trained personnel using trade (or profession)
recognised service procedures and correct tools for the purpose.
Provided warnings are not exclusive, as Robway could not possibly know, evaluate and
advise service people of all conceivable ways in which service might be performed or all
possible associated hazardous consequences.
Accordingly, anyone who uses service procedures or tools which are not recommended
by Robway must first satisfy themselves to their suitability and that neither personnel
safety or equipment safety will be jeopardised by the selected method.
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2.3 Limited Product Warranty
Robway Safety Systems P/L (RSS) warrants to the Buyer (Purchaser) of new products
manufactured or supplied by RSS that such products were, at the time of delivery to the
purchaser, compliant to RSS Quality Assurance documentation ISO 9001.
Any RSS product that has been repaired or altered in such a way, in RSS's judgement, as to
affect the product adversely, including installation methods and procedures, negligence,
accident or improper storage or use will be judged solely by RSS in regard to any partial or
full warranty claim.
RSS's obligation under this warranty is limited to repairing or, at RSS's option, replacement of
faulty parts. Any associated transportation or labour costs (other than those directly acceptable
by RSS and consumed at RSS premises) shall not be part of the warranty claim and shall be at
the originator's expense.
Associated re-installation costs shall be at the originator's expense.
Replaced (or repaired items) by RSS are warranted for the remainder of the warranty period
of the originally supplied goods as if they were supplied with the original goods.
This above warranty period extends for 12 months 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.
Tensiometer Linerider Measures hoist rope line-pull
Boom Angle sensor BAS Measures angle to horizon
Length sensor Boom length Measures telescoping boom sections
ATB Over-hoist Over-hoisting the hook into the boom
tip.
RCI LMI same, being Rated Capacity Indicator
or Load Moment Indicator.
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3 INTRODUCTION
3.1 Manual Contents
This manual contains installation, operation, calibration, maintenance and parts information
for the RCI-1550 Crane Rated Capacity Indicator system manufactured by Robway Safety
Systems suitable for installation to fixed or mobile telescopic cranes.
3.2 Scope of Manual
Refer to Contents section. This section is an itemised list of sections with their corresponding
section number and page number.
3.3 Intended Audience
This manual is intended for use by field engineering, maintenance, operation and repair
personnel trained by RSS or familiar with RSS methods and application knowledge.
3.4 Personnel Qualifications
The procedures described in this manual should be performed only by persons who have read
the safety notices in this manual, have read, and understood the relevant section and who are
suitably qualified and trained to perform the procedures within.
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4 SYSTEM DESCRIPTION
4.1 Application
This RCI-1550 manual covers all Telescopic Cranes of either
mobile or fixed installation.
This manual covers the use of Tensiometer (line rider) based sensors
and calibration refer to cranes where the tensiometers are fitted to
directly monitor the hook hoist line-pull.
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4.2 Purpose
The RCI-1550 automatic Rated Capacity Indicator (RCI) is designed to assist the operator in
the course of normal crane operation and consists of boom angle, length, slew and ATB
sensors. Additionally, the system has load-cells to monitor the hook hoist line-pull OR boom
pendant forces to more effectively warn the crane operator of;
impending overload.
actual overload
and is designed to activate function motion-cut (if fitted/connected)
4.3 Capabilities
The RCI-1550 display provides the following capabilities:
Multi-hoisting winch operation (4 winches maximum),
Provides monitoring and display of;
•Boom Length,
•Boom Angle & Luffing fly jib Angle (as applicable)
•Boom Tip Radius,
•Boom Tip Height,
•Lifted Load,
•Selected Hook Falls,
•Selected Crane configuration,
•Crane configured S.W.L,
•S.W.L. as a percentage of Crane configured SWL,
and
•Restricted Slew zones,
•Hoist/Luff direction (if required for friction compensation).
Provides visual and audible warnings, motion-cut and Anti-Two blocking detection,
Self-diagnosis and error codes,
Unique simulated analogue display for visual feedback of S.W.L. percentage,
Multi-line text character window to display messages,
Built-in calibration and fault-finding tools.
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4.4 Available Options
Options for
•slew-zone continuous monitoring encoder sensor
•hook height
•multiple switch/analogue input/output expansion
•engine management
•special alarms
•on-site configurable user data,
•data-logging ( customer formats optional ),
•printing,
LSI-Robway also cater for custom applications and special
user requirements. Please contact your nearest LSI-Robway
distributor or LSI-Robway directly.
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5 OPERATING INSTRUCTIONS
5.1 The LCD Display
Please see “RCI-1550 Operator’s Display Functions” on previous page for details and
description of each function.
5.1.1 The Bar Graph
This is the rectangular bar that is in the top centre of the LCD. This gives an “analogue”
indication of the percentage the current load is of the Safe Working Load.
The bar will start to grow when the load is 50% of the SWL and reach the amber section at
85%. The start of the red section corresponds to 100% rated capacity.
5.1.2 SWL
The displayed S.W.L. is extracted from memorised look-up load-charts and will depend on
the current crane configuration, duty, winch selected, the maximum line-pull and the falls
selected.
5.1.3 Length
This is the current TOTAL boom length as read from the boom length sensor plus any
attachments as specified by the current crane configuration duty.
eg. For a SINGLE WINCH CRANE with #1 winch selected for a MAIN BOOM
configuration, the boom length will be the MAIN boom, however, for a fly-jib selected
configuration the boom length will be the MAIN + FLY-JIB length.
eg. For a TWIN WINCH CRANE,
#1 winch selected will display MAIN BOOM length and,
#2 (or #3) winch selected will show TOTAL BOOM length inclusive of the Upper Boom
Point (rooster sheave) OR inclusive of the FLY-JIB.
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5.1.4 Angle
This is the current boom angle. This angle will be either the MAIN BOOM, OR the
LUFFING FLY (when selected and in use)
5.1.5 Radius
Shows the operating radius for the CURRENT CONFIGURATION and DUTY and WINCH
selection. The radius is calculated from the Boom Angle and Length sensors with
compensation applied to include, slew offset distance, head sheave radius and boom
deflection.
5.1.6 Load
This shows the current total lifted load for the selected winch. For endless/tandem reeving it
will show the total load of both winches. Please note that this load value may contain some
TARE value. The TARE lamp being on indicates this (see TARE function later in this
section).
Use the WINCH button to switch between #1,# 2 or #3 selection.
INVALID WINCH SELECTIONS WILL BE DISABLED IN SOFTWARE.
Although the RCI-1550 will always check safe operation for all 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-
1550 will activate audible and visual alarms.
5.1.6.1 Hook Load selection
MAIN WINCH SELECTED #1 AUX. WINCH SELECTED #2
Main load displayed Main SWL
displayed Main falls displayed Aux. Load displayed
Aux. SWL displayed
Aux. falls displayed
Note: #3 winch selection is reserved
for cranes with 3 hook winches. PROGRAMME REVIEWS AT ALL
TIMES
Main load - Main SWL
Main line pull
Aux. load - Aux. SWL
Aux. line pull
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5.1.7 Error Codes
Additionally, the lower area display LCD is used to display ERROR codes when any errors
are detected.
Should the operator press the ACK button with an error code number displayed, the text
window will revert to normal until a different error condition arises, or the acknowledge
timeout expires.
The original error code can be reviewed by simply pressing the ACK key a second time.
Please refer to the ‘Trouble Shooting’ section of this manual for the meaning of the displayed
error codes.
5.2 The Display Keypad
This section describes the operation of the keypad and the associated LED indicators.
Operationally, this window displays the selected crane configuration and provides warning
lamps to visually indicate the reason for activation of the audible alarm.
5.2.1 Function Key (F1, F2, F3)
These are general-purpose keys that may be assigned a job specific use. Any special
functions use will be listed in the appendix.
5.2.2 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 will have
assigned uses at any one time. Take careful note of the LCD as their use can change as you
navigate through menus. For example the right hand soft menu key is typically used to invoke
the menus during normal operating mode. Once the menu is used the two right-hand buttons
are used to scroll up and down the menu list.
Refer to the section titled “Menu Navigation” for more information on the functions of each
menu
5.2.3 Alpha-Numerical Keys
Used for data entry in Calibration mode. When the display is expecting a numerical input the
number assigned to each key will be used. If text data is required the first key-press will
generate the first letter above the pressed key. If the key is pressed again in quick succession a
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second time the letter will change to the second above the key and so on. If no key is pressed
for approximately 1 second the character on the screen will be accepted as being correct and
the display will move to the next character.
5.2.4 Ok (4) key
Used to ‘accept’ the currently displayed message or option on the LCD.
5.2.5 Cancel (5) Key
Used in Calibration mode to cancel incorrectly entered data or to escape out of various menus
5.2.6 Tare Key
The RCI-1550 allows the operator to TARE out the weight of the hook, rope and accessories
of the selected winch if required. This is a toggle function that turns on or off depending on its
current state and is a function of the currently winch selected.
If the TARE indicator is illuminated then the displayed load is the total weight minus the
accessory weight. When TARE is next pressed, the displayed load reverts to the total.
If the TARE indicator is off then the actual load shown in the load window at the time of
pressing the TARE button will be stored in the system as the tare load.
Please note that when the TARE function is active, the
%SWL is still determined by the total load,
irrespective of what is currently displayed.
All tared weights are removed on system start-up.
5.2.7 Rigging Key
Rigging mode is operator selectable via the MENU button and scrolling to Rigging Mode,
alternatively the rigging key on the front panel can be used to initiate rigging.
There are two forms of Rigging mode.
1. General Rigging mode, where motion-cut is over-ridden (if fitted) to luff down, hook
up and tele-out (telescopic cranes). This mode is ONLY intended for use during crane
lay-down or setup.
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