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

Page 1 of 72
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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