LSI-Robway RCI-1550 HRT User manual

RCI-1550 HRT Lattice Boom System
Instruction Manual
MAN-1075 Rev D
LSI-Robway Pty Limited, 32 West Thebarton Road, Thebarton, South
Australia, 5031
Phone: [phone] Fax: [phone]
www.lsirobway.com.au

CONTENTS
1. IMPORTANT SAFETY NOTICE......................................................................................................................5
2. SPECIAL NOTES ................................................................................................................................................5
2.1. BRANDNAMES,TRADENAMES AND TRADE MARKS.............................................................................................5
2.2. IMPORTANT SAFETY NOTICE ...............................................................................................................................5
2.3. LIMITED PRODUCT WARRANTY...........................................................................................................................6
2.4. GLOSSARY OF SOME USED TERMS........................................................................................................................6
3. INTRODUCTION ................................................................................................................................................6
3.1. MANUAL CONTENTS............................................................................................................................................6
3.2. SCOPE OF MANUAL..............................................................................................................................................6
3.3. INTENDED AUDIENCE ..........................................................................................................................................6
3.4. PERSONNEL QUALIFICATIONS..............................................................................................................................6
4. SYSTEM DESCRIPTION ...................................................................................................................................7
4.1. APPLICATION.......................................................................................................................................................7
4.2. PURPOSE..............................................................................................................................................................7
4.3. CAPABILITIES ......................................................................................................................................................7
4.4. AVAILABLE OPTIONS...........................................................................................................................................8
5. INSTALLATION - GENERAL...........................................................................................................................9
5.1. SETTING UP THE CRANE......................................................................................................................................9
5.2. ANGLE SENSORS..................................................................................................................................................9
5.3. ANTI-TWO-BLOCK (IF INSTALLED)......................................................................................................................9
5.3.1. Rectangular type Anti-two Block switches..................................................................................................9
5.3.2. Tubular type Anti-two Block switches.........................................................................................................9
5.3.3. Multiple Anti-two Block switches................................................................................................................9
5.3.4. Bob-weight (both types of switches)..........................................................................................................10
5.4. LOAD-LINE (LINE-PULL)BASED SYSTEMS ..........................................................................................................10
5.4.1. Overview...................................................................................................................................................10
5.4.2. Tensiometers (line-riders).........................................................................................................................10
5.4.3. Tension Load-line Plate Type Load-cell...................................................................................................11
5.5. CABLING AND GLANDS......................................................................................................................................11
5.6. DISPLAY UNIT ...................................................................................................................................................12
5.7. CONTROL UNIT..................................................................................................................................................13
5.7.1. Power Supply (PS)....................................................................................................................................13
5.7.2. CPU Section..............................................................................................................................................15
5.7.3. Analog Input Section.................................................................................................................................15
5.7.4. Digital IO Section.....................................................................................................................................16
5.8. UPGRADING TO RCI-1550 FROM EARLIER ROBWAY MODEL DISPLAYS..............................................................18
6. OPERATING INSTRUCTIONS.......................................................................................................................19
6.1. THE LCD DISPLAY............................................................................................................................................19
6.1.1. The Bar Graph..........................................................................................................................................20
6.1.2. SWL...........................................................................................................................................................20
6.1.3. Length.......................................................................................................................................................20
6.1.4. Angle.........................................................................................................................................................20
6.1.5. Radius.......................................................................................................................................................20
6.1.6. Load..........................................................................................................................................................20
6.1.7. Error Codes..............................................................................................................................................21
6.2. THE DISPLAY KEYPAD ......................................................................................................................................21
6.2.1. Function Key (F1, F2, F3)........................................................................................................................21
6.2.2. Soft Menu Keys .........................................................................................................................................21
6.2.3. Alpha-Numerical Keys..............................................................................................................................21
6.2.4. Ok (  ) key .................................................................................................................................................21
6.2.5. Cancel (x) Key ..........................................................................................................................................21
6.2.6. Tare Key....................................................................................................................................................22
6.2.7. Rigging Key ..............................................................................................................................................22
Page 2

6.3. LED INDICATORS ..............................................................................................................................................23
6.3.1. Override LED ...........................................................................................................................................23
6.3.2. Audible Alarm Disabled LED...................................................................................................................23
6.3.3. A.T.B. Indicator (anti-two-block or over-hoist)........................................................................................23
6.3.4. Approach to Rated Capacity LED ............................................................................................................23
6.3.5. 100% Capacity Exceeded LED.................................................................................................................23
6.3.6. Motion Cut LED........................................................................................................................................23
6.4. OVER-RIDE KEY-SWITCH (IF FITTED)................................................................................................................23
6.5. DISABLE KEY SWITCH (IF FITTED)....................................................................................................................24
6.6. TURNING ON THE RCI-1550 ..............................................................................................................................24
6.6.1. On Power Up............................................................................................................................................24
6.7. MENU NAVIGATION...........................................................................................................................................24
6.7.1. Config Change Menu................................................................................................................................25
6.7.2. Function Codes.........................................................................................................................................25
6.7.3. Display Options Menu ..............................................................................................................................26
6.8. DATA LOGGING AND DATA DOWN-LOADING ....................................................................................................26
7. CALIBRATION..................................................................................................................................................27
7.1. CALIBRATION PURPOSE.....................................................................................................................................27
7.1.1. Entering Calibration Mode and Selecting calibration functions..............................................................27
7.1.2. Function codes menu item ........................................................................................................................27
7.1.3. General information regarding text editing..............................................................................................28
7.2. CALIBRATION FUNCTIONS BREAKDOWN ...........................................................................................................28
7.2.1. Exit Calibration item ................................................................................................................................28
7.2.2. View Main Load and View Aux Load items..............................................................................................28
7.2.3. View Boom Angle item..............................................................................................................................29
7.2.4. View Jib Angle item ..................................................................................................................................30
7.2.5. Set Gain Trans 1 item ...............................................................................................................................30
7.2.6. Set Gain Trans 2 item ...............................................................................................................................30
7.2.7. Set MUX. Delay item ................................................................................................................................31
7.2.8. No. of Samples item ..................................................................................................................................31
7.2.9. Set Lift Value (Threshold) item.................................................................................................................31
7.2.10. Set Rigging Load Threshold item..............................................................................................................32
7.2.11. Set Rigging Length Threshold item...........................................................................................................32
7.2.12. View Directions item.................................................................................................................................32
7.2.13. View Load-Chart item...............................................................................................................................33
7.2.14. View Digital I/P item ................................................................................................................................33
7.2.15. Set Date item.............................................................................................................................................33
7.2.16. Set Time item.............................................................................................................................................34
7.2.17. Download Logger item .............................................................................................................................34
7.2.18. View Cal-Data item ..................................................................................................................................34
7.2.19. Change Duty item .....................................................................................................................................35
7.2.20. Change Falls item.....................................................................................................................................35
7.2.21. Back Up Cal-Table item............................................................................................................................35
7.2.22. Restore Cal-Table item.............................................................................................................................36
7.2.23. Erase Cal-Table! item...............................................................................................................................36
7.2.24. User Variables..........................................................................................................................................36
7.2.25. Viewing Errors..........................................................................................................................................37
7.2.26. Verifying Operation of Sensors.................................................................................................................37
7.3. TOOLS REQUIRED FOR CALIBRATION ................................................................................................................38
7.4. MAP OF CALIBRATION (SUGGESTED ORDER) .....................................................................................................39
7.5. CALIBRATING BOOM ANGLE ....................................................................................................................39
7.5.1. Calibrating a low boom angle ..................................................................................................................39
7.5.2. Calibrating a high boom angle.................................................................................................................39
7.6. CALIBRATING JIB ANGLE (LUFFING FLY JIBS ONLY) ..................................................................................40
7.6.1. Calibrating low Jib angle .........................................................................................................................40
7.6.2. Calibrating high Jib angle........................................................................................................................40
7.7. CALIBRATING TENSIOMETER BASED SYSTEMS ..................................................................................40
7.7.1. Calibrate the Main Winch with light load.................................................................................................40
7.7.2. Calibrate the Main Winch with heavy load...............................................................................................40
7.7.3. Calibrate the Aux winch with light load. ..................................................................................................41
Page 3

7.7.4. Calibrate the Aux winch with heavy load. ................................................................................................41
7.8. LOAD /ANGLE CORRECTION SOFTWARE...........................................................................................................41
7.8.1. What is Load angle Correction Software?................................................................................................41
7.8.2. How to calculate the Load / Angle Correction Factor..............................................................................42
8. MAINTENANCE................................................................................................................................................43
8.1. CHECK LIST.......................................................................................................................................................43
8.2. IN-CABIN ITEMS.................................................................................................................................................43
8.2.1. Additional detail .......................................................................................................................................43
8.3. ELECTRICAL EQUIPMENT..........................................................................................................................44
8.4. INSPECTION AFTER MAINTENANCE........................................................................................................44
8.5. RECORDS........................................................................................................................................................44
9. TROULBELSHOOTING ..................................................................................................................................45
9.1. ERROR CODE LIST .............................................................................................................................................46
9.1.1. Example Errors & Possible Causes..........................................................................................................46
9.1.2. Problems That Do Not Produce Error Codes...........................................................................................47
10. ELECTRICAL SPECIFICATIONS.................................................................................................................48
11. ELECTRONIC ANGLE SENSOR SPECIFICATIONS: ...............................................................................48
12. APPENDICES.....................................................................................................................................................49
12.1. DRAWINGS PART A-SYSTEM COMPONENTS.................................................................................................50
12.2. DRAWINGS PART B-GENERAL ARRANGEMENTS..........................................................................................51
12.3. SOFTWARE DOCUMENTS................................................................................................................................52
Page 4

1. Important Safety Notice
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.
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.
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.
Page 5

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.
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 a strut boom (lattice boom) crane.
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.
Page 6

4. SYSTEM DESCRIPTION
4.1. Application
The RCI-1550 is designed to suit Strut Boom 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.
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:
Suitable for mobile, crawler and fixed type strut-boom or telescopic-boom cranes, load-moment
or tensiometer (load-rider) sensor based,
Multi-hoisting winch operation,
Provides monitoring and display of;
Boom
Length,
Boom Angle & Luffing fly jib Angle (as applicable)
Boom Tip Radius,
Boom Tip 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.
Page 7

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,
ROBWAY also cater for custom applications and special user
requirements. Please contact your nearest ROBWAY distributor or
ROBWAY directly.
Page 8

5. INSTALLATION - GENERAL
5.1. Setting Up the Crane
Lower the crane boom to a safe and convenient position for installation of system components.
High tensile booms require proper welding
procedure specifications. Obtain specialist
assistance in these cases.
Please refer to the General Arrangement
drawings at the rear of the manual for an
overview of the configuration.
5.2. Angle Sensors
Fix the Boom Angle Sensor (BAS) mounting plate orientated to the RHS side of the boom in a
convenient position close to the operator's cab by bolting/welding the mounting bracket provided
(vertical and parallel) to the boom centre-line with the electrical connection to the bottom.
It is usual to mount the Boom Angle Sensor (BAS) to the ‘inside’ of the LHS boom butt section, this
provides more mechanical protection but maintains RHS orientation.
Ensure the ‘arrow label’ on the top of the BAS points
to the boom tip.
Mount the Boom Angle Sensor (BAS) on the bolts and route the cable carefully around the boom pivot
to the cab. Note that the 'stick-on' arrow label faces towards the boom tip. Fix the cable to the boom
and turret using adequate fixings ensuring that the cable is not pinched or stretched as the boom
moves through its full luffing arc. Only connect the cable to the Control Unit when finished welding.
5.3. Anti-Two-Block (if installed)
5.3.1. Rectangular type Anti-two Block switches
The switches require fitting at an offset angle to ensure correct operation throughout the full
working angle range of the boom. Fix the switch to the bolt and lock the nuts. Consult installation
drawings at the rear of this manual.
5.3.2. Tubular type Anti-two Block switches
Fix the anti-two-block switch mounting 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.
Consult installation drawings at the rear of this manual.
5.3.3. Multiple Anti-two Block switches
Additional switches (for fly-jibs) can be added. Connection is via plug and socket at the Junction
box adjacent to the main boom head. Consult installation drawings at the rear of this manual.
Page 9

5.3.4. Bob-weight (both types of switches)
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. Consult installation
drawings at the rear of this manual.
5.4. Load-line (line-pull) based systems
5.4.1. Overview
Load-line (line-pull) based systems directly sense the line-pull generated to lift the load. Sensors
can be dynamometers/tensiometers (line-riders) or tension plate type load-cells fitted into the dead-
end of the hoist reeving. Load-pin type load-cells may also be used at the dead-end termination
fitting.
Load sensors can be combinations of;
Dynamometers/Tensiometers (line-riders),
Tension load-cells,
Load-pins.
5.4.2. Tensiometers (line-riders)
5.4.2.1. Lattice Boom cranes
For cranes without fly-jibs, the dynamometers/tensiometers are usually rigidly mounted on
the boom tip section. Fabricated brackets may be required to attach the tensiometer to the
boom top and align it to the hoist rope. Consult layout drawings at the rear of this manual
for more detail.
For cranes with fly jibs, the fly-jib mast aux winch idler sheave necessitates using an
articulating arm mounting to allow the tensiometer to follow the aux rope natural line over
the mast idler sheave. Alternatively, the tensiometer may be mounted on the fly-jib tip
section, or, off the boom butt section using an articulating arm if the aux and main winches
are side by side. Consult layout drawings at the rear of this manual for more detail.
The RW5000 load cell will output an electrical signal proportional to the hoist rope line-pull
forces, the RCI-1550 will then convert this into hook-load weight in tons. Correctly
following the calibration procedures is essential for accurately determining the hook load
weight
Page 10

5.4.3. Tension Load-line Plate Type Load-cell
A dead-end tension plate type load-cell may be fitted into the attachment of the hoist rope at the
termination socket at the boom tip to sense the load-line line-pull.
Robway specified 'safety plates' must be fitted to the tension plate-cell before using in sub-
zero temperatures. (usually supplied ex stock from Robway).
Any specially prepared safety plates should provide for the existing rope wedge socket and pin to
be re-used.
Cranes working in Sub-zero temperatures MUST
have overload plates.
Robway safety-plates are designed to allow the
plate load-cell to react to the imposed forces but,
should a failure in the load-cell occur, then the
forces will be supported by the overload plates.
Robway designed Safety-plates use high alloy steel
to minimise weight. Robway stock various sizes and
types to assist with a variety of cranes. ROBWAY
can supply specific adaptors if dimensions are
provided.
The safety-plate assembly may require
modification to fit the rope fittings unless fitting
knowledge was provided prior to system
dispatch.
The Safety-Plate assembly is fabricated from
Bisalloy 80 (Sumiten 80) plate and the pins are
4140-grade materials.
If safety-plate modifications are performed ensure
they meet sound engineering practice and the end
product provides the minimum required structural
safety factors.
5.5. Cabling and Glands
Load cell cables should be fixed firmly to the crane structure and routed to ensuring freedom of
movement around the boom pivot pin and other moving parts etc. Clip cables at 2’ intervals. Manual
reeling drums are suggested cable storage devices for long lattice booms or on cranes that require
regular boom length changes.
The gland types used are designed to trap the braid or screen (or armour in certain applications) within
the braid for maximum EMI protection. Failure to terminate the screens in the glands will void the
Electro Magnetic Compatibility (EMC) compliance which the system carries and will put the unit at risk
of malfunction due to EMI. When armoured cable is used, then the armour must be trapped in the
gland body, and the internal cable braid or screen must be terminated in the chassis terminals on the
appropriate on board connectors. The gland termination of either armour or braid is also essential for
protection of the inner conductors in the event of lightning or other transient effects. Failure to correctly
terminate within the gland may also lead to destruction of the internal circuitry in such circumstances.
Page 11

5.6. Display Unit
Fit the RCI-1550 Display Unit in a convenient position in the cab such that the operator can view the
display and reach the push buttons comfortably
Check bonding between enclosure and chassis. If a good bond
cannot be ensured through the mounting bracket, then install
earth strap. It is a condition of installation that equipotential
bonding must be ensured between the display enclosure and the
Control Unit enclosure.
Page 12

5.7. Control Unit
The Control Unit (CU) contains the termination points for all modules within the RCI-1550 system. It
also contains all the user interfaces, signal conditioning and processing circuitry required to satisfy the
RCI/LMI functionality. The CU enclosure is a powder coated steel and carries an environmental
protection rating of IP 65 which is suitable for internal or external mounting. All cable entries are via a
gland plate mounted on the bottom of the enclosure.
Check bonding between enclosure and chassis. If
a good bond cannot be ensured through the
mounting bracket, then install earth strap. It is
a condition of installation that equipotential
bonding must be ensured between the display
enclosure and the Control Unit enclosure.
5.7.1. Power Supply (PS)
Also refer to drawings at the rear of this manual for this item.
The power supply is a 16W, triple output isolated power supply. The input connector has three
terminals for each of the supply positive (V+); and supply negative (V-), allowing for looping if
required.
The V+ is switched to the output connector via a single pole 5A relay only when the PS is running.
The output connector contains two sets of power/RS-485 connections, one being for the display
connection and the other for expansion modules. The front panel fuse protects power for this
output connector.
The RS-485 signals are electrically isolated from the power and care must be take to ensure that
no short circuit is introduced between them, otherwise the unit's transient protection will be
compromised.
Transient protection has been included on all inputs. All internal power rails are current limited and
short circuit protected using re-settable fuses. These fuses will reset only when the fault has been
corrected and the power to the unit has been removed for at least 30 seconds before re-
application. There are no operator adjustments or settings on this board.
For complete wiring details refer to the installation drawings.
Page 13

5.7.1.1. Specifications
Input supply: 10V - 40V dc @ 8W (max)
Input fuse: 5A slow blow
User output: Switched V+ when PSU is running (5A max)
Internal outputs: 5V @ 500mA (max)
12V @ 500mA (max)
12V (2) @ 500mA (max)
All supplies operate with 1mV p-p ripple.
5.7.1.2. Transient protection
Common mode to chassis: > 7kV on RS-485 signal, power input and outputs.
Differential (line-to-line): > 7kV on RS-485 signal lines
> 2kV on power input and outputs.
Page 14

5.7.2. CPU Section
The processor is an 8051 derivative which contains a number of enhancements over the standard
8051, including an on-board 10 bit ADC. For most applications this degree of resolution is more
than adequate.
The data memory is in the form of a single package which contains the memory device with real
time clock (RTC) and integral lithium battery. This package has guaranteed memory retention of 10
years, and when flat the whole package must be replaced.
The program memory may reside in either a 64kB EPROM or the Expansion EPROM package
labelled as U5 (refer to the PCB overlay). When the program has been put into U5, it will be
labelled with the application WA number, otherwise it will be labelled with an ID number. When it is
labelled with a WA number, there must be no EPROM loaded in location U8 otherwise damage to
the processor circuitry will result. The Expansion EPROM package must only be removed using the
correct extraction tool otherwise either the package or the socket may be damaged.
The high capacity Flash memory has been added to the 1550 to contain three main blocks of
information, being Load-charts, Load Moment (LM) calibration tables and Data-logging. The
memory is contained in two plug-in SIMM cards and depending on the application, any number of
these may be installed. Refer to the relevant software configuration sheets for more details.
The SIMM cards can only be inserted one way, however care must be take during installation and
removal. It is essential that the SIMM cards are installed in the correct sockets and that the correct
sequence is followed.
To install a SIMM card, simply push the card into the socket at an angle of approximately 45
degrees (with the components facing toward the centre of the main circuit board). Once the gold
pads on the leading edge of the card have entered the socket, gently push the card into the socket
while rotating it to a vertical position. Installation is complete when the retaining clips on each end
of the socket have captured the edges of the board and have fully returned to their original position.
To remove a SIMM card simply push the retaining clips at each end of the socket outwards until the
SIMM card springs away from its vertical position. The card can then be gently withdrawn from the
socket.
5.7.2.1. Specifications
Processor: 8051 derivative, operating at 18.4320MHz
Data Memory: 32kB of battery backed non-volatile SRAM
Program Memory: 64kB EPROM for program memory, expandable to
256kB
High Capacity Memory: up to 4MB Flash.
RS-232: 9600 baud (8N1)
RS-485: 19,200 baud. (8N1)
On-board ADC: 10 bit
PWM output: 8 bit.
5.7.3. Analog Input Section
The analog section is takes advantage of the CPU’s on board 10bit ADC. This board can support
up to four load cells, three angle sensors and three length sensors.
5.7.3.1. Sensor Excitation Supply
The excitation supply provides power for all the sensors connected to the Analog section.
The nominal output is 4v (or 12V for 4-20mA transducers). Do not connect either the
+VEX or the –VEX outputs to any external supplies or chassis.
5.7.3.2. Load Cell Inputs
The analog input section is capable of accepting load cells with sensitivities of 1, 2 or
3mV/V. Load cells of different sensitivities can be used on the one RCI-1550 at the one
time. The gain setting is controlled via software.
Page 15

5.7.3.3. Angle Inputs
Either oil damped or electronic inclinometers can be connected to the RCI-1550’s angle
inputs. Note that all angle sensors must be the same type and may not be mixed. The
analog section must be configured, via a single jumper link to accept the appropriate type
of sensor. See connection diagram in rear of manual.
5.7.4. Digital IO Section
Refer to drawings at the rear of this manual for this item.
The DIO section provides general-purpose inputs and output capable of sensing the state of 8
switch inputs and controlling 8 relay outputs. Connection is via plug-in Mini Combicon (R) screw
terminals. The DIO section is very versatile and reference should be made to the installation
drawings for details.
The digital section features LED indicators for input and output status. If the digital section detects
an input signal (voltage) the corresponding LED will be illuminated. If an output LED is on then the
given output relay is closed.
5.7.4.1. I/O Connections
Refer to drawings at the rear of this manual for this item.
5.7.4.2. Inputs
Refer to RCI-1550 User Wiring Detail – DIO2.
The DIO section contains 8 isolated inputs that require an external voltage source to
activate. This means that each input has two connections, a positive and a negative. This
allows the digital section to sense either switched high or switch low signals. To sense a
switched low signal, as would come from a switch with one side grounded, the output of
the switch is connected to the negative of the desired input and the positive side of the
input is tied to the supply. For a switched high signal as would come from a switch
connected to the supply, take the switch output to the positive of the desired input channel
and ground the negative side.
The DIO also contains a dedicated ATB input. This only requires a simple switch closure
between the two associated pin. No voltage is require to be applied to this input
Finally the DIO section has a disable input which forces the outputs to a predefined state.
This input has the same properties as the eight data inputs.
The function of the switch inputs is defined in software and reference should be made to
the software configuration sheets for details.
5.7.4.3. Outputs
All eight outputs consist of normally open voltage free contacts that close when the output
is on. Each output is isolated from all others. Hence to have an output switch high one side
must be tied to the supply and the other is used to drive the load. The opposite applies for
switch low output. Since all outputs a fully isolated from each other this allows some
outputs to switch high and others to switch low.
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Note: These outputs are not fuse protected through the
RCI-1550, hence the protection must be provided by
external means.
5.7.4.4. Snubber diode protection to crane fitted solenoids or relays
The use of snubbed inductive loads (ie solenoids and relays) is strongly recommended,
however care must be taken to ensure correct polarity connection to these devices.
5.7.4.5. Defining the status of Outputs (normally closed OR open)
Provision has been added to the circuit to define the state of each output if there is an on-
going fault in the CPU section. The reasoning for this provision is that the user may want
one output to fault to an off position (ie Motion Cut) and another to fault to an on position
(ie External audible alarm). The status is defined using DIP switch SW1 with the switch
position number referring to the respective output. When the switch is “ON”, the
corresponding output will be energised if the CPU fails, or alternatively when the switch is
“OFF” the corresponding output will be de-energised if the CPU fails. This ‘fault state’ can
be selected manually by the user by activating the disable input.
5.7.4.6. Specifications
Relay Outputs: 5 ampere @ 30 VDC
Switched Inputs: Input current approx. 6mA @ 24V DC
5.7.4.7. Anti-Two Block input
Refer to DIO connection drawing in the rear of the manual.
Provision has been made on the board for the direct activation of Output 1 via an external
switch.
This produces an instantaneous output signal, avoiding the possibility of delays caused by
software.
To use this facility, ensure that link P4 is in the “ON” position that allows the CPU to read
the status of the switch. The user then has the choice of allowing the CPU to over-ride the
condition (ie in Rigging mode) or to leave total control to the external switch. If CPU control
is desired, then link P3 must be in the “ON” position, otherwise leave it “OFF”.
If control has been given to the CPU, then the user must ensure that the fault status switch
for Output 1 is in the “OFF” position, otherwise in a fault condition the output will be over-
ridden. Once this has been set up, the status of the output is defined by the status of the
external switch connected as per the wiring detail, with the output relay being energised (ie
closed contacts) when the external switch is closed.
5.7.4.8. Slewing Zone Switch/es input/s
Fit slewing zone indicator micro-switch (or proximity switch) provided at a convenient place
near the centre of rotation providing run on and off ramps as required for the particular
application. This switch will convey a signal to the Control Unit when the crane moves into
a zone of restricted capacity rating. For correct wiring instruction refer to drawings at the
back of this manual.
The switch wiring requires a "voltage free"
connection. Never connect the switch wiring into
any other system/wiring loom unless the exact
nature of the connection is known.
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5.7.4.9. Motion Cut
If motion cut is required the client shall provide appropriate solenoid valves/devices to
activate the function and wire them as shown in this manual.
5.7.4.10. Connections
1. Permanent display damage may occur if
incorrect motion-cut connections are made.
2. POWER MUST BE DISCONNECTED before
attempting connections.
3. NEVER insert larger capacity fuses than those
originally supplied.
4. Obtain specialist assistance if you are
unfamiliar with crane electrics.
5. The Robway relay contact ampere rating must
not be exceeded when directly operating
hydraulic or mechanical solenoid devices or high
capacity relays. For such devices a “slave” relay
must be used.
5.7.4.11. Main & Aux. Winch Hoist Direction Switches (if required)
(If required due to high reeving friction differential between hoist raise and lower, usually
for greater than 14 parts-of-line)
Fit direction switches provided to control linkage for main and aux hoist functions. Connect
switches as shown on drawings in this manual.
The normal convention is that a switch closure should represent a downward hoisting
direction.
The switch wiring requires a "voltage free"
connection. Never connect the switch wiring into
any other system/wiring loom unless the exact
nature of the connection is known.
5.8. Upgrading to RCI-1550 from earlier Robway model displays.
The RCI-1550 display/controller utilises the same sensors as used on other RCI series systems.
However, it is recommended that all earlier version systems used negatively switched motion-cut
output signals. The RCI-1550 can be configured for either negative or positive type outputs. Please
ensure the preferred arrangement is connected via the digital section connector strips.
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