LSI-Robway RCI-1550 LM User manual

RCI-1550 LM Telescopic Boom System
Instruction Manual
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MAN-1078 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

CONTENTS
1. ......................................................................................................................5IMPORTANT SAFETY NOTICE
2. ................................................................................................................................................5SPECIAL NOTES
2.1. ............................................................................................5BRANDNAMES,TRADENAMES AND TRADE MARKS.
2.2. ...............................................................................................................................5IMPORTANT SAFETY NOTICE
2.3. ...........................................................................................................................6LIMITED PRODUCT WARRANTY
2.4. ........................................................................................................................6GLOSSARY OF SOME USED TERMS
3. ................................................................................................................................................6INTRODUCTION
3.1. ............................................................................................................................................6MANUAL CONTENTS
3.2. ..............................................................................................................................................6SCOPE OF MANUAL
3.3. ..........................................................................................................................................6INTENDED AUDIENCE
3.4. ..............................................................................................................................6PERSONNEL QUALIFICATIONS
4. ...................................................................................................................................7SYSTEM DESCRIPTION
4.1. ............................................................................................................................7MULTI-PURPOSE APPLICATION
4.2. ..............................................................................................................................................................7PURPOSE
4.3. ......................................................................................................................................................7CAPABILITIES
4.4. ...........................................................................................................................................8AVAILABLE OPTIONS
5. ...........................................................................................................................9INSTALLATION - GENERAL
5.1. ......................................................................................................................................9SETTING UP THE CRANE
5.2. ..................................................................................................................................................9ANGLE SENSORS
5.2.1. ........................................................................................................9Changing from RHS to LHS mounting
5.3. ................................................................................................................................................9LENGTH SENSORS
5.3.1. .......................................................................................................................................................9General
5.3.2. ....................................................................................................10110’ Length Sensor – (DRURW33LAA)
5.3.3. .....................................................................................................11140’ Length Sensor– (DRURW43LAA)
5.3.4. ...........................................................................................................................................12Pay-out Cable
5.4. ....................................................................................................................12ANTI-TWO-BLOCK (IF INSTALLED)
5.4.1. ................................................................................................12Rectangular type Anti-two Block switches
5.4.2. .......................................................................................................12Tubular type Anti-two Block switches
5.4.3. ..............................................................................................................12Multiple Anti-two Block switches
5.4.4. ..........................................................................................................12Bob-weight (both types of switches)
5.5. .......................................................................................................................12LOAD MOMENT BASED SYSTEMS
5.5.1. ...................................................................................................................................................12Overview
5.5.2. .................................................................................................12Pressure Transducers (Luffing Cylinder)
5.6. ......................................................................................................................................13CABLING AND GLANDS
5.7. ...................................................................................................................................................14DISPLAY UNIT
5.8. ..................................................................................................................................................15CONTROL UNIT
5.8.1. ....................................................................................................................................15Power Supply (PS)
5.8.2. ..............................................................................................................................................16CPU Section
5.8.3. .................................................................................................................................17Analog Input Section
5.8.4. .....................................................................................................................................17Digital IO Section
5.9. .............................................................19UPGRADING TO RCI-1550 FROM EARLIER ROBWAY MODEL DISPLAYS.
6. .......................................................................................................................20OPERATING INSTRUCTIONS
6.1. ............................................................................................................................................20THE LCD DISPLAY
6.1.1. ..........................................................................................................................................21The Bar Graph
6.1.2. ...........................................................................................................................................................21SWL
6.1.3. .......................................................................................................................................................21Length
6.1.4. .........................................................................................................................................................21Angle
6.1.5. .......................................................................................................................................................21Radius
6.1.6. ..........................................................................................................................................................21Load
6.1.7. ..............................................................................................................................................22Error Codes
6.2. ......................................................................................................................................22THE DISPLAY KEYPAD
6.2.1. ........................................................................................................................22Function Key (F1, F2, F3)
6.2.2. .........................................................................................................................................22Soft Menu Keys

6.2.3. ..............................................................................................................................22Alpha-Numerical Keys
6.2.4. .................................................................................................................................................23Ok (
 ) key
6.2.5. ..........................................................................................................................................23Cancel (x) Key
6.2.6. ....................................................................................................................................................23Tare Key
6.2.7. ..............................................................................................................................................23Rigging Key
6.3. ..............................................................................................................................................24LED INDICATORS
6.3.1. ...........................................................................................................................................24Override LED
6.3.2. ...................................................................................................................24Audible Alarm Disabled LED
6.3.3. ........................................................................................24A.T.B. Indicator (anti-two-block or over-hoist)
6.3.4. ............................................................................................................24Approach to Rated Capacity LED
6.3.5. .................................................................................................................24100% Capacity Exceeded LED
6.3.6. ........................................................................................................................................24Motion Cut LED
6.4. ................................................................................................................25OVER-RIDE KEY-SWITCH (IF FITTED)
6.5. ....................................................................................................................25DISABLE KEY SWITCH (IF FITTED)
6.6. ..............................................................................................................................25TURNING ON THE RCI-1550
6.6.1. ............................................................................................................................................25On Power Up
6.7. ...........................................................................................................................................26MENU NAVIGATION
6.7.1. ................................................................................................................................26Config Change Menu
6.7.2. .........................................................................................................................................26Function Codes
6.7.3. ..............................................................................................................................27Display Options Menu
6.8. ....................................................................................................27DATA LOGGING AND DATA DOWN-LOADING
7. ..................................................................................................................................................28CALIBRATION
7.1. .....................................................................................................................................28CALIBRATION PURPOSE
7.1.1. .............................................................28Entering Calibration Mode and Selecting calibration functions.
7.1.2. ........................................................................................................................28Function codes menu item
7.1.3. ..............................................................................................29General information regarding text editing
7.2. ...........................................................................................................29CALIBRATION FUNCTIONS BREAKDOWN
7.2.1. ................................................................................................................................29Exit Calibration Item
7.2.2. ..............................................................................................29View Main Load and View Aux Load items
7.2.3. ..............................................................................................................................30View Boom Angle item
7.2.4. ..................................................................................................................................30View Jib Angle item
7.2.5. ......................................................................................................................................30View Length item
7.2.6. ...............................................................................................................................31Set Gain Trans 1 item
7.2.7. ...............................................................................................................................31Set Gain Trans 2 item
7.2.8. ................................................................................................................................32Set MUX. Delay item
7.2.9. ..................................................................................................................................32No. of Samples item
7.2.10. .................................................................................................................32Set Lift Value (Threshold) item
7.2.11. ..............................................................................................................33Set Rigging Load Threshold item
7.2.12. .......................................................................................................33Correct Radius (Unladen boom) item
7.2.13. ............................................................................................................33Correct Radius (laden boom) item
7.2.14. ...........................................................................................................34Set Rigging Length Threshold item
7.2.15. .................................................................................................................................34View Directions item
7.2.16. ...............................................................................................................................34View Load-Chart item
7.2.17. ................................................................................................................................35View Digital I/P item
7.2.18. .............................................................................................................................................35Set Date item
7.2.19. .............................................................................................................................................35Set Time item
7.2.20. .............................................................................................................................36Download Logger item
7.2.21. ..................................................................................................................................36View Cal-Data item
7.2.22. .....................................................................................................................................37Change Duty item
7.2.23. .....................................................................................................................................37Change Falls item
7.2.24. ............................................................................................................37Transmit Load Moment Data item
7.2.25. ...............................................................................................................37RS-232 Communication Settings
7.2.26. ...............................................................................................................................37Receive Lm Data item
7.2.27. ............................................................................................................................37Back Up Cal-Table item
7.2.28. .............................................................................................................................38Restore Cal-Table item
7.2.29. ...............................................................................................................................38Erase Cal-Table! item
7.2.30. ..........................................................................................................................................38User Variables
7.2.31. ..........................................................................................................................................39Viewing Errors
7.2.32. .................................................................................................................39Verifying Operation of Sensors
7.3. ................................................................................................................40TOOLS REQUIRED FOR CALIBRATION

7.4. .....................................................................................................40MAP OF CALIBRATION (SUGGESTED ORDER)
7.5. .............................................................................................................................41CALIBRATING BOOM ANGLE
7.5.1. ..................................................................................................................41Calibrating a low boom angle
7.5.2. .................................................................................................................41Calibrating a high boom angle
7.6. ..........................................................................................41CALIBRATING JIB ANGLE (LUFFING FLY JIBS ONLY)
7.6.1. .........................................................................................................................41Calibrating low Jib angle
7.6.2. ........................................................................................................................41Calibrating high Jib angle
7.7. ...........................................................................................................................42CALIBRATING BOOM LENGTH
7.8. ...............................................................................................42CALIBRATING LOAD MOMENT BASED SYSTEMS
7.8.1. .......................................................................................................................................42Calibrating Load
7.8.2. ...............................................................................42Calibrating Load Overview - (Without Test-weights)
7.8.3. ...........................................................................................42Testing & calibrating Transducers Overview
7.8.4. .................................................................................................44Calibrating the Low end of Transducer 1
7.8.5. ................................................................................................44Calibrating the High end of Transducer 1
7.8.6. .................................................................................................45Calibrating the Low end of Transducer 2
7.8.7. ................................................................................................45Calibrating the High end of Transducer 2
7.9. .....................................................................................................46PREPARATION BEFORE CALIBRATING LOAD
7.10. ..................................................................................................46CALIBRATING ACTIVE (SELECTED)WINCH
7.11. .....................................................................................47BOOM STOP FRICTION (COMPRESSION)CORRECTION
7.11.1. ..............................................................................................................................................47Introduction
7.11.2. ...............................................................................................................47Boom Backstop Function Codes
7.11.3. ......................................................................................................................................47How to Calibrate
8. ................................................................................................................................................48MAINTENANCE
8.1. .......................................................................................................................................................48CHECK LIST
8.2. .................................................................................................................................................48IN-CABIN ITEMS
8.2.1. .......................................................................................................................................48Additional detail
8.3. ..........................................................................................................................49ELECTRICAL EQUIPMENT
8.4. ...........................................................................................................49RECOIL DRUM (TELESCOPIC CRANES)
8.4.1. ....................................................................................................49110’ Recoil Drum – (DRURW33LAAX)
8.4.2. ....................................................................................................50140’ Recoil Drum – (DRURW43LAAX)
8.5. ........................................................................................................51INSPECTION AFTER MAINTENANCE
8.6. ........................................................................................................................................................51RECORDS
9. ..................................................................................................................................52TROULBELSHOOTING
9.1. .............................................................................................................................................53ERROR CODE LIST
9.1.1. ..........................................................................................................53Example Errors & Possible Causes
9.1.2. ...........................................................................................54Problems That Do Not Produce Error Codes
10. .................................................................................................................55ELECTRICAL SPECIFICATIONS
11. ...............................................................................55ELECTRONIC ANGLE SENSOR SPECIFICATIONS:
12. .....................................................................................................................................................56APPENDICES
12.1..................................................................................................56DRAWINGS PART A-SYSTEM COMPONENTS
12.2. ..........................................................................................56DRAWINGS PART B-GENERAL ARRANGEMENTS
12.3. ................................................................................................................................56SOFTWARE DOCUMENTS

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.

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.
Length Sensor Boom Length Measures telescoping boom sections
Pressure Transducer Measures hydraulic pressure
Boom Angle sensor BAS Measures angle to horizon
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 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.

4. SYSTEM DESCRIPTION
4.1. Multi-purpose Application
The RCI-1550 is designed to suit Telescopic Boom Cranes of
either mobile or fixed installation.
This manual covers the use of Load Mom ent based sensors an d
calibration refer to cranes w here the te nsion cell/s are fitte d to
monitor the forw ard moment fo rces of the boom and then calcu late
the hook load.
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 tension cell/s to monitor the 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 telescopic-boom cranes, load-moment 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.

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.

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 specifi cations. Obtain special ist
assistance in these cases.
Please r efer to the General Arrangement
drawings at the rear of the manual for an
overview of the configuration.
5.2. Angle Sensors
The telescopic crane Boom Angle Sensor is mounted on the electrical sub-plate within the recoil drum.
Factory supply (unless ordered specifically) is for RH mounting. If mounting to LHS the BAS must be
realigned. Refer next paragraph.
5.2.1. Changing from RHS to LHS mounting
The Boom Angle Sensor (BAS) is physically mounted within the recoil set for RHS boom mounting as
standard. Should the recoil drum be mounted to the LHS of the boom, the BAS will need to be rotated to the
LHS mount position.
Undo the 2 mount screws and rotate the BAS clockwise to the alternative mount position.
Refix the 2 mount screws.
5.3. Length Sensors
5.3.1. General
Fix the recoil drum and pay-out cable to the RHS side of the main boom (LH installations require
the electronic angle sensor to be re-positioned on its mount, (refer to the above BAS section) by
welding the mounting bracket provided.
Route the cable carefully from the recoil drum back around the boom pivot to the cab. 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.