RaycoWylie i4500 User manual

Instruction Manual
i4500 Crane Information Center
Rated Capacity Indicator for Lattice Cranes
with Load Sensor on Hoisting Rope
(America)
Copyright © 2013
RaycoWylie Systems
All rights reserved.
Wylie Systems
(Rayco Technology Group)
1020 9th Avenue SW
Suite 124
Bessemer, AL
USA 35022
Tel: [phone]
Fax: [phone]
Rayco Electronic Systems
(Rayco Technology Group)
2440 Dalton Avenue
Ste-Foy, Qc
CANADA
G1P 3X1
Tel: [phone]
Fax: [phone]
Wylie Systems
(Rayco Technology Group)
Drury Lane
St-Leonards on Sea, East Sussex
ENGLAND
TN38 9BA
Tel: [phone]
Fax: [phone]
55M4500EBE00A Rev A
Ref: VH June 2013 Ref: A.A
Crane Warning Systems Atlanta
U.S. Distributor for Rayco / Wylie Systems
6175 Hickory Flat Hwy Suite #110-376
Canton, GA 30115
877-672-2951 Toll Free 678-261-1438 fax
www.craneindicators.com website
[email protected] email

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5
i4500 Lattice Boom Crane Instruction Manual
55M4500EBE00A-A55M4500CBF00-A
The purpose of this manual is to provide the customer with the operating
procedures essential for the promotion of proper machine operation for its
intended use. The importance of proper usage cannot be overstressed. All
information in this manual should be read and understood before any attempt is
made to operate the machine.
Since the manufacturer has no direct control over machine application and
operation, conformance with good safety practice in this area is the responsibility
of the user and of the operating personnel.
All procedures herein are based on the use of the system under proper operating
conditions, with no deviations from the original design. Alteration and/or
modication of the equipment are strictly forbidden without written approval from
RaycoWylie Systems.
The i4500 RaycoWylie Systems Crane Information Center must be regarded
only as an aid to the operator. When the parameters are set correctly, the
indicator will warn the crane operator of an approaching overload condition that
could damage the equipment, property, and/or cause injury to the operator or
people working near the crane and its load.
This system must never be used, under any circumstances, as a substitute for the
good judgment of a crane operator when carrying out approved crane-operating
procedures. The crane operator is responsible for the safe operation of the crane.
The indicator equipment will not necessarily prevent crane damage due to
overloading and related causes if not set properly.
Before operating a crane equipped with a RaycoWylie system RCI, the
operator must carefully read the information in both this manual and the crane
manufacturer operator’s manual. He must also be aware of all the federal,
state and local safety standards and regulations applicable to his job. Correct
functioning of the system depends upon routine daily inspection. Any suspected
faults or apparent damage should be immediately reported to the responsible
authority before using the crane.

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i4500 Lattice Boom Crane Instruction Manual
55M4500EBE00A-A
Since safety of personnel and proper use of the machine is of primary
concern, different symbols are used throughout this manual to
emphasize certain areas.
The following denitions indicate the level of hazard when these
symbols appear throughout this manual. Whenever one of these
symbols appears in this manual, personnel safety is a concern. Please
take the time to read and understand these denitions!
NOTE: PROVIDES INFORMATION THAT MAY BE OF
SPECIAL INTEREST.
DANGER: INDICATES A POTENTIALLY HAZARDOUS
SITUATION WHICH, IF NOT AVOIDED, COULD RESULT
IN DEATH OR SERIOUS MACHINE DAMAGE.
CAUTION: INDICATES A POTENTIALLY HAZARDOUS
SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN
MINOR OR MODERATE INJURY AND MINOR MACHINE
DAMAGE. IT MAY ALSO BE USED TO WARN AGAINST
UNSAFE PRACTICES.
IMPORTANT: INDICATES A SITUATION THAT MAY
CAUSE MACHINE DAMAGE.

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i4500 Lattice Boom Crane Instruction Manual
TABLE OF CONTENTS
EC Declaration of Conformity page 5
Warning page 7
1- GENERAL DESCRIPTION OF THE SYSTEM page 13
1.1 Introduction page 13
 1.2 PersonnelQualication       page13
1.3 Intended Use of the i4500 System page 13
1.4 Brief Description of the i4500 System page 14
1.4.1 Audible Alarm page 15
1.4.2 Visual Alarms page 15
1.5 Location & Description of Typical Components page 18
1.6 Block Diagram page 19
1.7 Technical Data page 20
2- DETAILLED DESCRIPTION OF THE DISPLAY UNIT page 21
2.1 Main Display (Default Screen) page 21
2.2 Display Box Overview page 22
2.3 Operating Buttons Description page 23
2.4 Main Modes page 25
2.5 Warning Lights and Indicators Location page 26
2.6 Warning Lights and Indicators Description page 27
3- INSTALLATION AND CALIBRATION page 31
4- OPERATING INSTRUCTIONS page 31
4.1 Safety Instructions page 31
4.2 Residual Risks page 32
4.3 Power On page 33
 4.4 SystemConguration       page34
4.4.1 Duty Selection page 34
4.4.2 Working with Main Boom, 1 or 2 Hoists page 35
4.4.3 Working with Jib, 1 Hoist page 39
4.4.4 Working with Main Boom or Jib page 43

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i4500 Lattice Boom Crane Instruction Manual
55M4500EBE00A-A
TABLE OF CONTENTS
4.4.5 SystemCongurationInformationScreen   page49
4.4.6 SystemSetupCongurationMode    page50
4.4.6.1UnitSelection page51
   4.4.6.2LanguageSelection     page52
   4.4.6.3DateandTimeSettings page52
   4.4.6.4Night/DayLightMode page53
   4.4.6.5BacklightMode page54
   4.4.6.6SetandRemoveTare     page55
  4.4.7-Bypass/RiggingMode      page56
   4.4.7.1-RiggingMode(MaintenanceandRigging)  page56
   4.4.7.2-AccessingRiggingMode    page57
   4.4.7.3-Bypass       page57
4.5 OperationalLimits       page58
  4.5.1-AccessingtheOperationalLimitsSettingMode  page59
  4.5.2-LimitValueAdjustments      page60
  4.5.3-Enable/DisableaLimit      page61
 4.6 RangeLimitingOptions       page62
  4.6.1-AccessingRangeLimitingMode    page64
  4.6.2-HeightLimit       page65
  4.6.3-FreeZone        page66
  4.6.4-VariableHeightLimit      page67
  4.6.5-VariableRadiusLimit      page69
(Continuedonnextpage)

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i4500 Lattice Boom Crane Instruction Manual
TABLE OF CONTENTS
5-DIAGNOSTIC & TROUBLESHOOTING page 72
5.1 Diagnostic Menu page 72
5.2 Angle Sensor page 74
5.3 Load Sensor page 74
5.4- Relays page 76
5.5 Slew Sensors (Range Limiting Options) page 77
5.6 Detected Addresses page 77
5.7 Error Messages page 78
5.7.1 Internal Peripherals page 78
5.7.2 External Peripherals page 80
6- INSPECTION AND MAINTENANCE page 84
6.1- Frequent Inspections page 84
6.2- Periodical Inspections page 84
6.3- Rated Load Test page 85
6.4- Maintenance page 86
6.5- Maintenance Procedure page 87
6.6- Adjustments and Repairs page 88

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13
i4500 Lattice Boom Crane Instruction Manual
55M4500EBE00A-A
-1-
General Description of the System
1.2 Qualications
The i4500 system shall be only operated by personnel who have no limitations in
the physical abilities of the upper limbs and no visual or hearing impairment. The
personnel must have completed all operator trainee qualication requirements
and have read and fully understood the instructions in this manual. Operator
requirements include: demonstrating the ability to read, write and use arithmetic.
He must also be able to read and understand the load / capacity charts in the
language used in the crane manufacturer’s operating instruction materials.
Maintenance of the system is intended only for fully qualied and trained personnel..
1.3 Intended Use
The i4500 system is intended to provide a valuable aid to the crane operator by
indicating all relevant parameters typically shown on the duty chart of the crane.
The i4500 system shall prevent the crane from supporting a load outside the
loads shown and described on the rated capacity chart when set, calibrated and
operated correctly.
This manual contains Operation, Troubleshooting and Maintenance information
for the i4500 system. When using the i4500 system, always observe the safety rules
and regulations applicable in the country where you operate the crane to reduce
the risk of injury or damage to the equipment. Each safety instruction throughout
this manual must be taken into consideration when using the i4500 system. The
information contained in this manual will enable qualied personnel to properly
operate the system and do the maintenance efciently.
1.1 Introduction

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i4500 Lattice Boom Crane Instruction Manual
The i4500 “Rated Capacity Indicator” is a computerized crane monitoring system
designed to help the operator to safely operate the crane and to respect the
maximum load authorized by the crane manufacturer.
The indicator automatically monitors the load lifted by the crane and constantly
compares it with the maximum load allowed for each position.
The display of the system allows the operator to see continuous information related
to the actual load lifted by the crane. It also warns the operator when he approaches
the limit or goes over the capacity of the crane.
The system has sensors installed on the machine in order to measure or verify:
-The boom angle
-The hook load
-The two-block condition (A2B)
The system takes this information to check overload conditions and to measure
the operating radius and the crane capacity. A slew sensor (optional) can also be
installed to measure the boom position (on 360 degrees) and give extra information
to the operator. The display is located inside the operator’s cab to provide an easy
access to the information. All the sensors are linked through a CAN bus network
(Controlled Area Network).
The actual load is expressed as a percentage of the permitted load (maximum load
or safe working load - % SWL). If this percentage exceeds a preset value, alarms
and safety functions are activated. The required crane duty charts are stored in
a non-volatile memory and can only be modied with the approval of the crane
manufacturer. The calculated crane parameters and calibration data are stored in
an additional non-volatile memory.
1.4 Brief Description of the i4500 System

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i4500 Lattice Boom Crane Instruction Manual
55M4500EBE00A-A
1.4.1 Audible Alarm
1.4.2 Visual Alarms
If you are wearing ear protection safety devices
or music earphones during crane operations, make
sure that they will not impair your ability to hear
the audible warning signals of the i4500 system.
The display of the i4500 system has been equipped with up to 3 warning lights to
warn the operator and signal for a specic course of action.
A yellow light will blink along with the audible alarm when the load reaches the
threshold point of the approach alarm (at 95% of the rated capacity).
A red light will illuminate when the rated capacity has been reached or exceeded.
WARNING
LIGHT
YELLOW REDGREEN
An intermittent buzzer located in the i4500 system display warns
the crane operator to take specic course of actions at the approach of
the rated capacity. The threshold of the approach alarm has been xed
at 95% of the rated capacity. The buzzer will sound in a continuous way when
the rated capacity is reached or exceeded (≥ 100%). Personnel in the danger zone
are warned by an external buzzer so that they can get out danger when the rated
capacity limiter is activated or overridden.
The crane operator will also be warned by the audible alarm when an operational
limit is activated and reached.

55M4500EBE00A-A
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i4500 Lattice Boom Crane Instruction Manual
External visual alarms are also provided with the external audible alarm to
warn the personnel in the danger zone so that they can be aware of the danger
when the rated capacity limiter is activated or overridden. Note that depending
on system conguration, your system may be equipped with one or with
three external lights. See tables 1 and 2 for external visual alarm operation.
I4500 system with three warning lights
Internal alarms External alarms
Event Green
Light
Yellow
Light
Red
Light
External
Buzzer
No event Off Off Off Off On Off Off Off
Approach
to SWL
(Alarm 1)
Blinking Off Off Intermittent Off On Off Off
Overload
(Alarm 2) On On Off Continuous Off Off On On
Motion Cut
(Alarm 3) On On On Continuous Off Off On On
Duty not
calibrated On On On Continuous Off Off On On
Bypass
Overload On On Off Continuous Off On On On
Bypass
ATB Off Off Off Off Off On On On
Bridging Switch
Activated Off Off Off Off Off On Off Off
A2B
(Normal Mode) Off Off On Continuous Off Off On On
A2B
(Calibration mode) X X X Continuous Off On On On
A2B
(Rigging Mode) Off Off Off Off Off On On On
Calibration mode X X X Off Off On Off Off
Approach
(Range Limiting) Off Off Off Intermittent Off On Off Off
Limit reached
(Range limiting) Off Off Off Continuous Off Off On On
Rigging Mode Off Off Off Off Off On Off Off
Table 1

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i4500 Lattice Boom Crane Instruction Manual
55M4500EBE00A-A
I4500 system with 1 external
warning light
Internal Alarms External Alarms
Event Red
Light
External
Buzzer
No event Off Off Off Off Off Off
Approach
to SWL
(Alarm 1)
Blinking Off Off Intermittent Off Off
Overload
(Alarm 2) On On Off Continuous On On
Motion Cut
(Alarme 3) On On On Continuous On On
Duty
Not calibrated On On On Continuous On On
Bypass
Overlaod On On Off Continuous On On
Bypass
A2B Off Off Off Off On On
Bridging
Switch Off Off Off Off Off Off
A2B
Normal Mode Off Off On Continuous On On
A2B
Calibration Mode X X X Continuous On On
A2B
Rigging Mode Off Off Off Off On On
Calibration
Mode X X X Off Off Off
Approach (Range
Limiting) Off Off Off Intermittent Off Off
Limit reached
(Range Limiting) Off Off Off Continuous On On
Rigging Mode Off Off Off Off Off Off
Table 2

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i4500 Lattice Boom Crane Instruction Manual
1.5 Location and Description of Typical Components
1) i4500 display box: It is also the central processing unit (CPU) of the
i4500 system. Its principal features are a CANBUS communication
interface and a graphical LCD screen.
2) Central I/O interface: This relay interface module is connected to
individual external I/O devices to be controlled or monitored by the i4500
system.
3) Load sensors: The load sensor is used to calculate the load on hook.
It is a dynamometer installed on the hosting rope
4) Anti-two block: the anti-two block is used make sure the block does not
hit the tip of the boom (optional).
5) Wind speed sensor: Shows wind speed value on the display (optional).
1
2
4
5
3

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i4500 Lattice Boom Crane Instruction Manual
55M4500EBE00A-A
1.6 Block Diagram of the i4500 Communication Link
Network
ROD SIDE
PRESSURE
SENSOR
BRIDGING
KEY SWITCH
All in 1
Integrated
control unit
CANbus RELAY CONTROLLER
BORE SIDE
PRESSURE
SENSOR
CAN
I/O
CANbus
LOAD CELL
INTERFACE
CAN
I/O
CABLE REEL
INTERFACE
CAN
I/O
EXTERNAL
VISUAL AND
AUDIBLE
ALARM
LOCKOUT
RELAY
RLD KEY
SWITCH
CAN 2.0B
Keypad
PRIMARY RCI
SAFETY
CRITICAL BUS
ECU
CAN
SECONDARY
BUS
Hydraulic
controller
CAN
CAN 2.0B
CANbus
INTERFACE
CAN
A2B SWITCHLENGTH
Angle
I/O
Slew Sensor
CANbus
INTERFACE
CAN
I/O
Anemometer
Video
IN
TFT Display
CAN 2
CAN 1
USB
Optional
Optional
i4500 Display
i4500 System
block diagram

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i4500 Lattice Boom Crane Instruction Manual
1.7 Technical Data
Accuracy: In accordance with SAE J159 or EN13000: 2010
Operating temperature: -20 ºC to + 70 ºC
Supply voltage: 9 to 32 VDC (maximum rating)
Display size: Available in:
4.3’’ LCD Screen
7.0’’ LCD Screen
10.4’’ LCD Screen
Display sealing: IP67
Memory capacity: 10,000 load/radius curves
CANbus sensors / interface: Default quantity Maximal quantity
- Load or pressure sensors 2 6
- Angle, Length sensors 1 5
- Relay output 5 32
- Digital inputs 4 16
- Provision for other sensors
Peripheral communication port RS-232