RaycoWylie i4500 User manual

Instruction Manual
i4500 Crane information center
Rated Capacity Indicator System for
Telescopic Cranes (America)
Copyright © 2012
RaycoWylie Systems
All rights reserved.
Ref: LD October 2012 Ref: A.A
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]
55M4500CBE01A Rev A

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I
Telescopic Crane i4500 Instruction Manual
i4500 Introduction
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 his 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 cause damage to equipment, property, and/or injury to the operator or site
workers in the vicinity of 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. Responsibility for the safe operation of the crane lies with the crane
operator. 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 standard 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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Telescopic Crane i4500 Instruction Manual
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 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 INJURY.
CAUTION: INDICATES A POTENTIALLY HAZARDOUS
SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN
MINOR OR MODERATE INJURY. IT MAY ALSO BE USED
TO ALERT AGAINST UNSAFE PRACTICES.
IMPORTANT: INDICATES A SITUATION THAT MAY CAUSE
MACHINE DAMAGE IF NOT CORRECTLY FOLLOWED.

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Telescopic Crane i4500 Instruction Manual
TABLE OF CONTENTS
EC Declaration of conformity
Warnings
1- GENERAL DESCRIPTION OF THE SYSTEM
1.1 Introduction page 4
 1.2 PersonnelQualication      page4
1.3 Intended Use of the i4500 System page 4
1.4 Brief Description of the i4500 System page 5
1.5 Typical Components Location & Description page 9
1.6 Block Diagram page 10
1.7 Technical Data page 11
2- DETAILED DESCRIPTION OF THE DISPLAY UNIT
2.1 Main Display (default screen) page 12
2.2 Display Box Overview page 13
2.3 Operating Buttons Description page 14
2.4 Main Modes page 15
2.5 Warning Lights and Indicators Location page 16
2.6 Warning Lights and Indicators Description page 18
3- INSTALLATION & CALIBRATION
4- OPERATING INSTRUCTIONS
4.1 Safety Instructions page 21
4.2 Residual Risks page 22
4.3 Power On page 21
 4.4 Systemconguration      page23
4.4.1- Duty Selection page 22
4.4.1a- Working with Main Boom Only page 25
4.4.1b- Working with Jib Only page 29
4.4.1c- Working with Main Boom or Jib page 33
  4.4.5-SystemCongurationInformationScreen  page40
4.4.4-SystemSetupCongurationMode   page41

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Telescopic Crane i4500 Instruction Manual
TABLE OF CONTENTS
4.4.6.1- Units Selection page 42
4.4.6.2- Language Selection page 44
4.4.6.3- Date & Time settings page 45
4.4.6.4- Night /Day Mode page 46
4.4.6.5- Backlight Mode page 47
4.4.6.6- Set & Remove Tare page 48
4.4.7- Bypass /Rigging Mode page 49
4.4.7.1- Rigging Mode (Erection Mode) page 49
4.4.7.2- Override Lockout system(bypass) page 50
4.4.8- Bridging Device page 51
4.5 Operational Limits page 54
4.5.1- Accessing the Operational Limits Setting Mode page 55
4.5.2- Limit Value Adjustments page 56
4.5.3- Enable / Disable a Limit page 57
4.6 Range Limiting Option page 59
4.6.1- Accessing Range Limiting Mode page 61
4.6.2- Limit high page 62
4.6.3- Free Zone page 63
4.6.4- Variable Limit Height page 64
4.6.5- Variable Limit Radius page 65

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Telescopic Crane i4500 Instruction Manual
TABLE OF CONTENTS
5- DIAGNOSTIC & TROUBLESHOOTING
5.1 Diagnostic Menu page 67
5.2 Angle/Length Sensor page 68
5.3 Load Sensor page 70
5.4- Relays page 70
5.5 Slew Sensors page 72
5.6 Detected Addresses page 72
5.7 Error Messages page 73
5.7.1 Internal Peripherals page 73
5.7.2 External Peripherals page 76
6- INSPECTION TESTING & MAINTENANCE
6.1- Frequent Inspections page 81
6.2- Periodical Inspections page 81
6.3- Rated Load Test page 82
6.4- Maintenance page 83
6.5- Maintenance Procedure page 84
6.6- Adjustements & Repairs page 85

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Telescopic Crane i4500 Instruction Manual
-1-
General Description of the System
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 of operation to reduce
the risk of personal 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 and efciently perform maintenance.
1.2 Personnelqualication
1.3 Intended use
The i4500 system shall be operated only by personnel without limitations in the
physical abilities of the upper limbs and no visual or hearing impairment, who
have completed all operator trainee qualication requirements and have read
and fully understood the instructions in this manual. Operator requirements
shall include: demonstrating the ability to read, write and comprehend and use
arithmetics and read and understand the load / capacity charts in the language
of the crane manufacturer’s operating instruction materials. Maintenance of
the system is intended only for fully qualied and trained personnel for this task.
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 limits of the permitted radii and outside the loads shown and described on
the rated capacity chart or the permissible working load of the ropes when set
and operated correctly.
1.1 Introduction

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Telescopic Crane i4500 Instruction Manual
The i4500 is a computerized crane monitoring system, designed as an operator
aid. It comprises sensors tted to the crane and a display located in the cabin of
the crane. This version measures the boom cylinder pressure, the boom angle
and length, and it indicates safe or critical conditions, while performing an
authorized lift of loads. Optional sensors may also be tted to monitor the slew
angle and the rotation of the hoist drum to provide some extra information to
the operator.
All the sensors are linked through a single CANbus (Controlled Area Network).
The pressure sensors provide electrical signals that are proportional to the
actual pressures in the hydraulic boom cylinder system of the crane. An
inclinometer provides a signal that is proportional to the boom angle and a
reeling drum provides a signal that is proportional to the boom extension. The
radius and the load are calculated from these signals with the dimensional
crane data preprogrammed in the i4500 system.
During operation the load lifted by the crane is calculated from the measured
boom cylinder pressure and is automatically compared with corresponding
data related to the maximum permissible crane loading.
The actual load is expressed as a percentage of the permitted load (% SWL).
If this percentage exceeds a preset value, alarms and safety functions are
activated. The values of the hook load, the permissible load, the main boom
angle and the radius are displayed in a digital form on a graphic liquid crystal
display (LCD).
If the additional sensors are tted, then some information about the current
slew angle and the hook height will also be available. 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. The
calibration of the system is performed only with the use of known loads, boom
angles, and other pre-determined data.
Audible alarms
An intermittent buzzer located in the i45000 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 alert 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.
(Continues on next page).
1.4 Brief description of the i4500 System

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Telescopic Crane i4500 Instruction Manual
The crane operator will also be warned by the audible alarm when the
operational limits or the range limiting function is activated and a selected
limit is reached. See Table (1) for more details on audible signal operation.
Visual alarms
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 at the threshold point of the approach
alarm (at 95%) of the rated capacity (100%).
A red light will illuminate when the rated capacity has been reached or exceeded.
An additional red light will also turn on when the rated capacity limiter is
activated (Cut Off).
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.
When wearing ear protection safety devices or
if using music earphones during crane operations,
make sure that they will not impair your ability
to hear the audible warning signals while operating
the i4500 system.

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Telescopic Crane i4500 Instruction Manual
Systemi4500with3warninglights
Internal alarms External alarms
Event Green
Light
Amber
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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Telescopic Crane i4500 Instruction Manual
Systemi4500with1warning
external 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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Telescopic Crane i4500 Instruction Manual
1.5 Typical component location and description
1) i4500 display box: It is also the central processing unit (CPU) of the
i4500 system. Its principal feature is a CANBUS communication interface
and 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.
There is 2 types of the load sensor, pressure sensor connecting on the
lifting cylinder or dynamometer installed on the lifting cable.
4) Cablereelwithangleandlengthsensor: A solid state angle sensor is
used to monitor the angle of the boom. A potentiometer is used to monitor
the boom length.
5) Anti-twoblock:the anti-two block switch is normally closed (with
weight hanging) spring-loaded switch (option).
6) Windspeedsensor:Shows wind speed value on the display (option).
1
3b
2
56
4
3a

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Telescopic Crane i4500 Instruction Manual
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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Telescopic Crane i4500 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 sensor 2 6
- Angle, Length sensor 1 5
- Relay output 5 32
- Digital input 4 16
- Provision for other sensors
Peripheral communication port RS-232

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Telescopic Crane i4500 Instruction Manual
-2-
Detailed description of the display unit
* The slew angle indicator (middle of the screen) is only present
when the range limiting option is installed in the machine.
The display should be used only as a guide, NOT as an
indication that the crane would or would not pass under a
structure of an accurately known height.
2.1 MainDisplay(defaultscreen)
OPERATING
RADIUS
SLEW
ANGLE*
BOOM ANGLE
DUTY
NUMBER
M= MAIN
BOOM
A= AUX.
BOOM
BOOM
LENGTH
PARTS
OF LINE
(FALLS)
BOOM TIP
HEIGHT
WARNING
ALARMS
HOOK
LOAD
MAX. SAFE
WORKING
LOAD
PERCENTAGE
OF SAFE
WORKING
LOAD

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Telescopic Crane i4500 Instruction Manual
WARNING LIGHT
When operating within normal conditions the green LED warning light turns
on. The yellow warning light turns on to indicate that a set operating limit is
being approached. The red warning light turns on to warn the operator that an
abnormal condition has occurred.
2.2 DisplayBoxOverview
MULTIFUNCTION
KEYS
MULTIFUNCTION
KEYS
WARNING
LIGHT
INTERNAL
BUZZER
GRAPHIC
DISPLAY
BAR GRAPH
GRAPHICDISPLAY
This menu driven communication interface allows access to the various menus
and options to control the i4500 unit system.
MULTIFUNCTION BUTTONS
Each of these buttons allows you to select and/or execute the indicated function
displayed on the screen in any given window. In this way, the task performed
by a given multifunction button will vary depending on the menu or window.
FUNCTION DESCRIPTION

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Telescopic Crane i4500 Instruction Manual
2.3 OperatingButtonsDescription
DUTYBUTTON
Choose this button to view the menu for the selection
of the duty by crane conguration. Select this button
to enable the selection of crane parameters such as
the boom length, the head type and the counterweight,
(if available).
ESCAPE BUTTON
Select Escape button on display to exit a menu
or any programming window without saving any
changes and to go back to the previous screen.
Select repeatedly to return to the main screen.
UP BUTTON
Select this button to scroll up through menu options or
to increase adjustable values.
DOWNBUTTON
Select this button to scroll down through menu options
or to decrease adjustable values.
MODEBUTTON
Enables you to select the mode of operation. Select this
button to choose one of these main operating modes:
-Limit Mode -Diagnostic Mode
-Cong. Mode -Calibration Mode (password-
-Info Mode -protected).
-Error Mode -Night Mode