RaycoWylie i4507 User manual

Instruction Manual
i4507 Crane Information Center
Rated Capacity Indicator for Oshore Lattice Cranes
Copyright © 2014
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]
55M4507OBE00 Rev B
Ref: VH Sept. 2014
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
i4507 Offshore Lattice Boom Crane Instruction Manual
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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 i4507 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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i4507 Offshore Lattice Boom Crane Instruction Manual

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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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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 i4507 System page 13
1.4 Brief Description of the i4507 System page 14
1.4.1 Audible Alarm page 15
1.4.2 Visual Alarms page 15
1.5 Description of Typical Components page 18
1.6 Technical Data page 19
2- DETAILED 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 33
4.1 Safety Instructions page 33
4.2 Residual Risks page 34
4.3 Power On page 34
 4.4 SystemConguration       page35
4.4.1 Duty Selection page 35
  4.4.2 SystemCongurationInformationScreen   page37
  4.4.3 SystemSetupCongurationMode    page38
4.4.3.1 Unit Selection page 39
4.4.3.2 Language Selection page 40
TABLE OF CONTENTS

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i4507 Offshore Lattice Boom Crane Instruction Manual
4.4.3.3 Date and Time Settings page 40
4.4.3.4 Night/Day Mode page 41
4.4.3.5 Backlight Mode page 42
4.4.3.6 Set and Remove Tare page 43
4.4.4 Bypass/Rigging Mode page 44
4.4.4.1 Rigging Mode (Maintenance and Rigging) page 44
4.4.4.2 Accessing Rigging Mode page 45
4.4.4.3 Bypass page 45
4.5 Operational Limits page 46
4.5.1 Accessing the Operational Limits Setting Mode page 47
4.5.2 Limit Value Adjustments page 48
4.5.3 Enable/ Disable a Limit page 49
4.6 Range Limiting Options page 50
4.6.1 Accessing Range Limiting Mode page 52
4.6.2 Height Limit page 53
4.6.3 Free Zone page 54
4.6.4 Variable Height Limit page 55
4.6.5 Variable Radius Limit page 57
5- DIAGNOSTIC & TROUBLESHOOTING page 59
5.1 Diagnostic Menu page 59
5.2 Angle Sensor page 61
5.3 Load Sensor page 61
5.4 Relays page 63
5.5 Slew Sensors (Range Limiting Options) page 64
5.6 Detected Addresses page 64
5.7 Error Messages page 65
5.7.1 Internal Peripherals page 66
5.7.2 External Peripherals page 67
TABLE OF CONTENTS

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6- INSPECTION AND MAINTENANCE page 71
6.1 Frequent Inspections page 71
6.2 Periodical Inspections page 71
6.3 Rated Load Test page 72
6.4 Maintenance page 73
6.5 Maintenance Procedure page 74
6.6 Adjustments and Repairs page 75
TABLE OF CONTENTS

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-1-
General Description of the System
1.2 Qualications
The i4507 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 i4507 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 i4507 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 i4507 system. When using the i4507 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 i4507
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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i4507 Offshore Lattice Boom Crane Instruction Manual
The i4507 “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 CANbus 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 i4507 System

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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 i4507 system.
The display of the i4507 system has been equipped with a warning light 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 i4507 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.

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i4507 Offshore 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.
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
A2B 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
i4507 system with three warning lights

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i4507 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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i4507 Offshore Lattice Boom Crane Instruction Manual
1.5 Description of Typical Components
i4507 Display Box
It is the central processing unit (CPU) of the i4507
system. It uses a CANbus network and is equipped
with a 7 inch color display.
Angle Sensor
The angle sensor is used to monitor the boom angle.
This inclinometer typically has a degree range of -10
to +90 degrees.
Load Sensor(s)
The load sensor is used to calculate the load on hook. It
can be a dynamometer or a dead-end load link. Others
options available upon request.
Termination Unit
This interface is connected to the various I/O sensors
installed on the crane. It transmits the information
to the i4507 display box using the CANbus network.
Optional explosion proof enclosure available.
Anti-two Block (optional)
The anti-two block switch prevent the hook block to
be pulled against the boom head. It is attached to the
boom tip on one end and to a chain leading to a weight
clamped around the hoist line at the other end. When
the block lifts the weight, it issues a warning and can
stops the upward movement.

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1.6 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:
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 YES
Peripheral communication port RS-232
Wind speed sensor (optional)
Shows wind speed value on the i4507 display.
Slew Encoder (optional)
The slew encoder is used to display the position of
rotation of the crane, to select the duties (for example:
over rear, over side) and nally, to program a limit
on the rotation in case as the range limiting device
version is installed in the system.

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