RaycoWylie i4000 Use and care manual

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Crane safety instrumentation
Copyright 2015
(Rayco-Wylie Systems).
All rights reserved.
Any part of this document may not be reproduced or transmitted in any form or by any means including
photocopy or any other information storage and retrieval system without the permission from
RaycoWylie Systems which will not normally be withheld assuming that the material is for internal use
only.
Wylie Systems Wylie Systems Rayco Electronic System
Drury Lane 1020 9th Avenue, SW 2440 Ave Dalton
St. Leonards-on-Sea Suite 124 Ste-Foy
East Sussex Bessemer, AL 35022 Québec G1P 3X1
England U.S.A. Canada
TN38 9BA
Tel:[phone] Tel:[phone] Tel:[phone]
Fax:[phone] Fax: [phone] Fax:[phone]
http://www.raycowylie.com/
Calibration Instructions
i4000 Multi-Purpose Indicator /Range
Limiting Device
for
telescopic cranes,
hoist rope load sensing
Crane Warning Systems Atlanta
U.S. Distributor for Rayco / Wylie Systems
6175 Hickory Flat Hwy Suite #110-376
Canton, GA 30115
866-672-2951 Toll Free 678-261-1438 fax
www.craneindicators.com website
[email protected] email

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The purpose of this manual is to provide the calibration technician with the procedures
essential for the promotion of proper machine operation for its intended purpose. The
importance of proper usage cannot be overstressed.
The calibration technician should have read, and be familiar with, the instruction
manual supplied with the system.
All information in this manual should be read and understood before any attempt is
made to calibrate 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 modification
of the equipment are strictly forbidden without written approval from RaycoWylie
Systems.
The i4000 RaycoWylie Systems Multi-Purpose Indicator (MPI) is to 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. Prior to the calibration being completed the system will not provide
correct warnings and it is essential that other means are used to establish safe use of
the machine.
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.

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Before operating a crane equipped with a RaycoWylie system MPI, the operator must
carefully read the information in the i4000 Instruction 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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TABLE OF CONTENTS
1INTRODUCTION.................................................................................................. 6
1.1 Personnel qualification and scope of this manual.......................................... 6
1.2 Using this manual .............................................................................................. 6
2CONFIGURATION............................................................................................... 8
2.1 Step #1: Accessing the calibration menu........................................................ 8
2.2 Step #2: “Enable/Disable sensor” Setting....................................................... 9
2.3 Step #3: “Calibration units” setting................................................................. 9
2.4 Step #4: “Load data” Entry............................................................................. 10
2.5 Step #5: “Limits data” Entry........................................................................... 10
2.6 Step #6: “Dimensions” Data entry ................................................................. 12
2.7 Step #7: “system options” setting................................................................. 15
2.8 Step #8: “Internal Relay Set-Up”.................................................................... 16
3CALIBRATION................................................................................................... 17
3.1 Step #9: “Zero sensor/Side of boom angle” angle sensor calibration ....... 17
3.2 Step #10: “Zero sensor/Span sensor” length sensor calibration ............... 18
3.3 Step #11: “Zero load/Span load” sensor calibration.................................... 20
3.4 Step #12: “Rotation” sensor calibration........................................................ 23
3.5 Step #13: “Unloaded boom deflection” ......................................................... 25
3.6 Step #14: “Loaded boom deflection” ............................................................ 26
3.7 Step #15: “Transfer” Calibration backup ..................................................... 28
3.8 “Transfer” restoring calibration..................................................................... 29
3.9 “Erase Memory” .............................................................................................. 30
4AUTOMATIC LOGS........................................................................................... 31
4.1 “Fault log”......................................................................................................... 31

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1 INTRODUCTION
This manual contains calibration information for the i4000 system. When performing
calibration of the i4000 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 i4000 system. The information contained in this manual
will enable qualified personnel to properly operate and efficiently perform calibration.
1.1 Personnel qualification and scope of this manual
Installation of the i4000 system shall be performed by a qualified technician.
Furthermore, calibration of the i4000 system must be performed by a RaycoWylie
trained technician. The RaycoWylie technician will perform a complete and structured
verification of the whole system before beginning the system’s calibration.
Failure to calibrate the system properly can result in overloading of the crane risking
machine breakage or tipping that could result in serious injury or death. Always refer to
a RaycoWylie trained technician to calibrate your system.
1.2 Using this manual
This manual must be used in conjunction with the Instruction Manual, refer to the
instruction manual for description of the system operation, especially the section
“Description of operation keys”.
All numbers shown on sample screens are examples only and must be substituted with
real information from the machine.

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Description of operational keys:
UP Key. Press to move up the screen when in a menu or to
increase the value of a highlighted number.
DOWN Key. Press to move down the screen when in a menu or to
decrease the value of a highlighted number.
Left Key. Press this key to scroll left through the tabs of the main
menu or, in Edit mode, to return to the previous digit of a
configurable value
Right Key. Press this key to scroll right through the tabs of the
main menu or, in Edit mode, to move to the previous digit of a
configurable value
CONFIRM Key. Press to enter a selection when in a menu or to
accept a changed value. Note that most changed values must also
be saved to permanently store them.
ESCAPE Key. Press to exit a menu or to escape an option without
saving.

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2 CONFIGURATION
To ensure a successful, first calibration follow each calibration step in sequence, do not
miss out any steps unless they are marked as optional.
Many calibration screens show reminder notes or hints on the bottom line, remember
to read these for guidance.
The normal mode of operation of the i4000sytem is organized into four separate
screens. We call it “Tabs”. Use the left or right arrow keys to navigate in these tabs.
INDICATOR
TAB
LOAD
TAB
RANGE LIMITING
TAB
TOOLS
TAB
2.1 Step #1: Accessing the calibration menu
1- Select the tool tab using the left or right keys
2- Scroll to highlight “Calibration Mode” using “”or “”.
3- Press “”to enter this menu.
4- The system will request a 5 digit password. The first digit will be highlighted, use
“”or “”to select the first digit and press “”to confirm and move on to the
second digit. Repeat this for all 5 digits, after confirming the 5th digit the system
will enter the calibration menu provided the password is correct. If the
password is not correct the system will return to the normal working screen.
5- If a mistake is made while entering the password, press “”to return to the
previous digit.

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Provided password is used the calibration menu will remain accessible until the system
is powered off. The password will be required every time the menu is selected after a
power on.
Your password number is: 98765
2.2 Step #2: “Enable/Disable sensor”Setting
Note: these settings reflect the configuration of your system and will generally be
made during factory testing prior to delivery and should not need changing.
1- In the calibration menu, scroll up or down to the menu "Enable/Disable sensor".
2- Press “”to enter this menu.
3- Scroll to select the sensor option to edit.
4- Press “”to highlight the value to edit. Scroll up or down to change to value
then Press “”to confirm.
5- Any change made is permanently registered after confirmation.
6- Press Escape key at any time to exit the menu when done.
All remaining items in the list are optional and set to OFF if not used.
Refer to the wiring diagram supplied with your system to determine which sensor
should be enabled, this will be indicated by a table or a notation adjacent to each
component.
2.3 Step #3: “Calibration units” setting
1- In the calibration menu, scroll up or down to the item "Calib units:".
2- Press “”to toggle between metric and imperial.
imperial: use x1000lbs and feet.
metric: use metric tons and metres (1 metric ton = 1000 kg).

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2.4 Step #4: “Load data” Entry
Note: these settings reflect the configuration of your system when a load sensor is
fitted and will generally be made during factory testing prior to delivery and should
not need changing.
Some or all of this information may be pre-loaded prior to delivery but all entries should
be verified and edited as required before proceeding. Length units in use will be feet or
meters depending on the setting made for ‘calib units’ in step #3.Please advise Rayco
Wylie of any changes required in this section.
1- In the calibration menu, scroll down to the item "Load data:".
2- Press “”to enter this menu.
3- Scroll to select the item to edit from the list below.
4- Press “”to highlight the value to edit. Scroll up or down to change the value
then Press “”to confirm.
5- Any change made is permanently registered after confirmation.
6- Press Escape Key at any time to exit the menu when done.
Rope Limit Main: This is the maximum tension that the cable is rated for per fall or
part of line (rope SWL) for the main rope.
Rope Limit Aux : This is the maximum tension that the cable is rated for per fall or
part of line (rope SWL) for the auxiliary rope.
Max parts of line: This is the maximum number of parts of line that can be rigged on
the crane and applies to all hoists.
Load Approach (%): Is the %SWL approach limit. If the %SWL is greater than this
value, an intermittent audible alarm will be activated and the yellow display LED will
blink. The external yellow lamp output will be ON.
Note: %SWL = (Load / Capacity) x 100.
Overload (%): Is the %SWL motion cut limit. If the %SWL is greater than this value, a
continuous audible alarm will be activated and the red display LED will be ON. The
external red lamp and audible alarm output will be ON. The motion cut output will
be in the stop condition (cut active).

2.5 Step #5: “Limits data” Entry
This menu contains the approach warning gaps for all the limits that can be set by the
operator in normal mode.

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After selecting “limits setting” from the main calibration menu the screen will show:
Set the approach gap for each limit in turn, angle approach gaps are in degrees, length,
radius and height gaps are set using the calibration units.
1- In the calibration menu, scroll down to the item "Limits data:".
2- Press “”to enter this menu.
3- Scroll to select the item to edit from the list below.
4- Press “”to highlight the value to edit. Scroll up or down to change the value
then Press “”to confirm.
5- Any change made is permanently registered after confirmation.
6- Press Escape Key at any time to exit the menu when done.
App Angle: This variable represents an approach warning gap before to reach the
angle limit set by the operator in the normal mode. If the angle goes over this
approach gap an intermittent audible alarm will be activated and the yellow display
LED will blink.
App Length: This variable represents an approach warning gap before to reach the
boom length limit set by the operator in the normal mode. If the boom length goes
over this approach gap an intermittent audible alarm will be activated and the yellow
display LED will blink.
App radius: This variable represents an approach warning gap before to reach the
radius limit set by the operator in the normal mode. If the radius goes over this
approach gap an intermittent audible alarm will be activated and the yellow display
LED will blink.
App Height: This variable represents an approach warning gap before to reach the
height limit set by the operator in the normal mode. If the height of the boom tip
goes over this approach gap an intermittent audible alarm will be activated and the
yellow display LED will blink.
App Wind (If Wind Speed Sensor Fitted): This variable represents an approach
warning gap before to reach the wind speed limit set by the operator in the normal

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mode. If the wind speed goes over this approach gap an intermittent audible alarm
will be activated and the yellow display LED will blink.
App Rotation(if Rotation sensor fitted) : This variable represents an approach
warning gap before to reach the slew limit set by the operator in the normal mode. If
the slew goes over this approach gap an intermittent audible alarm will be activated
and the yellow display LED will blink.
Time of return:This is the time that you have to return into safe condition before
the motion cut output will be activated, when you reach a limit.
2.6 Step #6: “Dimensions” Data entry
This menu contains crane dimensions that are necessary for the calculation of the load
radius and height of the boom tip.
Some or all of this information may be pre-loaded prior to delivery but all dimensions
should be verified and edited as required before proceeding. Units in use will be feet or
meters depending on the setting made for ‘calib units’ in step #3. To enter a negative
value press on “+/-“to toggle between positive and negative value.
CL1 (full retract): length of the main boom when fully retracted.
CL2 (Ext + Man)): length of the boom with all sections fully extended including any
manual or power pinned extension if fitted.
CL2MR (Ext + Man): length of the boom fully extended but with any manual or
power pinned extension retracted. Note: For full power booms without a manual
section CL2 and CL2MR are the same value.
CL8 (p2cb) –vertical distance between the boom foot pin and the boom centerline
with the boom horizontal. Instead of using the boom centerline as a reference, It is
common to use the boom foot pin, in this case CL8 = 0 but ensure that CL10 and CL11
use the same reference.
CL10 - vertical distance between the lower boom tip sheave pin (hook suspension
sheave) and the boom centerline (or boom foot pin, see CL8) with the boom
horizontal.
CL11 - vertical distance between the upper boom tip sheave pin and the boom
centerline (or boom foot pin, see CL8) with the boom horizontal.
CR1 (Sheave Rad.) - lower boom tip sheave pitch radius (hook suspension sheave).
CF (slew offset) –horizontal distance between the boom foot pin and the centerline
of rotation of the machine. If the boom foot pin is behind the centerline of rotation
then the distance is negative, otherwise it is positive.
CH1 (height offset) –vertical distance between the boom foot pin and the ground.
Nb Jib –Number of jib available to calibrate, if this value is greater than 0, we will have
to enter dimension shown in “Fly jib geometry” for each jib.

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Main boom geometry:
Note sign convention: All dimensions shown positive except cf, the centreline of slew is
generally in front of the boom pivot pin in which case cf is negative. If any other
dimension falls the opposite side of it’s datum line shown in the diagrams then it’s sign
will change eg if the boom foot pin is above the centreline of the boom then cl8 will be
negative etc.

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Rooster sheave geometry :
Fly jib geometry :

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2.7 Step #7: “system options” setting
The system options menu allows various features to be turned on and off and may vary
depending on the version of software installed in the i4000 system. These settings will
normally be pre-set before delivery and will not require changing.
Navigate through the calibration menu using “”or “”to highlight “system options”
and press “”to enter.
Bypass Timeout. Time allowed in seconds before to re-activate the motion cut after
pressed the Bypass key in normal mode.
Enable Radius Calcul. This is to allow the calcul of the radius. All dimensions entered
must be conform.
Absolute Limiter. This allow to enable the Absolute limiter.
Range Limiting. This allow to enable the range limiting option. When the range limiting
is enable, the following 3 features will be displayed.
Save limit. Optional feature, if enabled then setting this to ON will display a message on
start up indicating a limit is saved if a limit has previously been set.
Password Range. When set to ON, Limits of the Range limiting feature is protected by a
password.
Password. The Range Limiting feature will be protected by this password if set to a
value other than 0.
1- To set-up a password for the Range Limiting option Press “”to enter.
2- The system will request a 5 digit password. The first digit will be highlighted, use
“”or “”to select the first digit and press “”to confirm and move on to the
second digit. Repeat this for all 5 digits, after confirming the 5th digit the system
will enter the calibration menu provided the password is correct. If the
password is not correct the system will return to the normal working screen.
3- If a mistake is made while entering the password, press “”to return to the
previous digit.

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2.8 Step #8: “Internal Relay Set-Up”
This item allows the selection of which option the internal relay will be activated. There
is three options which are available: Absolute limiter, Overload and Range Limiting as
shown:

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3 CALIBRATION
3.1 Step #9: “Zero sensor/Side of boom angle” angle sensor calibration
Address selection dip switch:
Every angle sensor installed has its own dedicated address. These switches are factory
set prior to dispatch and will not normally require changing. Please refer to the wiring
diagram to see the address dip switch setting for each angle sensor interface.
Angle Sensor Side of Boom:
1) Use “”or “”to choose “Sensor Calibration” and press “”.
2) Use “”or “” to choose the “Select Sensor” and press the “”. Use “”or
“” again to choose the Angle sensor and press the “”.
3) Use “”or “”to choose “Side of boom angle” and press “”.
4) Press “” to highlight the value to edit and use “”or “” to edit the location
of the angle sensor (normally integrated into the length sensor (reel), press the
“”to confirm and then Escape to exit.
Note, “right” indicates right hand side of boom when viewed from the crane’s cab.

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Zero angle calibration:
Ensure the correct side of boom setting has been made before setting the zero datum, if
the side of boom setting is changed then the zero setting must be repeated.
1) Use “”or “” to choose “Zero” and press “”.
2) Boom down to zero degrees (main boom horizontal) using a precision angle
measure to accurately establish the true angle of the base boom section. The
angle is displayed in degrees and the sensor value is in bits. This value must be
above 100 bits. If smaller, turn the sensor to increase the value.
3) Press “”to edit the angle value using “”or “”.
4) Press “”again to confirm the zero.
5) Press Escape to return to the main calibration menu.
The boom angle need not be zero but it’s true value must be accurately known and
entered as described.
3.2 Step #10: “Zero sensor/Span sensor” length sensor calibration
Warning: The system does not store the ZERO LENGTH into permanent memory until
the SPAN LENGTH calibration has been completed. If a ZERO LENGTH calibration is
done, then a SPAN LENGTH calibration must also be done.
Zero extension calibration:
1) Use “”or “”to choose “Select sensors” and press “”.
2) Use “”or “”to choose the length sensor to be calibrated, press “”.
3) Use “”or “”to choose “Zero” and press “”.

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4) Retract the boom completely. The sensor’s value must be approximately 100 bits
(0,50 volts; adjust the potentiometer inside the cable reel if necessary).
5) Edit the zero value: when the boom is completely retracted, the value must be
set to zero.
6) Press “”to confirm the value. Note the indicated value will return to it’s earlier
state temporarily, the new zero value will be stored after the next step.
7) Press Escape to return to the sensor calibration menu.
Span extension calibration
1) Use “”or “”to choose “span” and press “”.
2) Fully extend all the boom sections up to and including the section that the length
sensor cable is attached to (for single reel installations this is all boom sections
including a manual section if fitted). The sensor value should be a minimum of
150 bits above the zero value. Enter the difference between the extended length
and the fully retracted main boom length using the units selected. For example:
A fully extended boom of 30m minus a fully retracted boom of 10m = 20m. Enter
20.0 for the span extension.
3) Press “”to edit the span value.
4) Edit the span value, then press “”to confirm the value.
5) Press Escape to return to the sensor calibration menu.

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3.3 Step #11: “Zero load/Span load” sensor calibration
When calibrating load sensors, always slowly hoist and stop the test loads smoothly in
order to eliminate errors in the load reading due to frictional effects. The frictional
effect on dynamometer (line rider) systems will cause the displayed load to decrease
when lowering the load and to increase when hoisting the load. On dead-end load cell
systems this effect is reversed. These friction effects can be minimised by ensuring
boom head sheaves and hook block are in good condition and properly maintained
before proceeding.
Warning: The system does not store the ZERO LOAD into permanent memory until the
SPAN LOAD calibration has been completed. If a ZERO LOAD calibration is done, then a
SPAN LOAD calibration must also be done.
Load sensor calibration must be done with two, accurately known test loads, a small
load and a large load. The large calibration load should provide between 50-90% line
pull on the hoist line while using as many parts of line as is feasible. If a large enough
load cannot be found, the crane can be reeved to fewer parts to increase the line pull
for a given calibration load. The smaller load should be approximately 5-10% of the
larger load and in many cases the block weight alone may be sufficient. The calculated
test loads should normally include the weight of the hook block and any slings, shackles
etc. that are used.
Note: The system must use the part of line currently rigged on the block in the load
value calculation, this value is set in the normal mode, make sure that this value is
conform to the number of part of line currently rigged on the block. If it’s not the case
you must adjust it in the normal mode.
Select the load sensor to be calibrated
1) Use “”or “” to choose “Select sensor” and press “”.
2) Use “”or “”to select the relevant load sensor and press “”.