RaycoWylie i4500 Use and care manual

55M4500CCE00 REV A
Calibration Instructions
i4500 Rated Capacity Limiter/Indicator
for
telescopic cranes, pressure sensing
Crane safety instrumentation

55M4500CCE00 REV A

55M4500CCE00 REV A
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 i4500 RaycoWylie Systems Rated Capacity Indicator (RCI) 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 RCI, the operator must
carefully read the information in the i4500 operator 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
1 INTRODUCTION....................................................................................................... 7
Personnel qualification and scope of this manual...................................................... 7
Using this manual ............................................................................................................ 7
2 CONFIGURATION .................................................................................................... 9
Step #1: Accessing the calibration menu.................................................................... 9
Step #2: “Enable/Disable i/o” Setting......................................................................... 10
Step #3: “Calibration units” setting............................................................................ 12
Step #4: “Calibration data” Entry................................................................................ 13
Step #5: “Dimensions” Data entry.............................................................................. 15
Step #6: “block capacities and block weights” setting ........................................... 18
Step #7: “system options” setting.............................................................................. 19
Step #8: “crane type”.................................................................................................... 20
Step #9: “bridging/bypass output” ............................................................................. 20
Step #10: “picture”........................................................................................................ 20
3 CALIBRATION........................................................................................................ 21
Step #11: “Zero sensor/Side of boom angle” angle sensor calibration................ 21
Step #12: “Zero sensor/Span sensor” length sensor calibration........................... 22
Step #13: “Zero pressure/Span pressure” sensor calibration................................24
Step #14: “select boom output sequence”................................................................26
Step #15: “No Load calibration”.................................................................................. 27
Step #16: “Loaded boom deflection” ......................................................................... 34
Step #17: Optional “Load adjustment” ...................................................................... 36
Step #18: Optional “Load offset” ................................................................................ 37
Step #19: Optional “Load correction” ........................................................................ 39
Step #20: “Friction compensation” ............................................................................ 43
Step #21: “Transfer” Calibration backup...................................................................43
“Transfer” restoring calibration and load chart files ................................................ 45
“Memory” ........................................................................................................................ 46
4 OPTIONS................................................................................................................. 47
“Limits setting” parameters.......................................................................................... 47

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“special calibration” ...................................................................................................... 47
“Users ID” Setting user pass codes for the data logger .......................................... 47
“rotation data” ................................................................................................................ 48
5 AUTOMATIC LOGS................................................................................................ 50
“Fault log” ....................................................................................................................... 50
“Event recorder” ............................................................................................................ 50

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UP button. Press to move up the screen when in a menu or to
increase the value of a highlighted number.
DOWN button. Press to move down the screen when in a menu or
to decrease the value of a highlighted number.
ESCAPE button. Press to exit a menu or to escape an option
without saving.
SELECT button. 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.
1INTRODUCTION
This manual contains calibration information for the i4500 system. When performing
calibration of 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 qualified personnel to properly operate and efficiently perform calibration.
Personnel qualification and scope of this manual
Installation of the i4500 system shall be performed by a qualified technician.
Furthermore, calibration of the i4500 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.
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
“Operating Buttons Description”.
Screenshots used in this manual are taken from a 4.3” display and some screens may
vary on larger display versions; calibration procedures, descriptions and functions are
identical for all display versions. All numbers shown on sample screens are examples
only and must be substituted with real information from the machine.
Navigating screens and editing data:

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Additional buttons used in the calibration mode only, refer to relevant text for detailed
use:
SAVE button. Press to save all recent changes into memory.
DELETE button. Press to delete a stage of some calibrations.
CLEAR button. Press to clear the fault log or the event log.
CHANGE SIGN button. Press to set a variable to negative or back to
positive.

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2CONFIGURATION
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.
Step #1: Accessing the calibration menu
1‐ Press the Mode button.
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.
Some systems are installed with dual level password access, this manual includes
information on all features accessible from the top level. Some features will not be
available when the lower level password is entered and will not appear in the calibration
menu. It will not normally be necessary to access these features after the initial
installation is completed.
The calibration menu will remain accessible until the system is powered off.

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Step #2: “Enable/Disable i/o” 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 i/o".
2‐ Press “” to enter this menu.
3‐ Scroll to select the I/O 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 must be permanently registered by pressing the “save”
button.
6‐ Press “” at any time to abandon any changes not saved or to exit the menu
when done.
As a guide, the minimum requirements for a basic system are:
Angle 1 ON
Length 1 ON
Load 1 ON
Load 2 ON
Relay board 1 ON
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 I/O should be
enabled, this will be indicated by a table or a notation adjacent to each component. See
example below: (Ref Load 1 and Load 2) means that these two I/O items need to be ON.