RaycoWylie i3500 User manual

Instruction Manual
i3500 Crane information center
Rated Capacity Indicator System for Telescopic
Cranes Pressure Sensing, Multi-Point Version
Copyright © 2010
RaycoWylie Systems
All rights reserved.
Ref: LD October 2010 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]
55M3500JBE00 Rev B
Crane Warning Systems Atlanta
770-888-8083 phone
678-261-1438 fax
www.craneindicators.com
[email protected]

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Telescopic Cranes Pressure Sensing Instruction Manual
EC Declaration of Conformity
Product type:
Authorised Representative:
Is in conformity with:
i3500 Rated Capacity Indicator
Wylie Systems
Drury Lane
St Leonards-on-sea
East Sussex , United Kingdom
TN38 9BA
The provisions of the Machinery Directive (Directive 2006/42/EC)
The provisions of the Electromagnetic compatibility Directive (Directive
2004/108/EC)
This conformity is supposed referring to the following standards,
documents and requirements:
EN 13000 Cranes – Mobile Cranes
EN 12077-2 Cranes Safety, limiting and indicating devices
EN 954-1 Safety and related parts of control systems.
Category 2
EN 60204-32 Safety of machinery. Electrical equipment of machine
Requirement for hoisting machine
EN 61000-6-2 Electromagnetic compatibility - immunity
EN 61000-6-4 Electromagnetic compatibility - emission
For and on behalf of Wylie Systems, a division of
RaycoWylie Systems:
………………………………………………
Luc Patry
RaycoWylie Quality & Certification Manager
December 23, 2009
This document is also the certificate of origin. The product is manufactured in more than one country and all European
Union import duties and taxes have been paid in the United Kingdom.
www.raycowylie.com
Rayco Wylie Systems
ISO9001:2008 FM 33972
Manufacturer :
Rayco Electronic Systems
2440 Av Dalton
Québec, PQ, Canada
G1P 3X1

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 i3500 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 Cranes Pressure Sensing 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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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 Intented use of the I3500 System page 4
1.4 Brief description of the I3500 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 Normal Mode Display (default screen) page 12
2.2 Display Buttons Location and Purpose page 13
2.3 Warning Lights and Indicators Location page 15
2.4 Warning Lights and Indicators Detailed Description page 16
3- INSTALLATION & CALIBRATION
4- OPERATING INSTRUCTIONS
4.1 Safety Instructions page 19
4.2 Residual Risks page 20
4.3 Power On page 21
 4.3 Systemconguration      page21
4.4.1- Duty Number Selection page 22
4.4.2- Hoist Selection page 24
4.4.3- Parts of Line Selection page 25
4.4.4- System Test page 27
  4.4.5-SystemCongurationInformationScreen  page28
4.4.6- System Setup page 29
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TABLE OF CONTENTS
4.4.6.1- Language Selection page 30
4.4.6.2- Units Selection page 31
4.4.6.3- Reverse Video page 32
4.4.7- Bypass/ Rigging page 32
4.4.7.1- Rigging Mode page 33
4.4.7.2- Overload Override (bypass) page 34
4.4.7.3- ATB Condition Override page 34
4.4.8- Bridging & Range Limiting Box page 35
4.4.8- Bridging Device page 35
4.4.8.2- Bypass Rigging using the range limiting box page 37
4.5 Operational Limits page 38
4.5.1- Accessing the Limits Mode page 39
4.5.2- Limit value Adjustments page 40
4.5.3- Enable / Disable a limit page 41
4.6 Range Limiting Option page 42
4.6.1- Accessing Range Limiting Mode page 44
4.6.2- Limit high page 45
4.6.3- Free Zone page 46
4.6.4- Variable Limit Height page 47
4.6.5- Variable Limit Radius page 48
5- DIAGNOSTIC & TROUBLESHOOTING
5.1 Diagnostic Menu page 50
5.2 Angle/Lenght Sensor page 51
5.3 Pressure Sensor page 53
5.4- Relays page 53
5.5 Slew Sensors page 55
5.6 Detected adresses page 55
5.7 Error Messages and the Use of the ‘‘ ? ’’ key page 56
5.7.1 Internal Peripherals page 56
5.7.2 External Peripherals page 59
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6- INSPECTION TESTING & MAINTENANCE
6.1- Frequent Inspections page 63
6.2- Periodical Inspections page 63
6.3- Rated Load test page 64
6.4- Maintenance page 65
6.5- Maintenance Procedure page 66
6.6- Adjustements & Repairs page 67
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-1-
General Description of the System
This manual contains Operation, Troubleshooting and Maintenance
information for the i3500 system. When using i3500 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
i3500 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 i3500 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 i3500 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 i3500 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 Cranes Pressure Sensing Instruction Manual
The i3500 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 i3500 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 i35000 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 i3500 System

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Telescopic Cranes Pressure Sensing 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 i3500 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 i3500 system.

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Telescopic Cranes Pressure Sensing Instruction Manual
Event Approach Overload Cut Audible Ext
Buzzer
Green
Light
Amber
Light
Red
light
No event Off Off Off Off Off On Off Off
Approach
to SWL
(Alarm 1)
Blinking Off Off Intermittent Off Off On Off
Overload
(Alarm 2) On On Off Continuous On Off Off On
Motion cut
(Alarm 3) On On On Continuous On Off Off On
Not calibrated On On On Continuous On Off Off On
Setup button
activated
within
working
range
deadlock
> 100 - 110%
override
X X X X On Off On On
Boom up
override X X X X On Off Off On
Bridging Key X X X X On Off Off On
A2B operating
mode X X On Continuous Off On Off Off
A2B
(Calibration
or Rigging
mode)
X X X Off Off Off On Off
Setup button
activated
in Erection/
Rigging to
override the
A2B
Off Off Off Off Off Off On On
Calibration
mode Off Off Off Off Off Off On Off
Range
Limiting
approach
On Off Off Intermittent Off Off On Off
Range
limiting
limit reached
On On On Continuous On Off Off On
Rigging mode Off Off Off Off Off Off On Off
Display External
Systemwith3warninglights
Table 1

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Telescopic Cranes Pressure Sensing Instruction Manual
Event Approach Overload Cut Audible Ext.
Buzzer
Red
light
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
(Alarm 3) On On On Continous On On
Not calibrated On On On Continous On On
Setup button
activated
within
working
range
deadlock
> 100 - 110%
override
X X X X On On
Boom up
override X X X X On On
Bridging Key X X X X On On
A2B X X X X Off Off
Setup button
activated
in Erection/
Rigging to
override the
A2B
Off Off Off Off On On
Calibration
mode Off Off Off Off Off Off
Range
Limiting
approach
On Off Off Intermittent Off Off
Range
limiting
limit reached
On On On Continuous On On
Rigging mode Off Off Off Off Off Off
Display External
Systemwith1warninglight
Table 2

1.5 Typical component location and description
1) i3500 display box: It is also the central processing unit (CPU) of the
i3500 system. Its principal feature is a CANBUS communication interface
and graphical LCD screen.
2) Angle sensor: A solid state angle sensor that is used to monitor the
angle of the boom.
3) Pressure sensors: Highly sensitive, built for precise lifting and
weighing in harsh environments.
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).
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Telescopic Cranes Pressure Sensing Instruction Manual

1.6 BlockDiagram
BlockDiagramofthei3500CANbus
CommunicationLinkNetwork.
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Telescopic Cranes Pressure Sensing Instruction Manual

1.7 TechnicalData
Accuracy: In accordance with SAE J159 or EN13000
Operating temperature: -20 ºC to + 60 ºC
Supply voltage: 10.2 to 36 VDC (maximum rating)
Display size: 6.25’’ x 8.5’’ x 3’’ (15cm x 21cm x 7.5cm)
Display sealing: IP65
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 Cranes Pressure Sensing Instruction Manual

2.1 NormalModeDisplay(defaultscreen)
DUTY
NUMBER
SLEW
ANGLE
PARTIAL DUTY
DESCRIPTION
(TOGGLE WITH
BUTTON #4)
HOIST:
M:MAIN
A:AUXILIARY
PARTS
OF LINE
(FALLS)
OPERATING
RADIUS
BOOM
LENGTH
SAFE
WORKING
LOAD
(S.W.L)
(RATED
CAPACITY)
HOOK LOAD
BOOM TIP
HEIGHT
BOOM ANGLE
-2-
Detailed description of the display unit
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.
The slew angle indicator (upper left corner of the screen)
is only present when the range limiting option is installed
in the machine.
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Telescopic Cranes Pressure Sensing Instruction Manual

2.2 DisplayButtonsLocationandPurpose
i3500 DISPLAY BOX OVERVIEW
OPERATING
BUTTONS
INTERNAL
BUZER
GRAPHICAL
DISPLAY
WARNING
LIGHTS
OPERATING BUTTONS PRESENTATION
MODEBUTTON
Shows system’s modes. Press this button to choose
one of these operating modes:
-Normal mode
-System Set Up mode
-Diagnostic mode
-Calibration mode (password protected).
HOIST/SCROLLUPBUTTON
Shows hoist menu for selection of the hoist currently
in use. Also used to scroll up through options or to
increase adjustable values.
PARTS/SCROLLDOWNBUTTON
Shows parts of line (falls) menu for selection of the
number of parts currently in use. Also used to scroll
down through options or to decrease adjustable values.
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Telescopic Cranes Pressure Sensing Instruction Manual

HELPBUTTON
This button will show the problem source when a fault
is detected by the system. Press it to see the description
of the problem.
DUTYBUTTON
Shows the menu for the selection of the duty by
number or by crane conguration. Press this button
to enable the selection of crane parameters like the
boom length, the head type and the counterweight, (if
available).
INFOBUTTON
Shows all the information regarding the current crane
conguration. Press it a second time to access the
operating system’s information screen and a third
time to see the data logger screen (option).
BYPASS/RIGGINGBUTTON
Used to enter the rigging mode. (See sections 4.4.7 &
4.4.7.1 for complete details)
TAREBUTTON
Toggles the load display between the actual load
and the tared load.
SELECTBUTTON
Used to select a highlighted item in a menu. In
normal mode, use this button to select the infor-
mation displayed in one of the pull-down menus.
If no menu is opened, used to scroll through the
conguration at the bottom line of the display.
ESCAPEBUTTON
Used to close a menu or to cancel the modication of a
value. Push it several times to return to normal mode.
TESTFUNCTION(Buttons9&10)
Press them simultaneously at any time during normal
operation, to check the functioning of the warnings
(withoutthe need tolift a load),keypad, relays ordisplay.
Note: The crane must not be in overload condition.
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Telescopic Cranes Pressure Sensing Instruction Manual