RaycoWylie i4000 User manual

Instruction Manual
i4000
Multifunction indicator/range limiting device
For Lattice crane
Copyright © 2018
RaycoWylie Systems
All rights reserved.
Wylie Systems
(Rayco Technology Group)
201 Prospect Avenue
Suite 106 - Box 159
Hagerstown, MD 21742
USA
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]
55M4000EBE00 Rev C
Crane Warning Systems Atlanta
6175 Hickory Flat Hwy Suite #110-376
Canton, GA 30115
877-672-2951 Toll Free
678-261-1438 fax
www.craneindicators.com
[email protected]

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i4000 Lattice Crane Instruction Manual
55M4000EBE00 Rev C
is manual provides users with the essential operating procedures for the good functioning
of the machine and its intended use. We cannot stress strongly enough the need to use this
system correctly. Make sure you have read and understood all the information included in
this manual before operating the machine.
Since the manufacturer has no direct control over the machine’s use, it is the user’s and the
personnel’s responsibility to comply with good safety practices. All procedures dealt with in
this manual are based on appropriate operating conditions which do not depart from the
intended use of the system. It is strictly forbidden to alter or modify the equipment without
written authorization from RaycoWylie Systems.
e i4000 system by RaycoWylie Systems (Multifunction indicator) is purely an aid to the
operator. When the parameters are correctly set, the indicator warns the crane operator of a
potential overload which could endanger the equipment or the goods, and cause injuries to
the operator or the workers who are close to the crane and its load.
is system must not be used as a substitute for the operator’s sound judgement while
performing tasks with the liing equipment. e operator is responsible for the safe operation
of the liing equipment. If the liing equipment is not correctly congured, the system may
not warn about possible damages due to an overload or other similar cause.
Before handling a crane equipped with a RaycoWylie multifunction indicator, the operator
mustreadcarefullythismanualandtheoperations manualprovided bythecranemanufacturer.
He must also be aware of all the national, state, or local safety standards and regulations
applicable to his work. e adequate functioning of the system requires a daily inspection.
Any apparent failure or damage must be immediately reported to the responsible person in
charge before operating the crane.

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i4000 Lattice Crane Instruction Manual
55M4000EBE00 Rev C
Since the personnel’s safety and the appropriate use of the machinery are a priority,
dierent symbols are used in this manual to highlight important points.
e following denitions indicate the level of risk each symbol represents. Each
time you see one of these symbols in this manual, the operator’s safety or the
machinery’s integrity are concerned.
Please take your time to read and understand these denitions!
NOTE: PROVIDES INFORMATION WHICH CAN BE OF
SPECIAL INTEREST.
DANGER: INDICATES A POTENTIALLY DANGEROUS
SITUATION WHICH, IF NOT AVOIDED, COULD RESULT
IN A PERSON’S DEATH OR IN SIGNIFICANT DAMAGE
TO THE MACHINERY.
ATTENTION: INDICATES A POTENTIALLY DANGEROUS
SITUATION WHICH, IF NOT AVOIDED, COULD RESULT
IN MINOR OR MODERATE DAMAGES. IT CAN BE USED
TO WARN ABOUT UNSAFE PRACTICES.
IMPORTANT: INDICATES A SITUATION WHICH COULD
DAMAGE THE MACHINERY.

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i4000 Lattice Crane Instruction Manual
55M4000EBE00 Rev C
CONTENTS
Warning page 5
1 GENERAL DESCRIPTION OF THE SYSTEM page 13
1.1 Introduction page 13
1.2 Operator skill page 13
1.3 Usefulness of the i4000 system page 13
1.4 Description of the i4000 system page 14
1.4.1 Audible alarm page 15
1.4.2 Visual alarm page 15
1.5 Location and description of typical components page 16
1.6 Overall scheme page 17
1.7 Technical information page 18
2 DETAILED DESCRIPTION OF THE DISPLAY UNIT page 19
2.1 Navigating the normal mode of operation page 19
2.2 Indicator tab page 20
2.3 Load tab page 21
2.4 Range limiting device tab page 22
2.5 Tools tab page 22
2.6 Overview of the display unit page 23
2.7 Description of operation keys page 24
2.8 Warning lights and messages page 25
2.8.1 Overload warnings page 26
2.8.2 Anti-two block and rope limit indicators page 27
3- INSTALLATION AND CALIBRATION page 29
4- OPERATING INSTRUCTIONS page 31
4.1 Safety recommendations page 31
4.2 Residual risks page 32
4.3 Power-up page 33

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i4000 Lattice Crane Instruction Manual
CONTENTS
4.4 System in CONFIGURATION mode page 34
4.4.1 Access the Conguration menu page 34
4.4.2 Selecting the Measuring unit page 35
4.4.3 Selecting the Language page 36
4.4.4 Selecting the Light intensity page 37
4.4.5 Adjust system time and date page 38
4.5 System in LIFTING mode page 39
4.5.1 Selecting crane conguration page 39
4.5.2 Selecting the liing hoist page 40
4.5.3 Adjusting the hoist’s parameters page 41
4.5.3.1 Maximum load allowed page 41
4.5.3.2 Number of parts of line page 42
4.5.4 Dening or removing the zero setting mode (tare) page 43
4.5.5 Bypassing a lockout page 44
4.6 System in ABSOLUTE LIMITING mode page 46
4.6.1 Accessing the absolute limiting adjustment mode page 47
4.6.2 Activating or deactivating an absolute limit page 47
4.6.3 Adjusting an absolute limit value page 48
4.7 RANGE LIMITING mode warnings page 49
4.7.1 Range limiting option page 50
4.7.2 Accessing the range limiting adjustment menu page 50
4.7.3 Height limit page 51
4.7.4 Free zone page 52
4.7.5 Variable height limit page 53
4.7.6 Variable radius limit page 55

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i4000 Lattice Crane Instruction Manual
55M4000EBE00 Rev C
CONTENTS
5- DIAGNOSTIC AND MAINTENANCE page 58
5.1 Diagnostic menu page 58
5.2 Angle sensor page 60
5.3 Load sensor page 61
5.4 Detected addresses page 61
5.5 Error messages page 62
5.5.1 Internal peripherals page 62
5.5.2 External peripherals page 63
6- INSPECTION AND MAINTENANCE page 66
6.1 Frequent inspections page 66
6.2 Periodic inspections page 66
6.3 Checking the displayed load page 67
6.4 Maintenance page 68
6.5 Maintenance procedure page 69
6.6 Adjustments and repairs page 70

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-1-
General description of the system
1.2 Operator skill
1.3 Usefulness of the i4000 system
e i4000 system is designed to aid the crane operator by indicating the machine’s parameters
which require special attention. If it is correctly calibrated, congured and operated, the i4000
system should work to prevent the crane from liing a load in excess of the nominal load
authorised for the crane or the liing rope.
is manual contains information regarding the operation, troubleshooting, and maintenance
procedures of the i4000 system. Please make sure you respect the safety rules currently in force
in the country where you are using the i4000 system, in order to reduce the risk of injuries or of
damages to the machinery. Please consider each safety directive mentioned in this manual when
using the i4000 system. is manual will help qualied personnel use the system and perform
its maintenance.
1.1 Introduction
The i4000 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
arithmetic 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 i4000 is not a Rated Capacity Indicator (RCI). The
displayed % represents the limit set by the operator rather
than the maximum lifting capacity established by the crane
manufacturer.

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i4000 Lattice Crane Instruction Manual
e i4000 « Multifunction indicator» is a computerized system designed to provide the operator
with the necessary information to operate the crane safely, and within the nominal load limits
authorized by the crane manufacturer.
e indicator works by indicating to the operator the load applied to the crane, so that he may
compare this load with the nominal load authorized for each liing position.
e system’s display unit provides the operator
continuous information regarding the crane’s
current load. It also warns the operator whenever
he approaches or exceeds the maximum load limit.
e system includes sensors installed on the crane
that measure or verify:
•the weight on the hook,
•the boom angle (optional),
•the boom length (optional),
•the position of the A2B block (optional).
When the above options are included, the system uses the information provided by the sensors
to calculate the operational radius, allowing the operator to assess the crane’s current capacity,
and to verify the overload conditions.
A rotation sensor (optional) can also be installed to measure the boom position within 360
degrees and provide the operator with additional information.
e system display is located inside the cabin, close to the operator controls for easy access to the
information. All sensors are connected through a CAN bus network.
e allowed capacity is assessed by the operator. With the measures provided by the i4000 system,
he will be able to identify the allowed load in the manufacturer’s chart.
e actual load is expressed as a percentage of the allowed capacity. is becomes the nominal
load or ‘safe working load’ - % SWL. If this percentage exceeds a predetermined value, the
alarms and safety functions will be activated.
e crane’s parameters and calibration data will be saved in a separate non-volatile memory.
1.4 Description of the i4000 system

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i4000 Lattice Crane Instruction Manual
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If you are wearing hearing protectors or
headphones during lifting operations, make sure
they do not impair your ability to hear the sound
alarms of the i4000 system.
1.4.2 Visual alarm
e i4000 system display has been equipped with a 3-colour warning light to alert the operator
and to indicate a specic action.
e ashing yellow light turns on together with the sound alarm when the load reaches the
approach alarm’s threshold, that is, 90% of the nominal capacity.
e light turns red when 100% of the nominal capacity is reached or exceeded.
is light is green under normal operating conditions.
1.4.1 Audible alarm
An intermittent audible alarm within the display unit warns the crane operator that
an intervention is necessary before the load reaches its nominal value. e default
threshold for the approaching alarm is 90% of the nominal capacity. e overload
alarm is activated continuously when 100% of the nominal capacity is reached or exceeded. e
crane operator will also be warned by the internal audible alarm when approaching or reaching
a limit that he had already dened.
WARNING LIGHT
YELLOW REDGREEN
e approach and overload alarm settings can be modied according to the user’s
preferences.

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i4000 Lattice Crane Instruction Manual
1. e i4000 display unit: It is also the central unit of the i4000 system. Its main characteristics
are the bus CAN communications interface and the liquid-crystal graphic display.
2. e central input/output interface: is relay interface module is connected to individual
external input and output devices controlled by the i4000 system (optional).
3. Load sensor: A load sensor is used in order to calculate the load on the hook. It is generally
integrated into a dynamometer installed on the liing rope.
4. Angle sensor: An angle sensor is used in order to measure the boom angle.
5. Limit switch (A2B) e limit switch helps to prevent the pulley block from colliding with
the boom head pulley (optional).
6. Wind speed sensors (anemometer) ey show the wind speed on the display unit screen
(optional).
1.5 Location and description of typical components

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i4000 Lattice Crane Instruction Manual
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1.6 Overall scheme

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i4000 Lattice Crane Instruction Manual
1.7 Technical information
Accuracy: In accordance with SAE J159
Operating temperature: -20°C to +60°C
Power supply: 9-32 VDC (maximum power supply)
Display unit dimensions: 3.5’’ Crystal liquid screen (320 x 240)
Display unit protection: IP67
Bus CAN interface/ sensors: Default quantity Maximum quantity
-Load or pressure sensors 1 2
-Angle or length sensors 1 1
- Relay output 1 1
- Rotation sensor 1 1
- Possibility of additional sensors YES
- Radio Module 0 1

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Detailed description of the display unit
2.1 Navigating the normal mode of operation
e normal mode of operation of the i4000 system is organized into four separate screens. We
call it “tabs”. Use the le or right arrow keys to navigate in these tabs.
ere are:
1) the indicator tab
2) the load tab
3) the range limiting tab
4) the tools tab
INDICATOR
TAB
LOAD
TAB
RANGE LIMITING
TAB
TOOLS
TAB
USE THE LEFT OR RIGHT
ARROW BUTTONS TO
CHANGE TABS

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i4000 Lattice Crane Instruction Manual
Some mini-dials are only displayed if the corresponding sensor is installed.
e parameter indicating the boom tip height should only be used as a guide and
NOT as an indicator of whether the crane may pass or not underneath a structure
whose exact height is known.
2.2 Indicator tab
It allows the display of multiple sensors, providing a good overview of the crane during operation.
RADIUS SLEW ANGLE*
BOOM ANGLE BOOM
LENGTH
PARTS OF
LINE
BOOM TIP
HEIGHT
ALARMS
WEIGHT ON
HOOK
MAIN
OR
AUXILIARY (AUX)
BOOM