ROBWAY RCI-4100 Instruction Manual

LSI
-
Robway
Pty L
imited
, 32 West Thebarton Road, Thebarton, South Australia, 5031
Phone: [phone] Fax: [phone]
www.lsirobway.com.au
RCI-4100 Tension-Based System
Operation and Installation
SINGLE / TWIN WINCH
STRUT BOOM CRANE
MAN-1111 Rev H

OPERATION AND INSTALLATION
RCI-4100 SYSTEM
MAN-1111 Rev H ©Copyright 2015 LSI-Robway Pty Ltd
CONTENTS
IMPORTANT SAFETY NOTICES.......................................................................................................................... 9
1. SYSTEM DESCRIPTION................................................................................................................................11
1.1. GENERAL ....................................................................................................................................................11
1.2. CAPABILITIES ..............................................................................................................................................11
1.3. HAZARDOUS AREA ......................................................................................................................................11
1.4. AVAILABLE OPTIONS ...................................................................................................................................11
1.5. REFERENCES ...............................................................................................................................................11
1.6. LIMITED PRODUCT WARRANTY....................................................................................................................12
1.7. INTENDED AUDIENCE...................................................................................................................................12
1.8. PERSONNEL QUALIFICATIONS ......................................................................................................................12
2. INSTALLATION..............................................................................................................................................13
2.1. SETTING UP THE CRANE ...............................................................................................................................13
2.2. POWER SUPPLY ...........................................................................................................................................13
2.3. INSTALLING BOOM COMPONENTS ................................................................................................................13
2.3.1. Boom Angle Sensor (EEx d).................................................................................................................14
2.3.2. Tension Cell Type................................................................................................................................15
2.3.3. Single Sheave Dynamometer with Load Pin .........................................................................................16
2.3.4. Telescopic Boom Length Sensor...........................................................................................................17
2.3.5. Anti-Two-Block (Optional Item)...........................................................................................................18
2.3.6. Cabling (Sensors)................................................................................................................................19
2.3.7. Display Unit (Ex ib).............................................................................................................................20
2.3.8. Hazardous Area Control Unit (if not Safe Area)...................................................................................20
2.3.9. Setting DIP Switches for Cable Length.................................................................................................21
2.3.10. Cable Glands ......................................................................................................................................22
2.3.11. Safe Area Control Unit (if not hazardous area) ....................................................................................22
2.3.12. Cabling Instructions ............................................................................................................................23
2.3.13. Earthing..............................................................................................................................................24
2.4. SWITCH INPUTS ...........................................................................................................................................24
2.5. RELAY OUTPUTS .........................................................................................................................................24
2.5.1. MOTION-CUT OUTPUT RL-1 ............................................................................................................24
2.6. INSTALLING SLEW RING COMPONENTS.........................................................................................................25
2.6.1. Restricted Slew Zone Encoder..............................................................................................................25
2.6.2. Proximity Switch (For optional Restricted Slew Zone feature) ..............................................................26
2.7. INSTALLING WINCH COMPONENTS ...............................................................................................................27
2.7.1. Hook Height Winch Encoder................................................................................................................27
3. OPERATING INSTRUCTIONS......................................................................................................................29
3.1. APPLYING POWER TO THE RCI-4100.............................................................................................................29
3.2. TURNING OFF THE RCI-4100 .......................................................................................................................29
3.3. OPERATING SCREEN ....................................................................................................................................30
3.4. DISPLAY FUNCTIONS ...................................................................................................................................31
3.4.1. ALPHANUMERIC LCD SCREEN AND ALARM LED INDICATORS ...................................................31
3.4.2. 4-DIGIT LCD SCREENS.....................................................................................................................33
3.4.3. ACTIVE WINCH and ATB LED INDICATORS ....................................................................................33
3.4.4. FUNCTION PUSH BUTTONS.............................................................................................................34
3.5. RESTRICTED SLEW ZONE MONITORING –OPTIONAL FEATURE ......................................................................34
3.6. WIND SPEED MONITORING –OPTIONAL FEATURE.........................................................................................34
3.7. WIND DIRECTION –OPTIONAL FEATURE ......................................................................................................34
3.8. GROSS OVER-MOMENT PROTECTION (GOP) –OPTIONAL FEATURE................................................................34
3.9. TILT SENSING -OPTIONAL FEATURE.............................................................................................................35
3.10. HOOK HEIGHT –OPTIONAL FEATURE .......................................................................................................35
4. DATA LOGGING AND DATA DOWNLOADING ........................................................................................37
5. UPLOADING CRANE SOFTWARE USING SD CARD................................................................................39
6. FUNCTION CODE DESCRIPTIONS .............................................................................................................41

OPERATION AND INSTALLATION
RCI-4100 SYSTEM
MAN-1111 Rev H ©Copyright 2015 LSI-Robway Pty Ltd
6.1. EXIT CALIBRATION MODE ...........................................................................................................................41
6.2. MAIN LOAD.................................................................................................................................................41
6.2.1. View Calibrated Main Load.................................................................................................................41
6.2.2. Calibrate Light Main Load ..................................................................................................................41
6.2.3. Calibrate Heavy Main Load.................................................................................................................41
6.3. AUX LOAD ..................................................................................................................................................41
6.3.1. View Calibrated Aux Load...................................................................................................................41
6.3.2. Calibrate Light Aux Load ....................................................................................................................41
6.3.3. Calibrate Heavy Aux Load...................................................................................................................41
6.4. ANGLE ........................................................................................................................................................41
6.4.1. View Uncalibrated Angle Input............................................................................................................41
6.4.2. View Calibrated Angle Input................................................................................................................41
6.4.3. Calibrate Low Angle............................................................................................................................41
6.4.4. Calibrate High Angle...........................................................................................................................42
6.5. LENGTH (TELESCOPIC CRANES ONLY)......................................................................................................42
6.5.1. View Uncalibrated Length Input ..........................................................................................................42
6.5.2. View Calibrated Length Input ..............................................................................................................42
6.5.3. Calibrate Short Length ........................................................................................................................42
6.5.4. Calibrate Long Length.........................................................................................................................42
6.6. VIEW UNCALIBRATED TRANSDUCER 1INPUT................................................................................................42
6.7. VIEW UNCALIBRATED TRANSDUCER 2INPUT................................................................................................42
6.8. OFFSET AND GAIN ADJUSTMENT ...............................................................................................................42
6.8.1. Set Gain and Offset for Channels 1 to 8 ...............................................................................................43
6.9. NUMBER OF SENSOR SAMPLES TO AVERAGE.................................................................................................44
6.10. LOAD CHART VIEW MODE .......................................................................................................................44
6.11. VIEW DIGITAL INPUTS..............................................................................................................................44
6.12. SET YEAR ................................................................................................................................................44
6.13. SET DAY AND MONTH..............................................................................................................................44
6.14. SET TIME.................................................................................................................................................44
6.15. DOWNLOAD LOGGER CONTENTS TO PC OR SD CARD................................................................................44
6.16. ERASE LOGGER CONTENTS.......................................................................................................................45
6.17. ALTER CALIBRATION DATA .....................................................................................................................45
6.18. CLEAR ALL CALIBRATION DATA –USE EXTREME CAUTION!..............................................................46
6.19. MAIN WINCH SLACK ROPE THRESHOLD ...................................................................................................46
6.20. AUX WINCH SLACK ROPE THRESHOLD .....................................................................................................46
6.21. USER VARIABLES (SWL %ALARMS,MOTION CUT)..................................................................................46
6.22. USER VARIABLES (CRANE GEOMETRY) ....................................................................................................46
6.23. USER VARIABLES (DATA LOGGING SETUP PARAMETERS)..........................................................................46
6.24. LOAD /ANGLE CORRECTION ....................................................................................................................46
6.25. MAIN WINCH RIGGING SWL....................................................................................................................47
6.26. AUXILIARY WINCH RIGGING SWL ...........................................................................................................47
6.27. BOOM HEIGHT OFFSET.............................................................................................................................47
6.28. METRIC/IMPERIAL UNITS SWITCHING .......................................................................................................47
6.29. TIME DELAY FOR MOTION CUT RETURN...................................................................................................47
6.30. SLEW ENCODER (IF APPLICABLE) ..............................................................................................................47
6.30.1. View Slew Encoder Raw Counts...........................................................................................................47
6.30.2. Counts per 360deg slewing of crane.....................................................................................................47
6.30.3. Slew Encoder direction........................................................................................................................47
6.31. HOIST ROPE FRICTION COMPENSATION.....................................................................................................47
7. CALIBRATION ...............................................................................................................................................49
7.1. CALIBRATION MODE....................................................................................................................................49
7.1.1. Entering Calibration Mode..................................................................................................................49
7.1.2. Using Calibration Functions................................................................................................................49
7.2. TOOLS/ITEMS REQUIRED FOR CALIBRATION: ................................................................................................50
7.3. MAP OF CALIBRATION (SUGGESTED ORDER): ...............................................................................................50
7.4. CALIBRATION PROCEDURE...........................................................................................................................50
7.4.1. Check/set year, day/month and time.....................................................................................................51
7.4.2. Check / Set the following: ....................................................................................................................51
7.4.3. Configuring User Variables.................................................................................................................51
7.4.4. Verifying Operation of Sensors............................................................................................................51
7.4.5. Calibrating Boom Angle ......................................................................................................................52

OPERATION AND INSTALLATION
RCI-4100 SYSTEM
MAN-1111 Rev H ©Copyright 2015 LSI-Robway Pty Ltd
7.4.6. Calibrating Load on the MAIN Winch (without Friction Compensation)...............................................53
7.4.7. Calibrating Load on the AUX Winch (without Friction Compensation).................................................53
7.4.8. Calibrating Load on the MAIN Winch (with Friction Compensation)....................................................54
7.4.9. Calibrating Load on the AUX Winch (with Friction Compensation) .....................................................54
7.4.10. Using Load/Angle Correction Function................................................................................................55
7.4.11. Set Main Winch Rigging SWL ..............................................................................................................56
7.4.12. Set Aux Winch Rigging SWL ................................................................................................................56
7.4.13. Slew Encoder Operation (If Installed)..................................................................................................56
7.4.14. Testing the Slack Rope Function ..........................................................................................................56
7.5. POST CALIBRATION CHECKS ........................................................................................................................57
8. TROUBLESHOOTING ...................................................................................................................................59
8.1. EXAMPLE PROBLEMS AND POSSIBLE CAUSES................................................................................................60
8.1.1. Problems That Produce Error Codes ...................................................................................................60
8.1.2. Error Codes Summary .........................................................................................................................62
8.1.3. Problems That Do Not Produce Error Codes .......................................................................................63
8.2. PROBLEMS WITH DIGITAL INPUTS,DIGITAL OUTPUTS AND RELAY OUTPUTS..................................................64
8.2.1. Description of Digital Inputs, Digital Outputs and Relay Outputs.........................................................64
8.2.2. What are the inputs and outputs on this crane? ....................................................................................64
8.2.3. Troubleshooting Digital Inputs ............................................................................................................65
8.2.4. Troubleshooting Digital Outputs..........................................................................................................66
Troubleshooting Relay Outputs...........................................................................................................................67
8.3. SENSOR REPLACEMENT................................................................................................................................68
8.4. FUSE REPLACEMENT....................................................................................................................................69
9. INSPECTION ...................................................................................................................................................71
9.1. PRE-INSTALLATION......................................................................................................................................71
9.2. POST-INSTALLATION....................................................................................................................................72
9.3. POST-COMMISSIONING .................................................................................................................................72
9.3.1. Detailed Inspection..............................................................................................................................72
9.3.2. Periodic Inspection..............................................................................................................................73
9.3.3. Visual Inspection from Floor Level ......................................................................................................73
9.4. INSPECTION AND TEST SCHEDULE ................................................................................................................74
10. MAINTENANCE..........................................................................................................................................75
10.1. CHECKLIST ..............................................................................................................................................75
10.2. REMOVAL OF ELECTRICAL EQUIPMENT.....................................................................................................75
10.3. MAINTENANCE WORK IN HAZARDOUS AREAS ..........................................................................................76
10.4. MAINTENANCE WORK IN NON-HAZARDOUS AREAS ..................................................................................76
10.5. MODIFICATION OR REPAIR .......................................................................................................................76
10.6. INSPECTION AFTER MAINTENANCE ...........................................................................................................76
10.7. RECORDS.................................................................................................................................................76
10.8. PRINTED CIRCUIT BOARD (PCB) HANDLING .............................................................................................76
10.9. CUFRCI4100 FLAMEPROOF CONTROLLER MATING SURFACES PRECAUTIONS ...........................................76
11. GENERAL SPECIFICATIONS...................................................................................................................77

OPERATION AND INSTALLATION
RCI-4100 SYSTEM
MAN-1111 Rev H ©Copyright 2015 LSI-Robway Pty Ltd
LIST OF APPENDICES
APPENDIX A, Safety and Installation Instructions, Model 4120 RCI-4100IS Display Barrier 81
APPENDIX B, Declaration of Conformity, RCI-4100IS Hazardous Area Rated Capacity Indicator System 93
APPENDIX C, ATEX EC Type-Examination Certificate 101
APPENDIX D, IECEX Certificate of Conformity, Display Module Type RCI-4100IS 105
APPENDIX E, IECEX Certificate of Conformity, Model 4120 Power Supply and I2C Barrier 109
APPENDIX F, Data Logging 113
APPENDIX G, Cable Gland Installation Instructions 127
APPENDIX H, Restricted Slew Zone Monitoring Option 131
APPENDIX I, Wind Speed Monitoring Option 139
APPENDIX J, Wind Direction Monitoring Option 143
APPENDIX K, Automatic Gross Overload Option 149
APPENDIX L, Tilt Sensing Option 157
APPENDIX M, Hook Height DISRCI4100 Display Option 163
APPENDIX N, System Drawings 169
APPENDIX O, Hook Height and Winch Speed RCI1550 Display Option 181
ATTACHMENTS, RCI System Configuration Documents
VERSION HISTORY
Version Issue Date Description
A (not issued) Initial draft
B 25Oct11 Minor formatting changes
C 17Feb12 Sect 4.4.1 FLASHING changed to ON. LED trip point thresholds described as
typical with reference to function codes. Removed specific Function code
references from body. Sect 8.3 Sensor replacement added. Datalogging Appendix
F, miscellaneous updates.
D 28May12 RCI-4100 Declaration of Conformity updated to RCI-4100 Declaration Rev G.
E 20Aug12 Revised Sections 2 to 8. Added Appendices J and H. Various minor changes.
RCI-4100 Declaration of Conformity updated to Rev H. RF Transmitter Caution
added.
F 14Jan14 Company Name Change
G 27 Jan 15 Minor edits for errata
H 27 Feb 15 Winch Speed and Hook Height Appendix added
Friction compensation information added

OPERATION AND INSTALLATION
RCI-4100 SYSTEM
MAN-1111 Rev H ©Copyright 2015 LSI-Robway Pty Ltd Page 9
Important Safety Notices
Notes, Cautions and Warnings are presented to aid in understanding and operating the equipment or
to protect personnel and equipment. At all times relevant codes applicable to location of service must
be adhered too.
A “Note” is an advisory or illustrative statement and does not contain any mandatory statements.
A “Caution” is used where non-compliance with text may result in damage to equipment.
A “Warning” is used where non-compliance with text may result in injury to, or death of, personnel.
NOTE: This Rated Capacity Indicator is fitted to assist the crane operator. This Rated
Capacity Indicator is not a substitute for operator judgement, experience or safe crane
operation. At all times the driver is ultimately responsible for safe crane operation.
The operator should, prior to operation of the crane, read this manual carefully and
thoroughly and shall ensure that all operational instructions and warnings are
understood and complied with.
Proper system operation requires the operator to select the proper crane setup and
working configuration
WARNING: THE RCI-4100IS SYSTEM IS INTENDED FOR USE IN A GROUP IIB ZONE 1
EXPLOSIVE GAS ATMOSPHERE.
WARNING: THE RCI-4100 SYSTEM IS A CRANE DEVICE WHICH WARNS THE
OPERATOR OF IMPENDING OVERLOAD CONDITIONS AND OVER-HOIST
CONDITIONS WHICH COULD CAUSE DAMAGE TO PROPERTY, CRANE
AND PERSONNEL.
PROVIDED WARNINGS ARE NOT EXCLUSIVE, AS LSI-ROBWAY COULD
NOT POSSIBLY KNOW, EVALUATE AND ADVISE SERVICE PEOPLE OF
ALL CONCEIVABLE WAYS IN WHICH SERVICE MIGHT BE PERFORMED OR
ALL POSSIBLE ASSOCIATED HAZARDOUS CONSEQUENCES.
ACCORDINGLY, ANYONE WHO USES SERVICE PROCEDURES OR TOOLS
WHICH ARE NOT RECOMMENDED BY LSI-ROBWAY MUST FIRST SATISFY
THEMSELVES TO THEIR SUITABILITY AND THAT EITHER PERSONNEL
SAFETY OR EQUIPMENT SAFETY WILL BE JEOPARDISED BY THE
SELECTED METHOD.
CAUTION: SAFE, RELIABLE OPERATION OF LSI-ROBWAY SYSTEMS REQUIRES THE
SYSTEMS TO BE MAINTAINED IN A PROPER MANNER AND SERVICED BY
TECHNICALLY TRAINED PERSONNEL USING TRADE (OR PROFESSION)
RECOGNISED SERVICE PROCEDURES AND CORRECT TOOLS FOR THE
PURPOSE.

OPERATION AND INSTALLATION
RCI-4100 SYSTEM
MAN-1111 Rev H ©Copyright 2015 LSI-Robway Pty Ltd Page 10
CAUTION: THE SYSTEM IS EQUIPPED WITH AN OVER-RIDE WHICH BYPASSES
ALARMS AND MOTION CUT FUNCTION AT WHICH TIME THE SYSTEM CAN
NO LONGER WARN OF IMPENDING OVERLOAD AND MUST ONLY BE
OPERATED STRICTLY IN ACCORDANCE TO THE CRANE
MANUFACTURER’S SETUP AND OPERATION PROCEDURES. OPERATION
OF THIS KEY IS FOR AUTHORISED PERSONNEL ONLY WHO SHALL BE
SOLELY RESPONSIBLE FOR ITS USE.
CAUTION: MOTION LIMITERS MAY HAVE BEEN FITTED TO STOP THOSE FUNCTIONS
THAT WILL INCREASE RADIUS AND HOIST-UP IF THE LOAD-CHART IS
EXCEEDED. THIS FEATURE IS PROVIDED AS AN AID TO SAFER CRANE
OPERATION.
IN CERTAIN SITUATIONS, SUCH AS CRANE SETUP, THE CRANE
OPERATOR MAY NEED TO ‘OVER-RIDE’ THE MOTION LIMITERS. AT
THESE TIMES, THE SYSTEM CAN NO LONGER WARN OF OVERLOAD AND
THE CRANE MUST ONLY BE USED IN STRICT ACCORDANCE TO THE
CRANE MANUFACTURER’S SETUP AND OPERATION PROCEDURES.
PROPER SYSTEM OPERATION REQUIRES THE OPERATOR TO
CORRECTLY PROGRAM THE LSI-ROBWAY SYSTEM TO MATCH CRANE
SETUP AND WORKING CONFIGURATION.
CAUTION: HIGH TENSILE BOOMS REQUIRE PROPER WELDING PROCEDURE
SPECIFICATIONS. OBTAIN SPECIALIST ASSISTANCE WHEREVER
APPLICABLE.
CAUTION: RADIO FREQUENCY EMITTING EQUIPMENT SHOULD NOT BE PLACED
NEAR THE RCI-4100 CONTROLLER, DISPLAY, CABLING OR SENSORS AS
IT MAY CAUSE INTERFERENCE DEPENDING ON THE TYPE, POWER
OUTPUT AND OTHER CHARACTERISTICS OF THE EQUIPMENT.