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LSI-Robway RCI-1502 LM Instruction Manual

Strut boom system
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RCI-1502 LM Strut Boom System
Instruction Manual
MAN-1072 Rev D
LSI-Robway Pty Limited, 32 West Thebarton Road, Thebarton, South Australia, 5031
Phone: +61 8 8238 3500 Fax: +61 8 8352 1684
www.lsirobway.com.au

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  • Page 1 RCI-1502 LM Strut Boom System Instruction Manual MAN-1072 Rev D LSI-Robway Pty Limited, 32 West Thebarton Road, Thebarton, South Australia, 5031 Phone: +61 8 8238 3500 Fax: +61 8 8352 1684 www.lsirobway.com.au...

  • Page 3: Table Of Contents

    5.5 Calibrating Load for Active Winch ............ 27 5.5.1 Calibrating Active Winch............. 27 5.6 Copying & Restoring Calibration Data Function ......28 6. Troubleshooting ....................34 7. Electrical Specifications .................. 40 8. Appendices ....................... 42 RCI-1502 LM Strut Boom Manual...

  • Page 5: Important Safety Notice

    Operation of this key is for authorised personnel only who shall be solely responsible for its use. RCI-1502 LM Strut Boom Manual...

  • Page 6: General Description

    Visual and audible alarms on warning (approach to overload), overload, motion-cut, two-blocking detection, and error detection, • Self-diagnosis and error codes, • Data-logging, • Built-in calibration and fault-finding tools, • Units conversion (imperial/metric) facility, • Anti-two-block (overhoist limit) facility. RCI-1502 LM Strut Boom Manual...

  • Page 7: Operating Instructions

    3.2. Turning OFF the RCI-1502 The unit will stop working as soon as the power is removed from it by switching off any of the switches indicated in Section 3.1 above. RCI-1502 LM Strut Boom Manual...

  • Page 8: Operating Screen

    Units in Use (OFF = Metric & ON = Imperial) Winch Select Setup/Cancel Test/Enter Button Button Button for Use (Pressing Test will Restart (Main or Aux) in Calibration the System; Enter is Used in Mode Calibration Mode) RCI-1502 LM Strut Boom Manual...

  • Page 9: Display Functions

    The numerical display shows the current maximum safe working load in unit selected (kilopounds or tonnes). The S.W.L. will depend on the current crane configuration (duty), winch selected (if twin winch), the maximum linepull and the falls selected. RCI-1502 LM Strut Boom Manual...
  • Page 10 When the ACTUAL LOAD exceeds the SWL for the current crane configuration the RCI-1502 will activate audible and visual alarms. RCI-1502 LM Strut Boom Manual...

  • Page 11: Data Logging And Data Downloading

    No. CABCOM 1261) between the RS-232 socket at the back of the RCI-1502 display and the PC. Please refer to Section 8.1. “DATA LOGGING ON RCI SYSTEMS” at the rear of the manual for usage information and details. RCI-1502 LM Strut Boom Manual...

  • Page 13: Installation

    Electronic angle sensor and typical installation at the boom butt section Load Sensor The lifted load is calculated from monitoring the total forward moment force of the boom and deducting the luffing effects of the boom (and fittings) dead- weight. RCI-1502 LM Strut Boom Manual...
  • Page 14 (when suspended from the switch) can be fitted to the static hoist rope below the rope anchor. Check that the switch works correctly as the boom luffs throughout its working range. RCI-1502 LM Strut Boom Manual...
  • Page 15 Dow Corning 4 “Electrical Insulating Compound” or any similar compound) on the plugs and sockets prior to connecting the cables. The silicone grease should be smeared across the connector contact points to increase the water proofing of the connector. RCI-1502 LM Strut Boom Manual...
  • Page 16 The switch will convey a signal to the display when the crane moves into a zone of different capacity rating. The RCI- 1502 system can interface with up to three switches maximum. RCI-1502 LM Strut Boom Manual...
  • Page 17 Relay Terminal No. Contact Output Description Normally Open Common Normally Closed The lockout solenoids on cranes are normally energised when crane is in safe condition (no alarm) and are de-energised when a motion cut condition occurs. RCI-1502 LM Strut Boom Manual...
  • Page 18 The Switchbox has a spare gland for motion cut cable entry. Please note that the motion cut cable is not supplied with the RCI-1502 System as a standard component. Drawing Reference: DWG 3336 – “RCI-1502 Switchbox V2 Wiring Diagram” RCI-1502 LM Strut Boom Manual...

  • Page 19: Calibration

    A notepad to record results, • Software configuration sheets and function codes list (please see Section 8.3. “Function Codes” provided at the back of this manual), • Known test weights to verify accuracy of load calibration. RCI-1502 LM Strut Boom Manual...
  • Page 20 (F-40) and all settings mentioned above. Refer to Section 5.6. “Copying & Restoring Calibration Data Function” for details and procedures. Copy also the K1 and K2 values on function codes (F-37, F-38). RCI-1502 LM Strut Boom Manual...

  • Page 21: Verifying Operation Of Sensors

    To turn a channel back on, you have to re-enter the same VIEW UNCALIBRATED... function and press the ENTER key again. Remember that you must always end a view function by pressing the CANCEL key. RCI-1502 LM Strut Boom Manual...

  • Page 22: Configuring User Variables

    This is useful when just verifying accuracy of the load readout and the calibration has not yet been finalised. 5.2.3. Calibrate Load for Active Winch (F-02) Please see Section 5.5. “Calibrating Load for Active Winch” for details. RCI-1502 LM Strut Boom Manual...
  • Page 23 (transducer 2). Please also Section 5.1. “Verifying Operation of Sensors” for details. 5.2.13. Function Codes (F-20 to F-22) – If Using Two Load Trasnducers These function codes are the same as function codes (F-16 to F18) but for the second transducer (transducer 2), if installed. RCI-1502 LM Strut Boom Manual...
  • Page 24 “00” (hidden). The seconds will begin incrementing once the OK button is pressed. 5.2.22. Download Logger Contents to PC (F-35) Please see Section 8.1. “Data Logging on RCI Systems” at the rear of the manual for details. RCI-1502 LM Strut Boom Manual...
  • Page 25 Visual and Audible Alarms as well as the Motion Cut control output. The preset or factory default values are based on standard safe parameter settings and may be used. These values can be edited and changed using these functions codes to suit requirements. RCI-1502 LM Strut Boom Manual...
  • Page 26 Please refer to Section 8.3. “Function Codes” at the rear of this manual for the applicable set of codes. Two sets of codes have been provided in Section 8.3. One is for Single Winch cranes and the other is for Twin Winch cranes. RCI-1502 LM Strut Boom Manual...

  • Page 27: Calibrating Boom Angle

    Verify that the boom angle is accurately measured by using function code (F-08) VIEW BOOM ANGLE. Luff the boom and stop on different boom angle points. Check boom angle with the Angle Finder and verify accuracy against the displayed angle. RCI-1502 LM Strut Boom Manual...

  • Page 28: Calibrating Low End & High End Of Transducer/S

    3 mV/V - 327 • Once set, screw the back cover in place, ensuring that any wires coming out from the enclosure are firmly placed back in position inside the enclosure before tightening the screws. RCI-1502 LM Strut Boom Manual...

  • Page 29: Calibrating The Low End Of Transducer 1

    If using two force transducers, repeat above procedures 5.4.2. and 5.4.3. using function code F-21 (Calibrate Low End of Transducer 2) and editing item “tr2” on F-40 (Alter Calibration Data). RCI-1502 LM Strut Boom Manual...

  • Page 30: Calibrating Load For Active Winch

    (or “0.0” if the hook weight is part of the crane, refer to crane manufacturer’s load chart). • Repeat above procedures on all Duties (crane configurations) used. This requires physically setting up the crane to the duty to be calibrated. RCI-1502 LM Strut Boom Manual...

  • Page 31: Copying & Restoring Calibration Data Function

    Load 2 Down 7. Only the “highlighted” items above must be copied (note: “tr2” must only be copied if using two transducers). To copy an item, select the item and press the ENTER key. RCI-1502 LM Strut Boom Manual...
  • Page 32 13. Press CANCEL key to return to the item An1 screen. 14. Select the next item, tr1, and repeat above procedures 6 to 13. Select and repeat the same on tr2 if two force transducers are used. RCI-1502 LM Strut Boom Manual...
  • Page 33 Dallas memory chip has been replaced with a new one). 17. To fully restore calibration data, K1 and K2 load moment calibration values must also be copied. Refer to Section 5.2.24. “Set K1 & K2 Values” for details and procedures. RCI-1502 LM Strut Boom Manual...
  • Page 34 ENTER key. 8. In the example shown, the default item An1 has been selected. Press the ENTER key while on the selected item (e.g. An1) to activate the Edit Codes. RCI-1502 LM Strut Boom Manual...
  • Page 35 12. Use the Up/Down Arrow keys to change the Lo_r value with the previously copied data. 13. Press the ENTER key to store this new value to Lo_r (e.g. from 128 to 109 as shown in this example). RCI-1502 LM Strut Boom Manual...
  • Page 36 (if using two transducers) 19. To fully restore calibration data, K1 and K2 load moment calibration values must also be restored. Refer to Section 5.2.24. “Set K1 & K2 Values” for details and procedures. RCI-1502 LM Strut Boom Manual...

  • Page 37: Troubleshooting

    Display Unit. If the calibration has been done incorrectly, or the configuration is incorrect, or something else is wrong, then the Display Unit readouts (e.g. the LOAD or ANGLE values) may provide you with misleading information. RCI-1502 LM Strut Boom Manual...
  • Page 38 Be systematic - make notes about what you have done and what you found. You will find that under pressure you can easily forget what you have checked and it becomes very easy to miss things. RCI-1502 LM Strut Boom Manual...
  • Page 39 The load cell is disconnected or there is an open circuit in one of the signal wires. • The signal - is connected to the shield. • The signal + and the excitation + are swapped. • The signal - and the excitation - are swapped. RCI-1502 LM Strut Boom Manual...
  • Page 40 This is indicating that the rated line pull has been exceeded. Possible causes: • A genuine line pull error exists. • The number of falls selected is incorrect for the load being lifted, or does not match the actual falls reeved. RCI-1502 LM Strut Boom Manual...
  • Page 41 This is indicating that the radius being measured is outside of its allowed range. Possible causes: • A genuine violation of the radius limits has occurred. • Wrong duty selected. • Check as per Error code 301. RCI-1502 LM Strut Boom Manual...
  • Page 42 ENTER button. The display will show “YES” to confirm. While “YES” is shown on the screen, press the ENTER button again until the display gets into the normal initialisation/ set-up routine and then to normal operating mode. RCI-1502 LM Strut Boom Manual...

  • Page 43: Electrical Specifications

    200 - 400 Ω Red - White Black - Green 200 - 400 Ω Black - White 200 - 400 Ω White - Green 350 Ω ± 2 Ω Shield/Screen to any other wire must be open circuit RCI-1502 LM Strut Boom Manual...
  • Page 44 V90-HT PVC (designed to comply to AS/NZ 3808:2000) Electrical Life: operations Cable Integrity: All cores tested for insulation resistance @ test voltage of 500V Sheath: Overall 5V90 UV stabilised PVC Current Rating: 3 amps Capacitance: 150 pf/m (core to core) RCI-1502 LM Strut Boom Manual...
  • Page 45 Appendix 8.1. Data Logging on RCI Systems...
  • Page 47 Data Logging on RCI Systems Introduction The RCI System Logging occurs automatically whenever the driver lifts a load OR whenever the RCI System detects an error condition on the crane such as moving outside the load chart. The installer has the option to set the percentage of SWL a load must reach before the load will be logged.
  • Page 48 Data Logging on RCI Systems A summary of the logging percentage Function Codes is displayed in the following table: Function Code Name Description Default Setting Low Load Lift counter swl percentage to record 20.0% Medium Load Lift counter swl percentage to record 40.0% High Load Lift counter swl percentage to record...
  • Page 49 Data Logging on RCI Systems The first two Function codes in the table are used for determination of a stable load. When a load is hoisted it is probable that the initial load reading will be greater than the actual load on the hook because of the "snatching effect". The stable load is recorded only when these dynamic factors have died down and the load can be considered to be hanging from the hook in a relatively motion free position.
  • Page 50 Data Logging on RCI Systems • load monitoring continues, the SWL percentage is continually checked against the SWL percentage which was stored, if the percentage increases, a new stable load will be recorded. A log cycle is completed when: • the current SWL % drops below the THRESHOLD for a period of time set by the Reset Time Function Code •...
  • Page 51 Data Logging on RCI Systems Example Load Lift Suppose a driver lifts a load and luffs out. If we assume the SWL % generated at the edge of the load chart is sufficient to cause a log to record then as soon as the driver exceeds the maximum radius on the chart, the active log cycle completes and is written to the logger prior to beginning an "out-of-chart"...
  • Page 52 Data Logging on RCI Systems Example Lift Cycles...
  • Page 53 Data Logging on RCI Systems Accessing the Data Logger When the RCI System is powered on the normal check routines are performed. If your display has logging enabled then the percentage of the logger which is full is displayed on start up in the LOAD window. The display will show the prompt "=LE="...
  • Page 54 Data Logging on RCI Systems Downloaded Data Format Each record will be printed in chronological order followed by a summary on the contents of the data logger. If no records have been stored a message to this extent is displayed on the RCI calibration window however, the summary information is still downloaded to the PC.
  • Page 55 Data Logging on RCI Systems Downloading of the logger can be performed any number of times without affecting the contents of the logger. Generally however, after downloading is performed, it is normally desirable to erase the contents of the logger. Downloading takes approximately 15 seconds per 100 records.
  • Page 56 Data Logging on RCI Systems Errors in Logger Data On powering the display the contents of the data logger is checked in three separate operations. In 99% of cases these checks will all pass OK. If however a check fails the state of the logger is immediately questionable.
  • Page 57 Appendix 8.2. Drawings DWG 2465 RCI-1502 General Arrangement for Typical Strut Boom Load Moment System DWG 0279 Dimensional Drawing, RCI-1502 Display DWG 2459 Dimensional Detail, RCI-1502 Switchbox DWG 3336 RCI-1502 Switchbox (Version 2) Wiring Detail DWG 1244 RCI Series Cable Connections DWG 1099 Electronic Angle Sensor, Dimensional Drawing DWG 0990...
  • Page 72 Robway Safety Systems WA 88153 2004-11-04 YZ Page 1 of 3 RCI-1502 CALIBRATION PROCEDURE FOR LOAD MOMENT SYSTEMS WITH USER CONFIGURABLE OPTIONS Turn the OVER-RIDE key on, Press and hold SETUP until F-xx appears on top digital display, ( where xx is the code for last calibration function ) Use UP/DOWN keys to select function then press ENTER to accept, Use UP/DOWN keys to set new value then press ENTER to accept, Repeat steps 2 and 3 for any other functions if required,...

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