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LSI-Robway RCI-1502 LM Instruction Manual

Telescopic boom system
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RCI-1502 LM Telescopic Boom System
Instruction Manual
MAN-1074 Rev G
LSI-Robway Pty Limited, 32 West Thebarton Road, Thebarton, South Australia, 5031
Phone: +61 (0) 8 8238 3500 Fax: +61 (0) 8 8352 1684
www.lsirobway.com.au

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Paul Tolnga
May 11, 2025

Steps for calibrating 30 tone crane

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1 comments:
Mr. Anderson
May 20, 2025

The steps for calibrating the LSI-Robway RCI-1502 LM 30-ton crane are:

1. Select the correct Duty, Falls, and Winch for the crane setup.
2. Luff the boom down to the lowest boom angle allowed by the load chart; wait until the hook block and boom are stable.
3. Enter calibration mode and select function code F-02 “Calibrate Load for Active Winch”.
4. Enter the weight of the empty Main block (or “0.0” if the hook weight is part of the crane), then press ENTER.
5. When the screen shows “HI”, luff the boom up slowly to just before the boom stops; keep it stable for about 10 seconds, then press ENTER.
6. Exit calibration mode.

For boom length calibration:

1. Calibrate Section 1 at fully retracted (e.g., 10.0 m).
2. Calibrate Section 16 at fully extended (e.g., 25.0 m).
3. Test load accuracy across the extension range.
4. If needed, calibrate additional sections, halving the distance each time (e.g., at 17.5 m for mid extension).

Additional system checks:

1. Set date and time (F-32 to F-34).
2. Ensure raw counts are within 33–999 (F-07, F-15, F-19 if two load sensors).
3. Review crane geometry (F-45 to F-60).
4. Check SWL % parameters (F-42 to F-44).
5. Review data logger points (F-61 to F-67).
6. Set measurement units using F-69 (Single Winch) or F-70 (Twin).

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Summary of Contents for LSI-Robway RCI-1502 LM

  • Page 1 RCI-1502 LM Telescopic Boom System Instruction Manual MAN-1074 Rev G LSI-Robway Pty Limited, 32 West Thebarton Road, Thebarton, South Australia, 5031 Phone: +61 (0) 8 8238 3500 Fax: +61 (0) 8 8352 1684 www.lsirobway.com.au...

  • Page 3: Table Of Contents

    Contents Page No. 1. Important Safety Notice ................... 3 2. General Description ..................4 3. Operating Instructions..................5 3.1. Turning On the RCI-1502..............5 3.2. Turning Off the RCI-1502 ..............5 3.3. Operating Screen................6 3.4. Display Functions................7 3.5. Data Logging and Data Downloading ..........9 4.

  • Page 4: Important Safety Notice

    1. Important Safety Notice The RCI-1502 System is a crane device which warns the operator of impending overload conditions and of overhoist conditions which could cause damage to property, crane and personnel. The system is not a substitute for good operator judgement, experience and safe crane operation.

  • Page 5: General Description

    2. General Description This Manual contains general information, installation, operation, calibration, maintenance and parts information for the RCI-1502 Rated Capacity Indicator to suit various Telescopic boom mobile cranes. Refer to drawing DWG 3063 “RCI-1502 GENERAL ARRANGEMENT FOR TYPICAL TELESCOPIC BOOM LM SYSTEM” on Section 8.2. of the Manual for an overview of the System.

  • Page 6: Operating Instructions

    3. Operating Instructions The following sections explain how to operate the RCI-1502 and make best use of its capabilities. 3.1. Turning On the RCI-1502 Power to the unit is from the crane battery (nominal 12 or 24 volts dc) through the start-up or ignition key.

  • Page 7: Operating Screen

    3.3. Operating Screen The following is the operating screen of the RCI-1502 showing the general display functions: Green/Amber/Red LED Indicator Lamps for Percentage of SWL Multi-function LED Indicator Display Lamps for (Length…Duty) Multi-function Select Button UP/DOWN Buttons (Length…Duty) for Changing Duty &...

  • Page 8: Display Functions

    3.4. Display Functions The RCI-1502 has 2 LCD display windows and 6 front panel push buttons. The display panel can also be grouped into four parts as follows: 3.4.1. “Approach to Rated Capacity” Indication Lamps This is the uppermost part of the display which contains three coloured lamps to indicate “approach to rated capacity”.
  • Page 9 FALLS The numerical display shows the number of falls (parts of line) used for the winch selected. To change the falls, press the UP/DOWN arrow keys to ramp to the desired falls number while the FALLS indicator is on, make sure the correct winch is selected. DUTY The numerical display shows the current duty (or configuration) number selected.

  • Page 10: Data Logging And Data Downloading

    If the overload is higher than the SWL % for MOTION CUT OUTPUT, set in calibration mode, the instrument will also activate the motion cut relay, if installed. This will then stop further over-loading of the crane. To bypass or temporarily disable motion cut, the operator must use the over-ride key which should be held by the site-supervisor.

  • Page 11: Installation

    4. Installation SETTING UP THE CRANE Lower the crane boom to a safe and convenient position. INSTALLING BOOM PARTS Recoil Drum The recoil drum contains both the angle sensor and length sensor for telescopic cranes. The payout cable of the drum is also used for wiring the ATB switch/es if required.
  • Page 12 Fully retract the boom. Extend the payout wire slightly and note the direction of rotation of the large gear wheel for an extending boom. Release the payout wire and allow it to retract to its' fully retracted position. Turn the large aluminium gear, by hand, in the opposite direction to that noted for an extending boom, until the gear stops.
  • Page 13 Bore (Force) Side Transducer The bore or force side transducer, also known as piston side transducer, must be fitted to the full bore side of the luff cylinder from which “live” pressure is measured. If a lock valve is fitted to the bore side, the transducer must be fitted to the “live”...
  • Page 14 Additional switches (for fly-jibs) can be added. Connection is via the bullet-type connectors from the cable. When more than one ATB switch is required (e.g. main & fly), connect the ATB cables of the switches in series via the bullet-type connectors.
  • Page 15 Connectors It is recommended that the installer applies a suitable silicone grease (e.g., 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.
  • Page 16 WIRING SLEW SWITCH/ES AND MOTION CUT OUTPUT Slew/Proximity Switch/es (Optional Items) The slew switch is used when the crane has different zones of SWL (e.g. over- rear ratings, over-side ratings, etc.). 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.
  • 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. Use contact terminals 4 (com) and 5 (NC) of the motion cut relay to wire the supply coil of the lockout solenoids.

  • Page 18: Calibration

    5. Calibration Before any calibration functions can be activated, you must enter CALIBRATION MODE. Entering Calibration Mode and Selecting Calibration Functions:  Make sure that the correct duty number (crane configuration) and falls (parts of line) are selected,  Insert the over-ride key switch into the RCI-1502 Switchbox and turn it on, make sure that the O/RIDE indicator on the front panel is lit, ...
  • Page 19 Map of Calibration (Suggested Order): 1. Set date and time (F-32 to F-34). 2. Verify that raw counts stay within 33-999 for full working range of all sensors (F-07, F-11, F-15, F-19). 3. Review all crane geometry against the supplied Crane Configuration settings for correctness (F-45 to F-59) –...
  • Page 20 18. Once satisfied with the calibration results, manually record (pen & paper) the calibration data using function code (F-40) and all settings mentioned above. Refer to Section 5.7. “Copying & Restoring Calibration Data Function” for details and procedures. Refer also to Section 5.2.30. “Send Load Moment Data to PC” and Section 5.2.31.

  • Page 21: Verifying Operation Of Sensors

    5.1. Verifying Operation of Sensors Before you start calibrating the RCI-1502, you must make sure that the sensors are working correctly and their signals are reaching the RCI-1502. The RCI-1502 'sees' the crane and its surroundings through sensors. The signals from these sensors are represented as numbers inside the RCI-1502.

  • Page 22: Configuring User Variables

    5.2. Configuring User Variables ROBWAY stores the load-charts, crane geometry, default alarm and motion control settings, default data logging parameters, fine-tuning settings, and other useful user variables in the memory of the RCI-1502 at the time of manufacture. As this information may vary from crane to crane, even if they are of the same model, the RCI- 1502 allows the installer to change these variables on site.
  • Page 23 5.2.4. View Uncalibrated Angle Input (F-07) Use this function to view the raw counts (or raw data) of the angle sensor. Please see also Section 5.1. “Verifying Operation of Sensors” for details. 5.2.5. View Calibrated Angle Input (F-08) The calibrated angle can be verified on normal operating mode (operator’s screen). This function is used to view the calibrated angle (in degrees) while still in calibration mode.
  • Page 24 5.2.13. View Calibrated Transducer 1 Input (F-16) Use this function to view the calibrated transducer 1 (bore or force side transducer) input. Please also Section 5.5. “Calibrating Low End & High End of Transducers” for details. 5.2.14. Calibrate Low End of Transducer 1 (F-17) Please see Section 5.5.1.
  • Page 25 5.2.22. Perform Laden Boom Radius Correction (F-29) This function code allows the installer to calibrate the system to account for laden boom deflection. As such it should only be used when the displayed load radius is less than the true operating radius of the crane. In such a case the installer should measure the physical load radius at a position where boom deflection is seen to have the maximum effect on the load radius.
  • Page 26 5.2.28. Send (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. 5.2.29. Erase Logger Contents (F-36) Please see Section 8.1. “Data Logging on RCI Systems” at the rear of the manual for details.
  • Page 27 5.2.33. Alter Calibration Data (F-40) This function is used for viewing and for manually copying and restoring the calibration data which must be done after completing the system calibration. Please see Section 5.7. “Copying & Restoring Calibration Data Function” for details and procedures. 5.2.34.
  • Page 28 5.2.39. Boom Movement Sampling Period (F-69) This function is used in conjunction with function code (F-68) and is also used by function codes (F-70 F-72) “Pressure Corrections Boom Luffing Down/Stationary/Luffing Up” for load readout correction purposes. The factory default setting must not be changed as this could affect the operation of the load correction functions (if used).

  • Page 29: Calibrating Main Boom Angle

    5.3. Calibrating Main Boom Angle 5.3.1. Calibrating Low Boom Angle  Safely luff the boom down to a low angle, e.g. 30°,  Enter calibration mode, if not already activated, and select the correct function code (F-09) for calibrating low boom angle, ...

  • Page 30: Calibrating Main Boom Length

    5.4. Calibrating Main Boom Length 5.4.1. Calibrating Short Boom Length  Retract the main boom fully,  Enter calibration mode, if not already activated, and select the correct function code (F-13) for calibrating short boom length,  Refer to the crane manufacturer’s load chart and verify fully retracted main boom length, ...

  • Page 31: Calibrating Low End & High End Of Transducers

    5.5. Calibrating Low End & High End of Transducers Before going on to calibrating the load for active winch on function code (F-02), the transducer/s must be checked for calibration. Transducers are normally supplied pre- calibrated from the factory. A re-calibration of the pressure transducers will ONLY be required if: ...

  • Page 32: Calibrating The Low End Of Transducer 2 (Rod Side)

     Refer to Section 5.7. “Procedures in Editing & Restoring Calibration Data” of this manual for further details and procedures on editing above items. 5.5.3. Calibrating the Low End of Transducer 2 (Annular or Rod Side)  Connect the transducer 2 to the display unit, ensuring no force is applied to the transducer (i.e.

  • Page 33: Calibrating Load For Active Winch

    5.6. Calibrating Load for Active Winch Calibration for Load Moment telescopic cranes requires separate calibration for each duty configuration. When a duty (or part of a duty as we will see shortly) is not calibrated, the display issues the special Error Code 320. A duty is only fully calibrated when the boom has been calibrated for a number of extension lengths (called sections) over the full extension range of the boom.

  • Page 34: Calibrating A Boom Section

    9. Once satisfied, select the next duty and repeat steps 2 – 7. 10. Once all duties are calibrated the crane is ready for commissioning. 5.6.2. Calibrating a Boom Section 1. Extend the boom to the desired length for calibrating. 2.

  • Page 35: Examples On Section Number Selection

    5.6.3. Examples on Section Number Selection Assume the load chart looks like this: Radius Boom Length Proportional Boom First calibrate: Section 1 at 10.0m (fully retracted) Section 16 at 25.0m (fully extended) Test the accuracy of the load over the extension range of the crane. If the accuracy varies, then more sections may be calibrated to improve the performance.
  • Page 36 If the boom has three telescoping segments and the minimum and maximum boom lengths have been calibrated as sections 1 and 16 respectively, then it is probably desirable to calibrate further sections at the points where each boom segment reaches full extension. The section numbers should be chosen to allow for further refinement of calibration if necessary.

  • Page 37: Copying And Restoring Calibration Data Function

    5.7. Copying and Restoring Calibration Data Function The latest software for the RCI-1502 System features a facility to easily VIEW, COPY, and RESTORE Calibration Data by using function code F-40 “Alter Calibration Data”. Procedures in Recording/Copying Calibration Data: 1. Access Calibration Mode. 2.
  • Page 38 8. In the example above, the default item An1 has been selected. 9. Press ENTER key while on the selected item (e.g. An1) to activate the Edit Codes. There are four (4) Edit Codes as follows: Edit Codes Description Lo_r Raw Counts of Calibrated Data (Low End) Lo_c...
  • Page 39 16. Ensure that the Edit Codes for the following items have been recorded/copied before exiting Calibration Mode: 17. Keep the record for future use (e.g. to re- calibrate the system when calibration data is lost due to faults, or when the Eprom software chip or Dallas memory chip has been replaced with a new one).
  • Page 40 Procedures in Editing & Restoring Calibration Data: 1. Access Calibration Mode. 2. Activate function code F-40 (Alter Calibration Data). 3. Press ENTER button to select and access the Alter Calibration functions. 4. Function will (Angle Channel) displayed on top window. An1 is the default item that comes up whenever F-40 (Alter Calibration Data) is activated.
  • Page 41 9. Use the Up/Down Arrow keys to go through the list of the four (4) Edit Codes as follows: Edit Codes Description Lo_r Raw Counts of Calibrated Data (Low End) Lo_c Calibrated Data (Low End) Hi_r Raw Counts of Calibrated Data (High End) Hi_c Calibrated Data (High End)
  • Page 42 14. The screen will then return to the Lo_r Edit Code screen. 15. Select next Edit Code repeat procedures 9 to 15 until all Edit Codes have been edited (i.e. calibration data have been restored). 16. Once all of the Edit Codes for An1 have been edited, press the CANCEL key to return to the An1 screen.

  • Page 43: Troubleshooting

    6. Troubleshooting The RCI-1502 system incorporates a number of software features that are designed to help the service person quickly identify a fault, however it must be stressed that these features cannot identify everything. They can only be used as a guide to identify additional checks that can be made.
  • Page 44 YOU MUST USE THE "VIEW UNCALIBRATED.." FUNCTION CODES TO DETERMINE THE CORRECT OPERATION OF THE EXTERNAL SENSORS, NOT THE "CALIBRATED" VALUES. It should be noted here that load related problems, "VIEW UNCALIBRATED function code must used, TRANSDUCER" "VIEW CALIBRATED LOAD". For correct operation these values must be in the range of 32 to 999 raw counts.
  • Page 45 EXAMPLE PROBLEMS AND POSSIBLE CAUSES Problems That Produce Error Codes: Error code 320. This is indicating that the Duty and/or Winch selected has not been calibrated. Possible causes:  Uncalibrated Duty and/or Winch selected. Error code 101. This is indicating that the signal from the angle sensor is too low or too high.
  • Page 46 Error code 201. This is indicating that the signal from the pressure transducer 1 (bore or force side) is too low or too high. This should be confirmed by viewing function code (F-15) “VIEW UNCALIBRATED TRANSDUCER 1 INPUT” and noting that the value shown on the LOAD LCD display is lower than 33, or higher than 999.
  • Page 47 Possible causes:  A genuine overload condition exists.  It has been caused by another Error code condition. Error code 301. This is indicating that the angle being measured is outside of its allowed range. Possible causes:  A genuine violation of the angle limits has occurred. ...
  • Page 48 Problems That Do Not Produce Error Codes: The load does not vary when I lift a weight. The load cable and/or the load sensor is/are faulty. Check the load cable for faults. If cable is good, check the resistance values of the load cell.

  • Page 49: Electrical Specifications

    7. Electrical Specifications Power Supply Input (VDC) Range: 10 VDC - 40 VDC Power Consumption < 1 amp (in full alarm) Temperature Range Operating: -20C to +70C Digital Inputs Total of three (3) digital inputs for connecting slew/proximity switches for monitoring different zones of operation, and/or for connecting other types of switches for any special crane requirement/application.
  • Page 50 Expected Resistances (for a standard 350-Ω cell): Red - Black 300 - 600 Ω Red - Green 200 - 400 Ω Red - White 200 - 400 Ω Black - Green 200 - 400 Ω Black - White 200 - 400 Ω White - Green 350 Ω...
  • Page 51 Anti-Two-Block Switch (Model BB5) Type: V4 IP67 sealed, leaf Contact Rating: 28 VDC/3A Electrical Life: operations Operating Force: 0.6 N (max) Release Force: 0.08 N (min) Cables General: 2-, 4-, 6-, & 10-core braided, UV stabilised, PVC sheathed cables DC Resistance: 38.2 ohms/km @ 20C (25.45 ohms/km for 2-core cable) Core Insulation: V90-HT PVC (designed to comply to AS/NZ 3808:2000)

  • Page 52: Appendices

    Robway Crane Safety Systems Pty Ltd Adelaide, South Australia 8. Appendices 8.1. DATA LOGGING ON RCI SYSTEMS 8.2. DRAWINGS 8. . RCI SYSTEM CRANE CONFIGURATION SHEET / DUTY LISTING RCI-1502 Boom Manual...
  • Page 53 Appendix 8.1. Data Logging on RCI Systems...
  • Page 55 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 56 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 57 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 58 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 59 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 60 Data Logging on RCI Systems Example Lift Cycles...
  • Page 61 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 62 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 63 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 64 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 65 Appendix 8.2. Drawings...
  • Page 86 RXXXXXXX...

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