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LSI-Robway RCI-1550 HRT Instruction Manual

Lattice boom system
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RCI-1550 HRT Lattice Boom System
Instruction Manual
MAN-1075 Rev D
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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  • Page 1 RCI-1550 HRT Lattice Boom System Instruction Manual MAN-1075 Rev D 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 IMPORTANT SAFETY NOTICE ........................5 SPECIAL NOTES ..............................5 2.1....................5 RANDNAMES RADENAMES AND RADE ARKS 2.2..........................5 MPORTANT AFETY OTICE 2.3..........................6 IMITED RODUCT ARRANTY 2.4......................... 6 LOSSARY OF SOME USED TERMS INTRODUCTION ..............................6 3.1.
  • Page 4 6.3. LED I .............................. 23 NDICATORS 6.3.1. Override LED ............................23 6.3.2. Audible Alarm Disabled LED ........................23 6.3.3. A.T.B. Indicator (anti-two-block or over-hoist) ..................23 6.3.4. Approach to Rated Capacity LED ......................23 6.3.5. 100% Capacity Exceeded LED ......................... 23 6.3.6.
  • Page 5 7.7.4. Calibrate the Aux winch with heavy load....................41 7.8......................41 NGLE ORRECTION OFTWARE 7.8.1. What is Load angle Correction Software?....................41 7.8.2. How to calculate the Load / Angle Correction Factor................42 MAINTENANCE..............................43 8.1................................ 43 HECK 8.2.

  • Page 7: Important Safety Notice

    Important Safety Notice The electronic load-charts in this system have been provided to assist the operator to drive the crane safely and productively. These load-charts have been provided to Robway by either the crane manufacturer or crane owner (or their representatives). Robway dutifully re-represent these load-charts into memory.

  • Page 8: Limited Product Warranty

    2.3. Limited Product Warranty Robway Safety Systems P/L (RSS) warrants to the Buyer (Purchaser) of new products manufactured or supplied by RSS that such products were, at the time of delivery to the purchaser, compliant to RSS Quality Assurance documentation ISO 9001. Any RSS product that has been repaired or altered in such a way, in RSS's judgement, as to affect the product adversely, including installation methods and procedures, negligence, accident or improper storage or use will be judged solely by RSS in regard to any partial or full warranty claim.

  • Page 9: System Description

    SYSTEM DESCRIPTION 4.1. Application RCI-1550 is designed to suit Strut Boom Cranes of either mobile or fixed installation. This manual covers the use of Tensiometer (line rider) based sensors and calibration refer to cranes where the tensiometers are fitted to directly monitor the hook hoist line-pull.

  • Page 10: Available Options

    4.4. Available Options  Options for  slew-zone continuous monitoring encoder sensor  hook height  multiple switch/analogue input/output expansion  engine management  special alarms  on-site configurable user data,  data-logging ( customer formats optional ),  printing, ROBWAY also cater for custom applications and special user requirements.

  • Page 11: Installation - General

    INSTALLATION - GENERAL 5.1. Setting Up the Crane Lower the crane boom to a safe and convenient position for installation of system components. High tensile booms require proper welding procedure specifications. Obtain specialist assistance in these cases. Please refer General Arrangement drawings at the rear of the manual for an overview of the configuration.

  • Page 12: Bob-Weight (Both Types Of Switches)

    Bob-weight (both types of switches) 5.3.4. Hang the bob weight assembly from the switch eye after cutting the chain to length if desired to suit winch line speed. Repeat the procedure if required for rooster or fly jib. Consult installation drawings at the rear of this manual.

  • Page 13: Tension Load-Line Plate Type Load-Cell

    Tension Load-line Plate Type Load-cell 5.4.3. A dead-end tension plate type load-cell may be fitted into the attachment of the hoist rope at the termination socket at the boom tip to sense the load-line line-pull. Robway specified 'safety plates' must be fitted to the tension plate-cell before using in sub- zero temperatures.

  • Page 14: Display Unit

    5.6. Display Unit Fit the RCI-1550 Display Unit in a convenient position in the cab such that the operator can view the display and reach the push buttons comfortably Check bonding between enclosure and chassis. If a good bond cannot be ensured through the mounting bracket, then install earth strap.

  • Page 15: Control Unit

    5.7. Control Unit The Control Unit (CU) contains the termination points for all modules within the RCI-1550 system. It also contains all the user interfaces, signal conditioning and processing circuitry required to satisfy the RCI/LMI functionality. The CU enclosure is a powder coated steel and carries an environmental protection rating of IP 65 which is suitable for internal or external mounting.
  • Page 16 5.7.1.1. Specifications Input supply: 10V - 40V dc @ 8W (max) Input fuse: 5A slow blow User output: Switched V+ when PSU is running (5A max) Internal outputs: 5V @ 500mA (max) 12V @ 500mA (max) 12V (2) @ 500mA (max) All supplies operate with 1mV p-p ripple.

  • Page 17: Cpu Section

    CPU Section 5.7.2. The processor is an 8051 derivative which contains a number of enhancements over the standard 8051, including an on-board 10 bit ADC. For most applications this degree of resolution is more than adequate. The data memory is in the form of a single package which contains the memory device with real time clock (RTC) and integral lithium battery.

  • Page 18: Digital Io Section

    5.7.3.3. Angle Inputs Either oil damped or electronic inclinometers can be connected to the RCI-1550’s angle inputs. Note that all angle sensors must be the same type and may not be mixed. The analog section must be configured, via a single jumper link to accept the appropriate type of sensor.
  • Page 19 Note: These outputs are not fuse protected through the RCI-1550, hence the protection must be provided by external means. 5.7.4.4. Snubber diode protection to crane fitted solenoids or relays The use of snubbed inductive loads (ie solenoids and relays) is strongly recommended, however care must be taken to ensure correct polarity connection to these devices.

  • Page 20: Upgrading To Rci-1550 From Earlier Robway Model Displays

    5.7.4.9. Motion Cut If motion cut is required the client shall provide appropriate solenoid valves/devices to activate the function and wire them as shown in this manual. 5.7.4.10. Connections 1. Permanent display damage may occur if incorrect motion-cut connections are made. 2.

  • Page 21: Operating Instructions

    OPERATING INSTRUCTIONS 6.1. The LCD Display Over-ride active indicator Cancel button Audible alarm disabled LED Soft menu buttons: - refer manual Two Block Indicator Alpha-numeric buttons: refer manual Approach to rated capacity LED “Up” button when Menu selected: - see also 18 100% capacity exceeded LED LCD Display: - refer manual Motion Cut activated LED...

  • Page 22: The Bar Graph

    The Bar Graph 6.1.1. This is the rectangular bar that is in the top centre of the LCD. This gives an “analogue” indication of the percentage the current load is of the Safe Working Load. The bar will start to grow when the load is 50% of the SWL and reach the amber section at 85%.

  • Page 23: Error Codes

    Error Codes 6.1.7. Additionally, the lower area display LCD is used to display ERROR codes when any errors are detected. Should the operator press the ACK button with an error code number displayed, the text window will revert to normal until a different error condition arises, or the acknowledge timeout expires. The original error code can be reviewed by simply pressing the ACK key a second time.

  • Page 24: Tare Key

    Tare Key 6.2.6. The RCI-1550 allows the operator to TARE out the weight of the hook, rope and accessories of the selected winch if required. This is a toggle function that turns on or off depending on its current state and is a function of the currently winch selected. If the TARE indicator is illuminated then the displayed load is the total weight minus the accessory weight.

  • Page 25: Led Indicators

    6.3. LED Indicators This section describes that operation of the 5 LED indicators that run along the tope edge of the RCI- 1550 display. Override LED 6.3.1. The Override Led is illuminated when the Override key switch is activated. Refer to the section on the Override key switch for more information.

  • Page 26: Disable Key Switch (If Fitted)

    6.5. Disable Key Switch (If Fitted) The purpose of the disable switch input is to bypass the RCI-1550 should a hardware fault develop. The override input simply signals to the software that if an overload is present to ignore it, hence is software controlled.

  • Page 27: Config Change Menu

    Config Change Menu 6.7.1. This selection is used when the operator wishes to change some aspect of the crane configuration. Upon selection of this item the “Config Menu” is displayed. The Config Menu typically allows the operator to change the following parameters: ...

  • Page 28: Display Options Menu

    Display Options Menu 6.7.3. This menu contains the settings that are specific to the look and “feel” of the display unit itself. Such items include the units displayed, the volume of the buzzer and contrast of the display as well as the setting for the Acknowledge Timeout.

  • Page 29: Calibration

    CALIBRATION 7.1. Calibration Purpose The monitoring sensors (Load-cells, Boom angle, Boom length etc) require calibration (scaling) so that their output directly relates to the crane. Entering Calibration Mode and Selecting calibration functions. 7.1.1. Make sure that the correct duty number, winch and falls are selected before entering Calibration mode.

  • Page 30: General Information Regarding Text Editing

    General information regarding text editing 7.1.3. Function codes that require editing will have a blinking cursor indicating where the edit will take place. The numeric buttons are used to enter the new value (unless stated otherwise). The OK button should be pressed when the edit is complete to accept the new value. Pressing the cancel button aborts the edit and any changes made are discarded.

  • Page 31: View Boom Angle Item

    7.2.2.1. CAL MAIN LOW and CAL AUX LOW items Allows the main winch and aux winch low load to be calibrated by using the numeric buttons. The current load value is displayed and below it the edited value. Once the edit is complete, pressing OK will result in the Display requesting the controller to do a calibration change.

  • Page 32: View Jib Angle Item

    View Jib Angle item 7.2.4. This function code item is only available for Luffing fly systems. The graphical LCD will appear similar to VIEW BOOM ANGLE. 7.2.4.1. CAL LOW J.ANGLE item This function code item is only available for Luffing fly systems. The graphical LCD will appear similar to CAL LOW B.ANGLE.

  • Page 33: Set Mux. Delay Item

    Set MUX. Delay item 7.2.7. Editing this value alters the multiplexer delay. The multiplexer delay is the settling time ( in ms ) for the analogue hardware. To edit the numeric buttons can be used or the Up/Down buttons. SET MUX. DELAY F22: Mux delay : hh:mm...

  • Page 34: Set Rigging Load Threshold Item

    Set Rigging Load Threshold item 7.2.10. Rigging the crane often requires that the boom be positioned outside of the normal operating regions of the load chart. It is not generally safe practice for the crane to be placed in such positions however, at times such actions are necessary.

  • Page 35: View Load-Chart Item

    View Load-Chart item 7.2.13. This function code is intended to allow easy viewing of the SWL over the operating range of the crane. This mode should NOT be used to actually monitor a lift, however, it is useful for determining whether a specific load will be tolerated at the desired operating position. The main and auxiliary ( if there is more than one hook ) safe working loads can be viewed.

  • Page 36: Set Time Item

    Set Time item 7.2.16. When changing the time, the graphical LCD will appear as shown in the following diagram. The time displayed is in the format HH:MM:SS. An invalid time will cause an error message to appear. Note: The seconds can’t be edited and will always be “00”. The seconds will begin incrementing once the OK button is pressed SET TIME F28:...

  • Page 37: Change Duty Item

    Once the Cal data item of interest has been selected and OK is pressed the graphical display should be showing the following information. VIEW CAL-DATA F32: Raw Lo = 123.0 222.0 Raw Hi = Cal Lo = 222.23 Cal Hi = 12.99 22.5 33.4...

  • Page 38: Restore Cal-Table Item

    Restore Cal-Table item 7.2.22. The backup calibration data can be restored by using “Restore Cal-Table” function code. Pressing the OK button will start the restore processes and the LCD will display “Executing …”. The calibration data is copied from backup memory to the calibration data that is used at run time. The success of the calibration backup and the optional backup of load calibration data (LM systems only) will be reported.

  • Page 39: Viewing Errors

    Viewing Errors 7.2.25. If errors exist they will automatically be displayed when the display is in normal operating mode (ie. provided no other menu displays are active). The graphical LCD will display an error code followed by a short description. Pressing the ACK button will temporarily silence the cabin buzzer and hide the error report from the screen.

  • Page 40: Tools Required For Calibration

    Please note that while in view mode, that is using either "VIEW UNCALIBRATED ..." or "VIEW CALIBRATED ..." functions, the ENTER key works as a toggle switch to turn that channel ON or OFF. This function allows the user to temporarily turn a sensor off if it is not needed. E.g.

  • Page 41: Map Of Calibration (Suggested Order)

    7.4. Map of Calibration (suggested order)  Set date and Time  Verify the raw counts stay within 33-999 for full working range of all sensors.  Ensure all digital inputs (switched) are wired correctly, incl. ATB.  Ensure all digital outputs (switched) are wired correctly. ...

  • Page 42: Calibrating Jib Angle (Luffing Fly Jibs Only)

    7.6. CALIBRATING JIB ANGLE (luffing fly jibs only) Calibrating low Jib angle 7.6.1.  Ensure that the angle sensor is mounted on the luffing fly and the cable is connected,  Safely luff the jib down to a low angle ( eg. 30° to the horizon ), ...

  • Page 43: Calibrate The Aux Winch With Light Load

    Calibrate the Aux winch with light load. 7.7.3. (Ensure the aux winch is selected, this must be done outside calibration mode) (Where direction switches are employed, both UP & DOWN require calibration)  If the crane has an Aux. winch fitted and has been included in the RCI-1502 load charts, proceed to calibrate the Aux.

  • Page 44: How To Calculate The Load / Angle Correction Factor

    How to calculate the Load / Angle Correction Factor 7.8.2. The number entered here is a correction value, when this number is 0.0 no correction is being applied (ie. Load / Angle correction is disabled). It expresses the load error (in tonnes) seen when the crane is luffed from the highest angle in the luff range to the lowest angle.

  • Page 45: Maintenance

    MAINTENANCE When maintenance is to be performed on the RCI-1550 system, care must be taken to ensure that the level of safety is not reduced. Such a reduction in the level of safety can easily be done by the careless use of tools or test equipment, either directly or by damage to safety components, wiring or clearances.

  • Page 46: Electrical Equipment

    8.3. ELECTRICAL EQUIPMENT When any electrical equipment is removed for maintenance, any exposed conductors that remain must be mechanically and electrically secured in a manner to prevent the occurrence of an unsafe condition. 8.4. INSPECTION AFTER MAINTENANCE Robway consider it essential by that a detailed Inspection is performed following any maintenance to ensure that the equipment and installation continue to comply with the documentation.

  • Page 47: Troulbelshooting

    TROULBELSHOOTING A trouble-shooting or fault-finding section is always a difficult document to write because things that are obvious to one person can be anything but obvious to another. One the other hand, most times when you read such a guide the fault you are trying to solve happens to be the very fault that has been left out! The main purpose of this section is to help both us at Robway and you the reader to find the problem and solve it quickly.

  • Page 48: Error Code List

    Check the obvious. Once you have found a problem with a sensor for example, check all of the obvious things to do with that sensor such as making sure all of the connectors are tight. Be systematic – make notes about what you have done and what you found.

  • Page 49: Problems That Do Not Produce Error Codes

    Problems That Do Not Produce Error Codes 9.1.2. The load does not Determine which winch you are looking at. If you are looking at the main vary when I lift a winch, then view the UNCALIBRATED TRANSDUCER 1 INPUT and noting weight.

  • Page 51: Electrical Specifications

    10. ELECTRICAL SPECIFICATIONS Controller Automotive alternator DC supply, nominally 12V or 24V Power Consumption Approximately 20VA (Watts). Operating -20C to +60C Temperature Range tested to (-30C to + 70C) Expected Resistance Values Load Cells Should have the following nominal resistance values, for a standard 350 ohm cell (note that these values may vary slightly from cell to cell).

  • Page 53: Drawings Parta - System Components

    12.1 Drawings Part A - System Components Page 50...

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