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RaycoWylie i3500 Calibration Instructions Manual

Rated capacity indicator system for telescopic cranes pressure sensing, multipoint version
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i3500 Rated Capacity Indicator system for
telescopic cranes pressure sensing, multi-
Copyright 2008 The B & A Engineering Co Ltd (RaycoWylie Systems).
All rights reserved.
Any part of this document may not be reproduced or transmitted in any form or by any
means including photocopy or any other information storage and retrieval system
without the permission from RaycoWylie Systems which will not normally be withheld
assuming that the material is for internal use only.
Ref: MP December 2007
RaycoWylie Systems
Drury Lane
St. Leonards-on-Sea
East Sussex
England
TN38 9BA
Tel:+44 (0) 1424 421235
Fax:+44 (0) 1424 433760
Telescopic cranes with derrick pressure sensors
Safety Instrumentation
Calibration Instructions
point version
RaycoWylie Systems
th
1020 9
Avenue, SW
Suite 124
Bessemer, AL 35022
U.S.A.
Tel:+1 (205) 481-2080
Crane Warning Systems Atlanta
Fax: +1 (205) 481-2081
877-672-2951 Toll Free
770-888-8083 Direct
http://www.raycowylie.com/
678-261-1438 Fax
www.cwsa.biz
55M3500MNE rev. E
RaycoWylie System
2440 Ave Dalton
Ste-Foy
Québec G1P 3X1
Canada
Tel:+1 (418) 266-6600
Fax:+1 (418) 266-6610
Calibration Manual i3500
1

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Summary of Contents for RaycoWylie i3500

  • Page 1 Any part of this document may not be reproduced or transmitted in any form or by any means including photocopy or any other information storage and retrieval system without the permission from RaycoWylie Systems which will not normally be withheld assuming that the material is for internal use only.

  • Page 2: Table Of Contents

    55M3500MNE rev. E Contents GENERAL DESCRIPTION ................4 Introduction ...................... 4 Personnel qualification and scope of this manual ........4 Brief description of the I3500 System ............4 THE I3500 SYSTEM ..................5 Troubleshooting ....................5 2.1.1 Diagnostic Menu ................5 2.1.2...
  • Page 3 RaycoWylie Systems. The i3500 RaycoWylie Systems Rated Capacity Indicator (RCI) is to be regarded only as an aid to the operator. When the parameters are set correctly, the indicator will warn...

  • Page 4: General Description

    SECTION 3 – THE CARD/ELECTRONICS INTERFACES Brief description of the I3500 System The I3500 is a computerized crane monitoring system, designed as an operator aid. It comprises sensors fitted to the crane and a display located in the cabin of the crane.

  • Page 5: The I3500 System

    The different pages available are: angle/length, load, relay, general info for a specific type of calibration (e.g. telescopic multi-point), rotation and also the addresses of sensors detected by the i3500 system. Depending on the system configuration, a minimum of three pages are always provided: angle/length, general info and detected addresses.
  • Page 6 It may vary between around 50 and 975 bits. The “length 1” sensor “ain2” value is reserved for future expansion. Note: “angle 1” sensor and “length 1” are physically located on the same card. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 7 It can reach a maximum of 4095 bits. The Dr + column is a regulated D.C. voltage level for the excitation of the pressure sensor and must be close to 5.00 VDC. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 8 Press “ ” when card 1 is highlighted to view the software version of a relay card. The displayed Information will look similar to this: relay card 1 --------------------------------------------------------------------- ver: 1.00 02may07 The “ver” line indicates the software version of the relay card and its creation date. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 9 “bars” of the main boom without load. pd12 is the total pressure in “bars” including the effect of lifted load. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...

  • Page 10: Error Messages And The Use Of The

    Detected addresses: This page gives the sensor addresses on the CAN network detected by the i3500 system. Addresses remain in memory as long as the system is powered even if a sensor stops communicating.
  • Page 11 - if system initializes often during operation mode, - if system never starts. 1- Unloaded hoist calibration There is no calibration for selected Not calibrated (empty) and unloaded duty. deflection must be done. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 12 “Main boom” chart. The smallest will be considered. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 13 2.1.2.2 External peripheries A) Angle/length and ATB interface circuit board errors: The i3500 system can support up to 5 angle interfaces. Activation of every angle sensor is done in the calibration menu section " -ent/sor activate/deactivate ". Error message Execution process...
  • Page 14 C) Relay and digital input interface board errors: The i3500 system can support up to 4 relay cards. Activation of every relay card is done in the calibration menu section “-ent/sor activate/deactivate”. Error message Execution process...
  • Page 15 E) Rotation interface board errors: The i3500 system can support only one rotation card. There are two different kinds: a relative one and an absolute one. Activation of rotation card is done in the calibration menu section “-ent/sor activate/deactivate”.

  • Page 16: Configuration And Calibration

    Warning: By performing the system initialization, all data in memory will be erased. This should only be done under the advice of a qualified RaycoWylie technician. Sensors used by the system must be configured. In the calibration menu scroll with “...
  • Page 17 2.2.1.2 Password protection If this option is activated in calibration then during startup of the i3500 system, a message is displayed on the screen asking to enter a user identification number. The lockout will be activated until a valid password is recognized by the i3500 system, after which it will enter the normal operation mode.

  • Page 18: Selecting Units Of Measure For Calibration: ("- Calib. Unit: Imperial")

    This function is used to allow the rigging of jibs or hook reeving at boom angles below the SWL chart. The RIG function is canceled when the operator booms up above the set angle or if the system is turned off. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 19 NO these changes will not be permitted unless the load is less than 20% of the SWL. This option must be set to NO for European operation. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...

  • Page 20: Entering Fixed Data Values: ("- Dimensions")

    (number of rams) – the number of boom lift cylinders, normally 1 or 2. ad (rod diameter) – the rod diameter of the lift cylinder. bd (bore diameter) – the bore diameter of the lift cylinder. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 21 5- Press “ ” to save the new value. 6- Repeat steps 1 to 5 for all the other variables. 7- Press #5 “ESC” to come back to the main calibration menu. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 22 If any dimension falls on the other side of the reference line shown in the diagram, then the sign will change. For example, if the boom cylinder’s head is above the hoist’s axis, then cl9 will be negative. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 23 55M3500MNE rev. E Diagram 2.2.4.2 Crane dimensions cnt’d Fully extended including manual section CL2MR Fully extended excluding manual section Fully retracted Ground level CH2 = CH1 + 0.1m Slew Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 24 CL28M V2582 CL6M CL28A V3346 CL5A V3505 CL5M V3999 CR2A Alternative location of hoist drums V3993 CR2M using guide sheaves on boom. For this situation dimensions cl6a and cl6m are negative. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 25 55M3500MNE rev. E Diagram 2.2.4.4: Jib dimensions CL12 (Fly) CL12 Lattice CLF (Fly) CLF Lattice CL13 Diagram 2.2.4.5 Rooster dimensions CL12 CLF = 0 A8 = 0 CL13 Telescopic cranes with derrick pressure sensors Calibration Manual i3500...

  • Page 26: Relays Configuration: ("- Relays Configuration")

    “Bypass” key and digital output “External bypass” will depend on this configuration. If the bypass configuration is disable, then the board key and digital output will be ignored. TABLE 3: Bypass configuration: Bypass Cutout + ATB Disable + Swing left+ Swing right Telescopic cranes with derrick pressure sensors Calibration Manual i3500...

  • Page 27: Digital Inputs Configuration: ("- Dig. Inputs Config.")

    The External Bypass is required for the EN13000 compliance. When this function is used the “bypass” key on the i3500 display is disabled. Only an external spring key switch can be used to bypass the system.

  • Page 28: Angle Calibration

    Press “ ” to edit the zero value (when the boom is completely retracted, the value must be set to zero). Press “ ” again to confirm the value. Press #5 “ESC” to return to the main calibration menu. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...

  • Page 29: Pressure Sensor Calibration

    Press “ ” to zero the bore side pressure sensor and press “ ” again to confirm. With an amplifier, if the reading is above 1200 and below 1680, the resolution of the system will be lower. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 30 4095 as seen by the control unit. The reading should be above 3200 and not exceed 3850. Repeat calibration procedure as defined for the bore side transducer above. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...

  • Page 31: Multi-Point No-Load Calibration: ("-No Load Calibration")

    For example separate no-load calibrations need to be done with the manual section in, the manual section out, each jib erected at each fixed offset etc. Refer to the computer printout supplied with the i3500. A ‘no-load’ calibration plus unloaded and loaded boom deflection calibrations are necessary for each duty where the ‘select’...
  • Page 32 Specified lengths must include lengths at which the boom telescoping sequence changes. Where no intermediate boom lengths are shown in the crane capacity chart, use the default lengths chosen by the system. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 33 1, length 2, etc. and enter separate minimum working angles for each calibration length as prompted. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 34 Press “ ” when ready to calibrate The display will show: The i3500 has now been programmed with all preset points and ready to calibrate. When ready press “ ” . Display shows; Where: aa.a is the current bore side pressure...
  • Page 35 Press “ ” , the display will change to show: – unloaded boom defle load: length: radius: corr: x.x ° up or down to edit to accept Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 36 With the hook block suspended and the boom at approximately 60° , telescope the boom in to the minimum length. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 37 Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 38 The hook weight should not be used to judge the load reading performance. This should be checked with at minimum load of 50% of capacity. It is recommended that this procedure be done while using the main boom, on outriggers if applicable. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 39 SWL with a retracted boom at approximately 60° boom angle. The calculated test load sh ould include the weight of the hook block and any slings, shackles etc. that are used. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 40 2.2.10.12 Friction compensation This procedure should not be performed except under guidance from RaycoWylie Systems except for down friction . All of the factors in this menu, except down friction, are used to compensate for static pressure decay over time but significant testing and analysis may be required before any of these default values are modified.
  • Page 41 50% of the Safe Working Load at each location. Calibrating a load correction factor with smaller test loads could result in unacceptable errors at 100% SWL. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 42 When completed, press #5 “ESC” to return to the normal display. Remember: When the calibration is finished set the calibration switch to the OFF position to prevent the calibration data from being modified or corrupted. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 43 No CF limited CF zones applied effect of omissions effect of omissions 7.12 3.11 6.11 3.10 6.10 No CF applied No CF No CF applied applied No CF No CF applied applied Telescopic cranes with derrick pressure sensors Calibration Manual i3500...

  • Page 44: Canbus Interfaces Board

    In the diagnostic mode, the system will display 1024 if a length value received in bits is greater than 1023 and will display 2 for the atb if a received value is greater than 1. Telescopic cranes with derrick pressure sensors Calibration Manual i3500...

  • Page 45: Basic Accelerometer's Calibration

    ATB will no longer function. The relay board will block the power to the coil of the relay assigned to the ATB at around 550ms. The Relay board is designed to supervise the communications with the I3500 system. If the relay board loses any communication with the I3500 system, it will automatically block all power to the coils of relays on the relay board within 5 seconds.

  • Page 46: Rotation Sensor Interface Board

    3.3.1 Relative Encoder The ratio must have a value other than 0. Otherwise, there will be a “ratio error” which will be displayed in the error message screen of the I3500 system. Angle Rotation = pointer * 360° / ratio The pointer represents the number of pulses generated by the encoder.

  • Page 47: Dimensions Data Sheets

    CL6M Boom CL5M CL5A Negative if boom centerline is below boom foot pin 2 Negative if boom foot pin is behind slew centerline 3 These dimensions are not available for editing Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 48 55M3500MNE rev. E Crane dimensions continue: Fully extended including manual section CL2MR Fully extended excluding manual section Fully retracted Ground level CH2 = CH1 + 0.1m Rotation center Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 49 CL29A CL29M CR22A CR22M Main boom pivot CL6A V2494 CL28M CL28A CL6M V1011 CL5A V3805 V3640 CL5M V3829 CR2A V3830 CR2M 1 This size will be negative Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 50 55M3500MNE rev. E Jib dimensions: CL12B CL12 (Fly) CL12A CL12 (Lattice) CLF1 CLF (Fly) CLF (Lattice) CL13A CL13 Telescopic cranes with derrick pressure sensors Calibration Manual i3500...
  • Page 51 55M3500MNE rev. E Rooster dimensions: CL12 CLF = 0 A8 = 0 CL13 Telescopic cranes with derrick pressure sensors Calibration Manual i3500...

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