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RaycoWylie i3500 Instruction Manual

Rated capacity indicator system for telescopic cranes pressure sensing, multi-point version
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i3500 Crane information center
Ref: LD October 2010
Wylie Systems
(Rayco Technology Group)
1020 9th Avenue SW
Suite 124
Bessemer, AL
USA 35022
Tel: (205) 481-2080
Fax: (205) 481-2081
Rated Capacity Indicator System for Telescopic
Cranes Pressure Sensing, Multi-Point Version
Instruction Manual
Rayco Electronic Systems
(Rayco Technology Group)
Crane Warning Systems Atlanta
770-888-8083 phone
678-261-1438 fax
2440 Dalton Avenue
www.craneindicators.com
sales@craneindicators.com
Tel: (418) 266-6600
Fax: (418) 266-6610
Copyright © 2010
RaycoWylie Systems
All rights reserved.
Ste-Foy, Qc
CANADA
G1P 3X1
55M3500JBE00 Rev B
Wylie Systems
(Rayco Technology Group)
Drury Lane
St-Leonards on Sea, East Sussex
ENGLAND
Tel: (+44) 1-424-421235
Fax: (+44) 1-424-433760
Ref: A.A
TN38 9BA

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  • Page 1 55M3500JBE00 Rev B i3500 Crane information center Rated Capacity Indicator System for Telescopic Cranes Pressure Sensing, Multi-Point Version Instruction Manual Ref: LD October 2010 Ref: A.A Wylie Systems Rayco Electronic Systems Wylie Systems (Rayco Technology Group) (Rayco Technology Group) (Rayco Technology Group)
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  • Page 4 Introduction Rayco Wylie Systems EC Declaration of Conformity Product type: i3500 Rated Capacity Indicator Authorised Representative: Wylie Systems Manufacturer : Drury Lane Rayco Electronic Systems St Leonards-on-sea 2440 Av Dalton East Sussex , United Kingdom Québec, PQ, Canada TN38 9BA...
  • Page 5 RaycoWylie Systems. The i3500 RaycoWylie Systems Crane Information Center must be regarded only as an aid to the operator. When the parameters are set correctly, the indicator will warn the crane operator of an approaching overload condition that could cause damage to equipment, property, and/or injury to the operator or site workers in the vicinity of the crane and its load.
  • Page 6 Introduction Since safety of personnel and proper use of the machine is of primary concern, different symbols are used throughout this manual to emphasize certain areas. The following definitions indicate the level of hazard when these symbols appear throughout this manual. Whenever one of these symbols appears in this manual, personnel safety is a concern.

  • Page 7: Table Of Contents

    Warnings 1- GENERAL DESCRIPTION OF THE SYSTEM Introduction page 4 1.2 Personnel qualification page 4 Intented use of the I3500 System page 4 Brief description of the I3500 System page 5 Typical Components Location & Description page 9 Block Diagram page 10...
  • Page 8 Introduction TABLE OF CONTENTS 4.4.6.1- Language Selection page 30 4.4.6.2- Units Selection page 31 4.4.6.3- Reverse Video page 32 4.4.7- Bypass/ Rigging page 32 4.4.7.1- Rigging Mode page 33 4.4.7.2- Overload Override (bypass) page 34 4.4.7.3- ATB Condition Override page 34 4.4.8- Bridging &...
  • Page 9 Introduction 6- INSPECTION TESTING & MAINTENANCE 6.1- Frequent Inspections page 63 6.2- Periodical Inspections page 63 6.3- Rated Load test page 64 6.4- Maintenance page 65 6.5- Maintenance Procedure page 66 6.6- Adjustements & Repairs page 67 Telescopic Cranes Pressure Sensing...

  • Page 10: 1- General Description Of The System

    Intended use The i3500 system is intended to provide a valuable aid to the crane operator by indicating all relevant parameters typically shown on the duty chart of the crane.

  • Page 11: Brief Description Of The I3500 System

    Introduction 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. This version measures the boom cylinder pressure, the boom angle and length, and it indicates safe or critical conditions, while performing an authorized lift of loads.
  • Page 12 Visual alarms The display of the i3500 system has been equipped with up to 3 warning lights to warn the operator and signal for a specific course of action. A yellow light will blink along with the audible alarm at the threshold point of the approach alarm (at 95%) of the rated capacity (100%).
  • Page 13 Introduction System with 3 warning lights Table 1 Display External Green Amber Event Approach Overload Cut Audible Buzzer Light Light light No event Approach to SWL Blinking Intermittent (Alarm 1) Overload Continuous (Alarm 2) Motion cut Continuous (Alarm 3) Not calibrated Continuous Setup button...
  • Page 14 Introduction System with 1 warning light Table 2 Display External Ext. Event Approach Overload Cut Audible Buzzer light No event Approach to SWL Blinking Intermittent (Alarm 1) Overload Continuous (Alarm 2) Motion cut Continous (Alarm 3) Not calibrated Continous Setup button activated within...

  • Page 15: Typical Components Location & Description

    Introduction Typical component location and description i3500 display box: It is also the central processing unit (CPU) of the i3500 system. Its principal feature is a CANBUS communication interface and graphical LCD screen. Angle sensor: A solid state angle sensor that is used to monitor the angle of the boom.

  • Page 16: Block Diagram

    Introduction 1.6 Block Diagram Block Diagram of the i3500 CANbus Communication Link Network. Telescopic Cranes Pressure Sensing Instruction Manual...

  • Page 17: Technical Data

    Introduction 1.7 Technical Data Accuracy: In accordance with SAE J159 or EN13000 Operating temperature: -20 ºC to + 60 ºC Supply voltage: 10.2 to 36 VDC (maximum rating) Display size: 6.25’’ x 8.5’’ x 3’’ (15cm x 21cm x 7.5cm)

  • Page 18: 2- Detailed Description Of The Display Unit

    Introduction Detailed description of the display unit 2.1 Normal Mode Display (default screen) SLEW PARTS DUTY BOOM TIP ANGLE OF LINE NUMBER HEIGHT (FALLS) BOOM LENGTH HOIST: M:MAIN A:AUXILIARY PARTIAL DUTY BOOM ANGLE OPERATING HOOK LOAD SAFE DESCRIPTION RADIUS WORKING (TOGGLE WITH LOAD BUTTON #4) (S.W.L)

  • Page 19: Display Buttons Location And Purpose

    Introduction 2.2 Display Buttons Location and Purpose i3500 DISPLAY BOX OVERVIEW WARNING LIGHTS GRAPHICAL DISPLAY INTERNAL BUZER OPERATING BUTTONS OPERATING BUTTONS PRESENTATION MODE BUTTON Shows system’s modes. Press this button to choose one of these operating modes: -Normal mode -System Set Up mode -Diagnostic mode -Calibration mode (password protected).
  • Page 20 Introduction SELECT BUTTON Used to select a highlighted item in a menu. In normal mode, use this button to select the infor- mation displayed in one of the pull-down menus. If no menu is opened, used to scroll through the configuration at the bottom line of the display.

  • Page 21: Warning Lights And Indicators Location

    Introduction Warning Lights and Indicators Location OVERLOAD MOTION APPROACH WARNING WARNING (RED LIGHT) (RED LIGHT) (YELLOW LIGHT) PRESET LIMIT(S) REACHED TWO-BLOCK RATED CAPACITY CONDITION LIMITED BY THE DETECTED HOIST ROPE Telescopic Cranes Pressure Sensing Instruction Manual...

  • Page 22: Warning Lights And Indicators Detailed Description

    Introduction 2.3 Warning Lights and Indicators Detailed Description The approach warning light blinks when the load on the hook is between 90% and 99.9% of the rated capacity (adjustable value; EN13000:2010: 90% and 97.5% ). This is accompanied by an audible warning device that is fitted inside the display unit. This light...
  • Page 23 Introduction The Rope Limit indicator appears just above the number of parts of line on the i3500 lcd screen. This indicates that the maximum load is limited by the rated strength and the number of parts of line of the hoist rope.
  • Page 24 In some systems, Limits values are not active when electric power is first applied to the i3500 and they are automatically disabled if electric power is removed. Reaching an operator’s Preset Limit (set in the Limits Setting Mode) will not result in crane motion cut-off.

  • Page 25: 3- Installation & Calibration

    2. The i3500 system is purely an aid to the operator. Responsibility for the safe operation of the crane lies with the crane operator. The i3500 system will not necessarily prevent crane damage due to overloading and/or other related causes.

  • Page 26: Residual Risks

    Improper configuration of the i3500 system may also cause a ‘‘Zero Capacity’’ if no chart is found to match the configuration set by the operator.

  • Page 27: Power

    4.3 Power On Switch on the electric power (i.e.: crane key switch) to the i3500 system. The indicator will perform a “Self-test” during which time (approx. 10 sec.) the audible alarm will sound, the approach, overload and motion cut lights will illuminate and the display will show the RaycoWylie’s logo.

  • Page 28: System Configuration

    Operation System Configuration The system configuration is done using the following three key buttons: Hoist/Scroll up button Used for hoist selection Parts/Scroll down button Used for parts of line (falls) selection. Duty button Used for duty number selection. 4.4.1 Duty Number Selection Carefully read and understand these instructions before selecting a duty number.
  • Page 29 * This document is a plasticized sheet of paper and it must be stored in the operator’s cab for duty selection purpose. In case of need of assistance, contact RaycoWylie with the serial number of your system for technical advice.
  • Page 30 Operation 4.4.1 Duty Number Selection (cont’d) Here you can input a specific duty number in the i3500 system. For example, if you know that the duty number 57 represents your crane rigged with a 100 ft boom length, outriggers extended and with a 40 ft jib at 10°, it would be more convenient to enter the number 57 instead of having to choose each correct parameters individually.

  • Page 31: 2- Hoist Selection

    The hoist/scroll up button allows the operator to select the hoist used. The operator can see the hoist selected on the i3500 screen near the boom base of the crane drawing (see fig. below). M = Main Hoist...
  • Page 32 Operation 4.4.3 Parts of Line Selection Carefully read and understand these instructions before selecting the Parts of line used. Selecting the wrong Parts of line can result in overloading the rope risking breakage that could result in serious injury or death. Make sure that the Parts of line displayed in the normal mode screen matches the current configuration of the machine.

  • Page 33: 4- System Test

    Operation 4.4.4 System Test Caution ! The crane must not be in overloading condition when using the test function. 1) Press Bypass/Rigging (9) and Tare (10) buttons simultaneously to check the operation of the display, the audible and visual alarms and the relays (digital outputs).

  • Page 34: 5- System Configuration Information Screen

    Chart Info Screen Once your system is properly configured, the i3500 Rated Capacity Indicator is ready to use The chart info screen is different for each crane model. The representation depicted above may not be identical to the chart info screen shown on your system.

  • Page 35: 6- System Setup

    Operation 4.4.6 System Setup Choose the System Set Up mode Operating Mode Selection Menu Numerous display parameters can be configured by the operator. These parameters are grouped in the system set up mode and they include: • Language •...

  • Page 36: 1- Language Selection

    Operation 4.4.6.1 Language Selection All of the i3500’s text messages can be displayed in multiple languages: English (default), as specified in the menu order. To change the language proceed as follows: 1) Repeat steps 1 to 3 of the preceding section (system setup options section).

  • Page 37: 2- Units Selection

    Operation 4.4.6.2 Units Selection Display unit menu It is possible to choose between 5 unit combinations. Each measure of length and load will be displayed on the main display. To change the units proceed as follows: 1) Repeat steps 1 to 3 of the system setup options sec- tion (see page 29 of this manual).

  • Page 38: 3- Reverse Video

    Warning! When in Rigging mode, the cutoff and overload alarms are disable. In this condition, the crane is not fully protected by the i3500, so it’s absolutely essential to obey the crane manufacturer’s advice regarding lifting the hook block, slewing or outriggers use.

  • Page 39: 1- Rigging Mode

    For example, the boom stowed position may be outside the maximum load radius or minimum boom angle specified on any load chart. For this reason, RaycoWylie systems provide a Maintenance/ Erection mode, where the boom may be lowered to or raised from the horizontal position without the external alarm continuously sounding or the motion cut (if fitted) operating.

  • Page 40: 2- Overload Override (Bypass)

    Operation 4.4.7.2 Overload Override (Bypass) When overriding the lock-outs during an overload condition, the speeds of the movements are limited to 15% (25% on some machines) of the permissible working speed for the corresponding load case. The external alarm and the external amber and red warning lights are activated.

  • Page 41: 8- Bridging & Range Limiting Box

    4.4.8.1 Bridging device When the bridging device is activated the crane is no longer protected by the i3500 system. Therefore, it is absolutely essential to obey the crane manufacturer’s advice regarding crane operations. Telescopic Cranes Pressure Sensing Instruction Manual...
  • Page 42 Operation 4.4.8.1 Bridging device (cont’d) A bridging device is an embedded electronic mechanism designed to be used in case of system component failure or in case of emergency. This safety feature can be accessed through a two-position momentary key switch. A Reset Button and a Status Led are also provided.

  • Page 43: 2- Bypass Rigging Using The Range Limiting Box

    Operation 4.4.8.2 Bypass / Rigging operation (Using the Bridging and Range limiting box) (Refer to section 4.4.8 of this manual) Reset button: Press and release the Reset button to cancel the override. Override Key Switch General override: Turn the override key switch to the ‘‘Indicator override’’ position and release for a complete override. The override indicator will be activated.

  • Page 44: Operational Limits

    In the Operational Limits Setting Mode, the operator can set and activate/ deactivate four (4) operational limits in addition to those automatically provided by the i3500 RCI system. These are as follows: The Minimum Boom Angle Limit. The Maximum Boom Angle limit.

  • Page 45: 1- Accessing The Limits Mode

    3) Press Select (4) button to enter the limits setting menu. Limits setting Menu Please note that limits are not active* when power is first applied to the i3500 system they automatically disabled if power is removed.

  • Page 46: 2- Limit Value Adjustments

    Operation 4.5.2 Limit Value Adjustment 1) Access the Operational limiting mode (refer to section 4.5.1 for more details). 2) Use the Hoist/Scroll up (2) and Parts/Scroll down (3) buttons to highlight the limit you want to edit. 3) Press Select (4) button to confirm your choice.

  • Page 47: 3- Enable / Disable A Limit

    Operation 4.5.3 Enable/Disable a Limit Limit Status 1) Access the Operational limiting mode (refer to section 4.5.1 for more details). 2) Press the Parts/Scroll down (3) button until the highlighted area moves to the first line of the column indicated above. 3) Use the Hoist/Scroll up (2) and Parts/Scroll...

  • Page 48: Range Limiting Option

    The range limiting option provided by the i3500 system shall not be used to delimit the prohibited zone. Refer to federal, state, local safety standards and regulations applicable in your country regarding operating cranes in proximity to power lines.
  • Page 49 Operation Range Limiting Option (cont’d) Shows which limit Shows which zone is programmed: is reached: limit high (roof) RADIUS variable limit height variable limit radius HEIGHT free zone (two walls) WALL RANGE LIMITING WARNINGS: APPROACH WARNING LIMIT CUT-OFF OF THE LIMIT REACHED...

  • Page 50: 1- Accessing Range Limiting Mode

    Operation 4.6.1 Accessing Range Limiting Mode access the range limiting mode proceed as follows: Turn the «Range limiting key switch» to the «slew range set» position (see fig. on section 4.4.8). Scroll down with Parts/Scroll down (3) button to highlight the range limiting option of your choice.

  • Page 51: 2- Limit High

    Operation 4.6.2 Limit High 1) The «Limit High» option is highlighted by default. Press Select (4) button to confirm your choice. 2) Boom up to the desired boom tip height limit. 3) Press Select (4) button to confirm the maximum boom tip height position.

  • Page 52: 3- Free Zone

    Operation 4.6.3 Free Zone VIEW FROM TOP First wall Second wall 1) Access the Range limiting main screen menu (see page 44). 2) Use the Parts/Scroll down (3) button to highlight ‘‘Free zone’’ and press Select (4) button to confirm your choice.

  • Page 53: 4- Variable Limit Height

    Operation 4.6.4 Variable Limit Height 1) Access the Range limiting mode (see page 44). 2) Use the Parts/Scroll down (3) button to highlight the ‘‘Variab limit height’’ option. 3) Press Select (4) button to confirm your choice. 4) Rotate the crane to the first limit position (first wall).

  • Page 54: 5- Variable Limit Radius

    Troubleshooting 4.6.5 Variable Limit Radius 1) Access the Range limiting mode (see page 44). 2) Use the Parts/Scroll down (3) button to highlight the ‘‘Variab limit radius’’ option. 3) Press Select (4) button to confirm your choice. 4) Rotate the crane to the first limit position (first wall).
  • Page 55 Troubleshooting This page has been intentionally left blank Telescopic Cranes Pressure Sensing Instruction Manual...

  • Page 56: Diagnostic Menu

    (for a specific type of calibration e.g. telescopic multi-point), rotation as well as the addresses of all sensors detected by the i3500 system. Regardless of system configuration, a minimum of three menu pages are always provided: angle/length, general info and detected addresses.

  • Page 57: Angle/Lenght Sensor

    Troubleshooting Angle/ Lenght Sensor In the diagnostic menu, this is the typical displayed information: sensor ain 1 ain 2 dr + Angle 1: 1428 1503 4.99 Length 1: 4.99 Some applications have more than one angle or length sensor. In this case, all of the angle sensors are listed first then length sensors will follow.
  • Page 58 Troubleshooting 5.2 Angle/ Lenght Sensor (cont’d) Press button when “Angle 1” is highlighted to see the software version of the angle sensor and it’s calibration state. The displayed information will look similar to this: Angle 1 ver: 1.01 07 jun 07 d1gx: 823.0...

  • Page 59: Pressure Sensor

    Troubleshooting Pressure Sensors Sensor Load 1 1325 4.96 Load 2 1109 4.98 The ain value represents cylinder pressure measured in bits by the pressure sensor. It can reach a maximum of 4095 bits. The Dr + column is a regulated D.C.
  • Page 60 Troubleshooting 5.4 Relays (cont’d) The information shown for the relay board 1 (fig. below) will look similar to this: Relay Inputs Relay Board 1 The information shown for the relay card EN13000:2010 (fig. below) will look similar to this: Press when Relay board 1 is highlighted.

  • Page 61: Slew Sensors

    Detected addresses: This menu page provides 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. Consult the i3500 Calibration Manual to view additional Diagnostic Menu pages with information related to internal calibration parameters.

  • Page 62: Error Messages And The Use Of The Key

    Troubleshooting 5.7 Error Messages and the use of the key During start up and other operation processes, the i3500 system analyses all interactions between internal peripherals (memories, controllers, extension cards, etc.) and also external ones (physical cards linked to the Canbus network) 5.7.1 Internal Peripherals If you have any questions or need technical assistance, please contact our Technical Service Department at RaycoWylie.
  • Page 63 Troubleshooting 5.7.1 Internal Peripherals (cont’d) Error message Execution process Cause of error Clock: The Logger option must 1) Verify if the black plastic Test failed be activated. The System cap is installed on the regularly verifies if the logger card (contains seconds are moving.
  • Page 64 Troubleshooting 5.7.1 Internal Peripherals (cont’d) Error message Execution process Cause of error External board The Logger option must be 1) The Logger card is not (Logger) activated. Upon startup, the installed, system verifies that logger 2) There is a problem card is present.

  • Page 65: External Peripherals

    Troubleshooting 5.7.2 External Peripherals A) Angle / Lenght and ATB interface circuit board errors The i3500 system can support up to 5 angle/length interfaces. Activation of every angle sensor is done in the calibration menu section ‘‘Enable/Disable I/O’’. Error message...
  • Page 66 Troubleshooting B) Load interface circuit board errors The i3500 system can support up to 4 load circuit boards. Activation of every load sensor is done in the calibration menu section ‘‘Enable/Disable I/O’’ Error message Execution process Cause of error load x out of range The Angle sensor value in bits is not valid (if <...
  • Page 67 Troubleshooting D) Generic interface board errors The i3500 system can support up to 4 generic cards: One for wind speed, one for inclination level, one for absolute rotation and another one for analogical output. Activation of every generic card is done in the calibration menu section ‘‘Enable/Disable I/O’’.
  • Page 68 On the other hand, if proximity is detected at start-up, then no error is displayed. Encoder communication The i3500 system does 1) The Rotation card is not receive anything from defective. the rotation card. If the 2) The Can Bus network “timeout”...

  • Page 69: Frequent Inspections

    Maintenance Inspection, Testing & Maintenance 6.1 Frequent Inspections (At the beginning of each shift during which a crane is used) • At system power up, check if all alarm lights are on, buzzer sounds and lockout are activated. • Verify that the system has been properly configured. • Verify the accuracy of the clock.

  • Page 70: Rated Load Test

    Maintenance Rated Load Test • Position and level the machine. • Testing personnel must be a qualified person for the crane and the i3500’s system. • The crane and the system must be configured properly. • The load chart must be respected.

  • Page 71: Maintenance

    RaycoWylie. Preventive maintenance • Your i3500 system has been designed to operate over long periods of time with minimum maintenance. However, continuous satisfactory operation depends upon system’s care and cleaning. Important: Do not use pressure steam on the i3500 display box, junction boxes, angle sensor, load cells or on any connectors.

  • Page 72: Maintenance Procedure

    Maintenance Maintenance procedure Before adjustments and repairs are started on a crane, the following precautions shall be taken as applicable: • Place crane where it will cause the least interference with other equipment or operations in the area. •...

  • Page 73: Adjustements & Repairs

    Service Department at RaycoWylie. If you have any questions or need technical assistance, please contact our Technical Service Department at RaycoWylie quoting the infor- mation found on the serial number label of your i3500 system. Telescopic Cranes Pressure Sensing Instruction Manual...
  • Page 74 Maintenance This page has been intentionally left blank Telescopic Cranes Pressure Sensing Instruction Manual...
  • Page 75 Maintenance Notes Telescopic Cranes Pressure Sensing Instruction Manual...

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