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Wylie W2245 Installation And Calibration

Rated capacity indicator
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Installation and Calibration
Telescopic cranes with derrick pressure sensors
Copyright 2001 The B & A Engineering Co Ltd
(Wylie Systems).
All rights reserved.
No part of these documents may be reproduced or transmitted in any form or by any means
including photocopy or any other information storage and retrieval system without permission
from Wylie Systems which will not normally be withheld assuming that the material is for
internal use only.
Ref: PAS May 2001
Wylie Systems
Rayco Technology Group
420 North Walnut Ave.
Broken Arrow, OK
USA 74012
Tel.: (918)-252-1957
Fax.: (918)-252-2048
Telescopic cranes with derrick pressure sensors
Safety Instrumentation
W2245
Rated Capacity Indicator
For
(Frame F45TH410 onward)
Crane Warning Systems Atlanta
1-877-672-2951 Phone
Rayco Electronic Systems
1-678-261-1438 Fax
Rayco Technology Group
www.cwsa.biz
2440, Avenue Dalton.
SteFoy, P.Q.
Canada G1P 3X1
Tel.: (418)-266-6600
Fax.: (418)-266-6610
Wylie Systems
Rayco Technology Group
Drury Lane
St Leonards-on-Sea,
East Sussex,
England TN38 9XS
Tel.: (44)-1-424-421-235
Fax.: (44)-1-424-433-760
1
SI 675
Issue B
EDI 8262
55M2245CNE
CALIBRATION W2245

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Summary of Contents for Wylie W2245

  • Page 1 No part of these documents may be reproduced or transmitted in any form or by any means including photocopy or any other information storage and retrieval system without permission from Wylie Systems which will not normally be withheld assuming that the material is for internal use only.

  • Page 2: Table Of Contents

    3.4 Multi-channel Amplifier (optional)..............13 CALIBRATION..............15 4.1 Keypad Operation .................... 15 4.2 Calibration – menu Description ................ 15 4.3 Calibration data....................29 4.4 Dimensions (crane constants)................33 4.5 System Configuration..................38 Telescopic cranes with derrick pressure sensors CALIBRATION W2245...

  • Page 3: Introduction

    The software in this system is designed to work on telescopic cranes with derrick cylinder pressure sensors, other software versions are available. The heart of the W2245 is the display unit. This box contains all the electronic components required to convert sensor signals into the meaningful information for the operator.
  • Page 4 SI 675 Issue B EDI 8262 Telescopic cranes with derrick pressure sensors CALIBRATION W2245...

  • Page 5: How The Indicator Works

    The results are then displayed to the operator using a liquid crystal display screen and indicator lights. The display is composed of two sections: the I/O board and the CPU board. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 6 SI 675 Issue B EDI 8262 2.6.1 The W2245 input/output board (I/O Board) The input/output (I/O board) board includes all the wire connections. On this board, signals are conditioned to be legible for the processor, and the power supply voltage is conditioned from an input range of 11 to 28 VDC to 5 VDC to supply both the processor and the sensors.
  • Page 7 REL1 : Driver for External Relay : Normally closed contact of relay : Normally open contact of relay Common contact of relay CAL : Calibration slide switch JP30 : Connection for Bypass Key Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 8 SI 675 Issue B EDI 8262 2.6.2 The W2245 CPU board The Central Processing Unit board reads all the sensor signals delivered from the I/O board. On the left of the board is situated a multiplexed amplifier which conditions load cell input. This board can multiplex 2 load sensor signals.

  • Page 9: Installation

    12 Volts DC is required. The power lead must be able to sustain a minimum of 11 Volts with a current of 5 amps if the unit is connected to a lockout device. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 10 When an ATB condition occurs, the ground on ATB Signal must be released. If the ATB is not used, a jumper must be installed between ATB and 0V. Wire colours are according to the Wylie standard cable. 3.3.1 Internal Amplifier Setting 3.3.1.1 Enter the Diagnostic menu and select sub-section 5, load sensor output (in bits).
  • Page 11 Note: While the transducer is not in the hydraulic line it is advisable to go to section 4.2.8 and set the transducer zero(s) and span(s) as described, this can be done out of sequence and will avoid having to disconnect and rewire the transducer more than once. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 12 When amplified inputs are used, (usually in conjunction with slip-rings) the gain of the display unit must be set to <1> and all gain adjustments carried out in accordance with section 3.4 Telescopic cranes with derrick pressure sensors CALIBRATION W2245...

  • Page 13: Multi-Channel Amplifier (Optional)

    2) together, and note the ‘CAL’ value and the rated capacity value engraved on the bore side sensor. NB. The sensors should not, at this stage be fitted in the hydraulic circuit. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 14 3.4.3.5 Amplifier Gain Setting Table Gain 1000 1248 1378 1882 2000 3.4.3.6 Repeat the whole of this section for TX1 (rod side sensor), adjusting the gain settings on board 2 as necessary. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...

  • Page 15: Calibration

    = decrease x 10 4.2 Calibration – menu Description The calibration mode is a separate entity of the W2245 system. It is totally independent of the regular operating mode as if it were a different system. The purpose of the calibration mode is to adjust the angle, length and load sensor inputs, to record the datum points of crane operation, and to set up the crane dimensions.
  • Page 16 P2 : 60º retract 17 = P3 : 60º 1/3 Ex 18 = P4 : 60º FullEx 19 = Boom Moment 20 = Cal Load : 0.0 21 = Load Bend Corr Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 17 If the system was configured during calibration E.G.: Main winch, 4 falls, Main boom only, it will not retain that configuration and will instead return to the last configuration set during operating mode. 4.2.4 Password Access Calib:#2↑ - #4↓ 1 – Calib Disable Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 18 The important aspect of the display in bits is to verify that the signal is variable through the entire working area of the boom angle, and that the resolution is above 3 bits per degree. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 19 The display will show the extension value calculated by the system in the upper right corner and the signal in bits on the bottom line. The system needs a minimum span of 150 bits above the zero. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 20 If the value is above 400, the resolution will diminish. 4.2.8.2 Pressure Sensor Span (Bore Side) Calib:#2↑ - #4↓ 8 – Span Pres Bore Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 21 Short the black and the white wires of the rod pressure sensor. Scroll down to 9 - SPAN PRES ROD and press ENTER. Repeat calibration procedure as defined for the bore side transducer above. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 22 4.2.12 Main Boom Calibration ° 4.2.12.1 20 Retracted Boom Calib:#2↑ - #4↓ 15 – P1 : 20º Retrac Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 23 Calib:#2↑ - #4↓ 17 – P3 : 60º 1/3 Ex press ENTER to request calibration. Press ENTER again to confirm. The system will scroll automatically to menu «18- P4:60° FULLEX». 4.2.12.4 60º Full Extension Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 24 When sample 9 is complete, the system will beep twice and return to the main menu. The display will step through the following 9 calibration points: Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 25 (angle5) (bore pressure) Pt#9 Length9 should be the same as length7, (angle9) (length9) angle9 should be the same as angle4 Ref4 now shown for reference (angle4) (bore pressure) Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 26 Calib:#2↑ - #4↓ 23 – Backup Scroll to menu «23- BACKUP». Press ENTER. The system will save the calibration in a spare bank called bank B. If in the next stages of calibration , Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 27 This option will place the contents of bank A into bank B and at the same time the contents of bank B in bank A. Both banks will be preserved but switched. The safety code must be entered to proceed. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 28 This must never be done during or after calibration. The safety code must be entered to proceed. 4.2.17.5 INIT. MEMORY C This option is not used. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...

  • Page 29: Calibration Data

    This value multiplied by the parts of line is used as the load limitation if lower than the rated capacity obtained from the load chart for the current crane configuration and radius or angle. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 30 This is the value that determines when the rigging mode is disabled for the auxiliary hook. The load on the auxiliary hook must remain below double this value to enable the rigging mode (see operator manual for more detail). Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 31 The OD (OUT of DUTY on RADIUS) will allow a straight line capacity from the chart value to zero and stretched over the distance set by this variable. OD distance 4000 2000 CAPACITY Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 32 Set to N to make limits temporary, this will mean that the limits will be lost when the system is turned off. After entering all the calibration data press ESC (#3) to return to the main menu. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...

  • Page 33: Dimensions (Crane Constants)

    Then scroll to the next value. The variables are listed in the following sections, all dimensions are set in metres or feet as defined on the display at start-up unless otherwise stated. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 34 SI 675 Issue B EDI 8262 Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 35 Dim: #2  - #4 ↓ 64 – P2MHV : 6.00 Vertical distance between centre of main hoist drum and boom base pin. If the drum is mounted on the boom, this dimension is 0.00 Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 36 The annular gain is the ratio between the full side and the rod side of the lift cylinder. The diameter of the rod squared divided by the bore diameter squared minus one equals the value required. ie:- Telescopic cranes with derrick pressure sensors CALIBRATION W2245...
  • Page 37 If the hoist drum is mounted on the boom this dimension is zero. This dimension allows calculation of the angle at which the hoist line applies a luffing tension on the boom. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...

  • Page 38: System Configuration

    ESC Key (#3). 4.5.3 Boom Moment 3) Boom Moment Bypass Enable Enable/disable Limit warning in calibration. Note this should normally be set to Disable. Press ESC (#3) to return to the main menu. Telescopic cranes with derrick pressure sensors CALIBRATION W2245...

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