Related Manuals for LSI-Robway RCI-1550 LM
Summary of Contents for LSI-Robway RCI-1550 LM
- Page 1 RCI-1550 LM Telescopic Boom System Instruction Manual MAN-1078 Rev B 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 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 6.2.3. Alpha-Numerical Keys ..........................22 6.2.4. Ok ( ) key ..............................23 6.2.5. Cancel (x) Key ............................23 6.2.6. Tare Key ..............................23 6.2.7. Rigging Key .............................. 23 6.3. LED I .............................. 24 NDICATORS 6.3.1. Override LED ............................24 6.3.2.
- Page 5 7.4...................... 40 AP OF ALIBRATION SUGGESTED ORDER 7.5..........................41 ALIBRATING NGLE 7.5.1. Calibrating a low boom angle ........................41 7.5.2. Calibrating a high boom angle ......................... 41 7.6................... 41 ALIBRATING NGLE UFFING FLY JIBS ONLY 7.6.1. Calibrating low Jib angle .........................
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Page 6: 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 7: 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 8: System Description
SYSTEM DESCRIPTION 4.1. Multi-purpose Application The RCI-1550 is designed to suit Telescopic Boom Cranes of either mobile or fixed installation. This manual covers the use of Load Mom ent based sensors an d calibration refer to cranes w here the te nsion cell/s are fitte d to monitor th e forw ard moment fo rces of the boom and then calcu late the hook load. -
Page 9: 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 10: 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 specifi cations. Obtain special assistance in these cases. Please r efer to the General Arrangement drawings at the rear of the manual for an overview of the configuration. -
Page 11: 110' Length Sensor - (Drurw33Laa)
110’ Length Sensor – (DRURW33LAA) 5.3.2. INSTALLATION- (Please read through before starting) Ensure that the face onto which the unit is to be mounted is flat, vertical and parallel to the line of cable pay-out. The mounting position should allow free uninterrupted pay-out of cable. -
Page 12: 140' Length Sensor- (Drurw43Laa)
140’ Length Sensor– (DRURW43LAA) 5.3.3. INSTALLATION- ( Please read through before starting Ensure that the face onto which the unit is to be mounted is flat, vertical and parallel to the line of cable payout. The mounting position should allow free uninterrupted payout of the cable. -
Page 13: Pay-Out Cable
Pay-out Cable 5.3.4. With the pay-out cable attached to the boom tip stand-off bracket, select positions for the intermediate cable guides provided, one for each telescoping section and one or more for the main boom allowing 9’-12’ between the drum and the nearest cable guide. Measure the distance from the cable to the sides of the booms, record lengths and mark the positions for the guides. -
Page 14: Cabling And Glands
5.6. Cabling and Glands Load cell cables should be fixed firmly to the crane structure and routed to ensuring freedom of movement around the boom pivot pin and other moving parts etc. Clip cables at 2’ intervals. Manual reeling drums are suggested cable storage devices for long lattice booms or on cranes that require regular boom length changes. -
Page 15: Display Unit
5.7. 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 16: Control Unit
5.8. 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 17: Cpu Section
5.8.1.1. 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 18: Analog Input Section
Analog Input Section 5.8.3. The analog section is takes advantage of the CPU’s on board 10bit ADC. This board can support up to four load cells, three angle sensors and three length sensors. 5.8.3.1. Sensor Excitation Supply The excitation supply provides power for all the sensors connected to the Analog section. The nominal output is 4v (or 12V for 4-20mA transducers). - Page 19 The function of the switch inputs is defined in software and reference should be made to the software configuration sheets for details. 5.8.4.3. Outputs All eight outputs consist of normally open voltage free contacts that close when the output is on. Each output is isolated from all others. Hence to have an output switch high one side must be tied to the supply and the other is used to drive the load.
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Page 20: Upgrading To Rci-1550 From Earlier Robway Model Displays
5.8.4.8. Slewing Zone Switch/es input/s Fit slewing zone indicator micro-switch (or proximity switch) provided at a convenient place near the centre of rotation providing run on and off ramps as required for the particular application. This switch will convey a signal to the Control Unit when the crane moves into a zone of restricted capacity rating. -
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
6.1.6.1. Hook Load selection MAIN WINCH SELECTED #1 AUX. WINCH SELECTED #2 Main load displayed Main SWL Aux. Load displayed displayed Main falls displayed Aux. SWL displayed Aux. falls displayed Note: #3 winch selection is reserved for PROGRAMME REVIEWS AT ALL cranes with 3 hook winches. -
Page 24: Ok ( ) Key
Ok () key 6.2.4. Used to ‘accept’ the currently displayed message or option on the LCD. Cancel (x) Key 6.2.5. Used in Calibration mode to cancel incorrectly entered data or to escape out of various menus 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. -
Page 25: Led Indicators
ROBWAY recommends that the over-ride key-switch be switched off (ie, normal position) at all times and the over- ride key held by the site-supervisor. 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. -
Page 26: Over-Ride Key-Switch (If Fitted)
6.4. Over-ride Key-Switch (If fitted) Should crane overload be reached (or other limitations exceeded, such as maximum radius, minimum angle, winch line-pull etc), the system will activate the motion cut relay, if installed. This will then stop further over-loading of the crane. To bypass or temporarily override motion cut, the operator can use the over-ride key which should be held by the site-supervisor. -
Page 27: Menu Navigation
6.7. Menu Navigation During normal operation the soft menu key with the label “Menu” can be pressed. This will cause the lower section of the LCD to display the main menu screen. By pressing the Up/Down soft menu keys the desired menu item can be selected. The currently selected menu item is highlighted by a solid bar, pressing the OK key will activate the selected item. -
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
View Boom Angle item 7.2.3. Displays the calibrated and un-calibrated values. VIEW BOOM ANGLE F07: Uncal. = 555 23.22 Cal. = hh:mm 7.2.3.1. CAL LOW BOOM ANGLE item Allows the low end of the selected item to be calibrated using the numeric buttons. The current raw value and calibrated value are displayed and below it the edited value. -
Page 32: Set Gain Trans 1 Item
Set Gain Trans 1 item 7.2.6. This function code allows the transducer gain to be input by software. The numeric buttons “1”, “2” “3” and “4” or the Up/Down buttons can be used to alter the gain for the selected transducer. The graphical will appear as shown: SET GAIN TRANS 1 F13:... -
Page 33: Set Mux. Delay Item
Set MUX. Delay item 7.2.8. 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 7.2.11. 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: Set Rigging Length Threshold Item
Maximum boom deflection occurs when the boom is fully telescoped and a load, which approaches the SWL, is suspended on the hook. On duties where the winches are both assumed to be reeved over the main boom head it is necessary to calibrate only for the main winch (winch 1). However, when a jib is installed it is possible to calibrate boom deflection both for the main boom head and for the head of the jib. -
Page 36: View Digital I/P Item
View Digital I/P item 7.2.17. The state of the digital inputs can be viewed on the graphical LCD by using this function code. To determine what a particular digital input signal is being used for in the software, please refer to the “System Configuration Sheets.”... -
Page 37: Download Logger Item
Download Logger item 7.2.20. Please refer to the Data Logging Manual supplied separately for details. View Cal-Data item 7.2.21. This function code is for the manual recording of calibration data just in case the calibration is lost or a display needs to be replaced. This is to be used in conjunction with the alter calibration data function code when inputting pre-recorded cal data. -
Page 38: Change Duty Item
Change Duty item 7.2.22. This function code is the same as if change duty was selected from the Config Change menu with the exception that the duty can be changed even if a lift has commenced. This feature is only provided in Calibration mode. -
Page 39: Restore Cal-Table Item
Restore Cal-Table item 7.2.28. 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 40: Viewing Errors
Viewing Errors 7.2.31. 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 41: 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 42: Calibrating Boom Angle
7.5. Calibrating Boom Angle Calibrating a low boom angle 7.5.1. Safely luff the boom down to a low angle, eg. 30°, Enter calibration mode and select the correct function code for calibrating low boom angle, Accurately measure the actual boom angle using an angle finder, ... -
Page 43: Calibrating Boom Length
7.7. Calibrating Boom Length Fully retract the boom, Enter calibration mode and select the correct function code for calibrating SHORT (LO) boom length, Use the UP/DOWN keys to ramp the display to the required value then press ENTER to accept this value. - Page 44 Activate the viewing function for the transducer you want to check (if using two transducers they must be checked in turn). Slowly luff the boom up and down through the entire working angle range and observe the numbers shown in the display window. The numbers displayed will be between 0 and 1023.
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Page 45: Calibrating The Low End Of Transducer 1
Calibrating the Low end of Transducer 1 7.8.4. This procedure will be required if using a load-cell not supplied by Robway with the initial sy stem supply, or, a load-cell is/has been changed from original. Plug the simulator cable into the Load 1 transducer input on the Controller Unit analog section. -
Page 46: Calibrating The Low End Of Transducer 2
Calibrating the Low end of Transducer 2 7.8.6. This procedure will be required if using a load-cell not supplied by Robway with the initial sy stem supply, or, a load-cell is/has been changed from original. Plug the simulator cable into the Load 2 transducer input on the Controller Unit analog section. -
Page 47: Preparation Before Calibrating Load
7.9. Preparation Before Calibrating Load Load calibration is a simple procedure, however, before the load can be calibrated the installer must make sure that the following procedures have already been done: Correct duty, falls and winch have been selected, ... -
Page 48: Boom Stop Friction (Compression) Correction
7.11. Boom Stop Friction (compression) correction Introduction 7.11.1. Some cranes attempt to limit the high angle of the boom by employing a physical boom Back-Stop. When this Back-Stop takes the form of a spring, acting so as to oppose the raising of the boom, it can affect the load reading on LOAD MOMENT systems. -
Page 49: 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 50: 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. RECOIL DRUM (Telescopic cranes) GENERAL In normal use little attention to maintenance is required. 110’... -
Page 51: 140' Recoil Drum - (Drurw43Laax)
8.4.1.3. Safety At all times, when handling spring operated cable reeling drums, keep full control of rotation. Be very careful, when handling loose rewind springs, to ensure that all of the coils remain within the captive band. 140’ Recoil Drum – (DRURW43LAAX) 8.4.2. -
Page 52: Inspection After Maintenance
Ensure that cable glands or seals are all correctly fitted and that reel rotates freely. 8.4.2.3. Safety At all times, when handling spring operated cable reeling drums, keep full control of rotation. Be very careful, when handling loose rewind springs, to ensure that all of the coils remain within the captive band. -
Page 53: Troulbelshooting
TROUBLESHOOTING 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 54: 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 55: 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 56: Electrical Specifications
10. ELECTRICAL SPECIFICATIONS Controller Automotive alternator DC supply, nominally 12V or 24V Power Consumption Approximately 20VA (Watts). Operating -20C to +60C Temperature Range tested to (-30C to + 70C) 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 57: Appendices
12. APPENDICES 12.1. Drawings Part A - System Components 12.2. Drawings Part B - General Arrangements and Wiring 12.3. Software Documents... - Page 58 Drawings Part A System Components...
- Page 73 Typical Pressure Transducer Installation on Telescopic Cranes ROD SIDE PRESSURE TRANSDUCER BORE SIDE PRESSURE TRANSDUCER (install cylinder side of any check or control valves) HIGH PRESSURE SOLID PIPING (or direct connect at fitting) FLOW OF HYDRAULIC OIL ON CYLINDERS DURING LUFF DOWN EQUALISING PIPE/HYDRAULIC HOSE FLOW OF HYDRAULIC OIL ON CYLINDERS DURING LUFF UP...
- Page 80 Drawings Part B General Arrangement and Wiring...
- Page 96 Appendix RCI System Crane Configuration Sheet / Duty Listing...
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