1. Manuals
  2. Brands
  3. RaycoWylie Manuals
  4. Construction Equipment
  5. i4500
  6. Instruction manual

RaycoWylie i4500 Instruction Manual

Information center, rated capacity indicator for lattice cranes with load sensor on hoisting rope
Hide thumbs Also See for i4500:
Table of Contents

Advertisement

Quick Links

i4500 Crane Information Center
Ref: VH June 2013
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 for Lattice Cranes
with Load Sensor on Hoisting Rope
(America)
Instruction Manual
Rayco Electronic Systems
(Rayco Technology Group)
Crane Warning Systems Atlanta
2440 Dalton Avenue
U.S. Distributor for Rayco / Wylie Systems
Ste-Foy, Qc
6175 Hickory Flat Hwy Suite #110-376
CANADA
Canton, GA 30115
G1P 3X1
877-672-2951 Toll Free 678-261-1438 fax
www.craneindicators.com website
sales@craneindicators.com email
Tel: (418) 266-6600
Fax: (418) 266-6610
Copyright © 2013
RaycoWylie Systems
All rights reserved.
55M4500EBE00A Rev A
Wylie Systems
(Rayco Technology Group)
Drury Lane
St-Leonards on Sea, East Sussex
ENGLAND
TN38 9BA
Tel: (+44) 1-424-421235
Fax: (+44) 1-424-433760
Ref: A.A

Advertisement

Table of Contents
loading

Related Manuals for RaycoWylie i4500

Summary of Contents for RaycoWylie i4500

  • Page 1 55M4500EBE00A Rev A i4500 Crane Information Center Rated Capacity Indicator for Lattice Cranes with Load Sensor on Hoisting Rope (America) Instruction Manual Ref: VH June 2013 Ref: A.A Wylie Systems Rayco Electronic Systems Wylie Systems (Rayco Technology Group) (Rayco Technology Group)
  • Page 2 This page has been intentionally left blank...
  • Page 3 This page has been intentionally left blank...
  • Page 4 This page has been intentionally left blank...

  • Page 5: Ec Declaration Of Conformity

    RaycoWylie Systems. The i4500 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 damage the equipment, property, and/or cause injury to the operator or people working near the crane and its load.
  • Page 6 This page has been intentionally left blank...

  • Page 7: Warning

    Used to WarN aGaiNst UNsafe Practices. imPortaNt: iNdicates a sitUatioN that may caUse machiNe damaGe. Note: Provides iNformatioN that may be of sPecial iNterest. i4500 Lattice Boom Crane Instruction Manual...

  • Page 8: Table Of Contents

    1- gEnEral dEsCription of thE systEm page 13 introduction page 13 1.2 Personnel Qualification page 13 intended Use of the i4500 system page 13 Brief description of the i4500 system page 14 1.4.1 audible alarm page 15 1.4.2 Visual alarms page 15 location &...
  • Page 9 4.4.6.6 Set and Remove Tare page 55 4.4.7- Bypass/Rigging Mode page 56 4.4.7.1-Rigging Mode (Maintenance and Rigging) page 56 4.4.7.2- Accessing Rigging Mode page 57 4.4.7.3- Bypass page 57 4.5 Operational Limits page 58 4.5.1- Accessing the Operational Limits Setting Mode page 59 4.5.2- Limit Value Adjustments page 60 4.5.3- Enable/ Disable a Limit page 61 4.6 Range Limiting Options page 62 4.6.1- Accessing Range Limiting Mode page 64 4.6.2- Height Limit page 65 4.6.3- Free Zone page 66 4.6.4- Variable Height Limit page 67 4.6.5- Variable Radius Limit page 69 (Continued on next page) i4500 Lattice Boom Crane Instruction Manual...
  • Page 10 6- insPection anD Maintenance page 84 6.1- Frequent inspections page 84 6.2- Periodical inspections page 84 6.3- rated load test page 85 6.4- Maintenance page 86 6.5- Maintenance Procedure page 87 6.6- adjustments and repairs page 88 Instruction Manual i4500 Lattice Boom Crane...
  • Page 11 This page has been intentionally left blank...
  • Page 12 This page has been intentionally left blank...

  • Page 13: 1- General Description Of The System

    Maintenance of the system is intended only for fully qualified and trained personnel.. Intended Use The i4500 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 14: Brief Description Of The I4500 System

    55M4500EBE00A-A Brief Description of the i4500 System The i4500 “Rated Capacity Indicator” is a computerized crane monitoring system designed to help the operator to safely operate the crane and to respect the maximum load authorized by the crane manufacturer. The indicator automatically monitors the load lifted by the crane and constantly compares it with the maximum load allowed for each position.

  • Page 15: Audible Alarm

    1.4.2 Visual Alarms The display of the i4500 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 when the load reaches the threshold point of the approach alarm (at 95% of the rated capacity).
  • Page 16 Note that depending on system configuration, your system may be equipped with one or with three external lights. See tables 1 and 2 for external visual alarm operation. I4500 system with three warning lights Internal alarms External alarms...
  • Page 17 55M4500EBE00A-A I4500 system with 1 external warning light Internal Alarms External Alarms External Event Buzzer Light No event Approach to SWL Blinking Intermittent (Alarm 1) Overload Continuous (Alarm 2) Motion Cut Continuous (Alarme 3) Duty Continuous Not calibrated Bypass Continuous...

  • Page 18: Location & Description Of Typical Components

    55M4500EBE00A-A Location and Description of Typical Components i4500 display box: It is also the central processing unit (CPU) of the i4500 system. Its principal features are a CANBUS communication interface and a graphical LCD screen. Central I/O interface: This relay interface module is connected to individual external I/O devices to be controlled or monitored by the i4500 system.

  • Page 19: Block Diagram

    55M4500EBE00A-A Block Diagram of the i4500 Communication Link Network i4500 System block diagram Hydraulic controller CAN 2.0B SECONDARY Optional ROD SIDE BORE SIDE PRESSURE PRESSURE SENSOR SENSOR A2B SWITCHLENGTH i4500 Display Angle TFT Display CABLE REEL CAN 2 INTERFACE All in 1...

  • Page 20: Technical Data

    10,000 load/radius curves CANbus sensors / interface: Default quantity Maximal quantity - Load or pressure sensors - Angle, Length sensors - Relay output - Digital inputs - Provision for other sensors RS-232 Peripheral communication port Instruction Manual i4500 Lattice Boom Crane...

  • Page 21: 2- Detailled Description Of The Display Unit

    NOT as an indication that the crane would or would not pass under a structure of which we precisely know the height. *You can see the slew angle indicator (middle of the screen) only when the range limiting option is installed on the machine. i4500 Lattice Boom Crane Instruction Manual...

  • Page 22: Display Box Overview

    GRAPHIC DISPLAY This menu driven communication interface allows access to the various menus and options to control the i4500 unit system. WARNING LIGHT When operating within normal conditions the green LED warning light turns on.

  • Page 23: Operating Buttons Description

    ESCAPE BUTTON Select Escape button to exit a menu or any programming window without saving any changes and to go back to the previous screen. Select repeatedly to return to the main screen. i4500 Lattice Boom Crane Instruction Manual...
  • Page 24 Press it to access the operating system’s information. QUICK DUTY CHANGE BUTTON Use the Quick Duty Change Button to alternatively select whether lifting the load with the main boom or the auxiliary jib. Instruction Manual i4500 Lattice Boom Crane...

  • Page 25: Main Modes

    55M4500EBE00A-A Main Modes LImIT mOdE WITHOuT ROTATION LImIT mOdE WITH ROTATION *optional cONfIG. mOdE mAIN mOdE INfO mOdE ERROR mOdE dIAGNOsTIc mOdE cALIbRATION mOdE NIGHT mOdE i4500 Lattice Boom Crane Instruction Manual...

  • Page 26: Warning Lights And Indicators Location

    LOckOuT AppROAcH WARNING WARNING (REd WARNING (YELLOW LIGHT) LIGHT) (REd LIGHT) WARNING ALARm IcONs GREEN YELLOW NORmAL AppROAcHING OVERLOAd LImIT OR cONdITION OVERLOAd OR LImIT REAcHEd WARNING LIGHT sYsTEm ERROR TWO-bLOck INdIcATOR cONdITION INdIcATOR Instruction Manual i4500 Lattice Boom Crane...

  • Page 27: Warning Lights And Indicators Description

    The crane has exceeded safe operational ratings and is now in an unsafe condition. Hoisting up and booming down functions will be stopped if a motion cut solenoid is connected to the system. i4500 Lattice Boom Crane Instruction Manual...
  • Page 28 Increase the number of parts of line between the sheave on the boom tip and the block and change the number of parts of line on the i4500 system to make this indicator disappear and to reduce a rope limit.
  • Page 29 These values are defined during the tests performed by the technician during the calibration of the system. Limits values are not active when the electric power is first applied to the i4500 and they are automatically disabled if electric power is removed.

  • Page 31: 3- Installation And Calibration

    2. The i4500 system is only an aid to the operator. Responsibility for the safe operation of the crane lies with the crane operator. The i4500 system will not necessarily prevent crane damage due to overloading and/or other related causes.

  • Page 32: Residual Risks

    Improper configuration of the i4500 system may also cause a ‘‘Zero Capacity’’ if no chart is found to match the configuration set by the operator.

  • Page 33: Power

    Power On When the i4500 system is powered on, it performs a self-test during which it verifies with the installed sensors the communication on the CAN bus network. It loads in its user memory all the informations stored in its read-only memory. The RaycoWylie logo is shown on the screen.

  • Page 34: System Configuration

    If you need assistance, contact RaycoWylie with the technical file number of your system. The current duty number associated by the i4500 system figures in the upper left corner of the display screen by default and additional configuration information can be seen by pressing the Info button (see fig.1)

  • Page 35: Working With Main Boom, 1 Or 2 Hoists

    55M4500EBE00A-A 4.4.1 Duty Selection (Cont’d) We need to provide the i4500 system with the proper information by answer- ing a series of questions in order to choose the proper duty that matches your crane configuration. 1. Select the Duty button.
  • Page 36 7. Press the Select button to confirm your choice, accept new value in the system and go to the next parameter or press on the Escape button to go back to the previous screen. Instruction Manual i4500 Lattice Boom Crane...
  • Page 37 12. Use the Up or Down buttons to select the position of the outriggers among the list. i4500 Lattice Boom Crane Instruction Manual...
  • Page 38 Escape button to go back to the previous screen. Once the duty selection is over, the i4500 automatically returns to the main screen (normal operating mode). You can use the «Info» button to see at a glance the configuration of the crane.

  • Page 39: Working With Jib, 1 Hoist

    4. Use the Up or Down button to select the jib configuration from the list. 5. Press the Select button to confirm your choice or press the Escape button to go back to the main screen. i4500 Lattice Boom Crane Instruction Manual...
  • Page 40 Escape button to go back to the main screen. This menu will appear if your crane has only one hoist. 8. Press the X button to answer “NO” to the following question: Is a block rigged on the main boom ? Instruction Manual i4500 Lattice Boom Crane...
  • Page 41 11. Now enter the number of parts of line used between the jib block and the head sheave. Use the Up or Down button to enter the first digit. 12. Press button highlight Select second digit. i4500 Lattice Boom Crane Instruction Manual...
  • Page 42 Keep answering the questions until you see the main screen. Figure 2b Instruction Manual i4500 Lattice Boom Crane...

  • Page 43: Working With Main Boom Or Jib

    4. Use the Up or Down button to select the jib configuration from the list. 5. Press the Select button to confirm your choice or press the Escape button to go back to the main screen. i4500 Lattice Boom Crane Instruction Manual...
  • Page 44 # 6. If you have decided to lift the load with the main boom, the following question will appear: Is there a block on the attachment? You need to answer “YES” in both cases. Instruction Manual i4500 Lattice Boom Crane...
  • Page 45 11.Now enter the number of parts of line used between the block of the jib and the head sheave. Use the Up or Down button to enter the first digit. 12. Press the Select button to highlight the second digit. i4500 Lattice Boom Crane Instruction Manual...
  • Page 46 Escape button to return to the previous screen 17. Now enter the number of parts of line for the main block. Use the Up or Down button to enter the first digit. Instruction Manual i4500 Lattice Boom Crane...
  • Page 47 You might have to answer extra questions according to your crane and its load chart, or for example if you have a counterweight that you need to configure. Keep answering the questions until you see the main screen. i4500 Lattice Boom Crane Instruction Manual...
  • Page 48 55M4500EBE00A-A 4.4.4 Working with the Main Boom or Jib (Cont’d) Press this button to choose to whether lift the load with the main boom or with the jib. Quick Duty Change Button Instruction Manual i4500 Lattice Boom Crane...

  • Page 49: System Configuration Information Screen

    1) Select the Mode button. 2) Use the Up / Down buttons to highlight Info Mode 3) Press the Select button to confirm your choice and enter the info menu screen. Chart Info Screen i4500 Lattice Boom Crane Instruction Manual...

  • Page 50: System Setup Configuration Mode

    4.4.5 System Configuration Information Screen (Cont’d) Once your system is properly configured, the i4500 Rated Capacity Indicator is ready to use. The info screen is different for each crane model. The representation shown in this manual may not be identical to the chart info screen shown on your system.

  • Page 51: Unit Selection

    1. Repeat steps 1 to 3 of the system setup configuration mode section (see above, section 4.4.6) 2. Select the line “Units”. 3. Use the Up or Down button to highlight the desired unit combination 4. Press the Select button to select the desired unit combination. i4500 Lattice Boom Crane Instruction Manual...

  • Page 52: Language Selection

    55M4500EBE00A-A 4.4.6.2 Language Selection The text on the i4500 can be displayed in many languages. The languages available can vary depending on the software version. To set the language, proceed as follows: 1. Repeat steps 1 to 3 of the system setup configuration mode section (see section 4.4.6 on page 51)

  • Page 53: Night/Day Light Mode

    This menu allows access to the screen brightness pre-sets. Select a setting that matches prevailing lighting conditions. Please note that the screen brightness level for the night mode is set in the backlight menu (see backlight mode on the following page). i4500 Lattice Boom Crane Instruction Manual...

  • Page 54: Backlight Mode

    100 % (maximum brightness). For the «night» level, a 30 % to 60 % backlight is suggested. 4. Use the Up or Down buttons to select the hundreds. Press the Select button. 5. Repeat the procedure to set the other digits. Instruction Manual i4500 Lattice Boom Crane...

  • Page 55: Set And Remove Tare

    5. Press the Select button to enable the Tare feature. 6. Repeat these steps to remove tare and to go back to normal mode. The tare indicator appears on the screen when some weight have been removed on the load displayed. i4500 Lattice Boom Crane Instruction Manual...

  • Page 56: 7- Bypass/Rigging Mode

    For this reason, the i4500 provides a Maintenance/ Erection mode where the boom may be lowered to the horizontal position without having the external alarm continuously sounding or the motion cut operating.

  • Page 57: 2- Accessing Rigging Mode

    The load is below the percentage of the capacity setted to activate the lockout system (120 % by default) • There is no more occurence of an ATB condition; or • The system resets. i4500 Lattice Boom Crane Instruction Manual...

  • Page 58: Operational Limits

    In the operational limits setting mode, the operator can set and activate/ deactivate the following four (4) operational limits in addition to those automatically provided by the i4500 system. Here are the limits 1) The minimum boom angle limit...

  • Page 59: 1- Accessing The Operational Limits Setting Mode

    If it is not the case, use the Up or Down buttons to highlight this line. 3. Choose the Select button to confirm your choice and access the operational limits mode. Limit setting menu i4500 Lattice Boom Crane Instruction Manual...

  • Page 60: 2- Limit Value Adjustments

    4. Press the Up and Down buttons to select the desired value for this particular limit. 5. Press Select button to confirm the selected value. 6. Press Escape button to return to the norma operating mode. Instruction Manual i4500 Lattice Boom Crane...

  • Page 61: 3- Enable/ Disable A Limit

    5. Press the Escape button to return to the normal operating mode. Maximum angle limit enabled Maximum angle limit disabled When the value of a given operational limit is changed (see section 4.5.2), the modified limit is automatically activated. i4500 Lattice Boom Crane Instruction Manual...

  • Page 62: Range Limiting Options

    The range limiting option provided by the i4500 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 near power lines.
  • Page 63 Menu options : When there is a range limiting option and a slew sensor installed on the crane, the i4500 automatically selects the range limiting mode as the only possible choice. In this case, the following “limit mode” menu options are offered: •...

  • Page 64: 1- Accessing Range Limiting Mode

    If it’s not the case, use the Up or Down button to highlight the line. 3. Press the Select button to confirm your choice and to access the range limiting mode. Range Limiting Mode Screen Instruction Manual i4500 Lattice Boom Crane...

  • Page 65: 2- Height Limit

    5. Press Select button to confirm the maximum height of the boom tip. As you release Select button, a 10-second countdown will allow you to boom down before your programmed height limit becomes active. Height limit programmed Height limit reached i4500 Lattice Boom Crane Instruction Manual...

  • Page 66: 3- Free Zone

    6. Press the Select button to confirm the position of the second wall. 7. As you release select button, a 10 seconds countdown will allow you to rotate the crane between the two walls before your programmed free zone limit becomes active. Instruction Manual i4500 Lattice Boom Crane...

  • Page 67: 4- Variable Height Limit

    2. Press the Down button to highlight the variable height limit line. 3. Press the Select button to confirm your choice. 4. Rotate the crane towards the first limit position (first wall). 5. Press Select button to confirm the position of the first wall. i4500 Lattice Boom Crane Instruction Manual...
  • Page 68 8. As you release Select button, a 10-second countdown will allow you to return between the two walls and boom down below the height limit before your pro- grammed variable height limit becomes active. Variable height limit programmed Right wall reached Left wall reached Height limit reached Instruction Manual i4500 Lattice Boom Crane...

  • Page 69: 5- Variable Radius Limit

    6. Rotate the crane towards the second limit position (second wall) with the boom always at the maximum radius permitted by the surrounding environ- ment. Note that you can change the maximum radius during this operation. i4500 Lattice Boom Crane Instruction Manual...
  • Page 70 Variable radius limit programmed Right wall reached Left wall reached Radius limit reached Instruction Manual i4500 Lattice Boom Crane...
  • Page 71 This page has been intentionally left blank...

  • Page 72: 5-Diagnostic & Troubleshooting

    55M4500EBE00A-A diagnostic & troubleshooting Warning! Troubleshooting shall be performed by a qualified technician or by an operator assisted by a RaycoWylie Service technician This section provides technical troubleshooting support. It will answer the most frequently asked questions that repair personnel may have when installing, repairing or performing maintenance on the i4500 system.
  • Page 73 If the interface is not a sensor, such as the relay interface, and therefore does not return a specific value, no value is displayed in the second column, however, the state of connection to the CanBus network is given in the third column i4500 Lattice Boom Crane Instruction Manual...

  • Page 74: Angle Sensor

    The following values will allow the RaycoWylie technician to diagnose a problem coming fron the sensor. If the angle sensor is not functionning properly, note these values and give them to a RaycoWylie technician.
  • Page 75 The basic criteria for a proper fucntionning of the load sensor are: the scale value must be smaller than 1,0. Dr+ must be close to 5,00 volts (DC). Press the Escape button to go back to the main screen of the diagnostic mode. i4500 Lattice Boom Crane Instruction Manual...

  • Page 76: Relays

    By pressing the Down button, you get access to the Input block. The displayed information will look like this: Press the Escape button to go back to the main screen of the diagnostic mode. Instruction Manual i4500 Lattice Boom Crane...

  • Page 77: Slew Sensors (Range Limiting Options)

    Detected addresses This menu of the diagnostic menu provides the addresses of the different sensors on the CAN network detected by the i4500 system. Even if a sensor stops communicating, addresses remain in memory as long as the system is on.

  • Page 78: Error Messages

    55M4500EBE00A-A Error messages During start up and other operation processes, the i4500 system analyses all interactions between internal peripherals (memories, controllers, extension cards, etc.) and external peripherals (various interfaces connected to sYsTEm the Canbus network). An error message will appear on the ERROR main screen if an error is detected.
  • Page 79 No parameter The crane dimensions must cL3, cL4 and cL7 values be correctly entered in the should never be at zero. system otherwise the load value will be non existant or wrong. i4500 Lattice Boom Crane Instruction Manual...

  • Page 80: External Peripherals

    55M4500EBE00A-A 5.7.2 External Peripherals A) Angle / Lenght and ATB Interface Errors The i4500 system can support up to 5 angle interfaces. Activation of every angle sensor is done in the calibration menu section ‘‘Enable/Disable I/O’’. Error message Execution process...
  • Page 81 55M4500EBE00A-A B) Load Interface Errors The i4500 system can support up to 4 load interfaces. 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 is out of range...
  • Page 82 55M4500EBE00A-A D) Generic Interface Errors The i4500 system can support up to 4 generic interfaces. Each one can support a wind speed sensor, an inclination level sensor and an absolute rotation encoder . Activation of every generic card is done in the calibration menu section ‘‘Enable/ Disable I/O’’.
  • Page 83 E) Rotation Interface Errors Relative rotation The i4500 system can support only one (1) rotation interface. There are two different kinds of slew sensors: a relative one and an absolute one. Activation of rotation interface is done in the calibration menu section ‘‘Enable/Disable I/O’’.

  • Page 84: 6- Inspection And Maintenance

    All cables (make sure they are no cuts or damages) as well as connectors (make sure they are no corroded contacts). • The plunger of the ATB switch for excessive corrosion. • If the lockout relay works well. Instruction Manual i4500 Lattice Boom Crane...

  • Page 85: Rated Load Test

    Note the actual and displayed radius. • Lower the load. • RaycoWylie recommends to sign and date all the test records and to keep a copy of the latest test available at all times. i4500 Lattice Boom Crane Instruction Manual...

  • Page 86: Maintenance

    RaycoWylie technician. Preventive Maintenance • Your i4500 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 i4500 display box, junction boxes, angle sensors, load cells or on any connectors.

  • Page 87: Maintenance Procedure

    After adjustments and repairs have been made, the crane shall not be used until all safety devices are reactivated and trapped air removed from the hydraulic system. The instructions for the removal of air from hydraulic circuits should be provided by the crane manufacturer. i4500 Lattice Boom Crane Instruction Manual...

  • Page 88: Adjustments And Repairs

    If you have any questions or need technical assistance, please contact our Technical Service Department at RaycoWylie quoting the information found on the serial number label of your i4500 system. Instruction Manual i4500 Lattice Boom Crane...
  • Page 89 55M4500EBE00A-A Notes i4500 Lattice Boom Crane Instruction Manual...
  • Page 90 This page has been intentionally left blank...
  • Page 91 This page has been intentionally left blank...

Table of Contents