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RaycoWylie i4500 Calibration Instructions Manual

Rated capacity limiter/indicator for telescopic cranes, pressure sensing
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55M4500CCE00 REV A
Crane safety instrumentation
Calibration Instructions
i4500 Rated Capacity Limiter/Indicator
for
telescopic cranes, pressure sensing

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Summary of Contents for RaycoWylie i4500

  • Page 1 55M4500CCE00 REV A Crane safety instrumentation Calibration Instructions i4500 Rated Capacity Limiter/Indicator telescopic cranes, pressure sensing...
  • Page 2 55M4500CCE00 REV A...
  • Page 3 RaycoWylie Systems. The i4500 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 Before operating a crane equipped with a RaycoWylie system RCI, the operator must carefully read the information in the i4500 operator manual and the crane manufacturer operator’s manual. He must also be aware of all the federal, state and local safety standard and regulations applicable to his job.

  • Page 5: Table Of Contents

    55M4500CCE00 REV A TABLE OF CONTENTS INTRODUCTION ....................... 7 Personnel qualification and scope of this manual ............7 Using this manual ......................7 CONFIGURATION ....................9 Step #1: Accessing the calibration menu ..............9 Step #2: “Enable/Disable i/o” Setting ................. 10 Step #3: “Calibration units”...
  • Page 6 55M4500CCE00 REV A “special calibration” ...................... 47 “Users ID” Setting user pass codes for the data logger .......... 47 “rotation data” ........................ 48 AUTOMATIC LOGS ....................50 “Fault log” ........................50 “Event recorder” ......................50...

  • Page 7: Introduction

    INTRODUCTION This manual contains calibration information for the i4500 system. When performing calibration of the i4500 system, always observe the safety rules and regulations applicable in the country of operation to reduce the risk of personal injury or damage to the equipment.
  • Page 8 55M4500CCE00 REV A Additional buttons used in the calibration mode only, refer to relevant text for detailed use: SAVE button. Press to save all recent changes into memory. DELETE button. Press to delete a stage of some calibrations. CLEAR button. Press to clear the fault log or the event log. CHANGE SIGN button.

  • Page 9: Configuration

    55M4500CCE00 REV A CONFIGURATION To ensure a successful, first calibration follow each calibration step in sequence, do not miss out any steps unless they are marked as optional. Many calibration screens show reminder notes or hints on the bottom line, remember to read these for guidance.

  • Page 10: Step #2: "Enable/Disable I/O" Setting

    55M4500CCE00 REV A Step #2: “Enable/Disable i/o” Setting Note: these settings reflect the configuration of your system and will generally be made during factory testing prior to delivery and should not need changing. 1‐ In the calibration menu, scroll up or down to the menu "Enable/Disable i/o". 2‐...
  • Page 11 55M4500CCE00 REV A For the Generic and GPio items there are various configuration options available once enabled, refer to the system wiring drawing for details of which selection to set.

  • Page 12: Step #3: "Calibration Units" Setting

    Refer to the wiring drawing supplied for the necessary settings for your system. Warning: these settings must match the relevant wiring drawing for proper operation of the i4500 system. Step #3: “Calibration units” setting 1‐ In the calibration menu, scroll up or down to the item "Calibration units:".

  • Page 13: Step #4: "Calibration Data" Entry

    55M4500CCE00 REV A Step #4: “Calibration data” Entry Some or all of this information may be pre‐loaded prior to delivery but all entries should be verified and edited as required before proceeding. Length units in use will be feet or metres depending on the setting made for ‘calibration units’...
  • Page 14 55M4500CCE00 REV A  Alarm 2: Is the %SWL overload limit. If the %SWL is greater than Alarm 2, a continuous audible alarm will be activated and the red display LED will be ON. The external red lamp and audible alarm output will be ON. ...

  • Page 15: Step #5: "Dimensions" Data Entry

    55M4500CCE00 REV A Step #5: “Dimensions” Data entry This menu contains crane dimensions that are necessary for the calculation of the load on the hook, based on the hydraulic cylinder pressure. This data refers to the winch and boom hoist cylinder geometry at the superstructure and some main boom dimensions. Some or all of this information may be pre‐loaded prior to delivery but all dimensions should be verified and edited as required before proceeding.
  • Page 16 55M4500CCE00 REV A  CH2 (height outrigger) – vertical distance between the boom pivot pin and the ground when on outriggers.  NR (number of rams) number of boom lift cylinders, normally 1 or 2.  –  RD (rod diameter) rod diameter of the lift cylinder.
  • Page 17 55M4500CCE00 REV A *Note 2: The chart file that contains all the relevant load charts and duty information for the machine also contains dimensions, weights and center of gravity for all the boom top attachments (fly jibs etc.). In some cases some of this data may not have been available during the system configuration at the factory.

  • Page 18: Step #6: "Block Capacities And Block Weights" Setting

    The capacity of each hook will be used by the i4500 system to determine whether the current SWL for the configuration and position of the machine is limited by the load curve, the parts of line or the hook capacity.

  • Page 19: Step #7: "System Options" Setting

    The system options menu allows various features to be turned on and off and may vary depending on the version of software installed in the i4500 system. These settings will normally be pre‐set before delivery and will not require changing.

  • Page 20: Step #8: "Crane Type

    Dyno version. Must be set to OFF for this pressure sensing version of the i4500. Step #8: “crane type”...

  • Page 21: Calibration

    55M4500CCE00 REV A CALIBRATION Step #11: “Zero sensor/Side of boom angle” angle sensor calibration Address selection dip switch: Every angle sensor installed has its own dedicated address. These switches are factory set prior to dispatch and will not normally require changing. Please refer to the wiring diagram to see the address dip switch setting for each angle sensor interface.

  • Page 22: Step #12: "Zero Sensor/Span Sensor" Length Sensor Calibration

    55M4500CCE00 REV A 4) Press “” to highlight the value to edit and use “” or “” to edit the location of the angle sensor (normally integrated into the length sensor (reel)), press the “” to confirm and then “” to exit. Note, “right”...
  • Page 23 55M4500CCE00 REV A 4) Retract the boom completely. The sensor’s value must be approximately 100 bits (0,50 volts; adjust the potentiometer inside the cable reel if necessary). 5) Edit the zero value: when the boom is completely retracted, the value must be set to zero.

  • Page 24: Step #13: "Zero Pressure/Span Pressure" Sensor Calibration

    55M4500CCE00 REV A Step #13: “Zero pressure/Span pressure” sensor calibration This step is only required for pressure transducers with mV output. For transducers with 4‐20mA or J1939 outputs calibration is not required, go to Step #14. Select the transducer to be calibrated 1) Use “”...
  • Page 25 55M4500CCE00 REV A The reading on the Sensor value is in bits and the maximum scale value is 4095. For the zero setting the display should read between 175 and 300 bits. The units are shown at the bottom of the screen and are in bar for metric calibration units and psi for imperial calibration units.

  • Page 26: Step #14: "Select Boom Output Sequence

    55M4500CCE00 REV A Step #14: “select boom output sequence” This section is only necessary and available if there is more than one boom extension reel fitted, if there is only one reel go to step #15. For machines with more than one length sensor (reel), multiple no load calibrations must be made depending on the boom telescoping sequence.

  • Page 27: Step #15: "No Load Calibration

    55M4500CCE00 REV A Step #15: “No Load calibration” Before proceeding with this section, ensure that all previous sections have been completed, in particular that all dimensions have been entered correctly and all sensors are correctly calibrated. The No load calibration procedure must be carried out for each of the Boom Mode configurations to record the empty boom weight.
  • Page 28 55M4500CCE00 REV A Start this procedure with the boom fully retracted. “” or “” to choose “No load calibration” and press “” to enter. If the selected configuration has been calibrated previously the system will prompt for a new calibration or give the option to escape: Warning: if you press delete “X”, the previous calibration will be lost.
  • Page 29 55M4500CCE00 REV A For single reel installations: xxx.xx. is the maximum working main boom length for this duty as measured by the extension sensor. This value is usually to the top of the last telescoping section or manual section and does not include extension fly jibs etc. The default value will be dimension CL2 or CL2MR, press ““...
  • Page 30 55M4500CCE00 REV A If more than two lengths have been entered the display now shows: Where length 2 is the second calibration length to be specified. The first and last lengths will automatically be set to the minimum and maximum values specified for calibration and other calibration lengths will default to evenly distributed lengths calculated by the system.
  • Page 31 55M4500CCE00 REV A Use “” or “” to set xx to the required number of angle steps for calibration length 1 then press “save” to accept. Enter the number of angle calibration points for each length step in turn as prompted. Setting the maximum boom angle: The display will show: Derrick the boom up to the maximum possible angle, that is, with the boom hoist...
  • Page 32 55M4500CCE00 REV A Recording the ‘no load’ pressure map: The i4500 has now been programmed with all preset points and is ready to calibrate. The following procedure to record unloaded boom weight pressures should be carried out with the hook block suspended at all times.
  • Page 33 Note the incomplete calibration will be lost if the duty is changed before returning to the no load calibration procedure. When the final calibration point is accepted the i4500 will automatically save the data and display the following confirmation screen: Press “”...

  • Page 34: Step #16: "Loaded Boom Deflection

    55M4500CCE00 REV A Step #16: “Loaded boom deflection” This procedure is used to add an allowance into the calculation of the hook radius to compensate for main boom and/or chassis deflection due to a suspended load. A separate calibration is available for each crane configuration that also has an individual no load calibration but is not used for configurations with boom attachments.
  • Page 35 55M4500CCE00 REV A 2) Press “”, the display will change to show the current boom angle followed by a target boom angle for calibration, normally 60°. Adjust the boom angle to the target angle, when the boom is at the correct angle for calibration the display will change to show: 3) Press “”, the display will change to show: Carefully lift the test load just clear of the ground.

  • Page 36: Step #17: Optional "Load Adjustment

    55M4500CCE00 REV A Step #17: Optional “Load adjustment” This procedure is optional: one load adjustment factor is available per attachment configuration and is used to increase the accuracy of the load on hook indication. This will compensate for minor geometric errors that may come from crane manufacturing tolerances or from the method used to take the dimensions, weights and centre of gravity locations of attachments.

  • Page 37: Step #18: Optional "Load Offset

    55M4500CCE00 REV A 2) Use “” or “” to modify the load adjustment factor until the displayed load is equal to the test load. Press “” to accept the change, the system will confirm the calibration is saved. 3) Press “” to return to the main calibration menu. Carefully set the test load on the ground.
  • Page 38 55M4500CCE00 REV A positioning the machine remember to make the last derrick motion boom up. Carefully lift the test load just clear of the ground. 2) Use “” or “” to modify the load adjustment factor until the displayed load is equal to the test load and press “”...

  • Page 39: Step #19: Optional "Load Correction

    55M4500CCE00 REV A Step #19: Optional “Load correction” This procedure is optional and a separate calibration is available for each crane configuration that also has an individual no load calibration. It is used to add an allowance into the calculation of the hook load to compensate for a potential build up of minor errors in either fixed data or previous calibration data.
  • Page 40 55M4500CCE00 REV A Case 2 Case 1 effect of one simple 2 point additional point CF calibration Case 3 Case 4 suggested sequence limited CF zones for better results 7.12 7.12 6.11 6.11 6.10 6.10 5.10 No CF applied No CF applied Case 6 Case 5...
  • Page 41 55M4500CCE00 REV A Only one load correction factor is stored at each angle/length location and the test load used to set this factor should represent greater than 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.
  • Page 42 55M4500CCE00 REV A Existing load correction points can be deleted if required, select the screen above but use button “” to decrease the point number to the one that is not required. The display will show : This screen will show the data stored for the selected calibration point rather than current data, press “X”...

  • Page 43: Step #20: "Friction Compensation

    A copy of the calibration file can be made at any time after completing a calibration step and should be made once the final calibration is completed. Note a USB memory stick must be connected to connector ‘B’ of the i4500 display unit using a Deutsch to USB converter lead (RaycoWylie part no. 33V0414) before proceeding.
  • Page 44 The final completed calibration file should be renamed: “cranename_serialnumber_date_tech.cal” where serialnumber is the serial number of the i4500 system, the date is the date the calibration file is completed/downloaded and tech is the initials of the calibrating technician. Some configuration specific calibration data may be stored in the load chart file and it is recommended to also make a backup copy of this second file: Select “load chart ‐>...

  • Page 45: Transfer" Restoring Calibration And Load Chart Files

    #21 as a precaution before continuing. If in doubt consult Rayco Wylie. A copy of the calibration and/or load chart files can be restored to the i4500 system at any time. Note a USB memory stick must be connected to connector ‘B’ of the i4500 display unit using a Deutsch to USB converter lead (RaycoWylie part no.

  • Page 46: Memory

    Select the relevant file from the list displayed and press “”, the selected file will be copied to the i4500 system and will replace any existing data. Once done, it is advisable to reboot the system (power off and on again) and reselect a valid configuration, do not accept the existing default duty presented on start up.

  • Page 47: Options

    This feature is only used if the data logger feature is fitted to the system and password protection is set to ON. It is a list of password numbers used to log into the i4500 on startup and can be used in conjunction with the Rayco Wylie data logger software for PC to record individual user data for each working session of the machine.

  • Page 48: Rotation Data

    2 onward but if the default value is changed remember to safely record the new value. The i4500 system must have a valid number entered before it will go to the normal working screen if password protection is set to ON.
  • Page 49 55M4500CCE00 REV A Absolute zero: This is used to set the zero datum point when an absolute encoder or single turn, twin wiper potentiometer is fitted as the slew sensor. To set the zero datum: Rotate the machine to the zero datum point, normally centred over the front of the machine, and press “”...

  • Page 50: Automatic Logs

    55M4500CCE00 REV A AUTOMATIC LOGS “Fault log” The fault log screen is a diagnostic tool used to record intermittent errors detected in various parts of the system. The numbers on the right hand side of this screen represent a count of the number of individual faults detected for each component and can be useful in tracing system faults.

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