RaycoWylie i4300 Calibration Instructions Manual
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RaycoWylie i4300 Calibration Instructions Manual

Rated capacity limiter/indicator for telescopic cranes, pressure sensing
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55M4300CCE00 Rev A
Crane safety instrumentation
Calibration Instructions
i4300 Rated Capacity Limiter/Indicator
for
telescopic cranes, pressure sensing
software ref sc162xxx
Copyright 2017
(Rayco-Wylie Systems).
All rights reserved.
Any part of this document may not be reproduced or transmitted in any form or by any means including
photocopy or any other information storage and retrieval system without the permission from
RaycoWylie Systems which will not normally be withheld assuming that the material is for internal use
only.

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Summary of Contents for RaycoWylie i4300

  • Page 1 Any part of this document may not be reproduced or transmitted in any form or by any means including photocopy or any other information storage and retrieval system without the permission from RaycoWylie Systems which will not normally be withheld assuming that the material is for internal use only.
  • Page 2 55M4300CCE00 Rev A...
  • Page 3 RaycoWylie Systems. The i4300 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 i4300 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

    55M4300CCE00 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 55M4300CCE00 Rev A “Limits setting” parameters ....................54 “Users ID” Setting user pass codes ................54 AUTOMATIC LOGS ....................56 “Fault log”..........................56 “Event recorder” ......................... 56 ANNEX 1 – Calibration of Main boom “Load correction” ........ 58 ANNEX 2 – Menu cross reference ..............63...

  • Page 7: Introduction

    INTRODUCTION This manual contains calibration information for the i4300 system. When performing calibration of the i4300 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 55M4300CCE00 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

    55M4300CCE00 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

    55M4300CCE00 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- Press “”...
  • Page 11 “” or “” to scroll through the available options and then press “save” when the required option is displayed. 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 i4300 system.

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

    55M4300CCE00 Rev A Step #3: “Calibration units” setting 1- In the calibration menu, scroll up or down to the item "Calibration units:". 2- Press “” to toggle between metric and imperial. imperial: use x1000lbs and feet. metric: use metric tons and metres (1 metric ton = 1000 kg).

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

    55M4300CCE00 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 55M4300CCE00 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

    55M4300CCE00 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 55M4300CCE00 Rev A  CL11 - vertical distance between the upper boom tip sheave pin and the boom centerline (or boom foot pin, see CL8) with the boom horizontal.   CR1 - lower boom tip sheave pitch radius (hook suspension sheave). ...
  • Page 17 55M4300CCE00 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 55M4300CCE00 Rev A Boom hoist cylinder geometry Winch geometry Winches or guide sheaves on superstructure...

  • Page 19: Step #6: "Block Capacities And Block Weights" Setting

    The capacity of each hook will be used by the i4300 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 20: 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 i4300 system. These settings will normally be pre-set before delivery and will not require changing.

  • Page 21: Step #8: "Picture

    The clock must be set to the correct local time and date to ensure any event recorded by the i4300 is simple to analyze. It is not necessary to be in the calibration mode of the i4300 for this setting, see also “System configuration mode settings” section of the instruction manual.
  • Page 22 55M4300CCE00 Rev A using the 24 hour clock. Set each highlighted field in turn using the “” or “” buttons to select the value and the “” button to save each setting and move to the next field. The screen will return to the main screen after the minutes have been set. Press “” at any time to exit to the main screen.

  • Page 23: Calibration

    55M4300CCE00 Rev A CALIBRATION Step #10: “Zero sensor/Side of boom angle” angle sensor calibration Address selection dip switch: The 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 the angle sensor interface.
  • Page 24 55M4300CCE00 Rev A Zero angle calibration: Ensure the correct side of boom setting has been made before setting the zero datum, if the side of boom setting is changed then the zero setting must be repeated. 1) Use “” or “” to choose “Zero sensor” and press “”. 2) Boom down to zero degrees (main boom horizontal) using a precision angle measure to accurately establish the true angle of the base boom section.

  • Page 25: Step #11: "Zero Sensor/Span Sensor" Length Sensor Calibration

    55M4300CCE00 Rev A Step #11: “Zero sensor/Span sensor” length sensor calibration Warning: The system does not store the ZERO LENGTH into permanent memory until the SPAN LENGTH calibration has been completed. If a ZERO LENGTH calibration is done, then a SPAN LENGTH calibration must also be done. Zero extension calibration: 1) Use “”...
  • Page 26 55M4300CCE00 Rev A sections including a manual section if fitted). The sensor value should be a minimum of 150 bits above the zero value. Enter the difference between the extended length and the fully retracted main boom length using the units shown at the bottom of the screen.

  • Page 27: Step #12: "Zero Pressure/Span Pressure" Press. Sensor Calibration

    55M4300CCE00 Rev A Step #12: “Zero pressure/Span pressure” press. 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 #13. Select the transducer to be calibrated 1) Use “”...
  • Page 28 55M4300CCE00 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 29: Step #13: Main Boom "No Load Calibration

    55M4300CCE00 Rev A Step #13: Main boom “No Load calibration” 3 important checks before proceeding with each No Load calibration: 1. Ensure that all previous sections have been completed, in particular that all dimensions have been entered correctly and all sensors are correctly calibrated. 2.
  • Page 30 55M4300CCE00 Rev A Notes: 1. During this procedure boom angle, boom length and pressures are displayed at various times for reference purposes on the display window. 2. The derrick motion immediately before recording a calibration point should always be up/in. If it was necessary to derrick down/out, then derrick up/in slightly before recording the calibration point.
  • Page 31 55M4300CCE00 Rev A and set the correct configuration in the normal working mode. Additional information regarding the current boom output sequence is displayed if relevant. After pressing “” to accept the duty to be calibrated the display shows: Single reel installations: xxx.xx. is the maximum working main boom length for this duty as measured by the extension sensor.
  • Page 32 55M4300CCE00 Rev A Telescopic band to be calibrated Minimum of points None 2 (minimum) Up to 6m (20ft) 6-10m (20-30ft) 10-14m (30-45ft) 14-18m (45-60ft) Over 18m (60ft) 7 (maximum) Use “” or “” to edit this number and press “save” to confirm the value and move to the next step.
  • Page 33 55M4300CCE00 Rev A When the last calibration length has been entered the display shows: Number of angle steps for Length 1 = xx Where xx is the number of angle steps to calibrate for length 1, length 1 represents the fully retracted boom.
  • Page 34 55M4300CCE00 Rev A Setting the minimum boom angle for each calibration length: The display will show: Minimum angle for length 1 = xx.xx Where xx.xx is the lowest working angle in degrees for length 1. Check the load chart and determine the lowest rated angle for each of the boom lengths you have previously entered;...
  • Page 35 55M4300CCE00 Rev A Recording the ‘no load’ pressure map: The i4300 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 36 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 i4300 will automatically save the data and display the following confirmation screen: Press “”...

  • Page 37: Step #14: Main Boom "Unloaded Boom Deflection

    55M4300CCE00 Rev A Before proceeding with additional calibration work check the overall performance by moving the unloaded hook around the working envelope; i.e. high/low angles and long/short boom. If an unacceptable variation in displayed hook weight is seen then check geometric dimensions entered earlier, re-calibrate the no load pressure map using more calibration angles and lengths, or proceed to add load adjustment, offset and/or correction calibrations.
  • Page 38 55M4300CCE00 Rev A With the hook block suspended, telescope the boom out to fully extended for the boom mode and telescoping sequence selected. This will generally be shorter than the target indicated when working with multi-reel applications or longer than the target indicated when calibrating the larger telescoping range when working with dual mode telescoping booms.

  • Page 39: Step #15: Main Boom "Loaded Boom Deflection

    55M4300CCE00 Rev A Accurately measure the actual radius of the suspended hook from the centre line of slew of the machine. Use “” or “” to adjust the Corr.: x.x value until the displayed radius equals the measured radius, note that the indicated radius should normally be increased, not decreased.
  • Page 40 55M4300CCE00 Rev A calculated test load should normally include the weight of the hook block and any slings, shackles etc. that are used. Ensure the current duty selection matches the actual crane configuration to be calibrated. Use “” or “” to highlight “Loaded boom deflection” and press “”...
  • Page 41 55M4300CCE00 Rev A Adjust the boom angle to the target angle, when the boom is at the correct angle for calibration the display will change to show: Press “”, the display will change to show one of these screens: Carefully lift the test load until it is just clear of the ground. Accurately measure the actual radius of the suspended load from the centre line of slew of the machine.

  • Page 42: Step #16: Main Boom "Load Adjustment

    55M4300CCE00 Rev A Step #16: Main boom “Load adjustment” This feature is optional and can be omitted if the displayed load is judged acceptable, it is normally used in tandem with section 3.8 ‘load offset’. 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 (refer to Section 3.11).

  • Page 43: Step #17: Main Boom "Load Offset

    55M4300CCE00 Rev A Where Load: represents the suspended load reading and 1.00 represents the adjustment factor (a value of 1.00 signifies that there is no applied adjustment). The main boom must be completely retracted for the mode selected and with an angle of approximately 60°.
  • Page 44 55M4300CCE00 Rev A A known test load is needed to perform this calibration and should be between 50% and 90% of SWL for the configuration to be calibrated. These SWL’s should be based on the capacity with a boom angle of approximately 60° and with the boom fully retracted for the boom mode selected.

  • Page 45: Step #18: Attachment "Jib Deflection

    55M4300CCE00 Rev A Step #18: Attachment “Jib deflection” This procedure is only available if jib duties are available and is optional depending on the accuracy of the radius indication of the jib, it is used to add an allowance into the calculation of the jib hook radius to compensate for jib deflection both with and without a suspended load.
  • Page 46 55M4300CCE00 Rev A Press “”, the display will change to show the first calibration screen. With just the hook suspended, accurately measure the actual radius of the hook from the centre line of slew of the machine. Use “” or “” to adjust the “Corr” value until the displayed radius equals the measured radius.

  • Page 47: Step #19: Attachment "Load Adjustment

    55M4300CCE00 Rev A Step #19: Attachment “Load adjustment” This feature is optional and can be omitted if the displayed load is judged acceptable, it is normally used in tandem with section 3.11 ‘load offset’. A separate load adjustment calibration is available for each and every jib attachment and is used to improve the accuracy of the load on hook indication.

  • Page 48: Step #20: Attachment "Load Offset

    55M4300CCE00 Rev A remember to make the last derrick motion boom up. Carefully lift the test load just clear of the ground. 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.
  • Page 49 55M4300CCE00 Rev A 1) Use “”or “” to highlight “Load offset” and press “” to enter. Where Load: represents the suspended load reading and 0.00 represents the offset factor (a value of 0.00 signifies that there is no applied offset). The main boom should be at an angle of approximately 60°.

  • Page 50: Step #21: "Friction Cylinder

    Note a USB memory stick must be connected to connector ‘B’ of the i4300 display unit using a Deutsch to USB converter lead (RaycoWylie part no. 33V0414) before proceeding. The USB memory stick must be formatted to FAT32 format.
  • Page 51 The final completed calibration file should be renamed: “cranename_serialnumber_date_tech.cal” where serialnumber is the serial number of the i4300 system, the date is the date the calibration file is completed/downloaded and tech is the initials of the calibrating technician. For early operating systems prior to rev sc122…v0200, some configuration specific...

  • Page 52: Transfer" Restoring Calibration And Load Chart Files

    3.14 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 i4300 system at any time. Note a USB memory stick must be connected to connector ‘B’ of the i4300 display unit using a Deutsch to USB converter lead (RaycoWylie part no.

  • Page 53: Memory

    Select the relevant file from the list displayed and press “”, the selected file will be copied to the i4300 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 54: Options

    “Users ID” Setting user pass codes This feature is only used if password protection is set to ON. It is a list of password numbers used to log into the i4300 on startup. Where this feature is not used the default login number is “99999”.
  • Page 55 2 onward but if the default value is changed remember to safely record the new value. The i4300 system must have a valid number entered before it will go to the normal working screen if password protection is set to ON.

  • Page 56: Automatic Logs

    55M4300CCE00 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.
  • Page 57 55M4300CCE00 Rev A Note the event status, these sample screens show 2 lifts performed between 50 and 60% SWL and also 2 ATB alarms recorded. Press “” to return to the main calibration menu or press “XX” to reset all the counters to zero.

  • Page 58: Annex 1 - Calibration Of Main Boom "Load Correction

    55M4300CCE00 Rev A ANNEX 1 – Calibration of Main boom “Load correction” Warning Note : This procedure will not normally be necessary and should not be used unless under the guidance of RW technical staff. It must not be used before exhausting other, more likely, causes of load reading errors such as dimensional errors or proper no load calibration using an adequate number of calibration points.
  • Page 59 55M4300CCE00 Rev A The following notes are intended to give general guidance only as each individual installation will be different. The full working envelope of the configuration can be divided into different zones for load correction calibration, see the following diagrams for examples.
  • Page 60 55M4300CCE00 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 61 55M4300CCE00 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 62 55M4300CCE00 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 63: Annex 2 - Menu Cross Reference

    55M4300CCE00 Rev A the load correction calibration should always be cleared before proceeding with a no load calibration, see section 3.4. ANNEX 2 – Menu cross reference Note: Items marked # are options and not available in all software versions. Item Manual Main boom...

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