RaycoWylie i4000 Instruction Manual
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RaycoWylie i4000 Instruction Manual

Multifunction indicator/range limiting device for lattice crane
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Multifunction indicator/range limiting device
Wylie Systems
(Rayco Technology Group)
201 Prospect Avenue
Suite 106 - Box 159
Hagerstown, MD 21742
USA
Tel: +1 888-252-1957
Fax: +1 (418) 266-6610
i4000
For Lattice crane
Instruction Manual
Crane Warning Systems Atlanta
Rayco Electronic Systems
(Rayco Technology Group)
6175 Hickory Flat Hwy Suite #110-376
2440 Dalton Avenue
Canton, GA 30115
877-672-2951 Toll Free
678-261-1438 fax
www.craneindicators.com
Tel: +1 (418) 266-6600
sales@craneindicators.com
Fax: +1 (418) 266-6610
Copyright © 2018
RaycoWylie Systems
All rights reserved.
Ste-Foy, Qc
CANADA
G1P 3X1
55M4000EBE00 Rev C
Wylie Systems
(Rayco Technology Group)
Drury Lane
St-Leonards on Sea, East Sussex
ENGLAND
TN38 9BA
Tel: +44 (0) 1424-421235
Fax: +44 (0) 1424-433760

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Summary of Contents for RaycoWylie i4000

  • Page 1 55M4000EBE00 Rev C i4000 Multifunction indicator/range limiting device For Lattice crane Instruction Manual Crane Warning Systems Atlanta Wylie Systems Rayco Electronic Systems Wylie Systems (Rayco Technology Group) (Rayco Technology Group) (Rayco Technology Group) 6175 Hickory Flat Hwy Suite #110-376 201 Prospect Avenue...
  • Page 5 It is strictly forbidden to alter or modify the equipment without written authorization from RaycoWylie Systems. The i4000 system by RaycoWylie Systems (Multifunction indicator) is purely an aid to the operator. When the parameters are correctly set, the indicator warns the crane operator of a potential overload which could endanger the equipment or the goods, and cause injuries to the operator or the workers who are close to the crane and its load.
  • Page 7 SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN MINOR OR MODERATE DAMAGES. IT CAN BE USED TO WARN ABOUT UNSAFE PRACTICES. IMPORTANT: INDICATES A SITUATION WHICH COULD DAMAGE THE MACHINERY. NOTE: PROVIDES INFORMATION WHICH CAN BE OF SPECIAL INTEREST. i4000 Lattice Crane Instruction Manual...

  • Page 9: Table Of Contents

    5 1- GENERAL DESCRIPTION OF THE SYSTEM page 13 Introduction page 13 Operator skill page 13 Usefulness of the i4000 system page 13 Description of the i4000 system page 14 1.4.1 Audible alarm page 15 1.4.2 Visual alarm page 15...
  • Page 10 Range limiting option page 50 4.7.2 Accessing the range limiting adjustment menu page 50 4.7.3 Height limit page 51 4.7.4 Free zone page 52 4.7.5 Variable height limit page 53 4.7.6 Variable radius limit page 55 Instruction Manual i4000 Lattice Crane...
  • Page 11 External peripherals page 63 6- INSPECTION AND MAINTENANCE page 66 Frequent inspections page 66 Periodic inspections page 66 Checking the displayed load page 67 Maintenance page 68 Maintenance procedure page 69 Adjustments and repairs page 70 i4000 Lattice Crane Instruction Manual...

  • Page 13: 1- General Description Of The System

    Please make sure you respect the safety rules currently in force in the country where you are using the i4000 system, in order to reduce the risk of injuries or of damages to the machinery. Please consider each safety directive mentioned in this manual when using the i4000 system.

  • Page 14: Description Of The I4000 System

    The system display is located inside the cabin, close to the operator controls for easy access to the information. All sensors are connected through a CAN bus network. The allowed capacity is assessed by the operator. With the measures provided by the i4000 system, he will be able to identify the allowed load in the manufacturer’s chart.

  • Page 15: Audible Alarm

    1.4.2 Visual alarm The i4000 system display has been equipped with a 3-colour warning light to alert the operator and to indicate a specific action. The flashing yellow light turns on together with the sound alarm when the load reaches the approach alarm’s threshold, that is, 90% of the nominal capacity.

  • Page 16: Location And Description Of Typical Components

    55M4000EBE00 Rev C Location and description of typical components 1. The i4000 display unit: It is also the central unit of the i4000 system. Its main characteristics are the bus CAN communications interface and the liquid-crystal graphic display. 2. The central input/output interface: This relay interface module is connected to individual external input and output devices controlled by the i4000 system (optional).

  • Page 17: Overall Scheme

    55M4000EBE00 Rev C Overall scheme i4000 Lattice Crane Instruction Manual...

  • Page 18: Technical Information

    3.5’’ Crystal liquid screen (320 x 240) Display unit protection: IP67 Bus CAN interface/ sensors: Default quantity Maximum quantity -Load or pressure sensors -Angle or length sensors - Relay output - Rotation sensor - Possibility of additional sensors - Radio Module Instruction Manual i4000 Lattice Crane...

  • Page 19: 2- Detailed Description Of The Display Unit

    Detailed description of the display unit Navigating the normal mode of operation The normal mode of operation of the i4000 system is organized into four separate screens. We call it “tabs”. Use the left or right arrow keys to navigate in these tabs.

  • Page 20: Indicator Tab

    The parameter indicating the boom tip height should only be used as a guide and NOT as an indicator of whether the crane may pass or not underneath a structure whose exact height is known. Some mini-dials are only displayed if the corresponding sensor is installed. Instruction Manual i4000 Lattice Crane...

  • Page 21: Load Tab

    BOOM OF THE LOAD AUX= AUXILIARY CAPACITY BOOM NUMBER OF STRANDS (PARTS OF LINE) WEIGHT ON THE HOOK NOMINAL (MAX) LOAD CAPACITY The (Load) tab will only be shown if a load interface is activated. i4000 Lattice Crane Instruction Manual...

  • Page 22: Range Limiting Device Tab

    Tools tab Under the tools tab you will find among others: the diagnostic mode, the error mode, the calibration mode and the day / night display mode. CURRENT CRANE CONFIGURATION Instruction Manual i4000 Lattice Crane...

  • Page 23: Overview Of The Display Unit

    AND ESCAPE BUTTONS WARNING LIGHT Under normal working conditions, the light is green. The light turns yellow to indicate the approach to a preset operating limit. The light turns red to warn the operator of any abnormality. i4000 Lattice Crane Instruction Manual...

  • Page 24: Description Of Operation Keys

    ESCAPE KEY Press this key to leave a menu or settings window, and to return to the previous screen without saving the changes. Press several times to return to the main menu. Instruction Manual i4000 Lattice Crane...

  • Page 25: Warning Lights And Messages

    RANGE LIMITING DEVICE BYPASS GREEN ACTIVATED LED (flashing) = YELLOW (APPROACH) NORMAL RED (REACHED) OPERATING ZONE OPERATING ZONE (RADIUS) (CEILING) LOAD TAB INDICATORS ANTI-TWO BLOCK MAXIMUM LOAD (A2B) CONDITION LIMITED BY THE ROPE DETECTED CAPACITY i4000 Lattice Crane Instruction Manual...

  • Page 26: Overload Warnings

    Solid red The crane’s nominal capacity has been reached or exceeded. A warning message will be displayed in the range limiting tab in order to inform the operator that a load limit has been reached. Instruction Manual i4000 Lattice Crane...

  • Page 27: Anti-Two Block And Rope Limit Indicators

    The anti-two block (A2B) indicator appears on The rope’s capacity limit indicator appears on the the screen of the i4000 when the hook pulley is screen of the i4000 system to indicate that the near the boon head pulley. This may block the allowed nominal load is limited by the rope’s safe...

  • Page 29: 3- Installation And Calibration

    Installation and Calibration The installation and calibration must be performed by a qualified person having a good understanding of all Raycowylie installation and calibration instructions. He must perform a complete and precise verification of the system installation before starting the calibration. The installation must have been done in compliance with Raycowylie instructions using only Raycowylie components supplied with the system.

  • Page 31: 4- Operating Instructions

    Please make sure you respect the safety rules currently in force in the country where you are using the i4000 system, in order to reduce the risk of injuries or of damages to the machinery. Please read the following safety instructions before trying to operate the system.

  • Page 32: Residual Risks

    The system does not indicate if the soil is stable. This may increase the risk of the machine breaking or tilting, thus causing injuries and even death. Instruction Manual i4000 Lattice Crane...

  • Page 33: Power-Up

    Once he has chosen a configuration, the i4000 system switches to its normal operating mode. If a limit has been set up and it has not been erased during the last session, the i4000 will then display the following screen: This tells the operator that a limit has been saved already and asks if it is still valid.

  • Page 34: System In Configuration Mode

    ‘Range limiting device’ will be present. 1. Navigate to the Tools tab with the LEFT or RIGHT keys. 2. Press the ‘ENTER’ key to access the configuration options. Now you can choose the option you wish to configure. Instruction Manual i4000 Lattice Crane...

  • Page 35: Selecting The Measuring Unit

    3. Press ‘ENTER’ to change the unit. 4. Choose the desired unit using the ‘UP/DOWN’ keys. 5. Press ‘ENTER’ again to save the unit. Or press the ‘ESCAPE’ key to quit without saving the changes. i4000 Lattice Crane Instruction Manual...

  • Page 36: Selecting The Language

    3. Press ‘ENTER’ again to change the language. 4. Choose the desired language using the ‘UP/DOWN’ keys. 5. Press ‘ENTER’ again to save the language. Or press the ‘ESCAPE’ key to quit without saving the changes. Instruction Manual i4000 Lattice Crane...

  • Page 37: Selecting The Light Intensity

    5. Then press the ‘ENTER’ key again to move to the following digit. Repeat steps 3 and 4 for the following digits. After entering the last digit, press 'ENTER' to save the value. At any time, press the 'ESCAPE' key to go back without saving changes. i4000 Lattice Crane Instruction Manual...

  • Page 38: Adjust System Time And Date

    6. Change the first digit by entering your desired value, using the 'UP/ DOWN' keys. Next, press 'ENTER' to move to the second digit. Repeat step 5 for the following digits. After entering the last digit, press 'ENTER' to save the value. Instruction Manual i4000 Lattice Crane...

  • Page 39: System In Lifting Mode

    Once the section 4.5 is entirely completed, the i4000 indicator will be ready for use. 4.5.1 Selecting crane configuration The i4000 is not a Rated Capacity Indicator (RCI). The displayed % represents the limit set by the operator rather than the maximum lifting capacity established by the crane manufacturer.

  • Page 40: Selecting The Lifting Hoist

    ‘ESCAPE’ key to quit without saving the changes. 4.5.2 Selecting the lifting hoist 1. In the main mode (operating mode), select the Load tab using the 'LEFT/RIGHT' keys. 2. Press ‘ENTER’ to view the 'lifting hoist parameters' menu. Instruction Manual i4000 Lattice Crane...

  • Page 41: Adjusting The Hoist's Parameters

    1. In the main mode (operating mode), select the Load tab using the 'LEFT/RIGHT' keys. 2. Press ‘ENTER’ to view the 'lifting hoist parameters' menu. 3. Scroll to the Max load line using the 'UP/DOWN' keys. i4000 Lattice Crane Instruction Manual...

  • Page 42: Number Of Parts Of Line

    To change the number of parts of line, follow these steps: 1. In the main mode (operating mode), select the Load tab using the 'LEFT/RIGHT' keys. Instruction Manual i4000 Lattice Crane...

  • Page 43: Defining Or Removing The Zero Setting Mode (Tare)

    This mode is used to remove the weight of the block, hook and hoisting rope. This way it only shows on the screen the weight of the lifted load. A YELLOW LIGHT INDICATES THAT THE TARE IS ACTIVATED (SOME WEIGHT HAVE BEEN REMOVED FROM THE CALCULATED LOAD) i4000 Lattice Crane Instruction Manual...

  • Page 44: Bypassing A Lockout

    4.5.5 Bypassing a lockout Be Careful! The i4000 does not support the rigging mode. In this situation, the crane is not entirely protected by the i4000, and it is therefore absolutely indispensable to comply with the manufacturer’s recommendations on how to lift the pulley block, use the stabilizers, and perform a rotation.
  • Page 45 10 seconds after it has been set or • When no brake measure is applied or • There is a faulty sensor or • An A2B situation comes up or • The i4000 system restarts. i4000 Lattice Crane Instruction Manual...

  • Page 46: System In Absolute Limiting Mode

    2) The maximum boom angle limit. 3) The maximum boom length limit. 4) The maximum boom head height limit. 5) The maximum work radius limit. Important: Please note that no brake measures are applied on absolute limits. Instruction Manual i4000 Lattice Crane...

  • Page 47: Accessing The Absolute Limiting Adjustment Mode

    Activating or deactivating an absolute limit 1. Use the ‘UP/DOWN’ keys to highlight the ‘Limit enabled’ line. 2. Press ‘ENTER’ to edit the value. Press the ‘UP/DOWN’ keys to choose between On-Off (active-inactive). 3. Press ‘ENTER’ to confirm your choice. i4000 Lattice Crane Instruction Manual...

  • Page 48: Adjusting An Absolute Limit Value

    'ENTER' again to save the value. Press the 'LEFT' key to go back to the previous digit. Press the 'RIGHT' key to go to the next digit. At any time, press the 'ESCAPE' key to go back without saving changes. Instruction Manual i4000 Lattice Crane...

  • Page 49: Range Limiting Mode Warnings

    The range limiting device option of the i4000 system should never be used to delimit the forbidden zone. Please consult the national, state, or local safety regulations applicable to his work, in order to learn more about operating cranes close to power lines.

  • Page 50: Range Limiting Option

    Range limiting option The system includes the Range limiting device option. When a rotation sensor is installed on the crane, and the Range limiting device of the i4000 system is activated, a new tab will appear on the selection bar.

  • Page 51: Height Limit

    6. As you release the Select button, a 10 seconds countdown will allow you to boom down before your programmed height limit becomes active. Height limit programmed (RED ZONE) Height limit reached Height limit approached i4000 Lattice Crane Instruction Manual...

  • Page 52: Free Zone

    7. Press ‘ENTER’ to confirm the position of the second wall. After you release the key, you will have a 10 second countdown to pivot the crane between both walls before your programmed limit is activated. Instruction Manual i4000 Lattice Crane...

  • Page 53: Variable Height Limit

    ‘ENTER’ key to access the range limiting adjustment menu. 2. Scroll up or down to the «Set highlight variable limit height» line. 3. Press the Select button to confirm your choice. i4000 Lattice Crane Instruction Manual...
  • Page 54 Variable Height Limit becomes active. LEFT WALL RIGHT WALL HEIGHT LIMIT (CEILING) Left wall reached Height limit reached Right wall reached Instruction Manual i4000 Lattice Crane...

  • Page 55: Variable Radius Limit

    3. Press the Select button to confirm your choice. 4. Rotate the crane until you reach the position of your first limit (first wall). 5. Press the Select button to confirm the position of your first limit. i4000 Lattice Crane Instruction Manual...
  • Page 56 Variable Radius Limit becomes active. Restricted area Free zone Left wall reached Right wall Radius limit reached reached Instruction Manual i4000 Lattice Crane...

  • Page 58: 5- Diagnostic And Maintenance

    In this section you will find the necessary technical assistance for performing the maintenance. This section provides answers to the questions frequently asked to the personnel during installation, reparation, or maintenance of the i4000 system. Diagnostic menu A diagnostic menu provides information on the system status as well as on the status of all the connected sensors.
  • Page 59 In such case, the pages showing these sensors will equally appear in this menu. The second column shows the connection status of the sensor in the CAN Bus network. Press ‘ESCAPE’ to access the previous menu or to quit the diagnostic mode. i4000 Lattice Crane Instruction Manual...

  • Page 60: Angle Sensor

    The information shown will look like this: These values will allow the RaycoWylie technician to diagnose a problem in the sensor. In case of an angle sensor multifunction, take note of these values and report them to a RaycoWylie Systems technician.

  • Page 61: Load Sensor

    This page of the diagnostic menu displays the addresses of the different sensors on the bus CAN network detected by the i4000 system. The addresses remain in the memory as long as the system is on, even if a sensor stops sending information.

  • Page 62: Error Messages

    (physical boards connected with the CAN Bus network). The system error indicator will appear on the main screen if an error is detected. 5.5.1 Internal peripherals If you have any questions or need assistance, please contact the RaycoWylie technical assistance department. Error message Runtime process...

  • Page 63: External Peripherals

    55M4000EBE00 Rev C 5.5.2 External peripherals A) Angle / Length interface and A2B errors The i4000 system can communicate with 1 angle/length interface. Each sensor is activated through the calibration menu in the ‘‘Enable/Disable sensors’’section. Error message Runtime process Error cause Angle 1: Sensor fail The value of the sensor’s...
  • Page 64 55M4000EBE00 Rev C 5.5.2 External peripherals (cont.) B) Load interface error The i4000 system can communicate with 2 load interfaces. Each sensor is activated through the calibration menu in the ‘‘Enable/Disable sensors’’section. Error message Runtime process Error cause Load 1 (or 2): Sensor fail...
  • Page 65 5.5.2 External peripherals (cont.) D) Rotation Sensor J1939 error Absolute rotation The i4000 system can communicate with only one rotation sensor. The rotation interface is activated through the calibration menu in the ‘‘Enable/Disable sensors’’section. Absolute rotation (same position kept at all times)

  • Page 66: 6- Inspection And Maintenance

    The rope drum is securely fixed to the extremity of the boom. • The A2B switch piston to see that there is not too much corrosion. • The A2B switch piston to see that there is not too much corrosion. • Relay functionality for the lockout. Instruction Manual i4000 Lattice Crane...

  • Page 67: Checking The Displayed Load

    Checking the displayed load • Position and level the machine. • The person who does the test should be qualified to operate the crane and the i4000 system. • The crane and the system must be correctly configured. • The capacity chart must be respected.

  • Page 68: Maintenance

    Replace the rope drum brushes if they show signs of wear. • Replace the A2B switches if the piston is too corroded. In order to ensure that the i4000 display is water resistant, make sure the back has an X-shaped tightening. Your i4000 system does not need any additional lubrication.

  • Page 69: Maintenance Procedure

    Once the adjustments and repairs are finished, the crane should still not be used until all the safety devices have been activated and the air released from the hydraulic system. The instructions to release the air from the hydraulic systems should be provided by the crane manufacturer. i4000 Lattice Crane Instruction Manual...

  • Page 70: Adjustments And Repairs

    All adjustments should be made in compliance with the tolerated values specified by RaycoWylie in order to keep each system component in proper working condition. • If you need spare parts to complete the maintenance or repairs, please contact the RaycoWylie technical assistance department.
  • Page 71 55M4000EBE00 Rev C Notes i4000 Lattice Crane Instruction Manual...

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