RaycoWylie i4000 Calibration Instructions Manual
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RaycoWylie i4000 Calibration Instructions Manual

Multi-purpose indicator /range limiting device for telescopic cranes, hoist rope load sensing
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i4000 Multi-Purpose Indicator /Range
Copyright 2015
(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.
Wylie Systems
Drury Lane
St. Leonards-on-Sea
East Sussex
England
TN38 9BA
Tel:+44 (0) 1424 421235
Fax:+44 (0) 1424 433760
Crane safety instrumentation
Calibration Instructions
Limiting Device
for
telescopic cranes,
hoist rope load sensing
Wylie Systems
th
1020 9
Avenue, SW
Suite 124
Crane Warning Systems Atlanta
Bessemer, AL 35022
U.S. Distributor for Rayco / Wylie Systems
U.S.A.
6175 Hickory Flat Hwy Suite #110-376
Canton, GA 30115
Tel:+1 (205) 481-2080
866-672-2951 Toll Free 678-261-1438 fax
Fax: +1 (205) 481-2081
www.craneindicators.com website
sales@craneindicators.com email
http://www.raycowylie.com/
1
55M4000BCE00 REV A
Rayco Electronic System
2440 Ave Dalton
Ste-Foy
Québec G1P 3X1
Canada
Tel:+1 (418) 266-6600
Fax:+1 (418) 266-6610

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Summary of Contents for RaycoWylie i4000

  • 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 55M4000BCE00 REV A...
  • Page 3 RaycoWylie Systems. The i4000 RaycoWylie Systems Multi-Purpose Indicator (MPI) is to be regarded only as an aid to the operator. When the parameters are set correctly, the indicator will warn...
  • Page 4 55M4000BCE00 REV A Before operating a crane equipped with a RaycoWylie system MPI, the operator must carefully read the information in the i4000 Instruction 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

    55M4000BCE00 REV A TABLE OF CONTENTS INTRODUCTION ....................6 Personnel qualification and scope of this manual .......... 6 Using this manual ....................6 CONFIGURATION ....................8 Step #1: Accessing the calibration menu............8 Step #2: “Enable/Disable sensor” Setting............9 Step #3: “Calibration units” setting ..............9 Step #4: “Load data”...

  • Page 6: Introduction

    INTRODUCTION This manual contains calibration information for the i4000 system. When performing calibration of the i4000 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 7 55M4000BCE00 REV A Description of operational keys: UP Key. Press to move up the screen when in a menu or to increase the value of a highlighted number. DOWN Key. Press to move down the screen when in a menu or to decrease the value of a highlighted number.

  • Page 8: Configuration

    55M4000BCE00 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 9: Step #2: "Enable/Disable Sensor" Setting

    55M4000BCE00 REV A Provided password is used the calibration menu will remain accessible until the system is powered off. The password will be required every time the menu is selected after a power on. Your password number is: 98765 2.2 Step #2: “Enable/Disable sensor” 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.

  • Page 10: Step #4: "Load Data" Entry

    55M4000BCE00 REV A 2.4 Step #4: “Load data” Entry Note: these settings reflect the configuration of your system when a load sensor is fitted and will generally be made during factory testing prior to delivery and should not need changing. 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.
  • Page 11 55M4000BCE00 REV A After selecting “limits setting” from the main calibration menu the screen will show: Set the approach gap for each limit in turn, angle approach gaps are in degrees, length, radius and height gaps are set using the calibration units. 1- In the calibration menu, scroll down to the item "Limits data:".

  • Page 12: Step #6: "Dimensions" Data Entry

    55M4000BCE00 REV A mode. If the wind speed goes over this approach gap an intermittent audible alarm will be activated and the yellow display LED will blink.  App Rotation(if Rotation sensor fitted) : This variable represents an approach warning gap before to reach the slew limit set by the operator in the normal mode. If the slew goes over this approach gap an intermittent audible alarm will be activated and the yellow display LED will blink.
  • Page 13 55M4000BCE00 REV A Main boom geometry: Note sign convention: All dimensions shown positive except cf, the centreline of slew is generally in front of the boom pivot pin in which case cf is negative. If any other dimension falls the opposite side of it’s datum line shown in the diagrams then it’s sign will change eg if the boom foot pin is above the centreline of the boom then cl8 will be negative etc.
  • Page 14 55M4000BCE00 REV A Rooster sheave geometry : Fly jib geometry :...

  • Page 15: 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 i4000 system. These settings will normally be pre-set before delivery and will not require changing.

  • Page 16: Step #8: "Internal Relay Set-Up

    55M4000BCE00 REV A 2.8 Step #8: “Internal Relay Set-Up” This item allows the selection of which option the internal relay will be activated. There is three options which are available: Absolute limiter, Overload and Range Limiting as shown:...

  • Page 17: Calibration

    55M4000BCE00 REV A CALIBRATION 3.1 Step #9: “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 18: Step #10: "Zero Sensor/Span Sensor" Length Sensor Calibration

    55M4000BCE00 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” 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 19 55M4000BCE00 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 20: Step #11: "Zero Load/Span Load" Sensor Calibration

    55M4000BCE00 REV A 3.3 Step #11: “Zero load/Span load” sensor calibration When calibrating load sensors, always slowly hoist and stop the test loads smoothly in order to eliminate errors in the load reading due to frictional effects. The frictional effect on dynamometer (line rider) systems will cause the displayed load to decrease when lowering the load and to increase when hoisting the load.
  • Page 21 55M4000BCE00 REV A Zero load calibration: 1) Use “” or “” to choose “Zero” and press “”. To zero the load sensor, position the boom at a safe radius for the large test load but attach and slowly lift the small test load until it is just clear of the ground. The reading on the Sensor value is in bits and the maximum scale value is 4095.
  • Page 22 55M4000BCE00 REV A these figures as possible. Note, values for test loads greater than 90%SWL are shown for reference only and should not be used for calibration purposes. Test load 100% 120% Max Bits value 1765 2100 2430 2765 3100 3430 4095 If the reading is unacceptable then adjust the gain setting jumpers in the transducer...

  • Page 23: Step #12: "Rotation" Sensor Calibration

    55M4000BCE00 REV A 3.4 Step #12: “Rotation” sensor calibration This sensor is available if the range limiting feature is fitted to the system, in this case a sensor is used to monitor the slew position of the crane. Encoder type: This will be factory set and should not be changed in “Enable/ Disable sensors”.
  • Page 24 55M4000BCE00 REV A machine 360° and return to the exact start point. 3) When satisfied that the machine is exactly one turn from the start, press “” to confirm the position. The system will give a value in terms of bits for single 360° rotation of the crane, only if you have selected a multi-turn encoder as 33S0047, otherwise the value stays at zero.

  • Page 25: Step #13: "Unloaded Boom Deflection

    55M4000BCE00 REV A 3.5 Step #13: “Unloaded boom deflection” This procedure is used to add an allowance into the calculation of the hook radius to compensate for natural main boom deflection. This procedure should only be used with machine configurations on outriggers or on crawlers.

  • Page 26: Step #14: "Loaded Boom Deflection

    55M4000BCE00 REV A 2) Accurately measure the actual radius of the hook block from the centre line of slew of the machine. 3) Use “” or “” to adjust the Corr.: x.x value until the displayed radius equals the measured radius, note that the indicated radius can only be increased, not decreased.
  • Page 27 55M4000BCE00 REV A With the hook block suspended, telescope the boom out to the target length specified on the display, this is normally the maximum length available for the duty so be sure to check that the hook block does not foul the boom tip and that the boom is at a high enough angle to safely permit maximum extension.

  • Page 28: Step #15: "Transfer" Calibration Backup

    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 ‘UBB’ of the i4000 display unit using a Deutsch to USB converter lead (RaycoWylie part no. 33V0338) before proceeding.

  • Page 29: Transfer" Restoring Calibration

    #16 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 i4000 system at any time. Note a USB memory stick must be connected to connector ‘USB’ of the i4000 display unit using a Deutsch to USB converter lead (RaycoWylie part no.

  • Page 30: Erase Memory

    55M4000BCE00 REV A “Erase Memory” Warning: Initialising memory operation or all will delete all the information stored in the calibration memory, be sure you have made a backup copy of the calibration file before using this option – if in doubt, don’t! Init all memory Select this option to re-initialize the system memory, a warning screen will be displayed to ask for confirmation, if confirmed all calibration data will be deleted.

  • Page 31: Automatic Logs

    55M4000BCE00 REV A AUTOMATIC LOGS 4.1 “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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