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RaycoWylie i4500 Instruction Manual

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i4500 Crane information center
Ref: LD October 2012
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 System for
Telescopic Cranes (America)
Instruction Manual
Rayco Electronic Systems
(Rayco Technology Group)
2440 Dalton Avenue
Ste-Foy, Qc
CANADA
G1P 3X1
Tel: (418) 266-6600
Fax: (418) 266-6610
Copyright © 2012
RaycoWylie Systems
All rights reserved.
55M4500CBE01A Rev A
Wylie Systems
(Rayco Technology Group)
Drury Lane
St-Leonards on Sea, East Sussex
ENGLAND
Tel: (+44) 1-424-421235
Fax: (+44) 1-424-433760
Ref: A.A
TN38 9BA

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  • Page 1 55M4500CBE01A Rev A i4500 Crane information center Rated Capacity Indicator System for Telescopic Cranes (America) Instruction Manual Ref: LD October 2012 Ref: A.A Wylie Systems Rayco Electronic Systems Wylie Systems (Rayco Technology Group) (Rayco Technology Group) (Rayco Technology Group) 1020 9th Avenue SW...
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  • Page 5 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 cause damage to equipment, property, and/or injury to the operator or site workers in the vicinity of the crane and its load.
  • Page 6 Used to alert aGaiNst UNsafe Practices. imPortaNt: iNdicates a sitUatioN that may caUse machiNe damaGe if Not correctly folloWed. Note: Provides iNformatioN that may be of sPecial iNterest. Telescopic Crane i4500 Instruction Manual...

  • Page 7: Table Of Contents

    Warnings 1- GEnEral DEsCription of thE systEm introduction page 4 1.2 Personnel Qualification page 4 intended Use of the i4500 system page 4 Brief Description of the i4500 system page 5 typical Components location & Description page 9 Block Diagram page 10...
  • Page 8 57 Range Limiting Option page 59 4.6.1- Accessing Range Limiting Mode page 61 4.6.2- Limit high page 62 4.6.3- Free Zone page 63 4.6.4- Variable Limit Height page 64 4.6.5- Variable Limit Radius page 65 Telescopic Crane i4500 Instruction Manual...
  • Page 9 6- insPection testing & Maintenance 6.1- Frequent inspections page 81 6.2- Periodical inspections page 81 6.3- rated load test page 82 6.4- Maintenance page 83 6.5- Maintenance Procedure page 84 6.6- adjustements & repairs page 85 Telescopic Crane i4500 Instruction Manual...

  • Page 10: 1- General Description Of The System

    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 11: Brief Description Of The I4500 System

    Introduction Brief description of the i4500 System The i4500 is a computerized crane monitoring system, designed as an operator aid. It comprises sensors fitted to the crane and a display located in the cabin of the crane. This version measures the boom cylinder pressure, the boom angle and length, and it indicates safe or critical conditions, while performing an authorized lift of loads.
  • Page 12 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 at the threshold point of the approach alarm (at 95%) of the rated capacity (100%).
  • Page 13 (Alarm 3) Duty not Continuous calibrated Bypass Continuous Overload Bypass Bridging Switch Activated Continuous (Normal Mode) Continuous (Calibration mode) (Rigging Mode) Calibration mode Approach Intermittent (Range Limiting) Limit reached Continuous (Range limiting) Rigging Mode Table 1 Telescopic Crane i4500 Instruction Manual...
  • Page 14 (Alarme 3) Duty Continuous Not calibrated Bypass Continuous Overlaod Bypass Bridging Switch Continuous Normal Mode Continuous Calibration Mode Rigging Mode Calibration Mode Approach (Range Intermittent Limiting) Limit reached Continuous (Range Limiting) Rigging Mode Table 2 Telescopic Crane i4500 Instruction Manual...
  • Page 15 Introduction Typical component location and description i4500 display box: It is also the central processing unit (CPU) of the i4500 system. Its principal feature is a CANBUS communication interface and 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 16: Block Diagram

    Video CAN 1 Keypad CAN 2.0B PRIMARY RCI SAFETY CRITICAL BUS CANbus CANbus INTERFACE INTERFACE CANbus RELAY CONTROLLER Anemometer Slew Sensor Optional EXTERNAL RLD KEY VISUAL AND BRIDGING LOCKOUT SWITCH AUDIBLE KEY SWITCH RELAY ALARM Telescopic Crane i4500 Instruction Manual...

  • Page 17: Technical Data

    Display sealing: IP67 Memory capacity: 10,000 load/radius curves CANbus sensors / interface: Default quantity Maximal quantity - Load or pressure sensor - Angle, Length sensor - Relay output - Digital input - Provision for other sensors RS-232 Peripheral communication port Telescopic Crane i4500 Instruction Manual...

  • Page 18: 2- Detailed Description Of The Display Unit

    * The slew angle indicator (middle of the screen) is only present when the range limiting option is installed in the machine. Telescopic Crane i4500 Instruction Manual...

  • Page 19: 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 20: Operating Buttons Description

    ESCAPE BUTTON Select Escape button on display 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. Telescopic Crane i4500 Instruction Manual...
  • Page 21 Select this button to access all the information regarding the current crane configuration. Press it to access the operating system’s information. QUICK DUTY CHANGE BUTTON Use the Quick Duty Change Button to alterna- tively select whether lifting the load with the main boom or the auxiliary jib. Telescopic Crane i4500 Instruction Manual...

  • Page 22: Main Modes

    Introduction Main Modes limits mode Config mode main mode info mode error mode diagnostiC mode Calibration mode night mode Telescopic Crane i4500 Instruction Manual...

  • Page 23: Warning Lights And Indicators Location

    Introduction Warning Lights and Indicators Location overload motion approaCh warning warning (red light) (red light) (yellow light) warning alarms iCons system two-bloCk warning error Condition alarm indiCator indiCator indiCator Telescopic Crane i4500 Instruction Manual...

  • Page 24: Warning Lights And Indicators Description

    The crane has exceeded safe operational ratings and is now in an unsafe condition. Hoist up, telescope out and boom down functions will be stopped if a motion cut solenoid is connected to the system. Telescopic Crane i4500 Instruction Manual...
  • Page 25 This indicator appears on the top-left corner of the i4500 lcd screen, when at least one preset limit is active on the system. This is not a warning! It is just there to remind you that an angle, radius or height limit has been set in the limits setting mode.
  • Page 26 In some systems, Limits values are not active when electric power is first applied to the i4500 and they are automatically disabled if electric power is removed. Reaching an operator’s Preset Limit (set in the Limits Setting Mode) will not result in crane motion cut-off.

  • Page 27: 3- Installation & Calibration

    2. The i4500 system is purely 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 28: 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 29 4.3 Power On Switch on the electric power (i.e.: crane key switch) to the i4500 system. The indicator will perform a “Self-test” during which time (approx. 10 sec.) the audible alarm will sound, the approach, overload and motion cut lights will illuminate and the display will show the RaycoWylie’s logo.

  • Page 30: System Configuration

    Thereafter, this duty is associated to a corresponding duty number by the system. In case of need of assistance, contact RaycoWylie with the technical file number of your system for technical advice.
  • Page 31 Operation 4.4.1 Duty Selection We need to provide the i4500 system with the proper variables information in the form of a series of questions in order to choose the proper duty that matches your crane configuration. 1. Select the Duty button. 2. Answer each question by selecting the right...
  • Page 32 2. Choose the Select button to accept new value into the system and go to the next parameter or press the Escape button to return to the previous screen. Telescopic Crane i4500 Instruction Manual...
  • Page 33 Use the Up or Down buttons to select the correct value. Press the Select button to accept the new value or press the Escape button to return to the previous screen. Telescopic Crane i4500 Instruction Manual...
  • Page 34 2. Choose the Select button to accept new value into the system and go to the main operating screen or press the Escape button to go back the previous screen. fig 2 Telescopic Crane i4500 Instruction Manual...
  • Page 35 2. Use the Select button to accept new value into the system and go to the next parameter or press the Escape button to return to the previous operating screen. Telescopic Crane i4500 Instruction Manual...
  • Page 36 2. Choose the Select button to accept new value into the system and go to the next parameter or press the Escape button to return to the previous operating screen. Telescopic Crane i4500 Instruction Manual...
  • Page 37 Use the Up or Down buttons to select the appropriate choice from the menu list. 2. Press the Select button to accept the new value into the system or press the Escape button to return to the previous screen. Telescopic Crane i4500 Instruction Manual...
  • Page 38 Use the Up or Down buttons to select the appropriate choice from the menu list. 2. Press now the Select button to accept the new value or press the Escape button to return to the previous operating screen. Telescopic Crane i4500 Instruction Manual...
  • Page 39 3. Use the Select button to accept new value into the system and go to the next parameter or press the Escape button to return to the previous operating screen. Telescopic Crane i4500 Instruction Manual...
  • Page 40 2. Choose the Select button to accept new value into the system and go to the next parameter or press the Escape button to return to the previous operating screen. Telescopic Crane i4500 Instruction Manual...
  • Page 41 1. Use the Select button to accept new value into the system and go to the next parameter or press the Escape button to return to the previous operating screen. Telescopic Crane i4500 Instruction Manual...
  • Page 42 Use the Up or Down buttons to choose the second digit. 2. Press now the Select button to accept the new value or press the Escape button to return to the previous operating screen. Telescopic Crane i4500 Instruction Manual...
  • Page 43 1. Use the Select button to accept new value into the system and go to the next parameter or press the Escape button to return to the previous operating screen. Telescopic Crane i4500 Instruction Manual...
  • Page 44 Use the Up or Down buttons to select the appropriate choice from the menu list. 2. Press now the Select button to accept the new value or press the Escape button to return to the previous operating screen. Telescopic Crane i4500 Instruction Manual...
  • Page 45 Fig. 3 Load lifted with the auxiliary jib. Fig.4 Load lifted with the main boom. * Use the Quick Duty Change Button to alterna- tively select whether lifting the load with the main boom or the auxiliary jib. Telescopic Crane i4500 Instruction Manual...

  • Page 46: 5- System Configuration Information Screen

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

  • Page 47: 4- 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 chart info screen is different for each crane model. The representation depicted in this manual may not be identical to the chart info screen shown on your system.

  • Page 48: 1- Units Selection

    Each measure of length and load will be displayed on the main display. to set the units proceed as follows: 1) Repeat steps 1 to 3 of the system setup section (see above). Select the Units menu. Telescopic Crane i4500 Instruction Manual...
  • Page 49 2) The Units menu line should be highlighted on the display by now. If not, scroll up or down with the Up or Down buttons to highlight the desi- red unit combination. 3) Choose the Select button to confirm your choice into the system. Telescopic Crane i4500 Instruction Manual...

  • Page 50: 2- Language Selection

    Language Selection choose the desired language All of the i4500’s text messages can be displayed in multiple languages: English (default), as specified in the following illustration (available languages may vary depending on software version): to set the language proceed as follows: 1) Repeat steps 1 to 3 of the system setup options sec- tion (see page 42 of this manual).

  • Page 51: 3- Date & Time Settings

    5) Now adjust the clock. Scroll up or down with the Up or Down buttons to select the desired hour value. Repeat procedure to adjust the minutes. Choose Select button to save changes and go back to main menu. Telescopic Crane i4500 Instruction Manual...

  • Page 52: 4- Night /Day Mode

    1) Press the Mode button. 2) Scroll down with the Down button to highlight the Night or Day mode line. 3) Press the Select button to confirm your choice and enter the desired menu. Telescopic Crane i4500 Instruction Manual...

  • Page 53: 5- Backlight Mode

    If not, scroll up or down with the Up or Down icons to select it. 3) Choose the Select icon to select desired choice. Use the Up or Down icons to adjust the level of screen brightness needed (night level). Telescopic Crane i4500 Instruction Manual...

  • Page 54: 6- Set & Remove Tare

    4) Scroll down with the Down button to highlight the Set Tare line. 5) Press the Select button to enable the Tare feature. 6) Repeat these steps to Remove Tare and go back to normal mode. Telescopic Crane i4500 Instruction Manual...

  • Page 55: 7- Bypass /Rigging Mode

    Warning! When in Rigging mode, the motion cut and overload alarms are disable. In this condition, the crane is not fully protected by the i4500, therefore it’s absolutely essential to obey the crane manufacturer’s advice regarding lifting the hook block, slewing or outriggers use.

  • Page 56: 2- Override Lockout System(Bypass)

    There is an ATB condition. The override is automatically cancelled when: • The load is below the percentage of the capacity setted to activate the lockout system; or • There is no more occurence of an ATB condition; or • The RCI/LMI resets. Telescopic Crane i4500 Instruction Manual...
  • Page 57 Operation This page has been intentionally left blank Telescopic Crane i4500 Instruction Manual...

  • Page 58: 8- Bridging Device

    Bridging device When the bridging device is activated the crane is no longer protected by the i4500 system. Therefore, it is absolutely essential to obey the crane manufacturer’s advice regarding crane operations. A bridging device is an embedded electronic mechanism designed to be used in case of system component failure or in case of emergency.
  • Page 59 Operation This page has been intentionally left blank Telescopic Crane i4500 Instruction Manual...

  • Page 60: Operational Limits

    In the Operational Limits Setting Mode, the operator can set and activate/ deactivate four (4) operational limits in addition to those automatically provided by the i4500 RCI system. These are as follows: The Minimum Boom Angle Limit. The Maximum Boom Angle Limit.

  • Page 61: 1- Accessing The Operational Limits Setting Mode

    3) Choose the Select icon to confirm your choice and enter the desired menu Limits setting Menu Please note that limits are not active* when power is first applied to the i4500 system they automatically disabled if power is removed.

  • Page 62: 2- Limit Value Adjustments

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

  • Page 63: 3- Enable / Disable A Limit

    ON and OFF state of the limit. 5) Press Escape button to return to the normal operating mode. When the value of a given Operational Limit is changed (see section 4.5.2) then, the modified Limit becomes automatically active. Telescopic Crane i4500 Instruction Manual...
  • Page 64 Operation This page has been intentionally left blank Telescopic Crane i4500 Instruction Manual...

  • Page 65: Range Limiting Option

    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 in proximity to power lines.
  • Page 66 High Limit • Free Zone • Variable Limit Height • Variable Limit Radius * In most systems, only one menu option can be chosen at the time; however, this may vary depending on software version. Telescopic Crane i4500 Instruction Manual...

  • Page 67: 1- Accessing Range Limiting Mode

    Scroll down with Down button to highlight the range limiting option of your choice. Press the Select button to select one of the following menu options: • High Limit • Free Zone • Variable Limit Height • Variable Limit Radius menu screen Telescopic Crane i4500 Instruction Manual...

  • Page 68: 2- Limit High

    10-second countdown will allow you to boom down before your programmed height limit becomes active. 4) T turn the o go back to Normal mode, ‘‘Range limiting key switch’’ to the ‘‘Normal run’’ position or ‘‘Tracks stopped’’ option (if available). Telescopic Crane i4500 Instruction Manual...

  • Page 69: 3- Free Zone

    ‘‘Free zone’’ and press Select button to confirm your choice. 3) Rotate the crane to the first limit position (first wall). Press Select button to confirm that this will be the position of the first wall. Telescopic Crane i4500 Instruction Manual...

  • Page 70: 4- Variable Limit Height

    ‘‘Variable limit height’’ option. 3) Press Select button to confirm your choice. 4) Rotate the crane to the first limit position (first wall). Press Select button to confirm that this will be the position of the first wall. Telescopic Crane i4500 Instruction Manual...

  • Page 71: 5- Variable Limit Radius

    6) T turn the o go back to Normal mode, ‘‘Range li- miting key switch’’ to the ‘‘Normal run’’ position or ‘‘Tracks Stopped’’ option (if available). 4.6.5 Variable Limit Radius Telescopic Crane i4500 Instruction Manual...
  • Page 72 6) T turn the o go back to Normal mode, ‘‘Range limiting key switch’’ to the ‘‘Normal run’’ position or ‘‘Tracks Stopped’’ option (if available). Telescopic Crane i4500 Instruction Manual...

  • Page 73: 5- Diagnostic & Troubleshooting

    Troubleshooting diagnostic & troubleshooting Warning! Troubleshooting shall be performed by a qualified technician or by an operator with assistance of a RaycoWylie Service technician. This section provides technical troubleshooting support. It will address most frequently asked questions that repair personnel may have when installing, repairing or performing maintenance on the i4500 system.

  • Page 74: Angle/Length Sensor

    CanBus network is given in the third column Angle 1 and Length 1 sensors are physically located on the same electronic board. Telescopic Crane i4500 Instruction Manual...
  • Page 75 The displayed information will look similar to this: The second line indicates the software version of the angle/length sensor and also its creation date. The following values will allow the RaycoWylie technician to diagnose a problem coming fron the sensor. The basic criteria for a proper functionning of the angle sensor are: D1gx and d1gy must be close to 820 .

  • Page 76: Load Sensor

    The second block is the input block, it has the status of 16 inputs DIN indicating whether the input is active or not. Up to 4 relay cards can be installed. Telescopic Crane i4500 Instruction Manual...
  • Page 77 By pressing the Down button, you get acces to the Input block. The displayed Information will look similar to this: return to the normal Press the Escape button to operating mode Telescopic Crane i4500 Instruction Manual...

  • Page 78: Slew Sensors

    5.6 Detected addresses: This menu page provides the sensor addresses on the CAN network detected by the i4500 system. Addresses remain in memory as long as the system is powered even if a sensor stops communicating. Telescopic Crane i4500 Instruction Manual...

  • Page 79: Error Messages

    Troubleshooting Error Messages During start up and other operation processes, the i4500 system analyses all interactions between internal peripherals (memories, controllers, extension cards, etc.) and also external ones (various interface connected to the Canbus network) 5.7.1 Internal Peripherals If you have any questions or need technical assistance, please contact our Technical Service Department at RaycoWylie.
  • Page 80 The smallest will be selected. no parameter The Crane dimensions must Cl3, Cl4 and Cl7 values be entered in the system. should not be at zero The Load value will be null or wrong. Telescopic Crane i4500 Instruction Manual...
  • Page 81 This page has been intentionally left blank...

  • Page 82: External Peripherals

    Troubleshooting 5.7.2 External Peripherals A) Angle / Lenght and ATB interface circuit board errors The i4500 system can support up to 5 angle/length interfaces. Activation of every angle sensor is done in the calibration menu section ‘‘Enable/Disable I/O’’. error message...
  • Page 83 Troubleshooting B) Load interface circuit board errors The i4500 system can support up to 4 load circuit boards. 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 84 Troubleshooting D) Generic interface board errors The i4500 system can support up to 4 generic Interfaces. Each one having feature to support wind speed sensor, inclination level sensor and absolute rotation encoder . Activation of every generic card is done in the calibration menu section ‘‘Enable/Disable I/O’’.
  • Page 85 Troubleshooting E) Rotation interface errors Relative rotation The i4500 system can support only one (1) rotation card. There are two differ- ent kinds: a relative one and an absolute one. Activation of rotation card is done in the calibration menu section ‘‘Enable/Disable I/O’’.
  • Page 86 Maintenance This page has been intentionally left blank Telescopic Crane i4500 Instruction Manual...

  • Page 87: 6- Inspection Testing & Maintenance

    The plunger of the ATB switch for excessive corrosion. • Excessive wear of brushes in the reeling drum. • Evidence of leakage at the pressure transducer connection. • Functionality of the bridging device. • Operation of the lockout relays. Telescopic Crane i4500 Instruction Manual...

  • Page 88: Rated Load Test

    Maintenance Rated Load Test • Position and level the machine. • Testing personnel must be a qualified person for the crane and the i4500’s system. • The crane and the system must be configured properly. • The load chart must be respected.

  • Page 89: Maintenance

    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 sensor, load cells or on any connectors.

  • Page 90: Maintenance Procedure

    The instructions shall be provided by the crane manufacturer for the removal of air from hydraulic circuits. Telescopic Crane i4500 Instruction Manual...

  • Page 91: Adjustements & Repairs

    Service Department at RaycoWylie. If you have any questions or need technical assistance, please contact our Technical Service Department at RaycoWylie quoting the infor- mation found on the serial number label of your i4500 system. Telescopic Crane i4500 Instruction Manual...
  • Page 92 Maintenance This page has been intentionally left blank Telescopic Crane i4500 Instruction Manual...
  • Page 93 Maintenance This page has been intentionally left blank Telescopic Crane i4500 Instruction Manual...
  • Page 94 Maintenance Notes Telescopic Crane i4500 Instruction Manual...

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