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B 55M3500JBE00 Rev B
i3500 Crane information center Rated Capacity Indicator System for Telescopic Cranes Pressure Sensing, Multi-Point Version Version
Manual Instruction Manual Ref: LD October 2010
Wylie Systems Systems Group) (Rayco Technology Group)
Ref: A.A
Rayco Electronic System Systems s Group) (Rayco Technology Group)
Wylie Systems Systems (Rayco Technology Group Group))
Bessemer, AL AL USA 35022 35022
2440 Dalton Avenue Ste-Foy, Qc CANADA 3X1 G1P 3X1
Drury Lane St-Leonards on Sea, East Sussex Sussex ENGLAND ENGLAND TN38 9BA
481-2080 Tel: (205) 481-2080 Fax: (205) 481-2081 481-2081
Tel: (418) 266-6600 266-6600 Fax: (418) 266-6610 266-6610
Tel: (+44) 1-424-421235 1-424-421235 Fax: (+44) 1-424-433760 1-424-433760
1020 9th Avenue SW Suite 124 124
Copyright © 2010 RaycoWylie Systems All rights reserved. reserved.
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Introduction i3500 Introduction
Rayco Wylie Systems Systems EC Declaration of Conformity Conformity Product type: i3500 Rated Capacity Indicator Authorised Representative: Representative: Wylie Systems Drury Lane Lane St Leonards-on-sea Leonards-on-sea East Sussex , United Kingdom TN38 9BA 9BA
: Manufacturer : Rayco Electronic Systems 2440 Av Dalton Dalton Québec, PQ, Canada G1P 3X1 3X1
Is in conformity with: with: The provisions of the Machinery Directive (Directive 2006/42/EC) 2006/42/EC) The provisions of the Electromagnetic compatibility Directive (Directive 2004/108/EC) 2004/108/EC) This conformity is supposed referring to the following standards, documents and requirements: requirements: EN 13000 Cranes Mobile Mobile Cranes Cranes EN 12077-2 Cranes Safety, limiting and indicating devices EN 954-1 Safety and related parts of control systems. systems. Category 2 2 EN 60204-32 Safety of machinery. Electrical equipment of machine Requirement for hoisting machine machine EN 61000-6-2 Electromagnetic compatibility - immunity –
EN 61000-6-4 Electromagnetic compatibility - emission emission For and on behalf of Wylie Systems, a division of RaycoWylie Systems: Systems:
………………………………………………
Luc Patry Patry RaycoWylie Quality & Certification Manager December 23, 2009 2009
ISO9001:2008 FM 33972 33972
This document is also the certificate of origin. The product is manufactured in more than one country and all European Union import duties and taxes have been paid in the United Kingdom. Kingdom. www.raycowylie.com www.raycowylie.com
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i3500 Introduction Introduction
The purpose of this manual is to provide the customer with the operating procedures essential for the promotion of proper machine operation for its intended use. The importance of proper usage cannot be overstressed. All information in this manual should be read and understood before any attempt is made to operate the machine. machine. Since the manufacturer has no direct control over machine application and operation, conformance with good safety practice in this area is the responsibility of the user and his operating personnel. personnel. under proper operating All procedures herein are based on the use of the system under conditions, with no deviations from the original o riginal design. Alteration and/or modification of the equipment are strictly forbidden without written approval from RaycoWylie Systems. Systems. The i3500 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. load. This system must never be used, under any circumstances, as a substitute for the good judgment of a crane operator when carrying out approved crane-operating procedures. Responsibility for the safe operation of the crane lies with the crane operator. The indicator equipment will not necessarily prevent crane damage due to overloading and related causes if not set properly. properly. Before operating a crane equipped with a RaycoWylie system RCI, the operator must carefully read the information in both this manual and the crane manufacturer operator’s manual. He must also be aware of all the federal, state state functioning and local safety standard and regulations applicable to his job. Correct functioning of the system depends upon routine daily inspection. inspection. Any suspected faults or apparent damage should be immediately reported to the responsible authority before using the crane. crane. Sensing Telescopic Cranes Pressure Sensing
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Introduction i3500 Introduction
Since safety of personnel and proper use of the machine is of primary concern, different symbols are used throughout this manual to emphasize certain areas. areas. The following definitions indicate the level of hazard when these symbols appear throughout this manual. Whenever one of these symbols appears in this manual, personnel safety is a concern. Please take time to read and understand these definitions! definitions!
DANGER: INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY. INJURY.
CAUTION: INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES. PRACTICES.
IMPORTANT: INDICATES A SITUATION THAT MAY CAUSE MACHINE DAMAGE IF NOT CORRECTLY FOLLOWED. FOLLOWED.
NOTE: PROVIDES INFORMATION THAT MAY BE OF SPECIAL INTEREST. INTEREST.
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CONTENTS TABLE OF CONTENTS EC Declaration of conformity Warnings Warnings
SYSTEM 1- GENERAL DESCRIPTION OF THE SYSTEM 1.1 Introduction
page 4
1.2
Personnel qualification
page 4
1.3
Intented use of the I3500 System
page 4
1.4
Brief description of the I3500 System
page 5
1.5
Typical Components Location & Description
page 9
1.6
Block Diagram
page 10 10
1.7
Technical Data
page 11 11
2- DETAILED DESCRIPTION OF THE DISPLAY UNIT UNIT 2.1 Normal Mode Display (default screen)
page 12 12
2.2
Display Buttons Location and Purpose
page 13 13
2.3
Warning Lights and Indicators Location
page 15 15
2.4
Warning Lights and Indicators Detailed Description
page 16
3- INSTALLATION & CALIBRATION CALIBRATION 4- OPERATING INSTRUCTIONS INSTRUCTIONS 4.1 4.1
Safety Instructions Instructions
page 19 19
4.2 4.2
Residual Risks Risks
page 20 20
4.3 4.3
Power On On
page 21 21
4.3 4.3
System configuration configuration
page 21 21
4.4.1- Duty Number Selection Selection
page 22 22
Selection 4.4.2- Hoist Selection
page 24 24
4.4.3- Parts of Line Selection Selection
page 25 25
4.4.4- System Test Test
page 27 27
Screen 4.4.5- System Configuration Information Screen
page 28 28
Setup 4.4.6- System Setup
page 29 29
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CONTENTS TABLE OF CONTENTS
4.5
4.6
4.4.6.1- Language Selection
page 30 30
4.4.6.2- Units Selection
page 31 31
4.4.6.3- Reverse Video
page 32 32
4.4.7-
page 32 32
Bypass/ Rigging
4.4.7.1- Rigging Mode
page 33 33
4.4.7.2- Overload Override (bypass)
page 34 34
4.4.7.3- ATB Condition Override
page 34 34
4.4.8- Bridging & Range Limiting Box
page 35 35
4.4.8- Bridging Device
page 35 35
4.4.8.2- Bypass Rigging using the range limiting box
page 37 37
Operational Limits
page 38 38
4.5.1- Accessing the Limits Mode 4.5.2- Limit value Adjustments
page 39 39 page 40 40
4.5.3- Enable / Disable a limit
page 41 41
Range Limiting Option
page 42
4.6.1- Accessing Range Limiting Mode
page 44 44
4.6.2- Limit high
page 45 45
4.6.3- Free Zone
page 46 46
4.6.4- Variable Limit Height
page 47 47
4.6.5- Variable Limit Radius
page 48
5- DIAGNOSTIC & TROUBLESHOOTING TROUBLESHOOTING 5.1 5.1 5.2 5.2
Diagnostic Menu Menu
page 50 50
Angle/Lenght Sensor Sensor
page 51 51
5.3 5.3
Pressure Sensor Sensor
page 53 53
5.4- 5.4-
Relays Relays
page 53 53
5.5 5.5
Slew Sensors Sensors
page 55 55
5.6 Detected adresses 5.6 adresses
page 55 55
5.7 5.7
page 56 56
Error Messages and the Use of the ‘‘ ? ’’ key key
5.7.1 Peripherals 5.7.1 Internal Peripherals 5.7.2 5.7.2 External Peripherals Peripherals
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i3500 Introduction Introduction
6- INSPECTION TESTING & MAINTENANCE MAINTENANCE 6.1- Frequent Inspections
page 63 63
6.2- Periodical Inspections 6.3- Rated Load test
page 63 63 page 64 64
6.4- Maintenance
page 65 65
6.5- Maintenance Procedure
page 66 66
6.6- Adjustements & Repairs
page 67 67
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Introduction i3500 Introduction
-1- -1- System General Description of the System
1.1
Introduction Introduction
This manual contains Operation, Troubleshooting and Maintenance information for the i3500 system. When using i3500 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. Each safety instruction throughout this manual must be taken into consideration when using the i3500 system. The information contained in this manual will enable qualified personnel to properly operate and a nd efficiently perform maintenance. maintenance.
1.2 Personnel qualiftcation qualiftcation The i3500 system shall be operated only by personnel without limitations in the physical abilities of the upper limbs and no visual or hearing impairment, who have completed all operator trainee qualification requirements and have read and fully understood the instructions in this manual. Operator requirements shall include: demonstrating the ability to read, write and comprehend and use arithmetics and read and understand the load lo ad / capacity charts in the language of the crane manufacturer’s operating instruction materials. mate rials. Maintenance of the the system is intended only for fully qualified and trained personnel for this task. task.
1.3 Intended use use The i3500 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. The i3500 system shall prevent the crane from supporting a load outside the limits of the permitted radii and outside the loads shown and described on the rated capacity chart or the permissible working load of the ropes when set and operated correctly. correctly.
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i3500 Introduction Introduction
1.4 Brief description of the i3500 System System cra ne monitoring system, designed as an operator The i3500 is a computerized crane 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. Optional sensors may also be fitted to to monitor the slew angle and the rotation of the hoist drum to provide some extra information to the operator. operator. All the sensors are linked through a single CANbus (Controlled Area Network). The pressure sensors provide electrical signals that are proportional to the actual pressures in the hydraulic boom cylinder system of the crane. An inclinometer provides a signal that is proportional to the boom angle and a reeling drum provides a signal that is proportional to the boom extension. The radius and the load are calculated from these signals with the dimensional crane data preprogrammed in the i3500 system. system. During operation the load lifted by the crane is calculated from the measured boom cylinder pressure and is automatically compared with corresponding data related to the maximum permissible crane loading. loading. The actual load is expressed as a percentage (% SWL). If percentage of the permitted load (% this percentage exceeds a preset value, alarms and safety functions are activated. The values of the hook load, the permissible load, the main boom angle and the radius are displayed in a digital form on a graphic liquid crystal display (LCD). (LCD). If the additional sensors are fitted, then some information about the current slew angle and the hook height will w ill also be available. The required crane cra ne duty charts are stored in a non-volatile memory and can only be modifted with the approval of the crane manufacturer. manufacturer. The calculated crane parameters and calibration data are stored in an additional non-volatile memory. The calibration of the system is performed only with the use of known loads, boom angles, and other pre-determined data. data. Audible alarms alarms An intermittent buzzer b uzzer located l ocated in the i35000 system display warns the crane operator to take specific course of actions at the approach of the rated r ated capacity. The threshold of the approach alarm has been be en fixed at 95% of the rated capacity. The buzzer will alert in a continuous way when the rated capacity is reached or exceeded (≥ 100%). Personnel in the danger zone are warned by an external buzzer so that they can get out danger when the rated capacity limiter is activated or overridden. overridden. page). (Continues on next page). Sensing Telescopic Cranes Pressure Sensing
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The crane operator will also be warned by the audible alarm when the operational limits or the range limiting function is activated and a selected limit is reached. See Table (1) for more details on audible signal operation. operation.
When wearing ear protection safety devices or if using music earphones during crane operations, make sure that they will not impair your ability ability to hear the audible warning signals while operating the i3500 system. system.
alarms Visual alarms
The display of the i3500 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 ra ted capacity (100%). (100%). A red light will illuminate when the rated capacity has been reached or exceeded. An additional red light will also turn on when the rated capacity limiter is activated (Cut Off). Off). External visual alarms are also provided with the external audible alarm to warn the personnel in the danger zone so that th at they can be aware of the danger when the rated capacity limiter is activated or overridden. Note that depending on system configuration, your system may be equipped with one or with three external lights. See tables 1 and a nd 2 for external visual alarm a larm operation. operation.
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System with 3 warning lights lights 1 Table 1 Display Display Event Event
Approach Approach Overload Overload Cut Cut
event No event
Off
Off
Off
Approach to SWL (Alarm 1) 1)
Blinking Blinking
Off
Overload (Alarm 2) 2)
On On
Motion cut (Alarm 3) 3) calibrated Not calibrated
External External Audible Audible Off
Green Amber Ext Buzzer Light Buzzer Light Light Light
Red light light
Off
On On
Off
Off
Off Intermittent Intermittent
Off
Off
On On
Off
On On
Off
Continuous Continuous
On On
Off
Off
On On
On On
On On
On On
Continuous Continuous
On On
Off
Off
On On
On On
On On
On On
Continuous Continuous
On On
Off
Off
On On
X
X
X
X
On On
Off
On On
On On
Boom up override override
X
X
X
X
On On
Off
Off
On On
Key Bridging Key
X
X
X
X
On On
Off
Off
On On
A2B operating mode mode
X
X
On On
Continuous Continuous
Off
On On
Off
Off
X
X
X
Off
Off
Off
On On
Off
mode) mode) Setup button activated activated in Erection/ Rigging to override the A2B A2B
Off
Off
Off
Off
Off
Off
On On
On On
Calibration mode mode
Off
Off
Off
Off
Off
Off
On On
Off
Range Limiting approach approach
On On
Off
Off Intermittent Intermittent
Off
Off
On On
Off
Range limiting limit reached reached
On On
On On
On On
Continuous Continuous
On On
Off
Off
On On
mode Rigging mode
Off
Off
Off
Off
Off
Off
On On
Off
Setup button activated within working range deadlock deadlock 110% > 100 - 110% override override
A2B A2B (Calibration or Rigging
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light System with 1 warning light Table 2 2
Display Display Event Event
Approach Approach Overload Overload Cut Cut
External External Audible Audible
Ext.
Red
Buzzer light Buzzer light No event event
Off
Off
Off
Approach to SWL (Alarm 1) 1)
Blinking Blinking
Off
Overload (Alarm 2) 2)
On On
Motion cut (Alarm 3) 3) Not calibrated calibrated
Off
Off
Off
Off Intermittent Intermittent
Off
Off
On On
Off
Continuous Continuous
On On
On On
On On
On On
On On
Continous Continous
On On
On On
On On
On On
On On
Continous Continous
On On
On On
X
X
X
X
On On
On On
Boom up override override
X
X
X
X
On On
On On
Bridging Key Key
X
X
X
X
On On
On On
A2B A2B
X
X
X
X
Off
Off
Off
Off
Off
Off
On On
On On
Calibration mode mode
Off
Off
Off
Off
Off
Off
Range Limiting approach approach
On On
Off
Off Intermittent Intermittent
Off
Off
Range limiting limit reached reached
On On
On On
On On
Continuous Continuous
On On
On On
Rigging mode mode
Off
Off
Off
Off
Off
Off
Setup button activated within working range deadlock deadlock 110% > 100 - 110% override override
Setup button activated activated in Erection/ Rigging the to override A2B A2B
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Introduction i3500 Introduction
1.5
Typical component location and description description
1) i3500 display box: box: It is also the central processing unit (CPU) of the i3500 system. Its principal feature is i s a CANBUS communication interface interface and graphical LCD screen. screen. sensor: A solid state angle sensor that is used to monitor the 2) Angle sensor: angle of the boom. boom. 3) Pressure sensors: sensors: Highly sensitive, built for precise lifting and weighing in harsh environments. environments. 4) Cable reel with angle and length sensor: sensor: A solid state angle sensor is used to monitor the angle of the boom. b oom. A potentiometer is used to monitor the boom length. length. 5) Anti-two block: the anti-two block switch is normally closed clo sed (with weight hanging) spring-loaded switch (option). (option). 6) Wind speed sensor: Shows wind speed value on the display (option). (option).
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1.6 Block Diagram Diagram
Block Diagram of the i3500 CANbus Communication Link Network. Network.
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1.7 Technical Data Data
Accuracy: Accuracy:
In accordance with SAE J159 or EN13000 EN13000
Operating temperature: temperature: Supply voltage: voltage: Display size: size: Display sealing: sealing: Memory capacity: capacity: interface: CANbus sensors / interface:
-20 ºC to + 60 ºC ºC 10.2 to 36 VDC (maximum rating) rating) 6.25’’ x 8.5’’ x 3’’ (15cm x 21cm x 7.5cm) 7.5cm) IP65 IP65 10.000 load/radius curves curves Default quantity quantity
Maximal quantity quantity
sensor - Load or pressure sensor
2
6
- Angle, Length sensor sensor
1
5
output - Relay output input - Digital input - Provision for other sensors sensors
5 4
32 32 16 16
Peripheral communication port port RS-232 RS-232
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-2- -2- Detailed description of the display unit unit screen) 2.1 Normal Mode Display (default screen)
SLEW
PARTS
BOOM TIP
DUTY
ANGLE ANGLE
OF LINE
HEIGHT HEIGHT
NUMBER
(FALLS) (FALLS)
BOOM LENGTH LENGTH
HOIST: M:MAIN A:AUXILIARY
PARTIAL DUTY
BOOM ANGLE ANGLE
DESCRIPTION
HOOK LOAD LOAD
OPERATING RADIUS RADIUS
SAFE WORKING
(TOGGLE WITH
LOAD
BUTTON #4) #4)
(S.W.L) (RATED CAPACITY) CAPACITY)
The display should be used only as a guide, NOT as an indication that the crane would or would not pass under a structure of an accurately known height. height.
left corner of the screen) The slew angle indicator (upper left is only present when the range limiting option is installed in the machine. machine. Sensing Telescopic Cranes Pressure Sensing
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i3500 Introduction Introduction
2.2 Display Buttons Location and Purpose Purpose
i3500 DISPLAY BOX OVERVIEW OVERVIEW
WARNING LIGHTS LIGHTS GRAPHICAL DISPLAY INTERNAL BUZER
OPERATING BUTTONS BUTTONS
OPERATING BUTTONS PRESENTATION PRESENTATION BUTTON MODE BUTTON Shows system’s modes. Press this button this button to choose one of these operating modes: modes: mode -Normal mode -System Set Up mode mode -Diagnostic mode mode -Calibration mode (password protected). protected). BUTTON HOIST / SCROLL UP BUTTON Shows hoist menu for selection of the hoist currently in use. Also used to scroll up through options or to increase adjustable values. values. PARTS / SCROLL DOWN BUTTON BUTTON Shows parts of line (falls) menu for selection of the number of parts currently in use. Also used to scroll down through options or to decrease adjustable values. values.
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ntroduction n i3500 IIntroductio
BUTTON SELECT BUTTON Used to select a highlighted item in a menu. In normal mode, use this button to select the information displayed in one of the pull-down menus. If no menu is opened, used to scroll through the configuration at the bottom line of the display. display. BUTTON ESCAPE BUTTON a Used to close a menu or to cancel the modification of a mode. value. Push it several times to return to normal mode. HELP BUTTON BUTTON This button will show the problem source when a fault is detected by the system. Press it to see the description of the problem. problem. DUTY BUTTON BUTTON Shows the menu for the selection of the duty by number or by crane configuration. Press this button to enable the selection of crane parameters like the boom length, the head type and a nd the counterweight, (if available). available). INFO BUTTON BUTTON Shows all the information regarding the current crane configuration. Press it a second time to access the operating system’s information screen and a third time to see the data logger screen (option). (option). BYPASS/ RIGGING BUTTON BUTTON Used to enter the rigging mode. (See sections 4.4.7 & & 4.4.7.1 for complete details) details) BUTTON TARE BUTTON Toggles the load display between the actual load and the tared load. load. TEST FUNCTION (Buttons 9 & 10) 10) Press them simultaneously at any time during normal operation, to check the functioning of the warnings (without the need to lift a load), loa d), keypad, relays or display. Note: The crane must not be in overload condition. condition. Sensing Telescopic Cranes Pressure Sensing
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2.2 Warning Lights and Indicators Indicators Location Location
APPROACH H APPROAC WARNING (YELLOW LIGHT) LIGHT)
OVERLOAD
MOTION
WARNING (RED LIGHT) LIGHT)
CUT CUT LIGHT) (RED LIGHT)
PRESET LIMIT(S) REACHED REACHED
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TWO-BLOCK
RATED CAPACITY
CONDITION
LIMITED BY THE
DETECTED DETECTED
HOIST ROPE ROPE
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Introduction i3500 Introduction
2.3 Warning Lights and Indicators Indicators Detailed Description Description The approach warning light blinks when the load on the hook is between 90% and 99.9% of the rated capacity (adjustable value; EN13000:2010: 90% and 97.5% ). This is accompanied by an audible warning device that is fitted inside the display display unit. This light (yellow in color) will also flash on and off if you are approaching within 5 units (feet, meters or degrees) of a predetermined limit (set in the limits setting mode). mode).
Operate with caution ! ! The crane is working near its maximum operating capacity. capacity.
The overload warning light (red in color) illuminates at or above 100% of the rated capacity. This light will also turn on if you are reaching a predetermined limit (set in the limits setting mode). mode).
The crane’s maximum capacity has been reached or exceeded. exceeded.
The motion cut warning light (red in color) illuminates at or above 100.1% of the rated capacity. This is usually associated with, for example, booming down, telescoping out or hoisting up. The exact operation is specific to the crane model. model.
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 atomotion cut solenoid is connected the system. system.
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The Rope Limit indicator appears just above the number of parts of line on the i3500 lcd screen. This indicates that the maximum load is limited by the rated strength and the number of parts of line of the hoist rope. Increasing the number of falls (parts of line) reeved and set in the display is normally required to reduce a rope limit. limit.
The Two-Block condition indicator appears near the crane boom tip depicted on the i3500 lcd screen when such a condition is detected by the system. This may block the hoist function, depending on crane model and/or on the options fitted on the machine. machine.
This indicator appears on the top-left corner of the i3500 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. mode.
One of these indicators appear on the screen when a preset Maximum Maximum or Minimum Angle Limit has been reached or is about to be reached. reached. If you are approaching a predetermined maximum or minimum angle limit, one these indicators will appear on screen, the approach warning wa rning light will blink and the internal buzzer will turn sound on and off. If you have reached a predetermined maximum or minimum angle limit, the overload warning light will be activated and the buzzer will sound continuously. continuously. Sensing Telescopic Cranes Pressure Sensing
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This indicator appears on the screen when a preset Maximum Radius Limit has been reached or is about to be reached. reached. If you are approaching a predetermined maximum radius limit, this indicator will appear on the screen, the approach warning light will blink and the internal buzzer will turn sound on and off. If you have reached a predetermined maximum radius limit, the overload warning light will light up and the buzzer will sound continuously. continuously.
This indicator appears on the screen when a preset Maximum Height Limit has been reached or is about to be reached. reached. If you are approaching a predetermined maximum height limit, this indicator will appear on the screen, the approach warning light will blink and the internal buzzer will sound on and off. If you have reached a predetermined maximum height limit, the overload warning light will light up and the buzzer will sound continuously. continuously.
The zones where the system will warn the operator that a Preset Limit is being approached can be changed as required. By default these values are set to: 5 degrees for a min/max angle limit and 2 feet or meters (depending on the units set at calibration) for a height or radius limit. limit. In some systems, Limits values are not active when electric power is first applied to the i3500 and they are automatically disabled if electric power is removed. removed.
Reaching an operator’s operator’s Preset Limit (set in the Limits Limits Setting Mode) Mode) will not result in crane motion cut-off. cut-off.
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i3500 Operation Operation
-3- -3- Installation & Calibration Calibration Installation of the i3500 system shall be performed by a qualified technician. Furthermore, calibration of the i3500 system must be performed by a RaycoWylie certified technician. The RaycoWylie technician will perform a complete and structured verification of the whole system before beginning the system’s calibration. calibration. Failure to calibrate the system properly can result in overloading of the crane risking machine breakage or tipping that could result in serious injury i njury or death. Always refer to a RaycoWylie certified technician to calibrate your system. system.
Installation and calibration manuals are available at RaycoWylie upon request. Please note that the installation and calibration instructions have intentionally not been included in this instruction manual. manual.
-4-4- Operating Instructions Instructions 4.1 Safety Instructions: Instructions: When operating the i3500 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. Read the following safety instructions before attempting to operate this system. system. 1.
The i3500 Rated Capacity Indicator must be properly set-up according to the crane’s configuration and operating work site situation. Wrong Set-up can cause the i3500 indicator system to show unreliable information which may result in hazardous conditions arising such as an overload. overload.
2.
The i3500 system is purely an aid to the operator. Responsibility for the safe operation of the crane lies with the crane operator. The i3500 system will not necessarily prevent crane damage due to overloading and/or other related causes. causes.
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i3500 Operation Operation
3.
Proper functioning of the equipment is dependent upon proper daily inspections and compliance to the operating instructions described in this manual. manual.
4.
During normal operation, the rated capacity of a crane should not be exceeded. Therefore the overload indication should not be used as a normal operating feature. feature.
5.
The crane should be operated at all times in such a way that the speed. crane’s motion occurs smoothly and at a safe speed.
6.
In order to have the proper rated capacity and radius, the system must be configured properly. p roperly. Failure to properly configure the system can result in machine breakage or tipping which could lead to serious injury or death. death.
7.
The operator must verify the crane configurations and number nu mber of parts of line for each available hoist every time he/she enters the crane and every time the crane is rigged. rigged. Note: each hoist has its own configuration set-up kept in memory and simply by changing the hoist from main to auxiliary the configuration and number of parts of line will change to suit. suit. Improper configuration of the i3500 system may also cause a ‘‘Zero Capacity’’ if no chart is found found to match the configuration set by the operator. operator.
4.2 Residual Risks Risks
In spite of the application of all relevant safety regulations and the implementation of safety devices, certain residual risks cannot be avoided: avoided: • Risks caused by no indication of malfunction of the output relays avoiding cut off motion to operate in overload conditions, causing machine breakage or tipping that could result in injury or death. death.
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Instruction Manual Manual
i3500 Operation Operation
4.2 Residual Risks (cont’d) (cont’d) • The system gives no indication of the presence of power lines in the crane working area, causing the risk of operating the crane in the proximity of power lines that could result in injury or death. death. • The system gives no indication whether the outriggers have been fully extended, causing the risk of machine breakage or tipping that could result in injury or death. death. machine • The system gives no indication of the crane level, causing risk of machine death. breakage or tipping that could result in injury or death. machine • System gives no indication of poor ground stability causing risk of machine breakage or tipping that could result in injury or death. death.
On 4.3 Power On
Switch on the electric power (i.e.: crane key switch) to the i3500 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 RaycoWylie’s ’s logo. logo. Subsequently, the i3500 system goes into normal operating mode as shown in Section 2.1 “i3500 normal mode display” display” of this manual. The normal mode screen allows you to visualize the etc. Hook Parts of line, etc. load, Rated capacity, Radius, Boom angle, Hoist used, the
Sensing Telescopic Cranes Pressure Sensing
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Instruction Manual Manual
Operation i3500 Operation
4.4 System Conftguration Conftguration The system configuration is done using the following three key buttons: buttons: Hoist/Scroll up button button selection Used for hoist selection
Parts/Scroll down button button Used for parts of line (falls) selection.
Duty button button Used for duty number selection. selection.
Selection 4.4.1 Duty Number Selection
Carefully read and understand these instructions before selecting a duty number. Selecting the wrong duty number can result in overloading of the crane risking machine breakage or tipping that could result in serious injury or death. Never select a duty number if you have any doubts, instead seek the advice of a qualified technician. Make sure that the duty number displayed in the normal mode screen matches the current configuration configuration of the machine. machine.
Sensing Telescopic Cranes Pressure Sensing
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Instruction Manual Manual
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