Raycaiylie Safety Instrumentation ‘SSM3DOMNE rev. E Indicator system for eee sensing, mnulty Copyright 2008 The B & A Engineering Co Ltd (RaycoWylie 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. Ref: MP December 2007 RaycoWylie Systems RaycoWylie Systems Drury Lane 1020 9" Avenue, SW St. Leonards-on-Sea Suite 124 East Sussex Bessemer, AL 35022 England USA TN38 9BA Tel:+44 (0) 1424 421235 Tel:+1 (205) 481-2080 Fax:+44 (0) 1424 433760 Fax: +1 (205) 481-2081 ‘Telescopic cranes with derrick pressure sensors RaycoWylie System 2440 Ave Dalton Ste-Foy Québec G1P 3X1 Canada Tel:+1 (418) 266-6600 Fax:+1 (418) 266-6610 ‘Calibration Manual i3500SBM3500MNE rev. E Contents 1.0 41.4___Introduction... 41.2 1.3 2.0 24 2.2 3.0 3.1 3.2 3.3 3.4 3.5 Dimensions Data Sheets GENERAL DESCRIPTION Personnel qualification and scope of this manual... Brief description of the 13500 System THE 13500 SYSTEM... Troubleshooting .. 2.4.4 Diagnostic Menu 2.4.2 Error Messages and the use of the “?” Configuration and calibration 2.2.1 System options .... see 2.2.2 _ Selecting units of measure for calibration: ("- c: imperial") seen ese 2.2.3 Calibration data: ("-calibration data ") 2.2.4 — Entering fixed data values: ("- dimensions") 2.2.6 Relays configuration: ("- relays configuration’ 2.2.4 Digital inputs configuration: ("- dig. inputs config. 2.2.7 Angle Calibration. 2.2.8 Length Sensor Calibration ati 2.2.9 Pressure sensor ci n 2.2.10 _Multi-point no-load calibration: ("-no load calibration") CANBUS INTERFACES BOARD. Angleflength and ATB sensor interface board 3.4.1 Errors detection... 7 3.1.2 Basic accelerometer’s calibration: 34300 ATB... event Relay and digital input interface board: Rotation sensor interface board... 3.3.1 Relative Encoder... 3.3.2 Absolute Encoder. Pressure transducer interface board: Sensor voltages. ‘Telescopic cranes with derrick pressure sensors ‘Calibration Manual i350‘S5M3500MNE rev. E 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 purpose. 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. 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. All procedures herein are based on the use of the system under proper operating conditions, with no deviations from the original design. Alteration and/or modification of the equipment are strictly forbidden without written approval from RaycoWylie Systems. The i3500 RaycoWylie Systems Rated Capacity Indicator (RCI) is to be regarded only as an aid to the operator. When the parameters are set correctly, the indicator will warn 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. 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. 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 and local safety standard and regulations applicable to his job. Correct functioning of the system depends upon routine daily inspection, ‘Any suspected faults or apparent damage should be immediately reported to the responsible authority before using the crane. Telescopic cranes with derrick pressure sensors. Calibration Manual i350——____1.1._Introduetion — 55M3500MNE rev. E 1.0 GENERAL DESCRIPTION This manual contains calibration, diagnostic and troubleshooting information for the i3500 system. Information in this manual will enable qualified personnel to calibrate and troubleshoot the 13500 system efficiently. 1.2 Personnel qualification and scope of this manual This manual is intended to be used by qualified installation technicians and repair technicians, who are fully qualified and trained to perform the procedures described in this guide. This manual is divided into the following sections: SECTION 1 - GENERAL DESCRIPTION SECTION 2 - THE i3500 SYSTEM SECTION 3 - THE CARD/ELECTRONICS INTERFACES 1.3. Brief description of the 13500 System The 13500 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. Optional sensors may also be fitted to monitor the slew angle and the rotation of the hoist drum to provide some extra information to the 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 pre-programmed in the 13500 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. The actual load is expressed as a percentage of the permitted load (%SWL). if 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). ‘Telescopic cranes with derrick pressure sensors. Calibration Manual i3500SBM350OMNE rev. E Audible alarms: an intermittent buzzer sounds if the percentage of the safe working load is between 85%-99% and a continuous buzzer sounds when the % of the safe working load is in the range of 100% to 120%. Visual alarms: A yellow led illuminates for an approach to an overload between 85%-99% of the safe working load. A red led laminates for an overload between 100%-119% of the safe working toad-and-an additional red led illuminates for a cut out > 120% of the safe working load. If the additional sensors are fitted, then some information about the current slew angle and the hook height will also be available. The required crane duty charts are stored in a non-volatile memory and can only be modified with the approval of the crane manufacturer. The calculated crane parameters and calibration data are stored in an additional non-volatile memory. The calibration of the crane is performed only with the use of known loads, boom angles, and other pre-determined data. 2.0 THE 13500 SYSTEM 2.4 Troubleshooting This section provides technical troubleshooting support. It will answer most questions that repair personnel may have when installing, repairing or performing maintenance on the i3500 system. 2.4.1 Diagnostic Menu A diagnostic menu provides information on the systems status and the state of all connected sensors. To access the diagnostic menu, press #1 “mode”, and use "A" or “vy” to highlight “diagnostic”, then press ““” to enter the diagnostic menu. The information is divided into several pages with each page applying to only one sensor or one type of information. The different pages available are: angle/length, load, relay, general info for a specific type of calibration (e.g. telescopic multi-point), rotation and also the addresses of sensors detected by the i3500 system. Depending on the system configuration, a minimum of three pages are always provided: angle/length, general info and detected addresses. Other pages are optional and are only shown if one or more sensors are activated by the system (refer to the option activate/deactivate /0' in calibration). Telescopic cranes with derrick pressure sensors Calibration Manual i35005EM3500MNE rev. E ‘The use of the up/down arrows (”A” and “‘w”) will allow the user to scroll in the menu. When pressing simultaneously on an “arrow” key and the “?” key, the display will move from one page to the other. Pressing “v” will show calibration details and also the original software version of the underlined sensor, this is not available for all sensors * Pressing #5 “ESC” takes you to the previous menu or exits from the diagnostic mode. Angle/length sensor: In the diagnostic menu, this is the typical displayed information: sensor length 1 203 NIA 4.99 0 Some applications have more than one angle or length sensor. In this case, all of the angle sensors are listed first then length sensors will follow. The first angle sensor to be listed is the one installed closest to the main boom base. Referring to the example above, for the “angle 1” sensor, values “ain1” and “ain2" vary depending on the inclinometers in the X and in Y axes that are used to calculate the angle. These values are normally between 1200 and 2900 bits. DR+ represents the D.C voltage level of excitation on the angle/length card and must be close to 5.00V. When the multiple reel option is required every angle/length card has an ATB option that can be activated by dipswitch #4. For the angle/length card, which is not monitoring the ATB, N/A is shown under a2b instead of 0 or 1, indicating it is not available on this card. Os a safe condition and 1 will show a two-block condition. For the “length 1” sensor, the value “ain1” represents the boom extension value in bits. It may vary between around 50 and 975 bits. The “length 1” sensor “ain2” value is reserved for future expansion. Note: “angle 1" sensor and “length 1” are physically located on the same card. Telescopic cranes with derrick pressure sensors: ‘Calioration Manual 13500‘S5M3SOOMNE rev. E To see the software version of the angle sensor and it's calibration state, press “Y” when “angle 1” is highlighted. The displayed information will look similar to this: = angle 1 7 ver: 1.01 O7jun07 digx: 823.0 digy: 822.0 dzerox: 2041.0 dzeroy: 2034.0 zero angle: -150.2 The line beginning with “ver” indicates the software version of the angle/length sensor and also its creation date. The next two lines indicate if a sensor has been calibrated or if the calibration is valid. dgx and digy must be close to 820 #1% dzerox and dzeroy must be close to 2048 #1%. Zero angle is the angle in degrees given by the angle sensor when the zero of the angle has been calibrated on the machine. To view the software version of the length sensor or it's calibration state, press “v” when ‘length. 1" is highlighted. The displayed Information will look similar to this: ver: 1.01 O7jun07 offset 57 scale 0.149661 The line beginning with “ver” indicates the software version of the angle/length sensor and also its creation date. The next two lines indicate if a sensor has been calibrated or if the calibration is valid. The “scale” value must be smaller than 1.0. Pressure nsors : The use of the up/down arrows will permit the user to scroll in the menu. sensor ain drt pt p2 1325 4.96 1 1 load 2 1109 4.98 1 1 The “ain” value represents cylinder pressure measured in bits by the pressure sensor. It can reach a maximum of 4095 bits. The Dr + column is a regulated D.C. voltage level for the excitation of the pressure sensor and must be close to 5.00 VDC. Telescopic cranes with derrick pressure sensors Calibration Manual i3500SBM350OMNE rev, E “p1” and “p2" values indicate the state of proximity sensors (prox1 and prox2). “p1” and “p2” are used to detect target for the rope direction sensor option, this option is not available for the telescopic crane pressure sensing, multi-point version. To know the Software version of a pressure sensor or ifs calibration state, press when “load1” is underlined. The displayed Information will look similar to this: load 4 ver: 1.00 07may07 offset : 373 scale : 0.142113 The line beginning with “ver” indicates the software version of the pressure sensor and its creation date. The next two lines indicate if a sensor has been calibrated or if the calibration is valid. The ‘scale’ value must be smaller than 1.0. Relay: The displayed Information will look similar to this: relay inputs The information shown for the relay cards is divided into two blocks: * ‘Relay’ block represents the individual state of every relay. “0” indicates that the relay coil is energized whereas “1” indicates that it is not energized. * “Inputs” block represents the state of the 4 DIN inputs. A “0” represents an active input. A maximum of 4 relay cards can be installed. Press “v” when card 1 is highlighted to view the software version of a relay card. The displayed Information will look similar to this: relay card 1 ver: 1.00 O2may07 The “ver” line indicates the software version of the relay card and its creation date. Telescopic cranes with derrick pressure sensors Calibration Manual i360S5M3SOOMNE rev, E General information: The displayed Information will look similar to this: HO: 100.0 Kt B41 dir.m dina: larg: 7.67 T. corr : 0.66 lah: 1.71 load : 0.66 fe ang: 1,00 defi fe len: 1.00 po: Telescopic cranes with derrick pressure sensors ‘Calibration Manual i300 pdt2: 60.24 tx0 and tx1 are pressure sensor readings. Their values are represented in ‘bars’ (metric pressure unit). dirm and dir.a indicate direction of hook movement for the main or auxiliary winch. Note: This is an option used when dynamometers or load links are installed for line tension measurements. larq (cable arm lever) and lah (cylinder arm lever) are values used by engineering to verify certain calculations. |. corr is the real load including correction factors. These factors are fo ang (correction based on angle points) and fc len (correction based on length points). ‘These factors are set in the calibration section *- load correction”. load is the indicated load before application of correction factors. fe ang and fc len are correction factors applied to the load, the first one refers to hoist angle and the second one refers to boom extension. defl represents boom deflection. p0 is the pressure in “bars” of the main boom without load. pd12 is the total pressure in “bars” including the effect of lifted load.S5M3SOOMNE rev, E Slew sensor (Rotation option) The displayed information will look similar to this —_ rotation ver:0.11 17apr07 rot: 782 ratio: 1304 zero prox: 191 prox detect: 0 The “ver’ line indicates the software version of the rotation interface and it's creation date. * rotis a rotation pointer and varies from 0 to ratio value minus one. (ex. 1304 -1). "ratio is rotation sensor ratio (number of pulses for a complete rotation). * zero prox is a rotation reference point. Angle of rotation is on ‘Zero prox’ value when the “proximity switch” is detecting the target. = prox detect shows “proximity switch” state. The “0” indicates that the proximity switch is detecting a metal target set to a predetermined azimuth angle. Detected addresses: This page gives the sensor addresses on the CAN network detected by the i3500 system. Addresses remain in memory as long as the system is powered even if a sensor stops communicating. 2.1.2. Error Messages and the use of the “2” During the start up and operation processes, the i3500 system analyses all interactions between intemal peripheries (memories, controllers, extension cards, etc.) and also external ones (physical cards linked to the Canbus network). Telescopic cranes with derrick pressure sensors Calibration Manual i600 10‘S5M35OOMNE rev. E 2.4.24 Internal peripheries Error message Execution process Cause of error tarp, the system verifes —/=-Legger card is notinstalled._— iol Logger Gard logger option [2 connector has detective Recording error |; activates logger opt soldering or is broken, - 3+ There is a problem with the logger card. When stariing system, thereisa | i Limit memory | verification (Writing/Reading) of the | There is aa with flash ‘error backup chip of the limit y programmed (limiter scope) 4- Load chart chip is not installed Upon startup, the system does a alled, , Load chart artup. 2+ Verify the kind of memory it crror |fe2d verication of oad chart flesh |" ict ne a lash momar. memory chip. 3- There is a problem with flash memory (U12). Upon startup, the system does a read/write verification of bank C , “or 1- There is a problem with ‘C’ memory | EEPROM chip. It is used as a error backup for the system's operation EEPROM memory (U45) parameters. Ex. winch, number of strands, # duty. Logger option must be activated. | Vatify if black plastic cap is System regularly verifies if seconds 99 Clock error roving iftyme dove not (contains battery crystal), are moving. ir me dose Nn 2- There is a problem with the change then there is a problem. logger card Upon startup, the system does a | ; ; “A* memory _| read verification of bank A 1 There a probiem Way) error EEPROM chip. It is used as a ry backup for calibration data 7. There is a problem with RAM memory (U3). With Logger option, the cause is RAM Upon startup, the system does a memory (U5). RAM memory | read/write verification of RAM chip. | _ - if system is behaving This is a volatile memory. strangely, = if system initializes often during operation mode, = if system never starts. 1- Unloaded hoist calibration Not calibrated were is no calibration for selected | (empty) and unloaded uty. deflection must be done. Telescopic cranes with derrick pressure sensors ‘Calibration Manual i3500 11SEM3500MNE rev. E Telescopic cranes with derrick pressure sensors Can Bus 1- There is a problem with general enor | C2" Bus controller verification. CANbus controller, either ‘$JA1000 or MCP2515 (U29) |Werification.of programmed load__|_, _ _ _ = Muif-languages [chart in the system. Must be multi |" re Programmed foad cha not supp. _ | languages. This option can P support up to 10 languages. 7- Memory extension card is , not installed, External Neriication of memory extension. 2. There is a problem with memory (LTM) | On for EPROM or Flash memory. 3- Connector has defective soldering or is broken. Extemal card | “Logger” option must be activated. |1- Logger card is not installed, (record) —_|Upon startup, the system verifies _|2- There is a problem with one (Logger) _| that logger card is present. of the two flash memories. ; 1 Logger card's plastic cap Recorder low | eee cioae on at Liha must be replaced. It batt. This ray cause clock to stop or contains the battery. (See (Logger) | |< illustration below for lose precision. replacement) + Verify ifthe load chart is corresponds to the crane to The actual crane configuration is calibrated. No load chart | unauthorized. The programmed | 2- Does load chart depend on load chart does not support it. rotation? 3 Does load chart depend on DIN entrees? Crane dimensions must be entered Parameters | in the system. Load value willbe |" CLS, Cl4 and cur values nullorwrong. should not be at zero. “Comparison angle/radius” option must be activated. Thus a jib capacity is evaluated by |‘ ae ne Toe fe kind of 2° Load chart is angle (offset) against the jtb's application. “One touch’ field not found | char. in comparison to the same is used in the load chart for b's capacity evaluated by its his enton radius against the “Main boom" chart. The smallest will be ___|considered. ‘Calibration Manual i350 12into slot Insert a flat serewdriver S8M3SO0MNE rev. E Battery replacement : (located: on-Loggercard=) Slowly press screwdriver backwards until cap is jetached from base [detach 2.4.2.2 External peripheries A) Angle/length and ATB interface circuit board errors: The i3500 system can support up to 5 angle interfaces. Activation of every angle ‘sensor is done in the calibration menu section " -ent/sor activate/déactivate ". Error message Execution process Cause of error Angle sensor The angle sensor value in volts is not valid (if < 1 volt or > 4 volts). 1- Accelerometer or converter 12 bits are cd defective. 7A OxFFFF code is sent by angie/iength | 1- Length sensor is not card to indicate that length sensor is installed, erat og OF | not present. 2- Awire is cut between length sensor and circuit board. Pre-calib. angle Indicates that angle/length card is in pre-calibration mode. 7- In operation mode, the jumper must be taken out from ‘Cal’ jumper located on the circuit board, # 2. Verify that calibration value in bits of the accelerometer is valid. Comm 13500 system does not receive data) 7- The angle/length circuit angleftongth # |™ angle sensor. If'time out’ delay board is defective, is reached, then a communication |2- Can bus network cable is error is displayed. broken. Not calibrated | Length sensor is not calibrated. length # Not calibrated | Angle sensor is not calibrated. angle # Telescopic cranes with derrick pressure sensors Calibration Manual i350 13S5M3500MNE rev. E sensor is done in The i3500 system can support up to 4 load Dre 5 volts reference voltage is not valid (if |1- Angle/length circuit board angleflength # | < 4.5 volts or > 5.5 volts). is defective. __B) Load interface circuit board errors: on a - the calibration menu section “-ent/sor ac ircuit boards. \ctivate/deactivate”. Activation of every load Error message Execution process Cause of error Off limits load # Angle sensor value in bits is not valid (if < 150 or > 3935). Not calibrated load # Load sensor is not calibrated. Dr+ load # 5 volts reference voltage is not valid (if < 4.5volts or > 5.5 volts). 1- Load card is defective. Communication load # 13500 system does not receive data from pressure sensor. If ‘time out” delay is reached, then a communication error is displayed. 1- Load card is defective, 2- Can Bus network cable is broken. The i3500 system can support up to 4 relay cards. done in the calibration menu section *-ent/sor activate/deactivate’. C) Relay and digital input interface board errors: Activation of every relay card is Error message Execution process Cause of error Communication relay # 13500 system does not receive data from relay card. If “time out” delay is reached, then a communication error 2- Can Bus network cable is is displayed. 1- Relay card is defective, broken. Note: There is no automatic test for the relay contacts on the relay circuit board. Therefore, if a relay becomes defective there may not be a warning. Periodically, the operator should test the lockout system. D) Generic interface board errors: The i3500 system can support up to 4 generic cards: One for wind speed, one for inclination level, one for absolute rotation and another one for analogical output. Activation of every generic card is done in the calibration menu section *-ent/sor activate/deactivate”. Error message Execution process. Cause of error ] Not calibrated |An appropriate, analogical sensor is generic __|not calibrated. _ Dr+ generic [5 volts reference voltage is not valid (if |1- Generic card is defective. < 4.5 volts or > 5.5 volts). Telescopic cranes with derrick pressure sensors Calibration Manual i3500 14SBM3500MNE rev. E Communication generic 13500 system does not receive data from generic card. If “time out” delay is reached, then a communication Lerror is displayed. + Generic card is defective, 2- Can Bus network cable is broken. E) Rotation interface board errors: The i3500 system can support only one rotation card. There are two different kinds: a relative one and an absolute one. Activation of rotation card is done in the calibration menu section *-e1 Relative rotation: nt/sor activate/deactivate”. Error message Execution process Cause of error Verify encoder [A GND wire indicates that the cable _|1- Replace cable between cable between the encoder and the rotation | encoder and rotation card is not cut. If the cable breaks, this| card. wire will become open. Then the rotation card will send an error message to the i3500 system. Encoder ratio [No ratio has been entered. 1- Puta different value than 0. Encoder _ | Proximity is not detected in configured |1- Proximity is defective. position prox._| position by i3500 system Encoder | If proximity switch has been detected | 1- Encoder is defective. when encoder did not receive a pulse. On the other hand, if proximity is detected when starting rotation card, then no error is displayed. Encoder [13500 system does not receive 1- Rotation card is, communication | anything from the rotation card. If defective, “time out” delay is reached, then a communication error is displayed. Can Bus network cable is broken. 2 Absolute rotation: (a generic card will be used for this typ. 3 of interface) Error message Execution process Cause of error communication Encoder ratio _| Ratio is not programmed. Encoder__| Works with serial link RS-422, In development phase Encoder |i3500 system does not receive 1- Rotation card is anything from rotation card. If “time out" delay is reached, then a communication error is displayed. defective, 2- Can Bus network cable is broken. Telescopic cranes wit ith derrick pressure sensors Calibration Manual (3500 15SSM3500MNE rev. E 2.2 Configuration and calibration This section provides the necessary information to calibrate the system. = Before starting a calibration, make sure that the overall system initialization has been completed. Otherwise, the system may behave erratically. To execute a global system initialization ‘init all’, it is necessary, prior to starting the system to press “A” and #5 “ESC” simultaneously until the system asks you to confirm the system initialization. erased. This should only be done under the advice of a qu: technician. = Sensors used by the system must be configured. In the calibration menu scroll with “A” or ““y” until reaching the menu *-enable/disable i/o". Press “¥” to confirm this choice. Use “A” or “¥” to highlight one of the sensor inputs, then press “Y” to change the sensor state. Repeat this procedure for each sensor. Press #5 “ESC” to return to the main calibration menu. 2.2.4 System options 2244 Data logger This option allows you to activate the registration of certain events like the A2B, at the beginning and at the end of a lift, and so on. An electronic “Logger card” is necessary (part # 22BCB0167). It is composed of a flash memory to backup data and also a RTC module (Real Time Clock) to log the event (ie. registered hour and date of an event). This card is installed on the display module of the 13500. It is mounted on a male header connector. NOTE: It should be noted that this card must be installed in the correct direction. A visual indicator has been printed on the circuit board to avoid any error. The switch RAM IN/EXT position must be switched from RAM IN to the RAM EXT. This allows the 13500 to use the real time clock module for hour and date. Telescopic cranes with derrick pressure sensors Calibration Manual i600 16‘55M3500MNE rev, E 2.2.1.2 Password protection If this option is activated in calibration then during startup of the. i3500 system, a message is displayed on the screen asking to enter a user identification number. The lockout will be activated until a valid password is recognized by the i3500 system, after which it will enter the normal operation mode. Normal lockout operation will be resumed. Warning: It should be noted that this should only be changed with the advice and consent of a certified RaycoWylie technician. Note: If the option ‘Data logger’ is activated, the option “Password protection” is automatically activated. Pressing key “v” when highlighted can deactivate it. 2.2.1.3 Limit saved message This allows the operator to turn the system on and off without losing limits. If the option “Message saved limit” has been activated if there is at least one limit programmed when starting the 13500 system, a message will appear on the screen informing the operator. He will then be able to judge whether this limit should be kept or erased. If erasure is - chosen, the programmed limits will all be removed. Warning: It should be noted that this should only be changed with the advice and ‘consent of a certified RaycoWylie technician. Note: To activate the “Rotation” option, select item “ -in/out on/off" In the calibration Menu then activate ‘Rotation Rel” for rotation with relative encoder ivate “ i ” oder. 2.2.1.4 Angle/radius comparison This option depends on the type of load chart programmed in the i3500 system. Special conditions should be added to the charts to support this option. If the chart does not support this comparison, and this option has been enabled, then an error “no load chart” will appear at any moment regardless of the duty chosen. Warming: It should be noted that this should only be changed with the advice and consent of a certified RaycoWylie technician. Telescopic cranes with derrick pressure sensors ‘Calibration Manual i600 17‘S5M3500MNE rev. E 2.2.2 Selecting units of measure for calibration: ("- calib. unit: imperial") Units of measure must be selected before starting the system's calibration. There are 2 _ possible choices: Imperial or metric Imperial: (inches x 1000 pounds) and in feet. Metric: in te (metric ton = x1000 kg) and in meters. In the calibration menu, using A” or “¥” to the "20-unit calibr.” and select the desired units by pressing “v”. Warning: Once all the required dimensions are entered (see next section), the system will not allow to modify the calibraton units of measurement. Do not mix this with the display unit, where units can be changed at any time in the operation mode with #4 “MODE” button. 2.2.3 Calibration data: ("-calibration data") Calibration data represents all the parameters used for the system based on the client's recommendations. 2.2.3.1 Rope limit (Main/Aux) Rope limit main: This is the maximum line pull permitted per part of line on the main hoist according to the chart. This value will be used as the load limitation if lower than the rated capacity. Rope limit aux: This is the maximum line pull permitted per part of line on the auxiliary hoist. This value will be used as the load limitation if lower than the rated capacity. um falls 2.2.3.2 The mai Set the maximum number of parts of line. This applies to both hoists. 2.2.3.3 Rigging angle ‘The RIG ANGLE is a set angle below which the operator can permanently bypass the lockout by pressing the RIG button; it should be set at the lowest practical boom angle possible. This function is used to allow the rigging of jibs or hook reeving at boom angles below the SWL chart. The RIG function is canceled when the operator booms up above the set angle or if the system is turned off. ‘Telescopic cranes with derrick pressure sensors Calibration Manual i350 18S5M3500MNE rev. E 2.2.3.4 Alarm zone Alarm 1: This alarm is the pre-alarm on load. When the set percentage is reached, an intermittent buzzer is activated as well as pre-warning indicator light. Alarm 2: This alarm is the maximum load limit set by the rope capacity or crane capacity (load chart). When the set percentage is reached, the red octagonal indicator light and the pre-warning indicator light turn on and the buzzer is continuous. The lockout is not activated. Alarm 3: This alarm signals the lockout (motion cut) load limit. When the set percentage is reached, the red octagonal indicator light with the octagon and the pre- warning indicator light turn on and the buzzer is continuous. The lockout is activated. 2.2.3.5 Load chart adjustments Outside duty radius: This variable represents a transition distance between the last radius rating and zero capacity. If the actual hook radius exceeds the maximum chart radius, the system alarms will be triggered. The system will not allow radii beyond the maximum radius given by the load charts. The OD (OUT of DUTY on RADIUS) will allow the SWL to decay evenly from the last point on the chart to zero over the distance set by this variable. Note, this is only valid if the chart interpolation is set to ‘on’, refer to section 3.7.6. Outside duty angle: This variable works in the same way as ‘outside duty radius’ but is used for charts where the SWL is determined by boom angle and not radius. Outside duty length: This variable represents an upper tolerance on the internal selection of the relevant load capacity chart for the actual boom length measured by the system length sensor. Inside duty length: This variable represents a lower tolerance on the internal selection of the relevant load capacity chart for the actual boom length measured by the system length sensor. 2.2.3.6 Number of hoists Set to the number of hoists (winches, or hooks) fitted to the crane, 1 for main hoist only or 2 for main and auxiliary hoists 2.2.3.7 ‘Changing of duty >20% SWL: If set to YES this option allows duty and parts settings to be changed while a load is ‘suspended, if set to NO these changes will not be permitted unless the load is less than 20% of the SWL. This option must be set to NO for European operation. ‘Telescopic cranes with derrick pressure sensors. Calibration Manual i350 19S5M3500MNE rev. E 8 Angle sensor position on main boom: It is important to specify the angle sensor position during the installation, so that it will work_correctly, even if ithas a 360 degree range. The angle sensor's position (left or right side of the boom) depends on the operator's location in the crane 2.2.4 Entering fixed data values: ("- dimensions") This menu contains crane dimensions that are necessary for the calculation of the hook load, based on the hydraulic cylinder pressure. See diagrams below. Enter all measurements seen diagram 2.2.4.2, 2.2.4.3, 2.2.4.4, and 2.2.4.5 where each value is described below; lt (full retract) — the length of the main boom when fully retracted. cl2 (full ext w ext) — the length of the boom fully extended including any manual or Power pinned extension if fitted cl2mr (full ext wio) - the length of thé boom fully extended but with any manual or power pinned extension retracted. Note : for full power booms without a manual section cl2 and cl2mr are the same value. cl (p2bIh) — the horizontal distance between the boom pivot pin and lift cylinder base in. ela (p2blv) — the vertical distance between the boom pivot pin and lift cylinder base pin. cl? (p2buh) — the distance between the boom pivot pin and lift cylinder top pin parallel to boom telescoping centerline. el8 (p2cb) — the vertical distance between the boom pivot pin and the boom centerline with the boom horizontal. 19 (ra2cb) - the vertical distance between the lift cylinder top pin and the boom centerline with the boom horizontal. If the boom centerline is greater than the lift cylinder top pin, then the distance is positive, otherwise it is negative cf (slew offset) — the horizontal distance between the boom pivot pin and the centerline of rotation of the machine. If the boom pivot pin is behind the centerline of rotation then the distance is negative, otherwise it is positive ch1 (height rubber) - the vertical distance between the boom pivot pin and the ground when on tires. ch2 (height outrigg) — the vertical distance between the boom pivot pin and the ground when on outriggers. nr (number of rams) - the number of boom lift cylinders, normally 1 or 2. ad (rod diameter) — the rod diameter of the lift cylinder. bd (bore diameter) - the bore diameter of the lift cylinder. Telescopic cranes with derrick pressure sensors, Calibration Manual i3500 20SEM3500MNE rev. E cr2m (m.h. radius) ~ the radius of the main hoist drum from the center to the middle of the hoist line layers. This distance is approximate and does not play a critical role in load accuracy. boom pivot pin. If the drum is mounted on the boom, this dimension is zero. cl6m (p2mhv) - the vertical distance between the center of main hoist drum and boom pivot pin. If the drum is mounted on the boom, this dimension is zero. ¢r22m — the radius of the boom base mounted, main hoist guide sheave, ‘see note 1 cl28m — the vertical distance between the boom base mounted, main hoist guide sheave and the boom pivot pin with the boom horizontal, *see note 1. 129m — the horizontal distance between the boom base mounted, main hoist guide sheave and the boom pivot pin with the boom horizontal, *see note 1. cr2a (ah. radius) — the radius of the auxiliary hoist drum from the center to the middle of the hoist line layers. This distance is approximate and does not play a critical role in load accuracy. clSa (p2ahh) — the horizontal distance between the center of the auxiliary hoist drum and boom pivot pin. If the drum is mounted on the boom, this dimension is zero. cl6a (p2ahv) - the vertical distance between center of auxiliary hoist drum and boom pivot pin. If the drum is mounted on the boom, this dimension is zero. ¢r22a - the radius of the boom base mounted, auxiliary hoist guide sheave, *see note 1. cl28a — the vertical distance between the boom base mounted, auxiliary hoist guide sheave and the boom pivot pin with the boom horizontal, *see note 1. 29a — the horizontal distance between the boom base mounted, au sheave and the boom pivot pin with the boom horizontal, *see note 1. jiary hoist guide Note 1: This option is rare and these values are generally set to zero. If a guide sheave is fitted but mounted on the superstructure (not the boom) then the sheave is treated as though it is the winch drum (see sketches). To modify one of these variables, proceed as follows: 1- Use “A” or “¥” to highlight line “-dimension” and press “¥” to go to submenu 2- Use “A” or “¥” to highlight the required variable. Note: there are 5 pages. 3- Press “Y” to edit the variable. 4- Use “A” or “Y” to modify the value. Note: If you keep “?” pressed in, it will accelerate the modification. 5- Press “Vv” to save the new value. 6- Repeat steps 1 to 5 for all the other variables. 7- Press #5 “ESC” to come back to the main calibration menu, ‘Telescopic cranes with derrick pressure sensors Calibration Manual 13600 21‘S5M35O0MNE rev. E 2.2.4.1 Diagram: Crane dimensions ‘*regatve it on opposte sé to main boom center ‘*2Negatve main boom pivot placed behind rotation center *3 These dimensions are not avalable for edting Note on the sign convent Every dimension is positive except ef. If the rotation center's axis is placed in front of the main boom’s pivot, then cf will be negative. If any dimension falls on the other side of the reference line shown in the diagram, then the sign will change. For example, if the boom cylinder’s head is above the hoist’s axis, then cl9 will be negative. Telescopic cranes with derrick pressure sensors: Calibration Manual [3500 22‘S5M3500MNE rev. E Diagram 2.2.4.2 Crane dimensions cnt'‘d rr Ineludng manal section Pp CL iy fecudrg manual section : @ gt ‘Telescopic cranes with derrick pressure sensors. Calibration Manual i3600 23,S5M3500MNE rev. E Diagram 2.2.4.3 Hoist Drum(s) on superstructure with boom mounted guide sheave(s) * anomatve ocatonof hoist sams tusng guide sneaves on boom. For {hs taton mensions da and ‘dem ae negative. Telescopic cranes with derrick pressure sensors. Calibration Manual i600 24SOM3S00MNE rev. E Diagram 2.2.4.4: Jib dimensions Diagram 2.2.4.5 Rooster dimensions Telescopic cranes with derrick pressure sensors. Calibration Manual i3500 25SSM3500MNE rev. E 2.2.5 Relays configuration: ("- relays configuration") Digital outputs can be configured according to Table 2 below. They are linked to the action of each relay involved. For example in Table 2, relay #5 activates an external buzzer or a roof light. While relay #3 activates the left counterbalance. This table can be modified so that each relay can activates with several functions. TABLE 2: Digitals outputs configuration (Relays): Relay #1 73°) ArBeLockout ATR Disable eH Relay #2 RL Lockout | DBabIe Reray BL Swng ten | DADC Rolay SR Swing Ren | OBBtIE Raley #5 Gang) External Alarm | Amber lamp for [Disable SP For overioad. | Range Limiting IRtD. Bevice Relay #6 Disabie Relay #7 Disabie Relay Disabie 2.26.1 Bypass configuration The “Bypass” function can be configured according to Table 3 below. Actions of the “Bypass” key and digital output "External bypass” will depend on this configuration. If the bypass configuration is disable, then the board key and digital output will be ignored. TABLE 3: Bypass configuration: Bypass Cutout *ATB] Disable + Swing left+ ‘Swing right Telescopic cranes with derrick pressure sensors ‘Calibration Manual i3600 26‘S5M3500MNE rev. & 2.2.4. Digi | inputs configuration: ("- dig. inputs config.") Digital inputs can be configured for different input types, or for their functionality as defined in Table 1. The Interlock inputs are used to detect if a boom section is locked in place with a pin. It can be detected using a magnetic or mechanical proximity switch. The Din inputs are use to detect working area, ie. over end, over side. It can be detected using a magnetic or mechanical proximity switch. The External Bypass is required for the EN13000 compliance. When this function is used the "bypass" key on the i3500 display is disabled. Only an extemal spring key switch can be used to bypass the system. Some options are available for specific customer needs. RaycoWylie Systems will determine which option should be selected in the installation instruction. TABLE 1: Digitals inputs configuration: DIN4 DIN3 DIN2 DIN4 = Option #1 | Interlock #1| Din #3 Din #2 Din #1 Option #2 | Interlock #1 | Interlock #1] Din #2 Din #1 Option #3 | Extemal | Interlock #2 | Interlock #1 Din #1 Bypass | — Option #4 | Optional #3 | Optional #2 | Optional #1| Bypass External Telescopic cranes with derrick pressure sensors ‘Calibration Manual i260 27‘S5M3500MNE rev. E 2.2.7 Angle Calibration 22.74 2.2.7.2 Zero Angle Use “A” or “¥" to choose the “- select sensor’ line and press “ Use “A” or “" to choose the angle sensor and press the “7, wait for the system's confirmation. Use “A” or “'¥” to choose the "- Zero sensor’ line and press “¥”, Boom down to zero degree (main boom parallel to ground). The angle is displayed in degrees and the sensor value is in bits. This value must be above 100 bits. If smaller, turn the sensor to increase the value. Press “¥” to edit the angle value using ”A” or “W”. Press “¥” again to confirm the zero and wait for the system confirmation. Press #5 “ESC” to go back in the main calibration menu. Span Angle This step is not required for the angle sensor. The importance of displaying the sensor signal in bits is to verify that it changes through the entire working area of the boom angle, and that the resolution is above 3 bits per degree. 2.2.8 Length Sensor Calibration 2.2.84 Zero Extension a) Use “A” or “W” to choose the “- select sensor’ line and press “Y”. b) Use “A” or “Ww” to choose the length sensor, press “7” and wait for the system confirmation. ©) When the change is approved, scroll using “A” or “W” to choose the “. zero sensor’ line and press “v7” 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) e) Press “¥” to edit the zero value (when the boom is completely retracted, the value must be set to zero). f) Press “v’” again to confirm the value. 9) Press #5 “ESC” to return to the main calibration menu. Telescopic cranes with derrick pressure sensors Calibration Manual i3500 28SSM3500MNE rev. E Span Extension Use “A” or “¥" to choose the “-span sensor’ line and press “¥"_____ Extend the boom completely. The sensor value should be 150 bits above the zero value. Please refer to the crane main boom chart. Enter the difference between the fully extended main boom length and the fully retracted main boom length. For example: A fully extended boom of 81 feet minus a fully retracted boom of 34 feet = 47 feet. You enter 47.0 at span extension. ©) Press “v” to edit the span value. d) Use “A” or “¥” to edit the span value. e) Press “¥” to confirm the value 1) Press #5 “ESC” to return to the main calibration menu. 2.2.9 Pressure sensor calibration 2.2.9.1 Pressure sensor zero calibration To zero the pressure sensors, open the hydraulic lines of both sensors in order to remove any residual pressure. Make sure the boom is resting at its lowest point to prevent sudden fall when the line opens. The pressure sensor must be connected according to the schematics for normal operation. Select pressure sensors a) Use “A” or “¥” to choose the “- sel load trans” line and press “ b) Use “A” or “W” to choose the Bore or Rod sensor, press “¥” and wait for the system confirmation. Zero pressure calibration When the change is approved, Use “A” or “¥” to choose the *-zero pressure” line and press “v7” The reading on the lower right corner is in bits. The total scale is 1023. The display should read between 20 and 50 bits or between 235 and 325 if connected through an amplifier. Press “¥” to zero the bore side pressure sensor and press “¥” again to confirm. With an amplifier, if the reading is above 325 and below 450, the resolution of the system will be lower. Telescopic cranes with derrick pressure sensors allbration Manual [3600 20S5M3500MNE rev, E To zero the rod pressure sensor, select the rod sensor using the “-sel load trans” line and repeat the zero pressure calibration steps. The value on the lower right corner will be greater than the bore side pressure sensor. The expected reading should be between 100.and.200, or between.300-and.400 when_using an amplifier. if reading are. below these values, negative pressure may cause the load reading to drop substantially when a load is left hanging on the hook for an extended period of time. if the value is above 400, the resolution will decrease. 2.2.9.2 Pressure Sensor Span (Bore Side) The pressure sensor must still be disconnected from the hydraulic line. In the pressure transducer interface box or the amplifier box, tun the RCAL switch to ON if available or temporarily connect the black and white wires of the full side pressure sensors together. a) Select the Bore sensor using the “- sel load trans" line b) Use “¥” to select the “span pressure” and press “Y”. The reading on the bottom represents the bits out of 1023 as seen by the control unit The reading should be above 670 and not exceed 875. c) Press “¥” to enter the value engraved on the pressure sensor below the label. A typical value will read: CAL 285.6 BAR d) Enter the value engraved on the pressure sensor. If there is two lift cylinders and one pressure sensor on the bore side of each cylinder, enter the average of the 2 engraved value. e) _ Edit using “A” or “V”, then press “¥” key to confirm. f) Turn the RCAL switch to OFF if available or put the black and white transducer wires to their original connections and reconnect the hydraulic line. If the bit reading is below or above the recommended values, and the pressure sensor is connected directly in the control box, change the amplifier jumpers. Refer to the relevant amplifier table as seen earlier in this manual. 2.2.9.3 Pressure Sensor Span (Rod Side) The pressure sensor must still be disconnected from the hydraulic line. In the pressure transducer interface box or the amplifier box, turn the RCAL switch to ON if available or temporarily connect the black and white wires of the full side pressure sensors together. a) Select the Rod sensor using the *- sel load trans” line b) Use “¥” to select the “-span pressure” and press “””. The reading on the bottom represents the bits out of 1023 as seen by the control unit. The reading should be above 670 and not exceed 875. c) Repeat calibration procedure as defined for the bore side transducer above. Telescopic cranes with derrick pressure sensors Calibration Manual i600 305S5M3500MNE rev. E 2.2.10 Multi-point no-load calibration: This procedure must be carried out for each different condition of dead weight of the boom. For example separate no-load calibrations need to be done with the manual section in, the manual section out, each jib erected at each fixed offset etc. Refer to the computer printout supplied with the i3500. A ‘no-load’ calibration plus unloaded and loaded boom deflection calibrations are necessary for each duty where the ‘select’ number is different (except rooster sheave duties) The crane needs to be rigged for each of these conditions and the appropriate duty need to be selected to complete the procedure. Since this also applies to boom deflection calibration, it is recommended to do both no-load and boom deflection calibrations while the machine is rigged'on one particular condition to save times. Notes: 1. During this procedure boom angle, boom length and pressures are displayed at various times for reference purposes on the display window. 2. The derrick motion immediately before recording a calibration point should always be up/in. If it was necessary to derrick down/out, then derrick up/in slightly before recording the calibration point. When telescoping in or out it is not necessary to derrick up/in, unless the crane has had to be derricked down/out during telescoping for some other reason. 3. Ensure that the crane chassis is level for all no load, boom deflection, and load correction calibrations. Note: it is essential that all the geometric data was checked and entered correctly in section 2.2.4 before continuing with this calibration. 2.2.10.1 Setting the length points for the No Load calibration Start this procedure with the boom fully retracted. Navigate through the calibration menu using “A” or “W” to highlight the field “- no load calibration”, press “¥” to confirm this choice. The display shows: Current Duty = x. Press 4 if OK Where x is the current selected duty number. This must correspond with the current crane configuration, if incorrect use #5 “ESC” to exit the calibration mode and set the correct duty number in the normal working mode. After pressing “v” to accept the duty to be calibrated the display shows: Maximum length for this Duty = xx.x Where xx.x. is the maximum working boom length as measured by the extension drum in the length units selected for calibration (not including extension fiy jibs etc ie usually at the top of the last telescoping section or manual section). If the boom is not to be used at the maximum length for this duty (e.g. last section(s) retracted) or to be used at Telescopic cranes with derrick pressure sensors Calibration Manual i3500 31S5M3500MNE rev, E a fixed length other than maximum (e.g. pinned) use “A” or “¥” to edit this number to the required value. Use “¥“ to confirm the maximum length to be calibrated for this duty. ‘The display Tow shows: 7 Number of Length Steps = xx The number of points selected will directly affect the calibration time and eventual system performance. More points mean a longer calibration sequence but with improved performance. As a guide select the number of points from the following table but note that these figures are intended as a minimum requirement and can be increased as required (up to a maximum of 7) to enable calibration lengths to coincide with rated boom lengths. This number of points includes the shortest and longest lengths for the duty, which are mandatory. Telescopic band to be Minimum of points calibrated None 2 (min) Up to 20 feet 3 20 to 30 feet 4 30 to 45 feet 5 ) 45 to 60 feet 6 Over 60 feet 7 (max) When the proper number of length steps is entered, press “¥™ to accept If more than two lengths have been entered the display now shows: Length 2 = xxx.x Where xxx.x is the second calibration length to be specified. The first and last lengths will automatically be set to the minimum and maximum values specified for calibration and other calibration lengths will default to evenly distributed lengths calculated by the system. Use A” or ““v” to change the default value of xxx.x to the boom length required for calibration length 2, if required, then press “¥” to accept. ‘Specified lengths should coincide with rated boom lengths where possible although not all rated boom lengths need be specified. Specified lengths must include lengths at ‘which the boom telescoping sequence changes. Where no intermediate boom lengths are shown in the crane capacity chart, use the default lengths chosen by the system. ‘Telescopic cranes with cerrick pressure sensors. Calibration Manual i350 32S5M3500MNE rev. E Enter the remaining lengths as prompted ensuring that each new calibration length is, larger than the preceding one and less than the maximum length. 2.2.10.2 Setting the angle points for the No Load calibration When the last calibration length has been entered the display shows: Angle step Length 1 = xx Where xx is the number of angle steps to calibrate for length 1. Length 4 is fully retracted. The number of angle steps must be between 2 (min) and 18 (max). The more points used the greater the accuracy, but the longer the calibration time. It is suggested that points at 5 degree intervals will give an acceptable result. Hence for example if the maximum angle is 80 degrees and minimum is 20 degrees then 13 points should be used. Use “A” or“ to set xx to the required number of angle steps for calibration length 1 then press “Y™ to accept. Enter the number of angle calibration points for each length step in turn as prompted. 2.2.10.3 Hook Block Weight After the last number of angle points is entered the display shows: Block = xxx Where x.xx represents the hook block weight that will be suspended during the no-load calibration process in metric tonnes or Ibs x 1000 depending on calibration units selected, Set the hook block weight x.xx using “A” or “W” and press “¥” to accept. 2.2.10.4 Maximum Boom Angle The display will show: Boom up to max possible angle then press “V” Derrick the boom up to the maximum possible angle, that is, with the boom hoist cylinder almost fully extended, just avoiding the maximum boom angle stops. Press “7” when done. 2.2.10.5 imum boom angle The display will show: Min Angle Length 1 = xx.x ‘Where xx.x is the lowest working angle in degrees for length 1 (retracted). Check the load chart and determine the lowest rated angle for each of the boom lengths you have previously entered; i.e. length 1, length 2, etc. and enter separate minimum working angles for each calibration length as prompted. Telescopic cranes with derrick pressure sensors Calibration Manual i300 33‘SSM35OOMNE rev. E 2.2.10.6 Recording the ‘no load’ pressure map The following procedure to record unloaded boom weight pressures should be carried ith the hook block suspended at all tim eful not to exceed the operating nefers of the crane particularly at tong iowangies-— The display will'show: Press “v” when ready to calibrate The 13500 has now been programmed with all preset points and ready to calibrate. When ready press “/™. Display shows; Where: sia | ES 2 aa.a is the current bore side pressure Panes pal Point 4 pd2: bb.b | Db-bis the current rod side pressure Bee eet ee etd | e.0 the current boom length Aue weet dd.d is the target boom length ee. is the current boom angle ff.fis the target boom angle Plus a message asking to telescope in or out to the required length. When the boom length is correct the display will change to: Calibration point 1 Press. pd1: aa.a_pd2: bb.b Boom length: cc.c is ok Angle: ee.e > fff Plus asking a message to boom up or down to the required angle. When the boom angle is correct the display will change to: Calibration point 1 Press. pd1:aa.a_pd2: bb.b Boom length: cc.c is ok Angle: ee.e is ok Ensure the last derricking motion to reach the calibration point is in/up and after allowing the crane to stabilise and settle (about 30 seconds), press “¥”” to record the calibration point. Repeat this procedure for each calibration point in turn starting with all angles for length 1 then length 2 etc. until all lengths and angles have been recorded. When the final calibration point is accepted the i3500 will automatically return to the main calibration menu and the calibration information will permanently be stored in memory. Note: If for any reason a no load calibration is abandoned before completion, no data will be permanently stored and the full routine will need to be repeated. To abandon a no load calibration at any point before completion press #5 “ESC”, confirm the action by selecting yes and pressing “Vv”. Telescopic cranes with derrick pressure sensors Calibration Manual i3500 34S5M3500MNE rev. E Before proceeding with additional calibration work check the overall performance by moving just the hook around the working envelope; i.e. high/low angles and long/short boom. Ensure that any variation of load reading is no more than 1 to 2 percent ofthe ‘SWE af that position. If greater variation Is seer then check entered in calibration mode, use more calibration angles and lengths, or proceed to add load correction calibrations (see separate section). Always check results at this stage after booming up. Boom down can be checked after the full calibration is completed 2.2.10.7 Unloaded boom deflection This procedure is used to add an allowance into the calculation of the hook radius to compensate for boom and/or chassis deflection before a load is lifted. A separate calibration is available for each crane configuration that also has an individual no load calibration. This procedure should only be used for machine configurations on outriggers or on crawlers, a separate routine is used to compensate for lifting on tires, if relevant, see section 2.2.9.8. For rooster configurations the unloaded deflection characteristics of the main boom will be inherited and a separate calibration is not required and should not be attempted. Ensure that the current duty selection matches the actual crane configuration to be calibrated. Navigate through the calibration menu using “A” or “¥” to highlight the field "- unloaded boom deflect”, press “¥” to confirm this choice. The display will show the current boom length and a target boom length for calibration. 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. When the boom is at the disired extension the display will change to show: + ¥ to continue Press “‘v”, the display will change to show the current boom angle and a target boom angle for calibration, normally 60°. Adjust the boom angle to the target angle, when the boom is at that angle for calibration the display will change to show: - ¥ to continue Press “Y”, the display will change to show: = unloaded boom defie Toad Ten radius: cor: xx = up or down to edit - ¥ to accept Telescopic cranes with derrick pressure sensors. ‘Calibration Manual i3500 35‘S5M3500MNE rev. E Accurately measure the actual hook radius from the centre line of slew of the machine and use “A” or “¥" to adjust the value of x.x until the displayed radius equals the measured radius, note that the indicated radius can only be increased, not decreased Press "7" to accept the change, tay will char length and a new target boom length. Without changing the boom angle, telescope the boom in to the new target length, when the boom is at the correct extension the display will change to show: -¥ to continue Press “v”, the display will change to show: — unloaded boom defle Toad: length: radius: corr: xx = up or down to edit, - ¥ to accept As before, accurately measure the actual hook radius from the centre line of slew of the machine and use “A” or “W” to adjust the value of x.x until the displayed radius equals the measured radius, note that the indicated radius can only be increased, not decreased and that the value of x.x must be less than the equivalent value entered with the boom at maximum extension. Press “/ to accept the change, the system will automatically return to the main calibration menu. 2.2.10.8 On tyres deflection This procedure is only relevant if the machine has lifting duties on tyres, only one calibration is available. It is used to add an allowance into the calculation of the hook radius to compensate for tyre deflection before a load is lifted. This procedure should only be used for the main boom configuration. Ensure the current duty selection matches the actual crane configuration to be calibrated, i.e. main boom on tyres. Navigate through the calibration menu using “A” or “¥” to highlight the field “- f.0.w deflection”, press “¥” to confirm the choice. The display will show the current boom length and a target boom length for calibration. With the hook block suspended and the boom at approximately 60°, telescope the boom in to the minimum length. Telescopic cranes with derrick pressure sensors. Calibration Manual i9600 36‘SSM3500MNE rev. E When the boom is fully retracted the display will change to show: - ¥ to continue Press “Y”, the display will change to show: —f.0.w. deflection Toad: length: radius: corr: _x.x° = up or down to edit - ¥ to accept Accurately measure the actual hook radius from the centre line of slew of the machine and use “A” or “Y” to adjust the value of x.x until the displayed radius equals the measured radius, note that the indicated radius can only be increased, not decreased. Press “¥” to accept the change, the system will automatically return to the main calibration menu. 2.2.10.9 Loaded boom deflection This procedure is used to add an allowance into the calculation of the hook radius to compensate for boom and/or chassis deflection due to the load being lifted. A separate calibration is available for each crane configuration that also has an individual no load calibration. This procedure should only be used for machine configurations on outriggers or on crawlers. For rooster configurations the deflection characteristics of the main boom will be inherited and a separate calibration is not required and should not be attempted A known test weight is required to carry out this calibration, the weight should be between 50% and 90% of the SWL for the duty being calibrated and should be based ‘on the SWL with a fully extended boom at approximately 60° boom angle. The calculated test load should include the weight of the hook block and any slings, shackles etc. that are used Ensure the current duty selection matches the actual crane configuration to be calibrated, Navigate through the calibration menu using “A” or “¥” to highlight the field "- loaded boom deflection”, press “v” to confirm this choice. The display will show the current boom length and a target boom length for calibration. 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. Telescopic cranes with derrick pressure sensors, Calibration Manual i360 37S5S5M3500MNE rev. E When the boom is at the desired extension the display will change to show: -¥ to continue ~ Press ”, the display will change to show the current boom angle and a target boom angle for calibration, normally 60°. Adjust the boom angle to the target angle, when the boom is at the correct angle for calibration the display will change to show: - ¥ to continue Press “Y”, the display will change to show: — unloaded boom defle Toad Tength cor: xx" = up or down to edit - 7 to accept Carefully lift the test load specified above just clear of the ground. Accurately measure the actual, suspended load radius from the centre line of slew of the machine and use “A” or “Y” to adjust the value of x.x until the displayed radius equals the measured radius, note that the indicated radius can only be increased, not decreased. Press “7” to accept the change, the system will automatically return to the main calibration menu. Carefully replace the test load on the ground. 2.2.10.10 Load adjustment This procedure is optional: one calibration is available per calibration configuration. Which means that the load readings for every machine's configuration will be modified by the new modification. It is used to increase the accuracy to the hook load’s calculation. This will compensate for minor geometric errors. For example, it is not always possible to know the exact piston “Bore” diameter of the lifting cylinders (see section 2.2.4.). This procedure should only be used if the load reading indicates a constant error percentage for different lengths and radius. If the error percentage is variable then verify all data entries concerning the crane geometry (see section 2.2.4) before going to section 2.2.9.13 (load correction). ‘The hook weight should not be used to judge the load reading performance. This should be checked with at minimum load of 50% of capacity. It is recommended that this procedure be done while using the main boom, on ‘outriggers if applicable. Telescopic cranes with derrick pressure sensors Calibration Manual i360 38S5M3SOOMNE rev. E ‘A known load is needed to perform calibration and should be between 50% and 90% of ‘SWL for the “duty” to be calibrated. SWL should be based on a given capacity (main boom) with an angle of around 60° with a retracted boom. The_known_test.load_should_include the hook weight and_all_other_supplementary weights used (“slings, shackles” and so on). Make sure that the selected “duty” coincides with the actual configuration of the crane to be calibrated. Scroll through the calibration menu using “A” or “” to highlight line “load adjustment”. Press “¥” to confirm your choice. The display will change to show: {Zload adjustment load : xx.x load adjust. factor = #2 or #3 to edit - ¥ to accept Where xx.x represents the lifted load reading and 1.00 represents the adjustment factor {a value of 1.00 signifies that there is no applied adjustment). The main boom must be completely retracted with an angle of around 60°. Slowly lift the standard load until it is off the ground. Use "A” or “” to modify the load adjustment factor. Modify this factor so that the displayed load is equal to the test load (known). Press “v” to accept this change. The system will automatically go back to the main calibration menu. Carefully place the test load back to the ground. 2.2.10.11 Load offset This procedure is optional: one calibration is available per calibration configuration. It is used to add an allowance into the calculation of the hook load to compensate for a potential build up of minor geometric errors. For example, it is not always possible to know precisely the effective bore diameter of the boom's lift cylinder(s), see section 3.4. This procedure should only be used if the indicated load reading is found to be in error by a constant load margin over a range of different lengths and radii. If variable errors are seen, then check the geometric data entered in section 3.4 before proceeding to section 3.2.15 — load correction calibration Use at least 3 different weights for this inspection; the hook block, 25% SWL, and a load greater than 50% SWL. It is recommended that this procedure be performed using each configuration, on outriggers if applicable, A known test weight is required to carry out this calibration, the weight should be 25% SWL, and a load in excess of 50% SWL for the duty being calibrated and should be based on the SWL with a retracted boom at approximately 60° boom angle. The calculated test load should include the weight of the hook block and any slings, shackles etc. that are used. Telescopic cranes with derrick pressure sensors Calibration Manual i3600 39‘S5M35O0MNE rev. E Ensure the current duty selection matches the actual crane configuration being used for ‘the calibration. Scroll through the calibration menu using “A” or ““” to highlight the field *- load offset”, press ““” to confirm the choice. 10.12 Friction compensation This procedure should not be performed except under guidance from RaycoWylie Systems except for down friction. Alll of the factors in this menu, except down friction, are used to compensate for static pressure decay over time but significant testing and analysis may be required before any of these default values are modified. The default screens are shown below for reference: wear factor 41.00 down friction 0.00 pres. offset low(bar) 0.0 pres. offset med(bar) 0.0 pres. offset hig(bar) 0.0 stab.coef.ptimelow 1 stab.coef.ptimemed 1 stab.coefptimehig 1 boom down pwr low(%) 100 boom down pwr med(%) 100 boom down pwr hig(%) 100 inf. lim, pres.med-bar 0.0 sup. lim. pres.med-bar 0.0 Boom down friction compensation should only be done once the no load calibration and various deflection calibrations have been completed. Only one boom down friction compensation value is available and it will affect all configurations of the machine. The down friction factor is best established by trial and error. Navigate through the calibration menu using “A” or “W” to highlight the field “- friction compensation”, press “¥” to confirm the choice. Scroll down to “- down friction” and press “W” to highlight the value for editing, To start, increase the default value from 0.00 to 0.10 and press “/” to confirm. Exit the calibration mode and retest the boom down performance to establish the effect, return to the down friction calibration and modify as required. 2.2.10.13 Load correction This procedure is optional and a separate calibration is available for each crane ‘configuration that also has an individual no load calibration. It is used to add an allowance into the calculation of the hook load to compensate for a potential build up of minor errors in either fixed data or previous calibration data. ‘Telescopic cranes with derrick pressure sensors ‘Calibration Manual 13600 40S5M3500MNE rev. E Note: This procedure should not normally be necessary and should not be used before exhausting other, more likely causes of load reading errors such as dimensional errors (section 2.2.4) or proper no load calibration using an adequate number of calibration points (section 2,2.6). Some inaccuracy of load indication with very small loads at high boom angles and short boom lengths is likely due to the small boom lift cylinder pressures encountered in this zone. Do not use the weight of the hook block alone to judge load indication performance, these calibrations should be done with loads in excess of 50% SWL. If @ load correction calibration is found to be necessary the minimum number of correction factor points that must be calibrated is 2, the maximum that can be calibrated is 20. The following notes are intended to give general guidance only as each individual installation will be different. The full working envelope of the configuration can be divided into different zones for load correction calibration, see diagram 2.2.13 for examples. Case 1 This shows a basic, two point calibration. These two points cannot have a common angle or boom length. A load correction factor will be applied to all boom positions whose angle and length are greater than point 1 and also whose angle and length are smaller than point 2. A load correction factor will not be applied to boom positions outside of this zone. Case 2 This shows the influence of adding one additional calibration point to case 1, the pair of numbers in each sub-zone show the calibration points used to determine the load correction factor calculated for various points in that sub-zone. Case 3 This shows a typical set of calibration points that will go on to use the most logical adjacent points for interpolation purposes and also cover the full working range of the machine. Case 4 This shows a more practical set of calibration points that will improve the most likely area for load errors. Case 5 and 6 These show the results of excluding one or more of the calibration points chosen in case 4. To add a load correction calibration point, ensure the current duty selection matches the actual crane configuration. ‘Only one load correction factor is stored at each angle/length location and the test load used to set this factor should be greater than 50% of the Safe Working Load at each location. Calibrating a load correction factor with smaller test loads could result in unacceptable errors at 100% SWL. Telescopic cranes with derrick pressure sensors Calibration Manual i600 4SBM350OMNE rev. E Navigate through the calibration menu using “A” or “W” to highlight the field “- load correction’, press “¥” to confirm the choice. The display will show: ~] = Toad correction — point # x load Com: 1.00 angle Len = up or down to edit ¥ to accept Where x represents the calibration point reference number. Load, angle and length indications are current values and corr: 1.00 is the default value for the load correction factor (1.00 represents no correction is applied). Press “¥” to accept the point number to be calibrated. Position the boom to the required angle and length and carefully lift the test load just clear of the ground. Use “A” or “W” to adjust the corr. value until the displayed load equals the calculated test load. Press “”” to accept the change, the system will automatically return to the main calibration menu. Carefully put the test load back on the ground. Repeat this procedure to enter a second and subsequent load correction points as required. The last load correction point can be deleted if necessary by selecting the screen above and pressing “v” to decrease the point number rather than pressing ““” to accept the new point. The display will show: — load correction point #: x load: com: 1.03 angle: len. = up or down to edit - ¥ to accept -_ tare to delete point This screen will show the data stored for the last calibration point rather than current data. Press #10 “TARE” to delete this point from the calibration memory. When completed, press #5 “ESC” to return to the normal display. Remember: When the calibration is finished set the calibration switch to the OFF Position to prevent the calibration data from being modified or corrupted. Telescopic cranes with derrick pressure sensors Calibration Manual i600 42‘S5M3500MNE rev. E Diagram 2.2.10.13 example of calibration for load zone to correct 2 2 cave 4 case2 < semi 2p sfectf - BR toc ‘addtional point SRNR, BRNER IN SSRN, RRR AIENN RIERA. INRA RNND RNEASY LORRAINE NNN AN LERRNN LAL CSRANEARS) BRA RRA RNA REERRRRRA 7 7 2 2 ‘1 jo Case3 suggested sequence case 4 i forbeter results limited CF rones a 0 + Hl | Fi ig 42 cases limited CF zones effect of omissions cases limited CF zones effect of omissions ‘Telescopic cranes with derrick pressure sensors Calibration Manual 13500 43‘S5M3500MNE rev. E 3.0 CANBUS INTERFACES BOARD Every electronic card must be supplied with a voltage between 12 and 24 volts DC. Every interface board has its own CANbus physical address. It is configurable using switches + to 3. The table below shows how to position these switches to select an address. ‘Switches Address 7 2 3 0 OFF | OFF | OFF 1 ON_[ OFF | OFF 2 OFF | ON | OFF 3 ON ON_| OFF 4 OFF | OFF | ON 5 ON | OFF | ON 6 OFF | ON | ON 7 ON ON | ON Voltage levels for different sensors are shown in section 3,5. = Every interface board has a termination resistance on the CANBus network. This resistance can be activated when putting a jumper on the connector header identified as ‘END’. Note that only the last card on the CANbus requires a termination resistance activated, that is one at each end of the network. 3.4 Anglellength and ATB sensor interface board 3.1.4 Errors detection For the length sensor: Maximum voltage for length sensor is 4.80V. If the voltage of the length sensor exceeds 4.80V, it will mean that either the length sensor is not installed on this card or +that there is an open circuit on the card (eg. cut wire). Acceptable range: Min: 39 bits (0.19Volts) Max: 985 bits (4.81V) In the diagnostic mode, the system will display 1024 if a length value received in bits is greater than 1023 and will display 2 for the atb if a received value is greater than 1 Telescopic cranes with derrick pressure sensors Calibration Manual 13500 “4‘S5M3500MNE rev. E For the angle sensor the ADXL203 generates signals between 1.5V and 3.5V on each of the 2 axes. Acceptable range: Min: 819 bits (1.0Volts) Max: 3277 bits (4.0Volts) Note: In the case of an error, the angle value sent is 999°. For the DR+ reference voltage an error is indicated if the DR+ reference voltage is lower than 4.5 volts DC, or higher than 5.5 volts DC. 3.1.2. Basic accelerometer's calibration: No jumper should be on the connector’s header “CAL” because this calibration is done at the factory. Warning: when there is a jumper in place, the interface will not work in its normal operation mode. If the "CAL" jumper (pre-calib.) is left in place, an error will display on the i3500 system in the normal operation mode. 3.1.3 ATB In order to activate the ATB, switch 4 must be tumed ON. If the ATB is not linked to the systems, ignore this section. Multiple ATBs can be installed on a crane and they will be supported by the display, as long as they are enabled. The ATB signal is sent to the display and to the relay board. The relay coil assigned to the ATB is controlled directly and exclusively by the signal received by the angle/ATB board. 3.2. Relay and digital input interface board: There are two models of relay boards, one composed of 5 relays (4 Bosch relays with 5 amp contacts + 1 “OMRON” relays with 2 amp), and another with 8 “OMRON” relays with 2 amp contacts. If the relay board loses communication with the Angle/Length and ATB interface board, the ATB will no longer function. The relay board will block the power to the coil of the relay assigned to the ATB at around 550ms. The Relay board is designed to supervise the communications with the 13500 system. If the relay board loses any communication with the 13500 system, it will automatically block all power to the coils of relays on the relay board within 5 seconds. Telescopic cranes with derrick pressure sensors Calibration Manual i350 45‘SSM350OMNE rev. 3.3 Rotation sensor interface board 3.3.1 Relative Encoder will be displayed in the error message screen of the 13500 system Angle Rotation = pointer * 360° / ratio The pointer represents the number of pulses generated by the encoder. 3.3.2 Absolute Encoder This encoder will be used with the generic (multi-purpose) interface board and will require specific programming. This may not be available with all systems. 3.4 Pressure transducer interface board: The electronic interface board: There are 2 board models for the load. One, with 1 pressure transducer input, and another with 2-pressure transducer input. It should be noted that the dual transducer interface will always have an even physical address on the CAN BUS network. See label inside the interface enclosure for more detail, this setting will be done at the factory except if spare parts are purchased, they will come with the default setting, Acceptable range: Min: 150 bits (0.18V) Max: 3945 bits (4.82V) On the Interface board there are jumpers, which are used to adjust the amplification of the sensor inputs. This adjustment must be done while making sure the signal is within ‘the above range. Since the available gain may differ depending on the revision of the interface, refer to the label inside the interface enclosure for more details. 3.5 Sensor voltages [Angle Length Load LDR+ I Telescopic cranes with derrick pressure sensors Calibration Manual i380 46