liftwatch rail - prolec

Liftwatch Rail Rated Capacity Indicator

Liftwatch Rail Operators Manual 560386-000 Issue 1.2 © Prolec Ltd - Feb2011

Operators Manual

Liftwatch Rail Operators Manual 560386-000 Issue 1.2 © Prolec Ltd - Feb 2011

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This guide describes the operation of the

PROLEC LIFTWATCH RAIL RATED CAPACITY INDICATOR FOR ROAD-RAIL EXCAVATORS

Model covered : MODEL Ref LIFTWATCH RAIL INTRODUCED October 2010 SYSTEM PART No. 002350-03X Liftwatch Rail RCI system has been designed for compliance with RIS-1530-PLT Issue 2. IMPORTANT : Before use, check the machine certification and documentation to confirm any limitations that may exist within the use of the machine and / or the RCI system.

DURING NORMAL OPERATION THE SWL OF A CRANE SHOULD NOT BE EXCEEDED. THEREFORE THE WARNING OF OVERLOAD

SHOULD NOT BE USED AS A NORMAL OPERATING FACILITY. IT SHOULD BE NOTED THAT CERTAIN STATUTORY

REQUIREMENTS DO NOT PERMIT THE SAFE WORKING LOAD TO BE EXCEEDED EXCEPT FOR THE PURPOSE OF TESTING

THIS RCI IS NOT SUITABLE FOR USE IN EXPLOSIVE ATMOSPHERES. ADJUSTMENT BY UNAUTHORISED PERSONS WILL INVALIDATE ANY WARRANTY OR CERTIFICATION SUPPLIED. IF A PROBLEM ARISES WHICH CANNOT BE RECTIFIED USING THIS GUIDE, AUTHORISED SERVICE SHOULD BE SOUGHT.

Prolec supports a nationwide network of fully trained service engineers. Warranty claims, service work, technical information and spare parts are available by contacting : Prolec Ltd Telephone +44 (0) 1202 681190 25 Benson Road Fax +44 (0) 1202 677909 Nuffield Industrial Estate Email [email protected] Poole Dorset BH17 0GB Manufacturers original instructions

'Where a data logging system is found not to be operational then the vehicle shall not be used until the vehicle is repaired and fully confirmed as operational. This requirement applies irrespective whether starting or part-way through an operation'.


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Contents

1. Getting Started 5 1.1 Entry code 5 1.2 Acknowledge normal operation 6 1.3 Site Information 6

2. Main operating display 7 2.1 Lifting regime and active lifting point 8 2.2 Lift capacity indication 9 2.3 Limit override 10 2.4 Key control 10 2.5 Duty numbering 11 2.6 Vertical and lateral measurements 12 2.7 Lifting mode 13

3. Non RCI mode 14 4. Lift planning 15 5. Load charts 16 6. Equipment position monitoring 17 6.1 Height limitation 18 6.2 Slew limitation 19 6.3 In gauge Indicator 21

7. Warning messages 22 8. Axle interlock 23 9. Daily checks 24 9.1 Duty 24 9.2 Relay, inputs and motion cuts 25 10. System test 26 11. Error messages 27 12. Master override keyswitch 29

13. Clock 30 14. Data logging 31 14.1 Data extraction 37 15. Editing Entry code database 38 15.1 Accessing the database 38 15.2 Creating/editing an entry 39 15.3 Deleting an entry 41 15.4 Editing the entry code 42

16. Touch screen calibration 43 17. System diagram 45


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1. Getting started

Liftwatch Rail is operated via the touch screen soft keys that appear along the base of the display. Once started, the system will revert to the same state as when it was last switched off. Once the system has automatically powered up, an introduction screen will appear. Press the EXIT key to continue. If no key is pressed, the system will automatically start after a period of 5 seconds.

Indicator LED’s Liftwatch Rail will automatically turn on with the ignition. The green and amber LED’s will flash alternately as the system starts. During this time the screen will remain blank. Touchscreen recalibration button.

The system has been configured to work with the on-board Operator Database and will prompt for a valid and in date operators pass code. Enter the correct operators pass code using the on-screen key pad and press ENTER. If a valid PTS number is entered the system will enter normal operation. If an incorrect entry is made, or the pass code has expired, the failure reason will be displayed and a prompt to retry offered. The database can be edited, see section 15 for further details.

1.1 Entry code

If problems with the touch screen are experienced, refer to the calibration procedure outlined in section 15.


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To comply with the Network Rail RIS-1530-PLT issue 2 standard, the opening alarm acknowledgment display will appear as shown here. The external alarms will operate, and the RED warning LED will flash. To cancel the alarms and resume normal operation - press the OK key. To enter site information press the SITE INFO key.

1.2 Acknowledge normal operation

Site information can be entered. This information will be added to each event data logging file. Pressing the SITE INFO Key will activate the screen here. Enter up to 60 characters using the keyboard. Press ENTER to save the entry and return back to the alarm acknowledge display. Press ESC to abandon site data entry and return back to the alarm acknowledge display.

1.3 Site information


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Maximum safe working load for the current lifting point radius, height and duty.

Lifting regime and active lifting point

Actual load (including any tool fitted)

Maximum working height

Current highest machine point

Bucket pin radius (from slew centre)

Bucket pin height (from rail/ground)

Rail cant indicator Active duty sector indicator

Total lift capacity indicator

Lifting duty number and chassis/axle lock status

Interlock indicator

Clock Lifting mode - Key controlled

View loadchart Set/clear height and

slew limitation - Key

controlled

System test

Slew limit

For more detailed information on any of the features highlighted, go to the

page indicated in the box.

Warning message

Error messages

2. Main Operation display

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1

3

4

4

15

5

8

9

13

12

3

14

2

3 3 7 Data logging indicator

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IN GAUGE INDICATOR If the machine is on-rail and the oscillating axle is unlocked, the GREEN symbol indicator will be displayed. The RED symbol indicates that the machine is in an out of gauge condition. WARNING The system is unaware of any additional attachments (bucket, ballast broom etc). Only the bucket pin, highest point and counter weight corners are monitored. See sections 2.6 and 6.3 for further information.

1

Data logging indicator 16


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The maximum safe working load will appear at the top left of the screen and is stated in TONNES. This maximum load is for the currently active lifting duty. Lifting duties are automatically selected using a combination of chassis status, axle lock status, slew angle, chassis angle and switch inputs. If a particular lift is limited by hydraulic capacity (87% of Main Relief Valve pressure) rather than stability, the maximum safe working load will be shown in RED. The maximum load is stated as a percentage of the ‘tipping load’ and in a standard installation will conform to the table shown below :

Lifting regime Safety factor Notes

Road 71% All road lifting duties regardless of chassis angles and oscillating axle lock status.

Network Rail 67% Lift and carry - oscillating axle unlocked

75% or 90% Static lift - oscillating axle locked. The maximum load will be either 90% of a load necessary to totally unload a single rail wheel, or 75% of a load necessary to totally unload both rail wheels - whichever is the lowest.

London Underground 75% All LUL lifting duties regardless of chassis angles and oscillating axle lock status.

Grabbing 50% If the ‘GRAB’ lifting point is selected (see below) all duties will revert to this safety factor regardless of bogie position, chassis angle or oscillating axle lock status.

Tandem Lifting 66% If ‘Tandem Lifting’ mode is selected all duties will revert to this safety factor regardless of bogie position, chassis angle or oscillating axle lock status.

Lifting point Notes

Bucket pin This is the default lifting point, and will be the only option if no other points have been enabled. Lifting at the bucket pin requires the use of a Lifting Yoke. If the system has been configured to MONITOR ‘quick-hitch’ angles, the lifting point will be the lifting eye on the ‘quick-hitch’.

Auxiliary lifting eye Liftwatch Rail can be configured to use an auxiliary lifting point. This can be anywhere on the machine arm and will have been set up during installation. If the auxiliary lift point is on a NON-MONITORED ‘quick-hitch’ or similar, refer to the manufacturer/convertor instructions regarding positioning of the device during lifting operations.

Grabbing Liftwatch Rail can be configured for grabbing duties. As the dynamic nature of grab operation cannot be accurately monitored by the RCI, grabbing duties have their safety margins reduced to 50% of the tipping load.

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2.1 Lifting regime and active lifting point

If Liftwatch Rail has been configured to use more than one lifting point, the active lifting point can be selected by pressing the LIFT POINT key from the lift mode menu. Where enabled, pressing the LIFT POINT key will cycle through the following options. See section for details on selecting lifting point. 5


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2

Safe Load The suspended load is less than 92.5%

of the maximum safe working load.

The HOOKLOAD symbol along with the current suspended load is displayed.

No alarms or warning messages are issued.

Approach to maximum safe load The suspended load is greater than

92.5% but less than 97.5% of the maximum safe working load.

A screen warning is issued, the amber LED will flash and the internal alarm will activate.

Overload The suspended load is greater than

102.5% of the maximum safe working load.

A screen warning is issued, the red LED will flash and the internal and the external alarms will activate.

Motion control of the machine will operate, the graphic denoting which motions have been cut and which are active.

2.2 Load capacity indication


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2.4 Key control

The key must be in the Lift mode position to access the lift mode menu. The lift mode menu provides the facility to set a lifting point, select tandem lifting, select lift planning mode, or to enable the NON-RCI mode used for basic excavator operations. See section 2.7 The key must be in the Set Limit position to access the limiting menu. The limiting menu provides the facility to set and clear height and slew limits. See section 6.1 and 6.2 Once set the key switch should be returned to the 0 position and the key removed.

2.3 Limit override

When an overload or a slew or height limit condition occurs the machine hydraulics will be physically disabled to prevent any further dangerous movements. Only those movements that allow safer operation remain active. The radius cannot be increased, the load cannot be raised, and all slewing is prevented.

To put the system into momentary OVERRIDE which will temporarily re-enable the machine hydraulics, turn the spring loaded Limit Override Keyswitch. The override symbol will be displayed on the screen, the external alarm will stay active, the red LED will flash and the external blue lamp will switch off. Once the alarm condition has been corrected the RCI will automatically clear the override request and revert to normal operation. The key should be removed under normal use.


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3

Wheeled Tracked

Floating Locked Floating Locked

Sta

bilis

ers

R

ail

R

oad

a b b

c c

d d e e

f

+ +

Duty Numbering Liftwatch Rail automatically constructs the duty number as shown below :

1 Road

2 Rail 0-50mm cant

3 Rail 50-150mm cant

4 Rail 150-500mm cant

NB the cant levels shown here are the default values. These can be adjusted as required during calibration.

Duty sectors are labelled from a-h clockwise from 0° slew (over floating axle). The sectors shown below are the default values. Each duty block (i.e. Road, Rail 0-50mm cant etc) can have a different numbers of sectors.

Axle status forms the last part of the duty number. Locked axle are labelled L, floating axle U. Tracked machines have no floating road duties. All stabiliser duties assume that the axle is locked, and append S to the duty number. Stabiliser duties are not supported in rail mode.

Active sector

Adjacent sectors

2.5 Duty numbering

Cant measurement shown refers to the machine turret.


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4

Slew centre line

Radius

Heig

ht

Height Limit

Highest point

= Equipment extremes measured by the system NB to account for extra equipment and pipework etc, both the bucket pin and arm ram pin can use an optional vertical safety ‘offset’ determined during RCI set-up and calibration.

Position measurement Liftwatch Rail measures equipment pin positions using equipment mounted angle sensors. All positions are corrected for chassis pitch (rail gradient), roll (rail cant) and slew. WARNING For In-Gauge calculation the system is unaware of any additional attachments (bucket, ballast broom etc). Only the bucket pin radius, highest point and counter weight corners are monitored.

2.6 Vertical and lateral measurements


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With the limit keyswitch in the Lift Mode position, the lift mode key from the main operating display will allow access to the selection menu as shown below :

1

Non RCI mode 6

Return to the Main Operation Display

Standard lifting operation as described in

Tandem lifting operation. This is similar to the Standard lifting mode but with the application of a further safety factor of 67%. e.g. tip load = 3.00t On rail axle unlocked (67% safety factor) Standard lifting SWL = 3.0 x 0.67 = 2.00t Tandem lifting SWL = 3.0 x 0.67 x 0.67 = 1.35t

Lifting point selection. This icon will only appear if the system has been configured to operate with more that one lifting point.

1

2.7 Lifting mode


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When the machine is not being used for lifting it can be put into ‘Non RCI mode’. This option allows the machine to be used for digging etc. When in this mode, the RCI still monitors all machine activity and safety status but will NOT warn of overload conditions and will not impose any form of overload hydraulic control. If enabled, the system will still physically prevent height and slew movement when those limits are exceeded, and will continue to monitor backward stability conditions. In this mode, the cab mounted blue lamp will indicate that the RCI is NOT active. Non RCI mode can only be activated via the Limit keyswitch, see sections 2.4 and 2.7.

3. Non RCI mode

Lift planning

Clock (press once) See section 13

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Return to lifting mode

Set time

Set backlight brightness

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Note : Use with an offset boom. If a slew limit is active and the offset boom is moved from straight ahead, the confirmation message shown here will appear. Press the red button to confirm that you are aware that the slew limit will be cancelled. This action is recorded in the event data log.


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Liftwatch Rail can be used for basic lift planning. The operator can perform a ’dummy’ lift to check the machines performance against the actual requirements for the lift. This option is code protected, when the system is in lift planning mode there is no safety functionality.

1. Enter the correct code to access the

lift planning mode.

2. Move the machine to the start position for the

planned lift. Press the ‘dustbin’ key to clear any data that may already be displayed.

3. With no load attached perform

the planned lift. A red trail will appear on the screen plotting the l lifting point’s progress. Lift data will be shown on the left of the screen.

Lift data Min SWL The minimum SWL encountered (duty in which it occurred). Min rad The minimum radius achieved (duty in which it occurred). Max rad The maximum radius achieved (duty in which it occurred). Min hgt Minimum bucket pin height encountered. Max hgt Maximum height encountered. Duties used List of duties the red trail passed through.

4. Lift planning


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Return to the main operating screen

Activate the instruction pop-up

Display the minimum loadchart (if available)

Display the maximum loadchart (if available)

Send the current chart to a ‘Printer’. This option is password protected.

Duty number Chart type

If the machine is equipped with an hydraulically adjustable boom both maximum and minimum charts are available. Hydraulically adjustable booms allow the machine to reach the same point in space (i.e. height and radius combination) with a variety of different equipment angles. The minimum loads shown refer to the least favourable angle combination. The main display operates in real-time with the current equipment angles, and therefore may show a load that is higher than the equivalent load shown here. Monoboom machines will only have a single load chart, the MIN and MAX icons will not appear. When load charts are being displayed the RCI is NOT monitoring machine safety status and will prevent ALL machine motions - if no action is taken, the system will automatically revert to normal operation after 5 seconds by default.

5. Load charts

To download a machine loadcharts you will require :

PC or Laptop

Prolec communications null modem cable (Part No 490046-002)

Communication program (e.g. ‘Hyperterminal’ as bundled with Windows®)

and knowledge of its use Communication parameters are fixed at 38400 baud rate, 8 data bits, 1 stop bit, No parity, and No flow-control


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Liftwatch Rail has the ability to continuously monitor both equipment height and slew angle (or lateral distance if required) and prevent movement beyond preset limits. Press KEY 4 from the main operational screen to access limit controls. A combination from the icons described below will appear :

Return to the main operational screen. Any settings made will be automatically saved, and reused when the system is next switched on.

There is no height limit currently active. Press this key to continue with the set height limit procedure.

A height limit is currently active. Press this key to cancel the current height limit.

There is no slew limit currently active. Press this key to continue with the set slew limit procedure.

A slew limit is currently active. Press this key to continue to current slew limit.

6. Equipment position monitoring


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Setting a height limit With the key switch in the Set Limit position, access height limiting via the LIMIT key and the screen will change as shown below. An instruction pop-up will appear and the ‘new’ maximum height will be the default height of 8m or the last set height limit value. Use the up/down (KEY 3 and 4) keys to adjust the displayed maximum height value. Press exit (KEY 1) to save the setting and return to the previous menu level. Height limiting is not active during this operation, If enabled, the system will still physically prevent slew movement when those limits are exceeded and will continue to monitor backward stability conditions. RCI remains fully functional, however, the external blue lamp will be switched off.

Maximum working height

Current highest machine point

Increase max height

Decrease max height

Save and exit

Clearing a height limit From the limit setting menu press the KEY 3 (shown left) to cancel the current maximum height. The keyswitch has be in the Set Limit position to clear any limit set.

6.1 Height limitation


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Setting a slew limit Liftwatch Rail offers two types of slew limitation, a virtual slew ‘wall’, or two angular limits. With the key switch in the Set Limit position, access slew limiting via the LIMIT key and the screen will change as shown below. Slew limiting is not active during this operation, if enabled, the system will still physically prevent height movement when that limit is exceeded and will continue to monitor backward stability conditions. RCI remains fully functional, however, the external blue lamp will be switched off.

Press TICK to use the virtual slew wall, or CROSS to use angular limits.

Using a slew ‘wall’ A virtual slew wall is a line parallel to the centre line of the machine. Use the left/right keys to move the ‘wall’ to the required position. The value given in the info pop-up box is the lateral distance from the machine centre line to the bucket pin. Press exit to save the settings and return to normal operation. Once set, the system will not allow the bucket pin or the left / right extremes of the counter weight to cross the ‘wall’ line. Note: The system is unaware of tool width, monitoring is to the centre of the bucket pin - wide tools will breach the line before the motion can be cut.

6.2 Slew limitation


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Using angular limits Use the four arrow keys to position the angle ‘bugs’ as required. The left pair controls the anti-clockwise limit, the right pair the clockwise limit. Press exit to save settings and return to normal operation. Once set, the system will not allow the bucket pin to cross either angle limit. Note: The system is unaware of tool width, all monitoring is to the centre of the bucket pin - wide tools will breach the limits before the motion can be cut.

Setting a slew limit (continued)

Clearing a slew limit From the limit setting menu press the KEY 4 (shown here) to cancel the current slew limit(s). The keyswitch has be in the Set Limit position to clear any limit set.


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6.3 In Gauge Indicator

IN GAUGE INDICATOR If the machine is on-rail and the oscillating axle is unlocked, a GAUGE indicator will be displayed. The GREEN symbol indicates that the right and left corners of the counterweight, bucket pin and the highest point of the machine are within the W6a gauge dimensions opposite. The RED symbol indicates that the machine is outside of the gauge dimensions. Only the bucket pin, highest point and counter weight rear corners are monitored. WARNING The system is unaware of any additional attachments (bucket, ballast broom etc). . See section 2.6. Machines with front and rear oscillating axles will indicate In Gauge when either the front or rear axles are unlocked or when both are unlocked. In gauge indication shall not be available if both (front and rear) axles are locked.

W6a Gauge Dimensions


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Warning messages can appear on the screen at any time during normal operation. They will automatically clear when the warning condition is rectified. Below is a summary of possible messages :

Certain duties may be barred. If an attempt is made to access a barred duty, this message will appear, the amber LED will flash the internal alarm will operate and further machine motion will be prohibited. Barred duties will have been established during installation and are usually to protect particularly poor lifting zones.

The RCI performs checks on adjacent duty sectors. If the machine is moving towards a sector that would be unsafe, this message will appear , the internal alarm will operate and the amber LED will flash. No motion control will occur. The RCI will check the adjacent duties only when within a pre-set number degrees from a duty change (default = 5°).

If the machine is working on rail in a lift and carry duty the RCI will continuously check the equivalent higher cant level duties. If the cant is increasing as the machine travels this message will appear if the impending duty change would be unsafe. The internal alarm will operate and the amber LED will flash. No motion control will occur.

This message will appear if the measured track cant exceeds a pre-define limit (default = 180mm). The internal alarm will operate and the amber LED will flash. No motion control will occur.

This message will appear if the measured track gradient exceeds a pre-define limit (default = 1 in 30). The internal alarm will operate and the amber LED will flash. No motion control will occur.

This message will appear if the current height limit is exceeded. The external and internal alarm will operate, the amber LED will flash and appropriate motion control will occur. The message will contain one of the following reasons: 1. Bucket pin too high 2. Arm ram pin too high 3. Artic pivot pin too high 4. Quickhitch too high (If quickhitch angle sensor fitted)

7. Warning messages


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Warning messages can appear on the screen at any time during normal operation. They will automatically clear when the warning condition is rectified. Below is a summary of possible messages :

7. Warning messages

If a slew limit is set, and the offset boom is utilised the system will cancel the slew limit, the warning message must be acknowledged.

Liebherr machines require confirmation that the machine has been successfully positioned on the rail. Once fully on-rail press the red button - this will automatically lock the oscillating road axle.

Fully extend/retract counterweight

This message will appear if the current slew limit is exceeded. The external and internal alarm will operate, the amber LED will flash and appropriate motion control will occur. The message will contain one of the following reasons: 1. Don’t slew left 2. Don’t slew right

This message will appear if the offset boom is not in the straight ahead position. This message will not appear in NON RCI mode.

This message will appear if the lifting duty entered would mean that the counter weight was on the low side of the cant. This is an optional feature, and is set during system configuration.

This message will appear when the use the auxiliary lifting point is not allowed in a certain lifting duty. This is an optional feature, and is set during system configuration.


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To promote safer operation Liftwatch Rail can optionally manipulate two interlocks.

1. When the oscillating rail axle is locked the symbol shown here will appear on the display. If the interlock was configured during installation the forward and rear travel functions will be disabled when this symbol is visible.

2. When the oscillating rail axle is locked Liftwatch Rail will start to monitor the equivalent UNLOCKED duty. If either the lift capacity or the backward stability level of the UNLOCKED duty is unsafe, the RED ‘padlocks’ will be shown on the display. If the interlock was configured during installation, the axle lock control will be disabled preventing the axle from being unlocked.

8. Axle interlock


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9. Daily checks

9.1 Duty

Place the machine in all its required duty configurations and confirm that the RCI reacts accordingly. Remember to place the machine on appropriately canted rail to check Duty 2, 3 and 4 operations. This will also confirm the correct operation of the AS7 Pitch and Roll (Cant) sensor. See section 2.5 for duty numbering and icon descriptions.

Current duty sector highlighted

Duty indication

Road / Rail / LUL duty


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9.2 Relays, inputs and motion cut

Relays and solenoids can be tested by switching the relays using KEYS 2 & 3 and testing the selected service for correct operation. A light grey motion control relay/ valve symbol denotes it has been cut for safety reasons and cannot be exercised as to do so maybe unsafe. Selecting the light grey relay will change its colour to dark grey but will not change its state. Inputs can be seen to change state on the signal input bank. The input will either be red or green. Some inputs are not used depending on machine design. The blue lamp, alarm (Internal and external), and display LEDs can be tested by pressing KEY 4.

Relays, inputs and motion cuts can be operated though the system test function which is available from the main operating screen. If no keys are pressed the system test screen will automatically exit after 5 seconds has elapsed by default. In this mode, the cab mounted blue lamp will be off indicating that the RCI is NOT active.

Relay in RED indicates service is inactive

Relay in GREEN indicates service is active


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The system test function is available from the main operating screen. If no keys are pressed the system test screen will automatically exit after 5 seconds has elapsed by default. In this mode, the cab mounted blue lamp will be off indicating that the RCI is NOT active. This option allows the functionality of the system to be verified, and basic trouble-shooting to be performed.

Motion control and interlock relays. These can be individually operated using the left/right keys (keys 2 and 3). When a relay is active it will appear RED. Any ‘relay’ shown in GREY cannot be manually operated. These relays have been set in the normal operating mode to prevent any dangerous movement.

Current highest equipment point (either bucket pin, arm ram pin, or artic pivot pin)

EQUIP lateral distance (rail centre line to the centre of the bucket pin—perpendicular to the rail centre line) TAIL left/right side tail lateral distance perpendicular to the rail centre line.

Slew and auxiliary slew switch animations. Active switches are shown in black. The lower single switch is the slew reference switch. The correct switch sequence is - 1 ON 2 OFF 1 ON 2 ON 1OFF 2 ON 1OFF 2 OFF

Code protected access to system set-up and calibration

Input signals (active signals shown in RED) : 1. Axle lock 2. Rail bogie 3. LUL 4. C/wt in / offset

boom 5. Stabs 6. Tele out 7. C/wt out 8. Keyswitch

Motion control

relay select Left / right

Return to main

operating screen

Main equipment angles (d-0.0)= Height rate of change

chassis angles (d-0.0)= slew angle rate of change

Pitch, roll and yaw (slew) are required to calculate cant and gradient

Boom lift cylinder pressures

Beacon, Alarm, and Display LED test

System status V.sup = Supply voltage V.can = CAN bus voltage level A.can = CAN bus current consumption (amp) T.chip = Main PCB temperature (ºC)

10. System test


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Liftwatch Rail continuously monitors the presence and condition of the equipment sensors. If any sensor fails the error message box shown below will appear. In the event of a sensor failure, ALL motion control relays will be operated, the cab mounted blue lamp will indicate that the RCI is NOT active and the red LED will flash and the internal and external alarms will sound.

If a sensor failure occurs the offending device will be marked with X. ‘Good’ sensors will display their message output frequency. BOOM Boom angle sensor and two boom lift cylinder pressure sensors ARM Arm angle sensor ARTIC Centre boom articulation angle sensor (N/A shown on monoboom machines) HITCH Quick-hitch angle sensor (N/A = not enabled) EXTN Tele-arm extension sensor (N/A = not enabled) CANT Chassis pitch and roll angle sensor SLEW1 Primary slew sensor SLEW2 Auxiliary slew sensor COMBI Relay controller and signal input monitor If the X is replaced with DR the sensor failure is due to output mis-match between the two sensors within a dual redundant sensor.

Combi box The Combi box (relay I/O controller) is a crucial component in the Liftwatch Rail system. This unit has the ability to monitor its own performance and will FAIL SAFE in the event of a malfunction. The fault state will be reported on the main screen in the standard warning box shown below:

Possible messages are : 1. WARNING! COMBI Relay feed-back mismatch … A motion control relay failed to switch correctly 2. WARNING! SLEW index switch failure (stuck HI) … Slew sensor index switch stuck high failure 3. WARNING! COMBI Relay fuse failure … one of more of the relay protection fuses has failed 4. WARNING! COMBI I2C sub-system failure … internal circuit failure 5. WARNING! Relay power failure ... Power to relays is not detected

11. Error messages


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Liftwatch Rail is fitted with a key operated Master override switch. Turning the switch to the override position will allow normal operation of any of the hydraulic services regardless of safety status. When the unit is in override the external alarms will stay active, and the cab RCI blue lamp will indicate that the machine is overridden, the red LED will flash and an OVERRIDE symbol will appear on the display. To access the keyswitch a seal must be broken.

12. Master override keyswitch


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Push key 1 once to display the clock. Normal operation will automatically resume after 5 seconds. See section 3 for access to the Time set function.

13. Clock


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Liftwatch Rail has two data-logging functions. These can only be viewed from the (code protected) system set-up area. Where a data logging system is found not to be operational then the vehicle shall not be used until the vehicle is repaired and fully confirmed as operational. This requirement applies irrespective whether starting or part-way through an operation.

1. The Event Logger will make a record of any significant operational event (overload, slew limit, etc), any error event (sensor failure etc), any manual intervention (override, clock set etc), and any activity within the system set-up (calibration adjustment etc). The current event log contains a maximum of 500 records. Once full, the event log is backed-up, and a new current event log created. Once more than 10 event ‘history’ logs exist they will start to ’rotate’. Only the latest 10 log files will be retained - providing a maximum of 5000 events. The red disk symbol on the top left of the screen will be displayed when an overload event or any manual override occurs. 2. The Periodic Logger only operates when the system is in the main operational mode. The REC symbol on the top right of the screen will be displayed when active. A record of the following data is taken every 1 second :

Date Time Lifting duty Load on hook Lift point radius Lift point height Slew angle Cant Gradient Operator code

The periodic logger will store a maximum of 100 hours worth of data (operational hours, NOT elapsed time).

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When Liftwatch Rail is powered-up it will check the logger status. If either logger if ‘full’ the message shown here will appear on the display, and a prompt to ‘archive’ the data will be issued. Once the data has been archived, all current logged data will be cleared and a new log created.

The following pages list all possible EVENT LOGGER entries. Those marked GREEN are events that can occur during normal operation. Other events can only occur during service, set-up, and calibration.

14. Data logging


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Logger message Reason

Data back up abort The ‘escape’ key was pressed during a data file upload via the serial port 1

Data backed up Serial data file upload successfully completed 2

Data restore abort The ‘escape’ key was pressed during a data file download via the serial port 3

Data restore (X unused entries) Serial data file download successfully completed (X = unrecognised variables in the download data) 4

Boom sensor failed/working Boom angle sensor working OK or not OK 5

Arm sensor failed/working Arm angle sensor working OK or not OK 6

Artic sensor failed/working Secondary boom angle sensor working OK or not OK (option) 7

Qhitch sensor failed/working Quick hitch sensor working OK or not OK (option) 8

Extn sensor failed/working Tele-arm extension sensor working OK or not OK (option) 9

Chassis sensor failed/working Dual-axis chassis angle sensor working OK or not OK 10

Slew sensor failed/working Primary slew angle sensor working OK or not OK 11

Aux slew sensor failed/working Secondary angle sensor working OK or not OK (option) 12

Combi failed/working Input/output controller working OK or not OK 13

Memory reset A complete memory reset was requested 14

Data copy aborted The ‘escape’ key was pressed during data file backup to local disc 15

Data copied from disc Data file copied successfully to local disc 16

Data copy failure Data file unsuccessfully copied to local disc 17

Data copied to disc Data file successfully restored from local disc 18

Main password now=XXXX The main password was changed to XXXX 19

Planning password now=XXXX The planning mode password was changed to XXXX 20

Bucket pin lift point ON/OFF Bucket pin selected as a possible lifting point (default = ON) 21

Aux lift point ON/OFF Auxiliary lifting eye selected as a possible lifting point (default = OFF) 22

Grab lift point ON/OFF Grabbing selected as a possible lifting point (default = OFF) 23

Tracked ON/OFF System set for either a tracked machine or a wheeled machine (default = OFF) 24

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Aux slew input ON/OFF Secondary slew monitor enabled or disabled (default = ON) 25

Allow slew limiting ON/OFF Enable or disable slew limiting (default = ON) 26

Allow height limiting ON/OFF Enable or disable height limiting (default = ON) 27

Mode Limit keyswitch ON/OFF Enable or disable the mode limit and lift point key switch (default = ON) 28

Customer X Customer number (X = 1, 2, 3 or 4) 29

Display relay action ON/OFF Enable or disable relay and opto input activity during normal operation (default = OFF) 30

Use SWL headroom ON/OFF Enable or disable the use of a minimum SWL ‘ headroom’ calculation (default = ON) 31

Cant sensor on chassis ON/OFF Enable or disable dual-axis chassis sensor mounted on chassis (default = OFF) 32

A/B legacy mode ON/OFF Enable or disable support for early combi-box hardware (default = OFF) 33

12 Volt machine ON/OFF Enable or disable use on 12 V machines (default = OFF) 34

Road travel inhibit ON/OFF Enable or disable travel inhibit monitoring (default = OFF) 35

Quick hitch fitted ON/OFF Enable or disable quick hitch angle monitoring (option, default = OFF) 36

Reeling drum fitted ON/OFF Enable or disable tele-arm extension monitoring (option, default = OFF) 37

Operator list ON/OFF Enable disable the use of Operator entry codes (default = ON) 38

Limit override switch ON/OFF Enable or disable the mode limit overrride key switch (default = ON) 39

Allow planning mode ON/OFF Enable disable the use of Lift planning mode (default = ON) 40

Dual redundancy sensors ON/OFF Enable or disable the use of dual redundant sensors (default = ON) 41

Edit basic machine data The basic machine data has been changed 42

Edit duty data for X Individual duty data/calibration has been changed 43

Log on opbypass Operator log on using the master code 44

LOG ON Service Service log on using the service code 45

PTS expired X Attempt to log on with a name where the PTS code has expired 46

Log on X Successful operator log on 47

Bad PTS No Attempted log on where the PTS code was invalid 48

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New op. file incompatible Attempt to download an incompatible operator list file 49

New op. file too big Attempt to download an operator list file that is too big 50

New operator file loaded Successful download of an operator list file 51

USB transfer launched USB file transfer was requested 52

Master override ON/OFF Combi-box override was instigated 53

Travel mode de/selected Travel mode either selected or deselected 54

Offset boom not/straight Offset boom either straight or not straight 55

On road/rail Rail gear either deployed or not deployed 56

Axle un/locked Oscillating axle either locked or unlocked 57

Network rail Network rail operation selected 58

London underground LUL operation selected 59

Stabs UP/DOWN Stabilisers either UP or DOWN 60

Tele retracted/extended Tele-arm either IN or NOT IN (Colmar machines only) 61

C/wt not/retracted Counter weight either IN or NOT IN (Colmar machines only) 62

Liebherr ‘On Rail’ Confirmation Leibherr ‘On Rail’ operation and confirmed 63

Set sensor X offset Angle sensor offset set (X = Boom, Artic, Arm or Quick Hitch) 64

Set sensor X polarity Angle sensor polarity set (X = Boom, Artic, Arm or Quick Hitch) 65

Edit sensor X offset Angle sensor offset edited (X = Boom, Artic, Arm or Quick Hitch) 66

Set sensor X average Angle sensor average set (X = Boom, Artic, Arm or Quick Hitch) 67

Calibrate slew sensor The slew sensor was calibrated 68

Calibrate dual-axis sensor The dual-axis chassis sensor was calibrated 69

Edit dual-axis sensor calib The dual-axis chassis sensor calibration was edited 70

Slew index failed HI The slew index switch has failed to operate (>370 degrees with no activity) 71

Relay power failed The independent power supply to the combi-box has been removed 72

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I2C combi failure Combi-box internal communication bus has failed 73

Fuse X failure A combi-box relay fuse has failed (X = 1 to 12) 74

Combi relay mismatch One or more of the combi-box relays has failed to operate as instructed 75

Slew channel failure Mismatch between the primary and secondary slew sensors 76

Edit/view slew sectors Attempt to edit or view the slew duty sector data 77

Access combi action Attempt to view or adjust the combi-box configuration 78

Test page accessed Access to test page 79

Touchscreen re-calibrated The touch screen calibration was viewed or re-adjusted 80

Lift point = Bucket pin The bucket pin was selected as the lifting point 81

Lift point = Aux lift The auxiliary lifting point was selected as the lifting point 82

Lift point = Grab The grab was selected as the lifting point 83

Soft limit override ON/OFF A change of state of the soft override function (not applicable to RIS1530 Issue 2) 84

Slew limiting ON/OFF Slew limitation was activated / deactivated 85

Height limiting ON/OFF Height limitation was activated / deactivated 86

Backward Stability Backward stability alarm activated 87

Non RCI mode Non-RCI mode selected 88

RCI mode RCI mode selected 89

Enter barred duty X An attempt was made to enter a lifting duty that is barred for use 90

Auto axle lock ON Auto-axle locking has been instigated (Colmar machines only) 91

Maximum cant exceeded The maximum allowable operational cant has been exceeded 92

Maximum gradient exceeded The maximum allowable operational gradient has been exceeded 93

Hyd.limit X The maximum allowable hydraulic pressure has been exceeded 94

Oload X X X X X X An Overload has occurred (X... = duty, %age overload, radius, height, and slew angle) 95

WARNING! X TOO HIGH The height limit was exceeded (X = offending component, boom, artic, arm, bucket pin or quickhitch) 96

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Slew limited The slew limit was exceeded 97

Maximum speed exceeded Maximum operational speed was exceeded 98

Limit override ON The limit override key switch has been manually activated 99

Limit override OFF The limit override key switch has been manually cancelled 100

Limit override auto-OFF The limit override key switch has been automatically cancelled 101

Back stab for duty X The backward stability data for duty X was set / altered 102

Calibrate duty for X The load calibration stability data for duty X was set / altered 103

Time set Real-time clock hours / minutes was adjusted 104

Date set Real-time clock date / month / year was adjusted 105

All event history cleared All even history was cleared 106

New log created A new event logging file was created 107

Power up The system was switched on 108

View loadchart X The load chart for duty X was viewed 109

Set limit entry fail An attempt to enter the limit set mode failed due to an incorrect code (not RIS1530 Issue 2) 110

Set lift mode entry fail An attempt to enter the lift mode set function failed due to an incorrect code (not RIS1530 Issue 2) 111

Non-tandem selected Non tandem lifting mode was selected 113

Tandem selected Tandem lifting was selected 114

Enter set-up failed An attempt to enter system set-up failed due to an incorrect code 115

Enter set-up System set-up was successfully accessed 116

Plan mode entry failed An attempt to enter the lift planning mode set function failed due to an incorrect code 117

Enter plan mode Lift planning mode was successfully accessed 118

Exit plan mode Lift planning mode was exited 119

Site location details Site information entered (prefixed to all subsequent event log files) 120

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14.1 Data extraction

Logged data can be extracted from Liftwatch Rail, a passcode held by Prolec Ltd and the machine convertor/service agreement holder is needed to upload this data.

Directory structure C:\

RR

HISTORY.LOG

HIST0001.LOG

HIST0002.LOG

. . . . . .

HIST0010.LOG

PERIOD.LOG

PERIOD01.LOG

PERIOD02.LOG

. . . . . .

PERIOD99.LOG

07$06$10.EVT

07$06$10.PRD

‘Active’ event logging file

Earlier event logging files, maximum 10. If files are not archived when the maximum has been reached will start to ‘rotate’ (oldest data will be lost)

‘Active’ periodic logging file

Earlier periodic logging files, maximum 99. If files are not archived when the maximum has been reached will start to ‘rotate’ (oldest data will be lost)

Event log archive (no limit to number)

Periodic log archive (no limit to number) Archive folders are named using the date when they were

created.

FILES

FOLDERS

HISTORY.LOG HIST0010.LOG

PERIOD.LOG PERIOD99.LOG

Both event and periodic logger files are in a binary format. The periodic logger files are also compressed. A Microsoft Windows® application is available from Prolec Ltd to convert these files in a CSV format suitable for import into a spreadsheet application.


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15. Editing the entry code database

The system has been configured to work with the on-board Operator Database and will prompt for a valid and in-date operator pass code each time the system is switched on. The operator database can be maintained using the following procedure.

15.1 Accessing the database

Type NEW OPERATOR and press enter

Enter a valid pass code and press Tick.

The current and unused entries will be listed. Use keys 3 and 4 (UP/DOWN) arrows to find an entry, press key 5 to enter the entry.

Scroll Up

Scroll Down

Save and exit

Select Edit pass code


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15.2 Creating / Editing an entry

Select the entry to be created or edited, enter the new name, operators code and expiry date, confirm each by pressing ENTER. Note, all three sections must be completed when editing. The ESC key can be used to exit back to the Operator summary screen.


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15.2 Editing an entry - continued

The new details will be displayed, press key 1 to exit and then key 4 to confirm changes made. The new entry will now be shown on the list.


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15.3 Deleting an entry

An entry can be easily deleted by pressing key 4. Note: you will not be asked to confirm that you wish to delete the entry.


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15.4 Editing the entry code

The entry code used to gain access to the editing facility can be changed by pressing key 2 on the entry listing screen. A pass code of up to seven digits can be used.


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16. Touch screen calibration

Liftwatch Rail features a touch screen display and will have been delivered in a pre-calibrated state. Should the touch screen calibration be corrupted or the physical properties of the actual touch screen change, then re-calibration will be necessary. If a corrupted calibration is detected the system will automatically launch the re-calibration function on start up. The re-calibration option can be manually accessed either via the system set-up, or by pressing the recalibration button three times in succession during normal operating mode.

Once accessed the re-cal function will start to ‘countdown’. If no action is taken within 10 seconds the re-calibration procedure will terminate. Press soft key 1 to exit. If a re-calibration is required use a suitable stylus (e.g. Pen, not a finger) to touch the screen as indicated by the cross-hairs. Press and hold for around 5 seconds to allow the software to ‘sample’ the position, then lift the stylus.

The cross-hairs will automatically move to the lower right of the screen.

Press and hold for around 5 seconds to allow the software to

‘sample’ the new position, then lift the stylus.

Calibration is now complete. To verify the accuracy touch the screen at any point. The cross-hairs should appear at the point of contact. If the accuracy is unacceptable, exit the function, and try again.

Once calibration is complete (or the ‘countdown’ has expired) there is an opportunity to adjust the touch screen pressure sensitivity. Use the PRESSURE softkey 5 to access pressure adjustment. The lower the value, the more sensitive the screen will become. If the required pressure value falls outside a range of around 80 to 1024 contact Prolec Ltd as the operation/durability of the unit may be in question.

3

1

2


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17. System diagram

CAB

FRONT END EQUIPMENT

SUPERSTRUCTURE

1

2

3

4

5 6

7 8

9

10

11

12

13

14

15 16 17

18 19

20

21

22


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Description Part Number

1 5.7” Touch Screen Computer/Display 002313-001

2 RAM 1.5” ball double socket short arm 480342-000

3 RAM 1.5” ball 2.5” base 480340-000

4 Mode Limit key switches 002380-000

5 Display power supply filter 002381-000

4 Amp fuse max 240102-000

6 CAN combi box Road Rail Mk 2 1530 002323-031

7 Combi power supply filter 002382-000

25 Amp fuse max 240101-000

8 Slew control proximity switch M12 npn NO (x 3) 200056-000

9 Rear remote alarm 001010-000

10 Forward remote alarm 001010-000

11 Master override key switch 002379-000

12 CAN quad sensor (secondary slew) 002386-000

13 Slew control proximity switch M12 npn NO (x 3) 200056-000

14 CAN AS7FS Dual axis sensor 002330-005

15 CAN AS7 Dual pressure angle sensor (master) 002318-012

16 CAN AS7 Dual pressure angle sensor (slave) 002318-022

17 CAN AS7FS Artic angle sensor 002330-002

18 CAN AS7FS Arm angle sensor 002330-001

19 CAN AS7FS Quick hitch angle sensor* 002330-003

20 M12 CAN female terminator 340753-000

21 AS7 Mounting shoe 010933-001

22 AS7 Mounting shoe 010933-004

Due to the variety of cable types, lengths, and terminations - the schematic is for guidance only. *Optional sensor


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Prolec Ltd 25 Benson Road

Nuffield Industrial Estate Poole

England BH17 0GB

Tel: +44 (0)1202 681190

E-mail: [email protected]

liftwatch rail - prolec

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