Robway SLI Manual

10.
1 SAFE LOAD INDICATOR

RCI-4100IS Tension Based System
FAVCO 350RL S/N: 1614

TWIN WINCH
STRUT BOOM CRANE
Version C1.07
Favelle Favco Cranes SDN. BHD.
SO 100419 15-10-2009

Robway Crane Safety Systems Pty Ltd, 32 West Thebarton Road, Thebarton, South Australia, 5031
Phone: (+61 8) 8238 3500 Fax: (+61 8) 8352 1684 mail@robway.com.au www.robway.com.au
MAN1124A
Robway Crane Safety Systems Pty Ltd

Adelaide, South Australia
Contents Page No.
1. Important Safety Notice ............................................................................................4
2. General Description ..................................................................................................5
3. Operating Instructions...............................................................................................7
3.1. Turning On the RCI-4100IS .........................................................................7
3.2. Turning Off the RCI-4100IS .........................................................................7
3.3. Operating Screen .........................................................................................8
3.4. Display Functions.........................................................................................9
3.5. Data Logging and Data Downloading ..........................................................13
3.6. Uploading Crane Software Using SD Card..................................................14
3.7. Restricted Slew Zone Monitoring – Optional Feature ..................................15
3.8. Wind Speed Monitoring – Optional Feature.................................................15
3.9. Gross Over-moment Protection (GOP) – Optional Feature.........................15
4. Installation .................................................................................................................16
5. Calibration .................................................................................................................24
5.1. Verifying Operation of Sensors ....................................................................27
5.2. Configuring User Variables ..........................................................................28
5.3. Calibrating Boom Angle ...............................................................................35
5.3.1. Calibrating Low Boom Angle.............................................................35
5.3.2. Calibrating High Boom Angle ............................................................35
5.4. Calibrating Load on the MAIN Winch (Load Pin 1) ......................................36
5.4.1. Calibrating Light Main Load ..............................................................36
5.4.2. Calibrating Heavy Main Load............................................................36
5.5. Calibrating Load on the AUX Winch (Load Pin 2)........................................37
5.5.1. Calibrating Light Aux Load................................................................37
5.5.2. Calibrating Heavy Aux Load .............................................................37
5.6. Using Load/Angle Correction Function ........................................................38
5.7. Testing the Constant Tension/Slack Rope Function....................................39
5.8. Copying and Restoring Calibration Data Function.......................................40
5.8.1. Copying Calibration Data ..................................................................40
5.8.2. Restoring Calibration Data................................................................40
6. Troubleshooting ........................................................................................................42
7. Maintenance..............................................................................................................49
7.1. Checklist.......................................................................................................49
7.2. Removal of Electrical Equipment .................................................................49
7.3. Maintenance Work in Hazardous Areas ..............................................50
7.4. Maintenance Work in Non-Hazardous Areas ......................................50
7.5. Modification or Repair ..........................................................................51
7.6. Inspection After Maintenance ..............................................................51
7.7. Records ................................................................................................51
8. General Specification................................................................................................52
9. Appendices ...............................................................................................................56
x Safety and Installation Instructions, Model 4120 RCI-4100
Display Barrier .............................................................................................56
x Declaration of Conformity, RCI-4100 Hazardous Area Rated
Capacity Indicator System ...........................................................................56
x Nemko EC Type-Examination Certificate (ATEX) .......................................56
RCI-4100IS HRT Pedestal (FFC) Manual Last Ammended: 02/06/2009
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x IECEx Certificate of Conformity, Display Module Type RCI-

4100IS..........................................................................................................56
x IECEx Certificate of Conformity, Model 4120 Power Supply and
I2C Barrier....................................................................................................56
x Data Logging on Robway RCI’s...................................................................56
x Restricted Slew Zone Monitoring – Optional Feature..................................56
x Wind Speed Monitoring – Optional Feature.................................................56
x Gross Over-moment Protection (GOP) – Optional Feature.........................56
x Drawings ......................................................................................................56
x RCI System Crane Configuration Sheets/Duty Listing/Function
Codes...........................................................................................................56
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MAN1124A

1. Important Safety Notice
The RCI-4100IS System is a crane device which warns the operator of impending
overload conditions and overhoist conditions which could cause damage to property,
crane and personnel.
The system is not a substitute for good operator judgement, experience and safe
crane operation. The operator is solely responsible for the safe operation of the crane.
The operator must, prior to operation of the crane, read this manual carefully and
thoroughly and shall ensure that all operational instructions and warnings are
understood and complied with.
Proper system operation requires the operator to correctly program the RCI System to
match the crane setup and working configuration.
The system is equipped with an override key which bypasses alarms and motion cut
function at which time the system can no longer warn of impending overload and must
only be operated strictly in accordance to the crane manufacturer’s setup and
operation procedures. Operation of this key is for authorised personnel only who shall
be solely responsible for its use.
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MAN1124A

2. General Description
This Manual contains general information, installation, operation, calibration,

maintenance and parts information for the RCI-4100IS Rated Capacity Indicator to suit
Favelle Favco (FFC) Offshore Pedestal Crane working in a hazardous area.
Applicable General Arrangement drawings and system wiring details can be found in
the Appendices at the back of this manual.
Drawing numbers, where applicable in the following Sections, are also provided in
each Section for quick reference.
The RCI-4100IS is an “Intrinsically Safe” system and a fully automatic Rated Capacity
Indicator which provides a display of the following functions:
x Safe Working Load (SWL),
x Boom Length,
x Boom Angle,
x Hoist Rope Falls,
x Duty (or Sea-State),
x Time and Date,
x Hook Radius,
x Actual Load,
x Actual Load as a Percentage of SWL.
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The RCI-4100IS display also provides the following features:
x Visual and audible alarms on warnings, motion-cut, and two-blocking

detection,
x Self-diagnosis and error codes,
x Data-logging,
x Built-in calibration and fault-finding tools,
x Tare facility,
x Units conversion (imperial/metric) facility,
x Anti-two-block (overhoist limit) facility,
x Restricted slew zone monitoring – optional feature,
x Wind speed monitoring – optional feature,
x Gross over-moment protection (GOP) – optional feature.
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MAN1124A

3. Operating Instructions
The following sections explain how to operate the RCI-4100IS and make best use of
its capabilities.
3.1. Turning On the RCI-4100IS
The RCI-4100IS can be powered by 9 VDC to 36 VDC supply.
The selected power supply may be permanently connected, however for

convenience it should be made via an ON/OFF switch or relay. If the Control
Unit is located within a hazardous area, the power MUST be supplied via steel
wire armoured cable.
As soon as power is applied to the RCI-4100IS, its display and other indicators
should light up and the RCI-4100IS should go through its self-test operation.
Drawing Reference:
DWG 3990 (Sheets 1of 7) – “Twin Winch Pedestal Crane, Customer
Wiring Details, Hazardous Area”
3.2. Turning Off the RCI-4100IS
The RCI-4100IS will stop working as soon as the power is removed from it by
switching off the supplies indicated in 3.1 above.
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MAN1124A

3.3. Operating Screen
The following is the operating screen of the RCI-4100IS showing the general
display functions:
LED Indicator
Lamps for Safe,
Warning &
Overload/Fault
Conditions Alphanumeric LCD
screen showing various
functions (SWL
Bargraph, Duty or Sea-
state, Falls, Boom
Length, Local Time,
Units, Override
LED Indicator Indication, Tare
Lamps for Indication & Error
Winch Selected Codes
(Main or Aux) &
ATB
Safe Working
Actual Load for Load (SWL)
Winch Display
Selected (Kips (Kips or Tonnes)
or Tonnes)
Working Radius
Boom Angle
Display
Display (Degrees)
(Feet or Metres)
Winch Select UP/DOWN Buttons

Button (Main for Changing Duty
or Aux) & Falls, and for Use
in Calibration Mode
Setup/Cancel Tare/Enter Button
Button for Use (Consult Manual for
in Calibration Using Tare; Enter is
Mode Used in Calibration
Mode)
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MAN1124A

3.4. Display Functions
The RCI-4100IS display is comprised of one 4x16 alphanumeric LCD, four 7-segment
LCD’s, three alarm LED ’s, three indicator LED’s and five push buttons. The functions
of these are as follows:
ALPHANUMERIC LCD SCREEN & ALARM LED INDICATORS
This top line of the screen is a horizontal bargraph used to indicate the
percentage of Safe Working Load (SWL). This bargraph shows the total load
as a percentage of the cranes' rated capacity in its current configuration with
the aid of a horizontal coloured band (Green, Amber & Red) on the decal just
above the bargraph.
The three alarm LED’s (Green-Safe, Amber-Warning & Red-Overload) at the

top of the display also work in conjunction with the SWL bargraph. Factory
settings are as follows:
x Green: 50 to 84%, Amber: 85 to 99%, Red: 100 to 110%

x Amber-Warning LED flashes when first trip point is reached (i.e. 85%
Rated Capacity) plus an intermittent audible alarm.
x Red-Overload LED will flash at 100% of rated capacity plus a
continuous audible alarm.
x Red-Overload will stop flashing and will continuously be ON when the
lifted load exceeds 110% of SWL plus a continuous audible alarm.
Crane motion controls are also activated at this stage if fitted.
The other lines on the alphanumeric screen show a numerical display of the
following functions:
DUTY - shows the current duty (or Sea-state) selected.
FALLS - shows the current parts of line or falls for the

winch selected.
BOOM LENGTH - shows the boom length, in unit selected (feet or

metres), for the winch selected.
TIME - shows the current local time. The time function is

also used to time stamp records in the data-
logger. The correct time can only be set in
calibration mode (refer to Section 5. “Calibration”
for details).
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MAN1124A

UNITS - shows the current unit (Metric or Imperial)

selected by the operator.
TARE - when activated by the operator, the load value on

the screen will show zero (i.e. all loads prior to
activating tare will be tared out).
OVERRIDE - the screen will show O/R on the upper left hand
side of the LCD when the override key or bypass
key is turned on. The override key is only used
when calibrating the system and/or when
temporarily overriding the alarms at which time
the system can no longer warn of impending
overload. Operation of this key is for authorised
personnel only who shall be solely responsible for
its use. ROBWAY recommends that the
override key be switched OFF at all times and
the override key be held by the site-
supervisor or any authorised personnel.
The TARE is an operator-settable function. It allows the operator to TARE out

the weight of accessories not considered part of the load.
Please note that when the TARE function is active, the %SWL is still
determined by the total load, irrespective of what is currently displayed.
Using the TARE function

The tare function can be activated by pressing the TARE button on the
lower part of the display. Once activated, the TARE indicator will be
shown on the screen and the displayed load will change from the
current load reading to zero (i.e. the load/weight prior to activating tare
will be tared out). This is useful when the operator wants to see only the
net weight of the load minus the accessory loads (e.g. wire rope slings,
rigging accessories, etc). When TARE is next pressed, the displayed
load reverts to the total load.
While in TARE mode, the tared load will be stored in the system
memory and will still be part of the total load calculation of the system.
The DUTY and FALLS are operator-settable functions. Prior to crane operation,
the operator must ensure that the correct DUTY and FALLS are selected to
match the actual crane configuration/operation and actual parts of line on the
winch selected/used.
The list of the programmed DUTIES for the specific crane is provided at the
rear of the manual. A copy is also provided to be placed in the crane cabin for
reference by the operator.
Selecting DUTY
To change the duty, press either the UP or DOWN arrow key until the
DUTY value on the screen flashes. While it is flashing, press the
UP/DOWN arrow keys to ramp to the desired sea state number,
ensuring the correct sea state is selected. Press the ENTER key to
complete selection, or wait 5 seconds when the display automatically
switches back to normal operating mode.
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MAN1124A

Selecting FALLS
To change the falls or parts of line, press either the UP or DOWN arrow
key until the FALLS value on the screen flashes. While it is flashing,
press the UP/DOWN arrow keys to ramp to the desired number of falls.
Ensure also that the correct sea state has been selected as the
changes in falls will appy to the active winch selected. Press the
ENTER key to complete selection, or wait 5 seconds when the display
automatically switches back to normal operating mode.
This screen is also used to display ERROR codes when any errors are
detected. The error code/s will be displayed automatically if there are any
errors. Please refer to Section 6. “Troubleshooting” for the meaning and
description of the error codes.
7-SEGMENT LCD SCREENS
There are four 7-segment LCDs on the lower part of the display which show a
numerical display of the following functions:
LOAD - shows the current load in unit selected (kips or

metric tonnes) for the active winch.
SWL - shows the current maximum safe working load in

unit selected (kips or metric tonnes) for the active
winch. The SWL will also depend on the current
duty, maximum hoist rope line-pull and falls.
RADIUS - shows the current operating radius in unit

selected (feet or metres) for the active
winch/hook.
ANGLE - shows the current boom angle in degrees.
ACTIVE WINCH & ATB LED INDICATORS
There are three LED indicators at the centre of the display as follows:
MAIN - illuminated when Main Winch is selected.

Selection can be done by pressing the LOAD
button on the lower left hand side of the display.
Pressing the LOAD button will toggle between
Main Winch and Aux Winch.
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MAN1124A

AUX - illuminated when Aux Winch is selected.

Selection can be done by pressing the LOAD
button on the lower left hand side of the display.
Pressing the LOAD button will toggle between
Aux Winch and Main Winch.
ATB - illuminated when two-blocking condition is

detected, at which point the Red-Overload LED at
the top of the display will also illuminate,
activating the continuous audible alarm and ATB
motion cut relay.
FUNCTION PUSH BUTTONS
There are five push buttons on the lower part of the display as follows:
LOAD - used for switching between Main Winch and Aux

Winch. Although the system will always check on
the safe operation for both winches, it is
important to ensure that the correct winch is
selected as the winch selection affects the values
shown on the display. When the actual load
exceeds the SWL for the current crane
configuration, the RCI-4100IS will activate audible
and visual alarms.
SETUP/CANCEL - dual-purpose button used for accessing

Calibration Mode (SETUP) in conjunction with the
override key, and for aborting changes (CANCEL)
to calibration data values during calibration/setup
(refer to Section 5. “Calibration” for details).
TARE/ENTER - dual-purpose button used for activating tare

function (TARE) and for confirming changes
(ENTER) to calibration data values during
calibration/setup. Refer also to previous sections
for details on the Tare function.
UP/DOWN ARROW - used for changing Duty and Falls when on normal
operating screen. When in Calibration Mode,
these keys are used for going through the list of
Function Codes and for incrementing/
decrementing numerical values when
calibrating/setting up a function.
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MAN1124A

3.5. Data Logging and Data Downloading
The RCI-4100IS Control Unit has an on-board SD card to which data from the
internal datalogger can be downloaded and saved for reading on a PC.
First, the internal logger records all data within the set parameters of the logger
and system. The data are then stored in the on-board flash memory chip.
In Calibration Mode, function code F-35 is used for downloading the logger
contents from the flash memory chip into the SD card. The SD card can then be
removed from the Control Unit and inserted into the card reader on a PC for
viewing, saving and printing the recorded data.
As the logger contents can only be done in Calibration Mode, only authorised
personnel with access to the override key and Calibration Mode can performed
this function.
A short procedure is as follows:
1. Turn the override key ON and access Calibration Mode.

2. Go to function code F-35 and press the ENTER key.
3. The default setting on the screen is “RS232” which means that
pressing the ENTER key at this point will download the logger
contents into a PC via the serial port. For using the SD card, use the
up/down arrow key to change the setting from “RS-232” to “SDCARD”.
4. While “SDCARD” is shown on the screen press the ENTER key and
this will download the logger contents into the SC card.
5. Carefully remove the SD card and insert it into the card reader on a
PC for viewing the logger contents. There will be two files on the SD
card, one is a *.HEX file which contains the crane software, and the
other is a *.TXT file which contains the logs.
6. Open the *.TXT file using any word processing program such as MS
Word or Notepad for viewing, saving and/or printing of data.
7. Once saved the *.TXT can be cleared/deleted from the SD card.
RCI-4100IS Control Unit board showing the SD card slot
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Please refer also to the Appendices at the back of this manual for usage
information and details.
3.6. Uploading Crane Software Using SD Card
The crane software can be uploaded into the CPU of the RCI-4100IS Control Unit
using the SD card.
During normal operation, the system reads and processes data from the CPU
and not from the SD card. The SD card is only used to upload new crane data or
changes in the crane data.
The crane software is a *.HEX file copied into the SD card either from the factory
at the time of supply or sent via email. The emailed crane software can be copied
into the SD card using a PC.
On system boot up, the system reads the SD card (if present) and compares two
parameters as follows:
x Software Version Number

x Crane Model
1. If both the Software Version Number AND Crane Model on the SD

card are different from the ones in the CPU, then the system will
upload the new crane data from the SD card, and will prompt the user
to “clear calibration data”. A recalibration of the system will be
required.
2. If only the Software Version Number is different but the Crane Model
is the same, then the system will upload the new crane data from the
SD card, but will NOT prompt the user to “clear calibration data”. A
recalibration will NOT be required.
3. If the Software Version Number is the SAME as the one in the CPU,
then the system will NOT upload data from the SD card.
4. In some cases where changes are made on the crane software with
the SAME Software Version Number, the changes can still be
uploaded but will first require uploading from a “dummy SD card”. The
dummy SD card is basically a data eraser which, when uploaded, will
clear the CPU. To do this, first insert the dummy SD card and power
up the system. The display will then prompt the user to clear the data.
Keep pressing the ENTER key until the display boots up. Then switch
off the system, remove the dummy SD card and install the one with
the changes made on the crane software. The system will again
prompt the user to clear calibration data and a recalibration of the
system will be required. Please contact Robway for further details and
assistance on the dummy SD card.
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MAN1124A

3.7. Restricted Slew Zone Monitoring – Optional Feature
Restricted Slew Zone Monitoring is an optional feature that can be integrated into
the RCI-4100IS system if required.
If this option is supplied, please refer to the Appendices at the back of this
manual for usage information and details.
3.8. Wind Speed Monitoring – Optional Feature
Wind Speed Monitoring is an optional feature that can be integrated into the RCI-
4100IS system if required.
3.9. Gross Over-moment Protection (GOP) – Optional Feature
Gross Over-moment Protection is an optional feature that can be integrated into

the RCI-4100IS system if required.
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4. Installation
SETTING UP THE CRANE
Lower the crane boom to a safe and convenient position.
INSTALLING BOOM PARTS
Boom Angle Sensor (EEx d)
Fix the angle sensor to the Right Hand Side “inside” the boom (as shown in
the photo below) in a convenient position close to the operator's cab. The
angle sensor comes complete with a standard mounting plate and kit
suitable for simple & fast direct mounting to either the boom butt area or
chord/lacings. Photo below shows direct mounting to the butt area where
bolts (or fabricated support plate) can be tack-welded (or drilled & tapped).
Mount the sensor on the bolts or plate, ensuring that when you look out of
the cabin, towards the boom, the angle sensor is vertical and is not tilting to
the left or right.
Open the angle sensor enclosure and ensure that the “clinometer” inside the
box is in a vertical orientation, with the pivot point at the top when the boom
is at 45°. If this is not the case, adjust the clinometer by loosening the
screws around it and rotate to correct orientation. Tighten screws once
orientation is correct.
Alternatively, the angle sensor can be “clamped” to the chord/lacing closest

to the boom butt area by using the universal mounting plate and bolts
provided. The position of the angle sensor box on the boom chord can be at
an angle (inclined to follow the chord angle), so long as the clinometer
inside is adjusted as above.
Route the cable carefully around the boom and boom pivot to the cabin. The
angle cable is passed through the Barrier box before terminating into the
RCI Control Unit. Fix the cable using adequate straps and fixings ensuring
that the cable is not pinched or stretched as the boom moves through its full
luffing arc (see also “Cabling – Boom Sensors” item in this Section).
Drawing References:
DWG 3800 – “Dimensional Detail, Ex d Angle Sensor (ANGES4130)”
DWG 3990 (Sheet 3 of 7) – “Twin Winch Pedestal Crane, Customer
Please note that high tensile booms require proper welding procedure
specifications. Obtain specialist assistance in these cases.
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Ex d angle sensor and typical installation at the boom butt section
Single Sheave Dynamometer with Load Pin

(Wired to Control Unit though an EEx ia Load Cell Isolating Barrier)
A load pin fitted in a single-sheave dynamometer can be mounted close to

the boom tip for hoist-rope-tension type installations. The load pin will
output an electrical signal in mV/V proportional to the linepull or tension on
the hoist rope and representing the forces exerted on the load pin’s sheave
by the hoist rope.
Each hoist rope will have a single-sheave dynamometer.
Route the cable carefully around the boom head, along the boom, and into
the RCI Control Unit. Fix the cable using adequate straps and fixings
ensuring that the cable is not pinched or stretched as the boom moves
through its full luffing arc (see also “Cabling – Boom Sensors” item in this
Section).
Drawing References:
DWG 3663 – “RW 1500CA Load Pin Connector & Assembly Detail”
Typical installation of load pins in single sheave dynamometers
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MAN1124A

Anti-Two-Block (Optional Item)

(Wired to Control Unit though an EEx ia Digital Switch Isolating Barrier)
Fix the anti-two-block (ATB) switch mounting pin to the main boom head
preferably so that the bob-weight (when suspended from the switch) can be
fitted to the static hoist rope below the rope anchor. The mounting pin has 2
x 9mm holes. It can either be welded on the boom head section (directly or
via a steel plate), or be screwed by drilling and tapping 2 holes on a suitable
location on the boom head.
Check that the switch works correctly as the boom luffs throughout its
working range. For twin winch cranes, additional switch can be added and
mounted at the rooster/aux winch head sheave.
There are two (2) types of bobweight assembly used: universal type (P/N:
BOBUNI01) for the main winch, and oval type (P/N: BOBWTWHIP) for the
whip line. Please refer to the General Arrangement drawing and related
drawings at the rear of the manual for installation details on the bobweights.
(Note: Cut chain to required length suitable for the winch line speed
and application. Loctite threadlocker, or similar, must be applied to all
shackles in the ATB assemblies.)
Fix the ATB cable/s through the junction box/es supplied and route the cable
carefully along the boom (or through a boom cable tray, if available) and
boom pivot to the cabin. Secure the cable on the boom using adequate
straps and fixings ensuring that the cable is not pinched or stretched as the
boom moves through its full luffing arc. Wire the cable into the RCI Control
Unit (see drawing DWG 3990 in the Appendices at the back of this manual
for wiring details).
Drawing References:
DWG 2934 – “Dimensional Detail, BB5 Anti-Two-Block Switch”
DWG 0946 – “Dimensional Detail, Universal Bobweight for Main Hoist”
DWG 3799 – “Dimensional Detail, Whip Line Bobweight for Whip Line”
DWG 3819 – “Installation Details, Whip Line Bobweight for Whip Line”
Please note that high tensile booms require proper welding procedure
specifications. Obtain specialist assistance in these cases.
Model BB-5 anti-two-block (ATB) switch and junction box
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*NOTE: It is important to ensure that the hole of the bobweight is kept

clean of any dirt or grease as these could stick to the hoist rope
and cause false activation of the ATB switch alarm and motion cut
(if installed). A periodic inspection of the ATB switch and
bobweight is recommended to ensure proper operation of the ATB
system.
Cabling (Sensors)
Sensor cables should be fixed firmly to where they are installed and routed
along the boom chords (and gantry/A-frame for the force transducer)
through to the crane cabin ensuring freedom of movement around the boom
pivot pin. Clip cables at approximately 600mm intervals or where suitable to
secure them firmly to the boom (and gantry/A-frame for the force
transducer).
Stainless steel cable ties are also supplied with the installation kit and to be
used where required.
Drawing Reference:
DWG 1047 – “Stainless Steel Cable Tie Tightening Instructions”
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MAN1124A

INSTALLING CABIN PARTS
Display Unit (Ex ib)
The RCI-4100IS Display Unit is a Group IIB Ex ib certified display which may
located in Zone 1 or Zone 2 of a hazardous area.
The display has overall dimensions of 260mm (H) x 150mm (W) x 60mm
(D), rated to IP65, and weighs about 3 kgs. It can be fitted in a convenient
position in the crane cabin such that the operator can view the displays and
reach the push buttons comfortably.
Standard ram bracket and kit comprising of bolts and nuts are provided.
Special bracket may need to be fabricated on site for suitable mounting in
the cabin.
Refer also to the “Safety and Installation Instructions, Model 4120 RCI-4100
Display Barrier” on the Appendices at the back of this manual for further
information and details.
Drawing References:
DWG 3798 – “Dimensional Detail, RCI-4100IS Display”
Wiring Details, Controller & Display
Safe Area”
Check bonding between enclosure and chassis. If a good bond cannot

be ensured through the mounting bracket, then install earth strap. It is
a condition of installation that equipotential bonding must be ensured
between the Display enclosure and the Control Unit enclosure.
Ex ib display unit and typical installation inside the cabin
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Control Unit
There are two types of Control Unit (or Controller) as follows:
1. Safe Area Control Unit
The Safe Area Controller enclosure is made of stainless steel with a

hinged lid and is designed for mounting inside the crane cabin.
The enclosure has overall outside dimensions of 275mm (H) x 350mm

(W) x 200mm (D) with an environmental protection of IP65.
The Controller contains the termination points for all modules within the
RCI-4100IS system. Terminate all connection cables at the Control Unit.
Drawing References:
DWG 3973 – “Control Enclosure, RCI-4100IS Safe Area”
DWG 4046 (Sheets 1-7 of 7) – “Customer Wiring Details, Controller
& Display Safe Area”
Check bonding between enclosure and chassis. If a good bond

cannot be ensured through the mounting bracket, then install earth
strap. It is a condition of installation that equipotential bonding
must be ensured between the Display enclosure and the Control
Unit enclosure.
Typical installation of safe area control unit inside the operator’s cabin
2. Hazardous Area Control Unit
The Hazardous Area Control Unit has Ex ia and Ex ib interfaces housed

in an Ex d flameproof enclosure for Zone 1 and Zone 2 applications.
The Controller is certified to EEx d IIB (ATEX) with environmental

protection of IP65. The enclosure has overall outside dimensions of
371mm (H) x 371mm (W) x 233mm (D) and weighs about 18 kgs.
The Controller contains the termination points for all modules within the
RCI-4100IS system. Terminate all connection cables at the Control Unit.
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Drawing References:
DWG 3992 – “CUFRCI4100 Enclosure, RCI-4100IS Control Unit”
DWG 3990 (Sheets 1- 7 of 7) – “Customer Wiring Details, Hazardous
Area”
Check bonding between enclosure and chassis. If a good bond

cannot be ensured through the mounting bracket, then install earth
strap. It is a condition of installation that equipotential bonding
must be ensured between the Display enclosure and the Control
Unit enclosure.
Typical installation of Ex d control unit inside the operator’s cabin
Cable Glands
The cable glands used on the flameproof Control Unit are barrier glands.
Instructions to fit cables & epoxy compound are included with each gland.
Once the epoxy has been installed, the gland must not be re-opened as the
seal would be broken. If any cable alterations are necessary, then a new
barrier gland must be used. The particular glands recommended utilise a
unique clamp arrangement which allows either SWA or screen braid to be
clamped within the gland. It is important to follow the instructions carefully to
use the correct orientation of the clamp to suit the particular cable, and that
either the armour (for power and relay cables) or the screen (I.S. cables) is
clamped correctly. Do not bring the screen connection through the gland (on
I.S. cables) unless the replacement gland is not suitable. In this case the
screens must be terminated at the earth terminal block located above the
relays on the mounting plate inside the Control Unit.
SWITCH INPUTS
The RCI-4100IS Control Unit has eight (8) digital switch inputs to suit specific
application and requirement, such as slew position limit switch, external duty
selector switch, etc.
Please refer to the RCI System Crane Configuration Sheet at the rear of the
manual for the list of inputs programmed in the software to suit the specific
application.
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Drawing References:
Safe Area”
RELAY OUTPUTS
The RCI-4100IS Control Unit has three (3) safety relays on board the PCB and
another three (3) switching relays on the terminal block.
The relays have voltage free contact rated to 5A and are only used to energise
the coils of external high-power SLAVE relays, such as motion cut, slack rope
detect output, boom up motion cut (minimum radius limit), etc.
Please refer to the RCI SYSTEM CONFIGURATION SHEET at the rear of the
manual for the list of relay outputs programmed in the software to suit the
specific application.
Drawing Reference:
Safe Area”
Please note that all inductive loads such as relays and solenoids
require snubber diodes for transient suppression.
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5. Calibration
Before any calibration functions can be activated, you must enter

CALIBRATION MODE.
Entering Calibration Mode and Selecting Calibration Functions:
x Make sure that the correct duty number (crane configuration) and falls
(parts of line) are selected,
x Insert the over-ride key switch into the RCI-4100IS and turn it on, make
sure that the override indicator (O/R) is shown on the screen,
x Press and hold the SETUP button for about 2 seconds,
x F-xx will be shown on the alphanumeric display, where xx is the last

calibration function performed or 00 if this is the first time you entered
calibration mode,
x Once calibration mode is entered use the UP/DOWN keys to ramp through
the calibration functions,
x When the correct function code is shown on the scree press the ENTER
button to select that function,
x To exit calibration mode either select F-00 or press the CANCEL key until
the F-xx code is cleared from the screen.
Tools/Items Required for Calibration:
x An accurate angle finder for calibrating boom angle sensor,
x An accurate tape meter (at least 100 ft. long) for verifying radius,
x Known test weights for calibrating loads,
x Software configuration sheets and function codes list.
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Map of Calibration (Suggested Order):
1. Set year, day/month, and time (FC-32 to FC-34).
2. Verify that raw counts stay within 50-4045 for full working range of all sensors
(FC-07, FC-15, FC-19).
3. Review all crane geometry against the supplied Crane Configuration settings
for correctness (FC-47 to FC-55) – refer also to the Appendices at the back of
this manual for the RCI System Crane Configuration Sheets and factory default
settings.
4. Review all SWL % parameters against actual requirements (FC-42 to FC-46)

and change if required – refer also to the Appendices at the back of this
manual for the RCI System Crane Configuration Sheets and factory default
settings.
5. Review the data logger recording points against actual requirements (FC-65 to
FC-71) and change if required – refer also to Appendices at the back of this
manual for the RCI System Crane Configuration Sheets and factory default
settings.
6. Check / Set the following functions:
x Amplifier gains (F-23) for load pins and and angle sensor as follows:
x Channel 1, Load Pin 1 – set to 480

x Channel 2, Load Pin 2 – set to 480
x Channel 3, Angle Sensor – set to 310
x Number of sensor samples to average (FC-27) – set to “8”, refer to Section

5.2.20. for details.
x Metric/Imperial units switching (FC-79) – set to required unit.
7. Calibrate low & high boom angle sensor (FC-09, FC-10) – refer to Section 5.3.
for procedure.
8. Calibrate light and heavy main winch load (FC-02, FC-03) – refer to Section
5.4. for procedure.
9. Calibrate light and heavy aux. winch load (FC-05, FC-06) – refer to Section 5.5.
for procedure.
10. Perform functional and operational checks and load tests to ensure accuracy of
system.
11. If the load readout decreases as the boom is luffed up, apply load/angle
correction factor (FC-72 to FC-75) – refer to Sections 5.2.38. and 5.6. for
details and procedure.
12. If required by specific requirement, apply a “winch rigging safe working load” for
the main hook (FC-76) and aux hook (FC-77) – refer to Sections 5.2.39. and
5.2.40. for details and procedure.
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13. Set the constant tension limits (FC-63 for main winch and FC-64 for aux winch)
and test the constant tension function – refer to Sections 5.2.35., 5.2.36., and
5.7. for details and procedure.
14. Once satisfied with the calibration results, manually record (pen & paper) the
calibration data (FC-40) and all the settings mentioned above. Refer to Section
5.8. “Copying & Restoring Calibration Data Function” for details and
procedures.
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5.1. Verifying Operation of Sensors
Before you start calibrating the RCI-4100IS, you must make sure that the sensors are
working correctly and their signals are reaching the RCI-4100IS.
The RCI-4100IS 'sees' the crane and its surroundings through sensors. The signals
from these sensors are represented as numbers inside the RCI-4100IS. The range of
possible numbers is 0 to 4095 for each sensor.
The RCI-4100IS allows the user to view both the UNCALIBRATED or the
CALIBRATED signal from a given sensor (refer to the Function Code Listing at the
rear of this manual).
When viewing the UNCALIBRATED signal from a sensor, make sure the number
displayed is less than 4045 and is more than 50 as you work the sensor through its
working range. This is the correct operating range. Also make sure that the numbers
displayed in the window are changing in a nice, smooth manner. If you find that the
number is too unstable (i.e. changes by more than 10), then you should check the
connections to the RCI-4100IS (refer to Section 6. “Troubleshooting”).
If the signal is less than 50, suspect a short circuit somewhere on that input channel,
e.g. the cable to the RCI-4100IS has been crushed and has an internal short circuit in
it. Moisture inside the plugs can look like short circuit too.
If the count displayed in the window is 4095, look for an open circuit on that input
channel. e.g. disconnected lead.
If the sensors check out then you can continue on and start with the calibration
procedure. If you find any problems, check the troubleshooting guide at the end of this
manual or seek help from your nearest ROBWAY distributor.
Please note that while in view mode, that is using either "VIEW UNCALIBRATED ..." or
"VIEW CALIBRATED ..." functions, the ENTER key works as a toggle switch to turn
that channel ON or OFF. This function allows the user to temporarily turn a sensor off
if it is not needed, e.g. if you want to use the main winch only on a twin winch system;
normally, if you have not connected the auxiliary sensor up, the RCI-4100IS will report
an error and activate motion cut. To prevent this you can press the ENTER key, while
in "VIEW UNCALIBRATED TRANSDUCER 2 function", to turn the auxiliary channel
off.
To turn a channel back on, you have to re-enter the same VIEW UNCALIBRATED...
function and press the ENTER key again.
Remember that you must always end a view function by pressing the CANCEL
key.
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5.2. Configuring User Variables
ROBWAY stores the load-charts, crane geometry, default alarm and motion control
settings, default data logging parameters, fine-tuning settings, and other useful user
variables in the memory of the RCI-4100IS at the time of manufacture. As this
information may vary from crane to crane, even if they are of the same model, the RCI-
4100IS allows the installer to change these variables on site. These user variables
include dimensions such as slew-offset, maximum falls for main/aux winches,
maximum line-pulls, sheave diameters, etc.
The actual values of these variables are printed on the RCI System Crane
Configuration Sheets (see Appendices at the back of this manual).
To verify or change the current value of any of these user variables follow the
procedure below:
x Enter calibration mode,
x Select the correct function code from the listing then using the UP/DOWN
keys ramp to that function code and press ENTER,
x If you want to change the value use the UP/DOWN key to select the new
value then press the ENTER key,
x If you only want to verify the current value press the CANCEL key when
finished viewing,
x Now you should be back at the F-xx prompt and can continue on with the
next operation.
Please note that the value of these variables is very important as they
affect the safe operation of the RCI-4100IS indicator. Therefore the values
of the user variables must be checked and corrected if necessary before
proceeding with further calibration or operation.
5.2.1. Exit Calibration Mode (FC-00)
Use this function to exit Calibration Mode. Alternatively, exiting calibration mode can
also be done by pressing CANCEL button when on a function code other than F-00.
Ensure that dashes (----) are shown on the bottom window before pressing CANCEL
button to exit.
5.2.2. View Calibrated Main Load (FC-01)
The calibrated Main Winch load can be verified on normal operating mode (operator’s
screen). This function is used to view the main calibrated load while still in calibration
mode. This is useful when just verifying accuracy of the load readout and the
calibration has not yet been finalised.
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5.2.3. Calibrate Light Main Load (FC-02)
Please see Section 5.4.1. “Calibrating Light Main Load” for details.
5.2.4. Calibrate Heavy Main Load (FC-03)
Please see Section 5.4.2. “Calibrating Heavy Main Load” for details.
5.2.5. View Calibrated Aux Load (FC-04)
The calibrated Aux Winch load can be verified on normal operating mode (operator’s
screen). This function is used to view the aux calibrated load while still in calibration
mode. This is useful when just verifying accuracy of the load readout and the
5.2.6. Calibrate Light Aux Load (FC-05)
Please see Section 5.5.1. “Calibrating Light Aux Load” for details.
5.2.7. Calibrate Heavy Aux Load (FC-06)
Please see Section 5.5.2. “Calibrating Heavy Aux Load” for details.
5.2.8. View Uncalibrated Angle Input (FC-07)
Use this function to view the raw counts (or raw data) of the angle sensor. Please also
Section 5.1. “Verifying Operation of Sensors” for details.
5.2.9. View Calibrated Angle Input (FC-08)
The calibrated angle can be verified on normal operating mode (operator’s screen).
This function is used to view the calibrated angle (in degrees) while still in calibration
mode. This is useful when just verifying accuracy of the angle readout and the
5.2.10. Calibrate Low Angle (FC-09)
Please see Section 5.3.1. “Calibrating Low Boom Angle” for details.
5.2.11. Calibrate High Angle (FC-10)
Please see Section 5.3.2. “Calibrating High Boom Angle” for details.
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5.2.12. View Uncalibrated Transducer 1 Input (FC-15)
Use this function to view the raw counts (or raw data) of the Main Load transducer
(main load sensor). Please also Section 5.1. “Verifying Operation of Sensors” for
details.
5.2.13. Function Codes (FC-16 to FC-18) – Not Used
These function codes are used on Load Moment-Based systems only and are not
applicable for this crane.
5.2.14. View Uncalibrated Transducer 2 Input (FC-19)
Use this function to view the raw counts (or raw data) of the Aux Load transducer (aux
load sensor). Please also Section 5.1. “Verifying Operation of Sensors” for details.
These function codes are used on Load Moment-Based systems only and are not
applicable for this crane.
5.2.16. Set Gain for Channels 1 to 8 (FC-23)
This function code refers to the gain setting of the amplifiers to match the signal output
of the sensors. There are a total of 8 channels, but only channels 1 to 3 are usable.
Channel 1 is the main load sensor, channel 2 is the aux load sensor and channel 3 is
the angle sensor. Correct setting of the gain are as follows:
Channel 1 Gain (Main Load) - 480

Channel 2 Gain (Aux Load) - 480
Channel 3 Gain (Angle) - 310
5.2.17. Set Offset for Channels 1 to 8 (FC-24)
This function code contains the factory default setting of the gain offset for the
sensors. The factory default settings are as follows and need not be changed:
Channel 1 Offset (Main Load) - 500

Channel 2 Offset (Aux Load) - 500
Channel 3 Offset (Angle) - 977
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5.2.19. Number of Sensor Samples to Average (FC-27)
This function is used to stabilise the display in the event that the numbers (readouts
during normal operating mode) are changing erratically. This value can be edited by
using the Up/Down buttons. Default setting is “0” and the maximum selectable value is
“25”.
It is recommended that this value is set to “8” prior to performing calibration.
5.2.21. Load Chart View Mode (FC-30)
This function code can be used to view the load charts programmed in the software. It
is not part of the calibration or set-up procedures. It is mainly used by Robway for
software checking.
5.2.22. View Digital Inputs (FC-31)
This function code is used to view the state (i.e. open or closed) of the eight digital
(switch) inputs. The inputs are used for wiring slew limit switches (or proximity
switches), external duty selector, etc. to suit specific application. This function is also
useful during troubleshooting as the input switch status can be viewed easily from the
display unit in the cabin. The format is binary where input state 0 = On (low) and input
state 1 = Off (high). For example, “11110101” means that switch #5 and #7 are both
“on” and the rest are “off”.
5.2.23. Set Year (FC-32)
Use this function to set the current year.
5.2.24. Set Day and Month (FC-33)
Use this function to the current day and month.
5.2.25. Set Time (FC-34)
Use this function to set the current time. The time displayed is in the format HH:MM.
An invalid time will cause an error message to appear. The seconds can’t be edited
and will always be “00” (hidden). The seconds will begin incrementing once the OK
button is pressed.
5.2.26. Download Logger Contents to PC or SD Card (FC-35)
Please see previous Section 3.5 “Data Logging and Data Downloading” for details and
procedure.
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Refer also to the Appendices at the back of this manual for further details on data
logging.
5.2.27. Erase Logger Contents (FC-36)
Please see previous Section 3.5 “Data Logging and Data Downloading” for details and
procedure.
Refer also to the Appendices at the back of this manual for further details on data
logging.
5.2.29. Alter Calibration Data (FC-40)
This function is used for manually copying and restoring the calibration data which
must be done after completing the system calibration. Please see Section 5.10.
“Copying & Restoring Calibration Data Function” for details and procedures.
5.2.30. Clear All Calibration Data (FC-41) – USE EXTREME CAUTION!
Activating this function will clear all the calibration data. This must only be used by
Robway-trained personnel for troubleshooting purposes.
The display will prompt the operator to press ENTER if he wishes to erase the
calibration data. Pressing ENTER here will clean out the memory system and default
back to hard coded software. Any on-site changes made will be lost.
5.2.31. User Variables (SWL % Alarms, Motion Cut)
Function codes (FC-42 to FC-46) are used to set the Safe Working Load (SWL)
percentages for activating Visual and Audible Alarms as well as the Motion Cut output
function. The preset or factory default values are based on FFC SLI Specification.
5.2.32. User Variables (Crane Geometry)
Function codes (FC-47 to FC-55) are used to set the actual physical dimensions
(geometry) of the crane.
The factory default values are based on details and information received at the time of
order and supply of system. Any changes to geometry will also require changing of
these values on these function codes.
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5.2.34. Main Winch Contant Line Tensioning Threshold (FC-63)
This function code is used to set the required load limit or threshold of the main winch
for activating safety relay (RL3) in the RCI Control Unit. This function is used to control
the crane’s main hoist by activating “hoist up” when the load on the block is equal to or
less than the limit set in this function code. The factory default setting is -0.4t and can
be changed to suit specific application.
Please see also Section 5.7. “Testing the Constant Tension Function” for details.
5.2.35. Aux Winch Contant Line Tensioning Threshold (FC-64)
This function code is used to set the required load limit or threshold of the aux winch
for activating safety relay (RL3) in the RCI Control Unit. This function is used to control
the crane’s aux hoist by activating “hoist up” when the load on the block is equal to or
less than the limit set in this function code. The factory default setting is -0.2t and can
be changed to suit specific application.
Please see also Section 5.7. “Testing the Constant Tension Function” for details.
5.2.36. User Variables (Data Logging Setup Parameters)
Function codes (FC-65 to FC-71) are user variables relating to the setup prameters of
the internal data logger. Please see also Appendices at the back of this manual for
details.
5.2.37. Load / Angle Correction (FC-72 to FC-75)
Load/Angle correction function is designed for use in cases where the displayed load
is seen to increase by a reasonable amount as the boom is luffed down through it's
operating range. This phenomenon is particularly apparent when a single sheave
tensiometer is used at the boom tip.
Please see Section 5.6. “Using Load/Angle Correction Function” for details and
procedure.
5.2.38. Main Winch Rigging SWL (FC-76)
This function is used to set a rigging SWL value for the crane and the boom to get past
the maximum radius without activating the alarms. The value set must not exceed the
weight of the Main hook block. When this function is used, the crane will assume a
SWL equal to the weight of the hook block; thus, allowing the boom to go further down
to the ground for rigging purposes without alarms as long as no load is lifted on the
Main block.
The factory default setting is 0.0t (or no rigging SWL allowance) and can be changed
using this function code to suit specific application.
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5.2.39. Auxiliary Winch Rigging SWL (FC-77)
This function is the same as the Main Winch Rigging SWL (refer to Section 5.2.39.) but
for the Aux Winch.
The factory default setting is 0.0t (or no rigging SWL allowance) and can be changed
using this function code to suit specific application.
5.2.40. Boom Height Offset (FC-78)
Use this function to set the “Boom Height Offset” which is the vertical distance from the
BOOM FOOT pin to the platform (required reference point). Ensure that this is
measured accurately and set for accurate indication of boom tip HEIGHT.
5.2.41. Metric/Imperial Units Switching (FC-79)
Use this function to select the required unit of measure (Metric or Imperial). Factory
default setting is “Metric”.
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5.3. Calibrating Boom Angle
5.3.1. Calibrating Low Boom Angle
x Safely luff the boom down to a low angle, e.g. 30°,
x Enter calibration mode, if not already activated, and select the

correct function code (FC-09) for calibrating low boom angle,
x Accurately measure the actual boom angle using an angle finder,
x Use the UP/DOWN keys to ramp the display to the required value
then press ENTER to accept this value. Proceed to next Section
5.3.2. “Calibrating High Boom Angle”.
5.3.2. Calibrating High Boom Angle
x Safely luff the boom up to a high angle, e.g. 65°,

correct function code (FC-10) for calibrating high boom angle,
x Accurately measure the actual boom angle using an angle finder,
then press ENTER to accept this value.
Verify that the boom angle is accurately measured by using function code (F-08)
VIEW BOOM ANGLE. Luff the boom and stop on different boom angle points.
Check boom angle with the Angle Finder and verify accuracy against the
displayed angle.
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5.4. Calibrating Load on the MAIN Winch (Load Pin 1)
5.4.1. Calibrating Light Main Load
x Safely lift a light, known test load. The load should be heavy enough
to produce approximately 10% of the maximum main winch linepull,
- The total weight of any lifting gear or tackle under the hook
block (such as slings, lifting frames, etc.) must be added to
the weight of the light test load.
- If a light test load is not available, raise the empty hook block
off the ground/platform and use the weight of the block as
light load.
- For some cranes where the hook block is considered part of
the crane, raise the empty hook block off the ground/platform
and use the value “0.0t” as light load.

correct function code (FC-02) for calibrating a light load on the main
winch,
(i.e., calculated light load above),
x Press ENTER to accept value. Proceed to next Section 5.4.2.

“Calibrating Heavy Main Load”.
5.4.2. Calibrating Heavy Main Load
x Safely lift a heavy, known test load. The load should be heavy
enough to produce approximately 70% of the maximum main winch
linepull,
the weight of the heavy test load.
the crane, do not include the weight of the hook block to the
total heavy load.

correct function code (FC-03) for calibrating a heavy load on the
main winch,
(i.e., calculated heavy load above),
x Press ENTER to accept value.
Verify that the MAIN LOAD is accurately measured, using the VIEW
CALIBRATED MAIN LOAD (FC-01) function.
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5.5. Calibrating Load on the AUX Winch (Load Pin 2)
5.5.1. Calibrating Light Aux Load
x Safely lift a light, known test load. The load should be heavy enough
to produce approximately 10% of the maximum aux winch linepull,
the weight of the light test load.
- If a light test load is not available, raise the empty hook block
off the ground/platform and use the weight of the block as
light load.
the crane, raise the empty hook block off the ground/platform
and use the value “0.0t” as light load.

correct function code (FC-05) for calibrating a light load on the aux
winch,
(i.e., calculated light load above),
x Press ENTER to accept value. Proceed to next Section 5.5.2.

“Calibrating Heavy Aux Load”.
5.5.2. Calibrating Heavy Aux Load
x Safely lift a heavy, known test load. The load should be heavy
enough to produce approximately 70% of the maximum aux winch
linepull,
the weight of the heavy test load.
the crane, do not include the weight of the hook block to the
total heavy load.

correct function code (FC-06) for calibrating a heavy load on the
aux winch,
(i.e., calculated heavy load above),
x Press ENTER to accept value.
Verify that the AUX. LOAD is accurately measured, using the VIEW CALIBRATED
AUX. LOAD (FC-04) function.
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5.6. Using Load/Angle Correction Function
On cranes using single sheave load-line sensors, the rope dead-weight is greatest at
low boom angle but disappears at higher angles. This changing dead-weight influence
needs to be compensated for as it will cause the load-weight display to increase
marginally as the boom is luffed down.
Load/Angle correction is accessible to the Calibrator through use of four Calibration

Function Code routines as follows:
Low Angle for Load Correction (FC-72) - Applies to both Main & Aux winch
High Angle for Load correction (FC-73) - Applies to both Main & Aux winch
Load / Angle Correction Factor for Main Winch (FC-74)
Load / Angle Correction Factor for Aux Winch (FC-75)
These function codes allow the operator to enter the luffing range (FC-72 & FC-73) of
the crane and a change in the load (FC-74 & FC-75) that is observed over this range.
The Low Angle you enter should be the lowest angle the crane can actually luff to in
operation. Similarly the High Angle should be set to the highest angle the crane can be
luffed to.
How to Calculate the Load / Angle Correction Factor

The number entered here is a correction value, when this number is 0.0 no correction
is being applied (i.e. Load / Angle correction is disabled). It expresses the load error (in
tonnes) seen when the crane is luffed from the highest angle in the luff range to the
lowest angle. This correction is applied progressively from the highest boom angle
through to the lowest boom angle.
To determine the error value simply position the boom at the highest boom angle and
take note of the load reading. Luff the boom through the entire operating range (taking
notice the load value is increasing when luffing lower) and once at the lowest possible
boom angle record the load value again. The correction factor is simply the difference
between the two load values you have recorded.
Enter the correction value against the appropriate Function Code (FC-74 for Main and
FC-75 for Aux) and luff the crane through it's operating range once again to ensure
the correction was successful.
Example:
x A test weight of 20 t is lifted on the Main winch at the highest possible boom angle
(Note: It is not necessary to use a test weight, the hook block alone will suffice for
the test).
x The 20t load is luffed through the entire angle range and the displayed load is seen
to rise to 25.3 t at the lowest possible boom angle.
x The error in this reading is the highest displayed load minus the known test weight
ie. 25.3 t - 20.0 t = 5.3 t error.
x Hence, in this example, the Load / Angle Correction Factor (FC-74) should be
entered as 5.3 t.
x Repeat the same procedure on the Aux winch (FC-75).
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5.7. Testing the Constant Tension/Slack Rope Function
This function is used to automatically activate “hoist up” on the selected winch (Main or
Aux) to maintain tension on the winch rope when it gets slack, e.g. when lowering the
hook block on the deck of a boat/vessel or platform, etc.
Function codes (FC-63 for Main Winch and FC-64 for Aux Winch) are used to set the
load activation threshold.
When the load sensed by the selected winch is equal to or less than the value set, the
function is activated.
This function is controlled by safety relay RL3 of the RCI Control Unit which gets
energised when this function is activated.
The factory default setting for both winches is 0.0t. Activate function code FC-63 and
enter the “weight” of the empty Main hook block. Repeat the same for the Aux block
using function code FC-64. This setting will enable the function to operate when the
load on either block gets lower than its weight (i.e., slack condition).
To test the function, lower either one of the hook blocks on the deck or platform until
the rope gets slack and the rope is hoisting up.
Drawing Reference:
DWG 4046 (Sheet 2 of 7) – “Twin Winch Pedestal Crane, Customer Wiring
Details, Controller & Display Safe Area”
DWG 3990 (Sheet 2 of 7) – “Twin Winch Pedestal Crane, Customer Wiring
Details, Hazardous Area”
Please note that all inductive loads such as relays and solenoids require
snubber diodes for transient suppression.
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5.8. Copying and Restoring Calibration Data Function
The following procedure covers instructions on how to view and copy (manually, using
pen and paper) the calibration data for service records by accessing function code FC-
40 “Alter Calibration Data”.
In any event the system needs to be re-calibrated, for example, due to replacement of
parts and/or sensors, these data can be restored into the system simply by keying in
the values without the need to luff the boom or lift test loads.
Access function code F-40 by selecting it in calibration mode and pressing the ENTER
key. The screen will then show “An1” (which means Angle channel) on the screen.
This is the default function that comes up on the screen. Pressing the Up/Down arrow
keys will scroll through the various functions, but only the following functions need to
be copied (the rest can be ignored):
Function Description
An1 Angle
Ld1u Load 1 (or Main Load) Up
Ld1d Load 1 (or Main Load) Down
Ld2u Load 2 (or Aux Load) Up
Ld2d Load 2 (or Aux Load) Down
Once a function is selected, press the ENTER key again to access the calibration
codes for the particular function as follows:
Cal Code Description

Lo_r Raw Counts (Low)
Lo_c Calibrated Data (Low)
Hi_r Raw Counts (High)
Hi_c Calibrated Data (High)
5.8.1. Copying Calibration Data
A table similar to the one below can be used to record the calibration codes of all the
above functions.
Angle Channel Load 1 (Main) Load 2 (Aux)

An1 Ld1u Ld1d Ld2u Ld2d
Lo_r
Lo_c
Hi_r
Hi_c
Table to record calibration data using Function code F-[40]
5.8.2. Restoring Calibration Data
Restoring the calibration data requires entering the calibration code values copied from
above procedure “Copying Calibration Data” into the RCI-4100IS system using the
same function code F-40.
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Similar to the above procedure in “Copying Calibration Data” function, select the
function and then the calibration codes (Lo_r, Lo_c, Hi_r, Hi_c) for this function. But
this time, press the ENTER key again to access the EDIT MODE (i.e. the screen will
show “Edit”).
Once “Edit” is active on the screen, use the Up/Down arrow keys to change the current
value of the particular calibration code with the values copied from Section 5.8.1.
Press the ENTER key to save this new value.
Repeat this procedure on all the calibration codes whose data need to be restored.
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MAN1124A

6. Troubleshooting
A trouble-shooting or fault-finding section is always a difficult document to write

because things that are obvious to one person can be anything but obvious to
another. On the other hand, most times when you read such a guide the fault
you are trying to solve happens to be the very fault that has been left out! The
main purpose of this section is to help both us at Robway and you the reader to
find the problem and solve it quickly. Some times this takes patience, which
isn't always easy when you are on the site, your customer is angry because
you haven't fixed it yet, and the Robway guy at the other end of the phone
wants you to tell him all over again what you just did!! What we have found
many times is that when a situation is described by the service person a couple
of times extra details come out in the conversation that are vital to solving the
problem. It seems that the more trouble we have finding the faults, the more
simple the cause was!
The RCI-4100 IS system incorporates a number of software features that are

designed to help the service person quickly identify a fault, however it must be
stressed that these features cannot identify everything. They can only be used
as a guide to identify additional checks that can be made. Some notes are
provided below, followed by some example faults and possible causes.
1. Identify the symptoms. Take time to find out exactly what is happening to
indicate a problem. If possible have the problem demonstrated so you can
"describe it in your own words". Sometimes what someone else has told
you is only part of the story.
2. Leave the calibration alone! Too many times a re-calibration has been
attempted in order to rectify a problem before that problem has been
correctly identified. This leads to added confusion as the perspective is
generally moved from the real fault to "calibration problems". We have often
received a message indicating that our display has "not accepted the
calibration data". Most times this is due to a fault in a cable or sensor which
was not identified prior to re-calibration. Re-calibration must only be
performed when all physical inputs have been verified for correct operation,
and in actual fact is rarely ever needed.
3. Do you have your simulator with you? A simulator is a very quick way to
verify if the fault is external to the display and will save you a lot of
heartache. A simulator is purely resistive and hence considered simple
apparatus and can be used freely in a hazardous area.
4. Have you read the manual? When all else fails, read the manual! Your
answer may actually be in there.
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5. Know what information you need to gather. If you collect the correct
information from the display the job is half done. Before you begin to
suspect faults with the system, you must satisfy yourself that the display is
correctly configured for the crane environment. In other words, check that
the correct duty, falls, slew zones etc. have been selected. Are all of the
sensors connected? In general if sensors have been supplied with the
system, they must always be connected. The display will check them
continuously and issue an error if that sensor cannot be detected. Check
your length, angle and radius against the chart to verify that the equipment
is permitted to be in that situation. If there is still a problem once these have
been checked, then you will need to check the hardware.
6. The main pieces of useful information obtainable from the displays are
the raw counts. The raw count shows what the actual inputs are doing (i.e.
like a signal strength indication). These raw counts are manipulated in
software according to the calibration data stored in the display to produce
the readouts on the Display Unit. If the calibration has been done
incorrectly, or the configuration is incorrect, or something else is wrong,
then the Display Unit readouts (e.g. the LOAD or ANGLE values) may
provide you with misleading information. YOU MUST USE THE "VIEW
UNCALIBRATED...." FUNCTION CODES TO DETERMINE THE
CORRECT OPERATION OF THE EXTERNAL SENSORS, NOT THE
"CALIBRATED" VALUES. It should be noted here that for load related
problems, the "VIEW UNCALIBRATED TRANSDUCER" function code
must be used, and not "VIEW CALIBRATED LOAD". For correct operation
these values must be in the range 32 to 999. Anything outside of this range
will produce an error. Refer to Section 5. “Calibration” on how to access
these raw counts.
7. Check the obvious. Once you have found a problem with a sensor for
example, check all of the obvious things to do with that sensor such as
making sure all of the connectors are tight. Be systematic - make notes
about what you have done and what you found. You will find that under
pressure you can easily forget what you have checked and it becomes very
easy to miss things.
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EXAMPLE PROBLEMS AND POSSIBLE CAUSES
Problems That Produce Error Codes:
Error code 101.
This is indicating that the signal from the angle sensor is too low or too
high. This should be confirmed by viewing the UNCALIBRATED ANGLE
INPUT and noting that the value shown in the LOAD display is less than
50, or higher than 4045.
Possible causes:
x Angle sensor incorrectly mounted. This is especially critical for the

Electronic Angle Sensor. Refer to Section 4. “Installation” of the
manual for installation of the angle sensor.
x The angle sensor signal wire is short circuited to the shield or to the
angle 0V.
x The angle sensor signal wire is shorted to the excitation positive
wire.
x The angle sensor is not connected or there is an open circuit in
either the angle sensor signal wire or the angle excitation positive
wire.
x The angle sensor excitation voltage is shorted. If this is the case it
will also affect the length and load channels.
x The angle sensor 0V wire is open circuit.
Error code 201.
This is indicating that the signal from the main load sensor (load pin 1)
is too low or too high. This should be confirmed by viewing the
UNCALIBRATED TRANSDUCER 1 INPUT and noting that the value
shown in the LOAD display is lower than 50, or higher than 4045.
Possible causes:
x Load cell signal wires shorted together.

x The signal + is shorted to the shield.
x The excitation - is shorted to the shield.
x The excitation supply is shorted together. This will obviously affect
all of the external sensors. Measure the excitation voltage and
compare it with the expected value. If this is the cause, the
UNCALIBRATED value will generally be non-zero, but below 50.
x The load cell is disconnected or there is an open circuit in one of the
signal wires.
x The signal - is connected to the shield.
x The signal + and the excitation + are swapped.
x The signal - and the excitation - are swapped.
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MAN1124A

Error code 202.
This is indicating that the signal from the auxiliary load sensor (load pin
2) is too low or too high. This should be confirmed by viewing the
UNCALIBRATED TRANSDUCER 2 INPUT and noting that the value
shown in the LOAD display is lower than 50, or higher than 4045.
Possible causes:
x Load cell signal wires shorted together.

x The signal + is shorted to the shield.
x The excitation - is shorted to the shield.
x The excitation supply is shorted together. This will obviously affect
all of the external sensors. Measure the excitation voltage and
compare it with the expected value. If this is the cause, the
UNCALIBRATED value will generally be non-zero, but below 50.
x The load cell is disconnected or there is an open circuit in one of the
signal wires.
x The signal - is connected to the shield.
x The signal + and the excitation + are swapped.
x The signal - and the excitation - are swapped.
Error code 240.
This is indicating that an overload has been detected. This error

generally accompanies most other errors simply because most other
errors will place the display into an overload condition. This being the
case, you need to check what other errors are present and correct them
first. Once these have been addressed the E240 error generally takes
care of itself. The exception is of course, when the equipment has been
put into a genuine overload situation which has not been caused by any
external faults.
Possible causes:
x A genuine overload condition exists.

x It has been caused by another Error code condition.
Error code 280.
This is indicating that the rated line pull has been exceeded.
Possible causes:
x A genuine line pull error exists.
Error code 301.
This is indicating that the angle being measured is outside of its allowed
range.
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MAN1124A

Possible causes:
x A genuine violation of the angle limits has occurred.

x The angle sensor mounting may have loosened allowing the sensor
to move.
x Check the angle displayed against the actual angle of the boom.
Error code 304.
This is indicating that the radius being measured is outside of its

allowed range.
Possible causes:
x A genuine violation of the radius limits has occurred.

x Check as per Error code 301.
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Problems That Do Not Produce Error Codes:
The load does not vary when I lift a weight.
The load cable and/or the load sensor is/are faulty. Check the load
cable for faults. If cable is good, check the resistance values of the load
cell. This, however, does not give the complete story. Even if the
resistances are correct, there is still a chance that a fault on the sensor
exists. Replace the load cell.
The load display is very erratic and displays massive changes in value.
Check the view UNCALIBRATED TRANSDUCER INPUT for that

channel. If the values are flickering by 2-3 counts while the display is
changing by say a number of tonnes, then the cause is most probably
calibration. One common cause of this is if different load values were
entered for the high and low calibration without the actual load being
altered (or of course there was an error in a load channel while you
were calibrating). In other words you forgot to lift the heavy load! (It
happens often) In this situation the display is confused because the
calibration data is telling it that the signal it is seeing represents both the
low load value and the high load value simultaneously. Correct the
calibration.
This can also occur if only part of the calibration procedure has been
completed. You should expect strange results if you have not
completed the calibration of that sensor.
When the system starts in the morning the displays are erratic, but settle
during the day.
This is a common sign of moisture ingress into either the display, the
connectors, the sensors or the cable. These should be checked, dried
and sealed.
The display does not start.
Check the power supply. Refer to Section 8. “Electrical Specifications”

for the required voltage range. If the supply is within range, open the
RCI Control Unit and check the fuses.
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On start-up the display shows “LCtrl” on top screen and then hangs (boot
up not completed).
x This is a data logger control error. It happens when the internal data
logger has been corrupted; when an upgraded or new software has
been installed; or when the memory chip (Dallas IC) has been
replaced with a new one.
x To fix this error, insert and turn the override (bypass) key ON, then
press the ENTER button. The display will show “YES” to confirm.
While “YES” is shown on the screen, press the ENTER button again
until the display gets into the normal initialisation/ set-up routine and
then to normal operating mode.
Page 48 of 127
MAN1124A

7. Maintenance
When maintenance is to be performed on the RCI-4100IS system, care must

be taken to ensure that the level of safety is not reduced. Such a reduction in
the level of safety can easily be done by the careless use of tools or test
equipment, either directly or by damage to safety components, wiring or
clearances. Therefore it is essential that maintenance be performed by
competent personnel only.
The following are recommendations from the Standard on maintenance

procedures.
7.1. Checklist
It is recommended that a checklist similar to the one below be prepared prior to

maintenance.
Maintenance Checklist
Pre- Necessary documents are available.

maintenance All records have been examined.
Test gear is available and is satisfactory for use in hazardous areas.
Permission to enter or work has been granted.
The area is safe to enter.
Any precautions necessary have been taken.
Maintenance All reconnections have been made.
Equipment is functional.
Malfunctions have been reported.
Installation conforms to drawings and documentation.
Any modifications have been approved.
Area classification is still valid.
Earthing requirements are still valid.
General check in accordance with the Inspection and Test Schedule
completed.
Post- Documentation is completed and filed.
maintenance Inspection report is complete.
Company and operator requirements have been satisfied.
7.2. Removal of Electrical Equipment
When any electrical equipment is removed for maintenance, any exposed IS

conductors which remain must be mechanically and electrically secured in a
manner to prevent the occurrence of an unsafe condition.
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7.3. Maintenance Work in Hazardous Areas
When the Control Unit is installed in a hazardous area it is protected by a

Flameproof enclosure and must not be opened when a hazard is present. To
work on the Control Unit, all power must be removed for at least four (4)
minutes before the lid can be removed. Alternatively a gas free permit may be
obtained allowing for the removal of the lid while power is still connected. The
same constraints apply to the power and motion control cabling as these are
not I.S.
Work external to the Control Unit should be restricted to the following:
x Disconnection of, and removal or replacement of, items of electrical

equipment and cabling although it is recommended that power be removed
from the Control Unit prior to this being done.
x Measurement of various parameters such as loadcell excitation voltage or

resistance, or other such maintenance activities. Note, however, that such
measurements can ONLY be done with certified test instruments (e.g.
Multimeters) otherwise a gas free permit must be obtained. The
parameters that may need checking are listed in the Trouble shooting
section.
It is important that the person performing the maintenance tasks ensures that
the equipment meets the requirements of the relevant documentation on
completion.
7.4. Maintenance Work in Non-Hazardous Areas
There are few items in the RCI-4100 IS system that are located in a non-
hazardous area, these being;
1. Applications where the Control Unit is located in a safe area and contained
within an enclosure other than a flameproof enclosure,
2. Power supply for the Control Unit, and
3. the motion control solenoids or relays.
If any work is required to be done on the above items other than

measurements, then the power must be removed from the Control Unit.
Measurements made on the IS circuits in the Control Unit must only be made
with a certified test instrument if a hazard still exists on the other end of the
cables. Failure to do this may cause an ignition source to be transferred into
the hazardous area from the test instrument. Care should also be taken to
ensure that safety components are not "bypassed" by the test instrument, thus
voiding the safety aspect of the Control Unit.
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7.5. Modification or Repair
Repairs performed in a hazardous area are specifically discouraged by the

Standard. Such repairs should be performed away from the hazardous location.
7.6. Inspection After Maintenance
It is considered essential by the Standard that a Detailed Inspection is

performed following any maintenance to ensure that the equipment and
installation continue to comply with the documentation.
7.7. Records
The Standard requires that the dates of all inspections, tests and maintenance,
and any details of defects found be recorded.
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8. General Specification
Controller and Display Control Unit:

The Control Unit has Ex ia and Ex ib interfaces and is
optionally housed in an Ex d flameproof enclosure for Zone 1
applications. May be used without Ex d enclosure in safe
zones. The control unit contains the 24 volt input power
supply and processor module. For Zone 1 applications the
Ex d enclosure is supplied with 10 standard (up to 12
maximum) Ex d certified glands for wiring to display unit,
external sensors, switches, etc.
Display Unit:
The Display is certified Group IIB Ex ib Zone 1 applications.
Explosive Atmosphere Display:

Certifications o IECEx 60079
o Ex ib IIB T4 (-20 < Ta < +60°C)
o ATEX
o Environmental Protection, IP65
o Al-Si Aluminum Alloy housing, black powder-coated
finish
Control Unit in Flameproof Housing, Hinged Lid:
o LOM 02 ATEX 3060 U Class 1, Zone 1 and Zone 2
o II 2 G - EEx d, II B T4 to T6
o IEC 60079 BKI 07.0018 Class 1, Zone 1 Ex ib IIB, T4
o Al-Si Aluminum copper-free alloy, grey powder-
coated finish
Sensors:
o Safe Area, Optional Zone 0 Ex ia IIB, T4
Display 5 Liquid Crystal Display (LCD) Windows:

o Top, 4x16 alphanumeric LCD, multifunction display
o Centre, (2) 4-digit LCD, Load, SWL display
o Bottom, (2) 4-digit LCD, Angle, Radius display
o White LED Backlighting
LED indicators for hook selection and ATB Status
Display Cable o 4-core, screened instrumentation cable

o 5-metre length
o Hard-wired with gland at the back plate of display to
Ex d gland of the Control Unit
o DC resistance, 38 /km @ 20°C
o Inductance, 277 μH/km
o Capacitance, 17 nF/km
o L/R ratio, 7.29 μH/
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MAN1124A

Display Alarm LED Indicators:

o Green (safe)
o Amber (warning)
o Red (overload)
o Main
o Aux
o ATB
Audible Alarm:
o Piezo ceramic buzzer
o Intermittent – approach to SWL or override active
o Continuous – overload and/or error(s)
Text Messages:
o Alphanumeric Alarm/Error conditions
Override Feature Key switch on Display Unit
Analogue Voltage Inputs o 8 channels

o Resolution, 12 bits
o Option for Ex ia Zone 1 interface, or safe area
o Load cells with 1, 2, or 3 mV/V output and typical
bridge impedance of 350
o 4-20 milliamp input
o Voltage or potentiometer input
o Excitation 4 or 12 volts DC
Analogue Outputs o Number of Outputs: 2

o Safe Area
o Application:
Load
Constant Tension
Gross Over-Moment Protection
Anti 2 Blocking Input o 2 channels

o Switch input with open and short circuit detection
Digital Inputs o 8 channels

o Option for Ex ia, Zone 1 interface or safe area
o Configurable:
State (e.g. proximity switch)
Quadrature (e.g. slew)
Accumulator (e.g. event counter)
Frequency (e.g. wind speed)
o Open circuit switch voltage: approx. 3 VDC
o Closed circuit switch current: 3 mA
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MAN1124A

Relay Outputs o 6 channels (3 safety relays for general safety critical

Safe Zone indication)
o Safe Area
o Rating: 5 amp, 250 VAC
o Function: Limiting, External Alarm, External
Indicators, etc.
o An optional Digital Expander Module (safe area)
with 8 relay outputs can also be supplied if more
outputs are required
Sensors Supported o Analog Voltage (length, angle, etc.)

o 4-20 milliamp current
o RS485 / RS232
o Load Cells
o RS485
o Digital Input (proximity switches, etc.)
o Quadrature input (slew angle encoders, etc.)
o Frequency (wind speed, winch speed, etc.)
Serial Communications o RS-232:

Safe area, Ex ib Zone 1 Optional
Data log download
Configuration upload/download
Program upload/download
9600 baud factory configured
o RS485:
Safe area, Ex ib Zone 1 Optional
9600 baud factory configured
Processor Speed 25 Mips
System Memory o Data Memory:

128 kByte of non-volatile FRAM (calibration,
setup)
8 Mbyte FLASH (load charts, datalog)
o Program Memory:
128 kByte FLASH
o SD Card:
Up to 32 GByte can be accommodated
Program upload/download
Calibration upload/download
Logged Data download
System o Microprocessor Watchdog

o Onboard Timekeeping with power backup
o Automatic System Diagnostics
On-board Calibration System Calibration via Operator Console
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Unit Conversion Conversion between metric and imperial units
Power Supply Input o Voltage: 9 VDC – 36 VDC

o Power: 15 VA
Physical o Display Unit:

260 mm (H) x 150 mm (W) x 60 mm (D)
Weight, approx 3 kgs
o Control Unit:
Hinged lid, 371 mm x 371mm x 233mm
(depth)
Weight, approx 18 kgs
Environmental o Display:
Operating Temperature -20qC to +60qC
Dust and Water Ingress, IP65
o Control Unit with Ex d Housing:
Operating Temperature -20qC to +60qC
Dust and Water Ingress IP65
EMC o 61000-6-4
o 61000-6-2
RoHS Compliant Yes
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9. Appendices
Below is a list of documents included in the following pages of this manual.

Items marked as “Optional Feature” may not be included in the attachments if
these are not supplied with the RCI-4100IS system. Only applicable drawings
are also included in the attachments.
x Safety and Installation Instructions, Model 4120 RCI-4100 Display

Barrier
x Declaration of Conformity, RCI-4100 Hazardous Area Rated Capacity

Indicator System
x Nemko EC Type-Examination Certificate (ATEX)
x IECEx Certificate of Conformity, Display Module Type RCI-4100IS
x IECEx Certificate of Conformity, Model 4120 Power Supply and I2C

Barrier
x Data Logging on Robway RCI’s
x Restricted Slew Zone Monitoring – Optional Feature
x Wind Speed Monitoring – Optional Feature
x Gross Over-moment Protection (GOP) – Optional Feature
x Drawings
Part A: System Components

Part B: General Arrangement & Wiring Details
x RCI System Crane Configuration Sheets/Duty Listing/Function Codes
Page 56 of 127
MAN1124A
Safety and Installation Instructions, Model 4120

RCI-4100 Display Barrier
Page 57 of 127
MAN1124A
Safety and Installation Instructions

Model 4120 RCI-4100 Display Barrier
MAN1107 REV A
Robway Crane Safety Systems

32 West Thebarton Road
Thebarton, SA 5031 Australia
+61 8 8238 3500
www.robway.com.au
Page 58 of 127
MAN1124A

RCI-4100 Display and Isolating Barrier System
This installation manual must be read and used by qualified personnel during system design and installation
of the RCI-4100 Display and the Model 4120 Isolating Barrier.
Warning
The 4100 Display is a Group IIB Ex ib certified display which may be located in Zone 1 or Zone 2 of a
hazardous area.
The 4100 Display must be operated within environmental limitations and must only be connected to certified
intrinsic safety barriers meeting the Model 4100 input parameters.
The 4100 Display and the 4120 Display Barrier must only be installed by qualified personnel in accordance
with the relevant international installation standards. Particular care must be given to physical control and
clear identification of IS cabling.
The 4100 Display may be installed in a Hazardous Area only with proper protection from the weather.
The 4120 Display Barrier must not be connected to equipment that uses or generates more than 250 Vrms
with respect to earth ground.
The Model 4120 Barrier must be operated within environmental limitations.
The Model 4120 Barrier is an isolated Intrinsically Safe (IS) apparatus to be installed on a standard EN50022
T35 DIN rail located in a safe area / non-hazardous location.
The Model 4120 Barrier may be installed in a Hazardous Area ONLY if enclosed in an appropriately
approved and/or certified “explosion proof” housing conforming to applicable standards.
The 4100 Display and Display Barrier cannot be repaired by the end user thus any units exhibiting a failure
must be returned to the manufacturer or its authorized representative.
SAFETY ANALYSIS
In a system safety analysis, always check that the Hazardous Area / Hazardous location devices conform to
the relevant standards. The 4100 Display and Barrier system as supplied with its 10 metre cable conforms
to the specified product certification but there may be other relevant installation standards which must be
met.
Although longer interconnecting cable runs may function satisfactorily Robway does not warrant the system
working with a longer interconnecting cable than that supplied. In addition, if the interconnecting cable is to
be extended beyond what is supplied the capacitance and inductance values must not exceed the limits
given. If a longer cable run is desired please consult the factory.
Model 4120 Hazardous Area Isolating Barrier Group IIB

4100 Display + Cable Parameters Must be
Load Parameters
Ci + C of cable < Co
(Li device + L cable) / (R cable) < Lo / R
L of cable < Lo
MAN1107 REV B Page 1 of 9 Robway Crane Safety Systems
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MAN1124A

OPERATION
The Robway Model 4100 Display is intended to be used with the Model 4120 Display Barrier. The Model
4120 Barrier provides isolated power to the Model 4100 display and also an isolated intrinsic safety barrier
for I2C communications from a host data system located in a safe area.
Proper operation of the 4100 Display is indicated by the LCD backlights being illuminated and the alarm
sounding. If a data system is connected and functioning properly then digits will also appear on the display
according to the relevant system manual. If normal operating conditions are not apparent when 24 VDC
nominal is applied to the system then the 4100 display and/or the 4120 Isolating Barrier must be considered
faulty and may only be repaired or replaced by qualified personnel after the system fault is determined and
rectified.
INSTALLATION
Display
The 4100 Display is a Group IIB Ex ib device is housed in an IP65 style enclosure; however it is only
intended to be mounted in a location protected from direct weather and condensing humidity. The 4100
Display is not certified to IP65 protection levels.
A gimbaled mounting arm is provided for securing the 4100 Display to a dash panel or other solid mounting
surface. Other mounting methods may be possible however the 4100 Display must be mounted securely
and the integrity of the enclosure must be maintained. The 4100 display is not certified for use as a portable
device.
The 4100 Display has a captive cable supplied which meets the specified cable parameters. Inside the 4100
Display is a 4-pole terminal block from which the cable may be disconnected for ease of cable routing or
shortening of the cable. This cable may only be lengthened after it is determined that the cable parameters
do not exceed allowable parameters. Although the 4100 Display and Barrier may function satisfactorily, the
4100 Display and Barrier system is not warranted for operation with longer cable than supplied. Consult
factory if longer cable runs are desired.
If the 4100 display cable is to be shortened and re-attached at the display end, the cable conductors must be
stripped and terminated in an identical manner as originally supplied. Generally speaking the cable must be
installed in a secure manner and protected from physical damage along its entire length. The 4100 Display
cable must be segregated from non-IS conductors and wired in accordance with relevant national and
international installation standards.
Although the 4100 Display earth strap is not required to meet the intrinsic safety certification it should be
connected to a suitable earthing point which is determined to have a reliable path to earth. The earthing
strap is required to provide a higher level of noise and transient immunity.
A vinyl dust-cover with transparent window is offered as a factory option however it is not covered under the
4100 Display IECEx Ex ib certification and must be considered to be a static hazard. The dust cover can
only be used in accordance with relevant national/international installation standards.
Isolating Barrier
The 4120 Isolating Barrier does not require an earth for its protection. If using the 4120 Isolating Barrier in
an “explosion-proof” enclosure the appropriate “explosion-proof” cable gland must be used and
manufacturer’s instructions followed. The Um of the 4120 Isolating Barrier “Safe” terminals is 250 Vrms.
The 4120 Isolating Barrier must not be connected to any equipment which is connected to or can produce a
voltage higher than 250 Vrms.
Warning
The 4100 Display provides a minimum IP 20 protection. If the 4100 Display is to be installed outdoors then
additional protection is required.
If either the 4100 Display or 4120 Isolating Barrier enclosure needs to be cleaned use a slightly dampened
anti-static cloth to avoid static discharge risk. Avoid any penetration of cleaning fluids into either enclosure
as this could effectively bypass intrinsic safety protection measures.
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MAN1124A

4100 Display Power/Data Wiring Detail
4100 DISPLAY TO BARRIER WIRING

Barrier 4120 Isolating Conductor 4100 Display Display
Description Barrier Terminal Colour Terminal Description
Supply- 10 Black 1 0V
Supply+. 11 Red 2 6V
SDA 14 Green 3 SDA
SCL 13 White 4 SCL
STARTUP
Before applying power to the system check that all wires are properly connected, particularly supply
conductors and their polarity, and serial data wires. Also check that IS conductors and cables are
segregated from any other circuits including other IS circuits. Check conductors for exposed wires that could
touch each other causing dangerous shorts.
Apply power to the system. The green LED on the top of the Model 4120 Barrier should come on and there
should be a nominal 6 volts across the power output terminals. The LCD backlights should come on and the
Alarm will sound continuously. There will not be any data displayed if there is no data system connected to
the Model 4120 Barrier. If a data system is connected and functioning normally then data will be displayed
according to the data system manual.
If these conditions are not observed, promptly remove power from the system and locate and remedy the
fault before re-applying power to the system.
STORAGE
The ambient temperature may exceed the operating temperature limits of -20°C to +60°C for limited periods
of time such as experienced during air transport.
DISPOSAL
The 4100 Display and 4120 Isolating Barrier are compliant with the Directive 2002/95/EC of The European
Parliament on the Restriction of the use of certain Hazardous Substances (RoHS). Neither the 4100 Display
nor the 4120 Isolating Barrier has any on-board batteries. Please separate and dispose of electronic goods
responsibly and follow guidelines and regulations for your region.
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INSTALLATION CONTROL DRAWING
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Technical Data
RCI-4100 Display
4100 Display
Compliance IECEx Certificate Number ITA 08.0021X
Ex ib, Group IIB
ATEX Certificate Number NEMKO 08 ATEX 1433X
Temperature Classification T4, -20°C < Tamb <+60°C
RoHS Yes
Product Markings ATEX Ex ib IIB/IIA T4
-20°C < Ta < +60°C
NEMKO08ATEX1433X
II 2 G
IECEx Ex ib IIB T4
-20°C < Ta < +60°C
IECEx ITA 08.0021X
Intrinsic Safety Parameters Ui 8 VDC
Ii 3A
Ci 7.7 uF
Li 15 uH
LED Indicators Safe Working Load Green
Approach to Overload Yellow
Overload Red
Main Hook in Use Red
Aux Hook in Use Red
ATB Condition Red
LCD Indicators Alphanumeric 4 x 16 characters
7-Segment Numeric 4
Power Supply Voltage 6 VDC nominal
Current 30 milliamps
Physical Dimensions (excluding mount) 60 x 150 x 280mm(h x w x d)
Weight (excluding cable) 1.8 kg
Cable Length 10 m
Cable Diameter 10.5 mm
Cable Capacitance 85 pF/m core-to-core
Cable Construction 4-core, 20 AWG, UV-stable PVC sheath
Tinned Copper Braid-shield
IP Rating 20
Environmental Operating Temperature -20°C to 60°C
Humidity 0 to 95%, non-condensing
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Technical Data
4120 Isolating Barrier

Compliance IECEx Certificate Number ITA 08.0020X
Ex ib, Group IIB
ATEX Certificate Number NEMKO 08 ATEX 1433X
[EEx ib] IIB
Temperature Classification T4, -20°C < Tamb <+60°C
RoHS Yes
Product Markings ATEX [Ex ib] IIB/IIA
(Associated Apparatus) -20°C < Ta < +60°C
NEMKO08ATEX1433X
II (2) G
IECEx [Ex ib] IIB
(Associated Apparatus) -20°C < Ta < +60°C
IECEx ITA 08.0020X
I/S Parameters Um 250 V
Safe Area Terminals
I/S Parameters Uo 7.14 V
Hazardous Area Terminals Io 2.81 A
Po 1.81 W
Ci Negligible
Li Negligible
I/S Parameters, Load, Capacitance 268 μF
Group IIB
(maximum values) Inductance 0.018 mH
-OR- L/R Ratio 28.4 μH/
I/S Parameters, Load, Capacitance 1000 μF
Group IIA
(maximum values) Inductance 0.081 mH
-OR- L/R Ratio 56.7 μH/
Indicators Status LED Green = OK
Input Power Supply Voltage 20 to 30 VDC
Current, no load 30 milliamps
Current with 4100 Display 90 milliamps
Output I/S Power Supply Voltage 6 VDC nominal
Current 90 milliamps
Physical Dimensions 75 x 67 x 105 mm (l x w x h)
Weight 0.5 kg
IP Rating 20
DIN rail EN50022 T35
Environmental Operating Temperature -20°C to 60°C
Humidity 0 to 95%, non-condensing
System, Isolating Barrier and Display

EMC 61000-6-2, Immunity, Industrial
61000-6-4, Emissions, Industrial
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Technical Data
Ordering Information
DISRCI4100 LCD Operator Display, Group IIB, Ex ib Operator console with 4x16 alphanumeric display
and four 7 segment displays
BAREX4120 Power and I2C Isolating Barrier
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Declaration of Conformity
EC Declaration of Conformity
in accordance with EN 45014 (ISO/IEC22)
Robway Crane Safety Systems Pty. Ltd.

Declares that Associated Apparatus Models:
BAREX4120 Isolating Barrier
RCI-4100 IS Display
are in accordance with the following European Directives:
94/9/EC Equipment intended for use in potentially explosive atmospheres (ATEX)

2002/95/EC Restriction of the Use of Certain Hazardous Substances in Electrical And Electronic Equipment
and have been designed and manufactured according to the following standards:
IEC 61000-6-4:2001 EMC Emission Standard for Industrial Environments

IEC 61000-6-2:2001 EMC Immunity Standard for Industrial Environments
IEC 60079-0 Electrical apparatus for explosive gas atmospheres. Part 0: General Requirements
IEC 60079-11 Explosive atmospheres. Part 11: Equipment protection by intrinsic safety ‘i’
ISO 9001:2000 Quality Management System
and are covered by:
IECEx ITA 08.0020X IECEx Certificate of Conformity for Barrier Module Type BAREX4120
IECEx ITA 08.0021X IECEx Certificate of Conformity for Display Module Type RCI-4100 IS
NEMKO 08 ATEX 1433 X ATEX Type Examination Certificate for Hazardous Areas
NEMKO 09 ATEX 4069 Q Product Quality Assurance Notification
Executed on: 18 March 2009
Jonathan P. Koval
Engineering Manager
32 West Thebarton Road, Thebarton, SA 5031, Australia

Tel: +61 8 8238 3500 - Fax: +61 8 8352 1684
E-mail: info@robway.com.au - Web site: www.robway.com.au
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Document Revision History
Revision History
Rev Description Approved
A Initial Release J. Koval
B Added Revision History J. Koval
Corrected Display I/S Parameters
Corrected Isolating Barrier Um = 250V
Added “Declaration of Conformity Statement”
Added markings information
Added control drawing
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Declaration of Conformity, RCI-4100 Hazardous

Area Rated Capacity Indicator System
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Declaration of Conformity
Declares that:
RCI4100 Hazardous Area Rated Capacity Indicator System
Are covered by one or more of the following certifications:

LOM03ATEX2004X RCI4100 Controller
IECEx BKI 07.0018 EEx d IIB T4 -20qC < Ta < +60qC
II 2 G
NEMKO 08ATEX1433X Display Module Type RCI-4100 IS
IECEx ITA 08.0021X Ex ib IIB/IIA T4 -20qC < Ta < +60qC
NEMKO 09 ATEX 4069 Q
II 2 G
NEMKO 08ATEX1433X Isolating Barrier Module Type BAREX4120
IECEx ITA 08.0020X [Ex ib] IIB/IIA
NEMKO 09 ATEX 4069 Q
II (2) G
LOM 02ATEX2037 Boom Angle Sensor Model ANGES4130
IECEx BKI 07.0026 EEx d IIC T6 -20qC < Ta < +55qC
II 2 GD
DNV-2004-OSL-ATEX-0199 Load Cell Isolating Barrier Model BAREX1063
IECEx DNV 07.0001 [EEx ia] IIC -20qC < Ta < +55qC
II (1) GD
DMT 01 ATEX 042 X Digital Proximity Switch Isolating Barrier Model BAREX1031
IECEx BVS 07.0027 [EEx ia] IIC/IIB/IIA
II (1) GD
DMT 01 ATEX 042 X 4-20 Milliamp Isolating Barrier Model BAREX1072
IECEx BVS 07.0027 [EEx ia] IIC/IIB/IIA
II (1) GD
Shaft Encoder, BEI, Quadrature
EEX d IIB T4
II 2 G
UL Class 1, Div 1, Group C,D
Shaft Encoder, BEI, Absolute
EEX d IIB T4
II 2 G
UL Class 1, Div 1, Group C,D
Shaft Encoder, Scancon, Quadrature
EEX d IIC T6
II 2 GD
Assessed as Simple Load Cell Models CELRW15OOCA, CELTPK6P, CELTPT10P, CELTPT15P
Apparatus CELBTD5P, DRU320L0320M
Wind Monitor IS
UL 913 Class 1, Div 1, Group A,B,C,D
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AusEx 1424 Explosion Proof Cable Glands (alternate Ex d glands available on demand)
Ex d IIC

32 West Thebarton Road, Thebarton, SA 5031, Australia
Tel: +61 8 8238 3500 - Fax: +61 8 8352 1684
E-mail: info@robway.com.au - Web site: www.robway.com.au
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Nemko EC Type-Examination Certificate (ATEX)
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Page 1 of 4
PROD 004
[1] EC TYPE-EXAMINATION CERTIFICATE

[2] Equipment or Protected System Intended for use
in Potentially explosive atmospheres
Directive 94/9/EC
[3] EC-Type Examination Certificate Number: Nemko 08ATEX1433X
[4] Equipment or Protective System: Display Module (RCI-4100 IS) and Display Barrier
(BAREX4120)
[5] Applicant / Manufacture: Robway Crane Safety Systems Pty Ltd
[6] Address: 32 West Thebarton Rd,
Thebarton
South Australia, 5031
Australia
[7] This equipment or protective system and any acceptable variation thereto is specified in the schedule to this
certificate and the documents therein referred to.
[8] Nemko AS, notified body number 0470 in accordance with Article 9 of Council Directive 94/9/EC of 23 March
1994, certifies that this equipment or protective system has been found to comply with the Essential Health and
Safety requirements relating to the design and construction of equipment and protective systems intended for
use in potentially explosive atmospheres given in Annex II to the Directive.
The examination and test results are recorded in confidential report no. 119260
[9] Compliance with the Essential Health and Safety Requirements has been assured by compliance with:
CENELEC EN 60079-0: 2006, CENELEC EN 60079-11: 2007
[10] If the sign “X” is placed after the certificate number, it indicates that the equipment or protective system is
subject to special conditions for safe use specified in the schedule to this certificate.
[11] This EC-TYPE EXAMINATION CERTIFICATE relates only to the design, examination and tests of the
specified equipment or protective system in accordance to the directive 94/9/EC.
Further requirements of the Directive apply to the manufacturing process and supply of this equipment or
protective system. These are not covered by this certificate.
[12] The marking of the equipment or protective system shall include the following :
II 2G Ex ib IIB/IIA T4 -20oCTa+60oC
CE0470
II (2)G [Ex ib] IIB/IIA -20oCTa+60oC
Oslo, 2009-04-03
Rolf Hoel
Certification Manager, Ex-products
This certificate may only be reproduced in its entirety and without any change, schedule included.
Postal address: Office address: Telephone: Enterprise number:
P.O.Box 73 Blindern Gaustadalléen 30 +47 22 96 03 30 NO 974404532
N-0314 OSLO, NORWAY 0373 OSLO Fax:
+47 22 96 05 50
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Date: 2009-04-03 Page 2 of 4
Nemko 08ATEX1433X
[13] Schedule
[14] EC-TYPE EXAMINATION CERTIFICATE No Nemko 08ATEX1433X
[15] Description of Equipment or Protective System
Display Barrier:
The Display Barrier (BAREX4120) is designed to power hazardous area circuits from within a non-hazardous
(safe) area.
The apparatus comprises four printed wiring boards upon which are mounted electronic components
including a transformer and opto-coupler devices which provide galvanic isolation between non-
hazardous area circuits and hazardous area circuits. The apparatus utilize shunt connected zener
diodes and series current limiting resistors to limit the energy into the hazardous area circuits.
Display Module:
The RCI-4100 Display (DISRCI4100) comprises a single printed wiring board(pwb) upon which are
mounted electronic components including a Liquid Crystal Display (LCD) and a piezo electric
buzzer all housed within a metallic enclosure fitted with a window, tactile push buttons and Light
Emitting Dioes (LEDs). External connections are made via the integral lead. The apparatus is
designed to provide alpha numerical data to an operator on several process parameters.
The Robway Model 4100 Display (DISRCI4100) is intended to be used with the Model Display
Barrier (BAREX4120). The Model 4120 Barrier provides isolated power to the Model 4100 display
and also an isolated intrinsic safety barrier for I2C communications from a host data system located
in a safe area.
[16] Report No. 119260
Descriptive Documents Display Barrier (BAREX4120)

Title: Drawing No.: Rev. Date:
DISRCI4100 BARRIER ENCLOSURE (TOP) 3864 1.0 2008/12/16
MACHINING DETAIL
RCI-4100 DISPLAY BARRIER BOX 3860 1.1 2008/12/23
Sheets 1 to 4
TRANSFORMER ASSEMBLY DETAIL 3812 1.1 2008/12/23
Sheets 1 to 3
Top Board 4100 IS Barrier DWG 3832 1.2 2008/12/01
Sheets 1 to 4
Board 1 4100 Barrier DWG 3834 1.2 2008/12/01
Sheets 1 to 4
Sheets 1 to 4
Sheets 1 to 4
4100 PSU Top Board Cert 387701 1.2 2008/12/12
4100 PSU Board 1 Cert 387801 1.2 2008/12/12
4100 PSU Board 2 Cert 387901 1.2 2008/12/12
+47 22 96 05 50
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Date: 2009-04-03 Page 3 of 4
Nemko 08ATEX1433X
4100 PSU Board 3 Cert 388001 1.2 2008/12/12

4100 PSU TOP BOARD PCB ASSEMBLY BILL OF 0141 1.2 2008/12/12
MATERIALS
4100 PSU BOARD 1 PCB ASSEMBLY BILL OF 0138 1.3 2008/12/23
MATERIALS
MATERIALS Sheets 1 & 2
TOP PCB CONFORMAL COATING DETAIL 3946 1.0 2008/12/23
BOARD 1 PCB CONFORMAL COATING DETAIL 3947 1.0 2008/12/23
ATEX Certification Marking 3996-1 1.0 2009/03/20
ATEX & IECEX IDENTIFICATION MARKINGS 3821-1 1.0 2009/03/30
Descriptive Documents RCI-4100 Display(DISRCI4100)

ATEX & IECEx IDENTIFICATION MARKINGS DWG 3821-1 A 2009/03/20
RCI-4100 DISPLAY PCB ASSEMBLY BILL OF 0131 1.2 2008/12/19
4100 Display IS Interface Cert 3876010A 0_6 2008/09/12
Sheet 1 of 3
4100 Numeric Display Cert 3876020A 0_6 2008/09/12
Sheet 2 of 3
4100 Control Cert 3876030A 0_6 2008/09/12
Sheet 3 of 3
ASSEMBLY DETAIL DWG 3797 1.0 2008/12/01
Sheets 1 to 4
DISPLAY PCB ASSEMBLY DETAIL DWG 3831 1.0 2008/12/02
Sheets 1 to 3
ENCLOSURE MACHINING DETAIL DWG 3751 1.1 2008/04/16
Sheets 1 & 2
DISPLAY PCB COMPONENT POTTING DETAIL DWG 3840 1.0 2008/12/01
Sheets 1 & 2
MEMBRANE KEYPAD DWG 3779 1.0 2008/12/02
Sheets 1 to 6
PCB3780 V1_2 4100 Display Cert Drawing Border.PcbDoc 3780 1.2 2008/12/09
Sheets 1 to 4
NYLON SPACER DWG 3823 1.0 2008/12/01
M5 x 25 THREADED STUD MACHINING DETAIL DWG 3863 1.0 2008/12/01
WIRING DETAIL DWG 3945 1.0 2008/12/01
KEYSWITCH ASSEMBLY DETAIL DWG 3950 1.0 2008/12/01
BUZZER ASSEMBLY DETAIL DWG 3951 1.0 2008/12/01
DISPLAY CABLE ASSEMBLY DETAIL DWG 3952 1.2 2009/01/13
EXTERNAL EARTH LEAD DWG 1050 1.1 1998/01/22
PCM1604A Details 389001 1.0 2008/09/12
Sch 3959 PCM1604A Design Details 395901 1.0 2008/09/12
+47 22 96 05 50
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Date: 2009-04-03 Page 4 of 4
Nemko 08ATEX1433X
[17] Special Conditions for Safe Use

Display Barrier (BAREX4120)
1. It is a condition of manufacture that each transformer is subject to the non mains transformer routine
type test as prescribed in IEC 60079-11 Edition 5 Clause 11.2.
2. The following input / output parameters are taken in to account in every installation;
Non Hazardous Area Terminals
Um = 250 V
Hazardous Area Terminals
Uo = 7.14 V
Io = 2.81 A
Po = 1.81 W
Ci = Negligible
Li = Negligible
The capacitance and either the inductance or the inductance to resistance (L/R) ratio of the hazardous area
load connected to the hazardous area terminals must not exceed the following values;
GROUP Capacitance Inductance OR L/R Ratio

(µF) (mH) (µH/
IIB 268 0.018 28.4
IIA 1000 0.036 56.7
The above load parameters apply where;

1. The external circuit contains no combined lumped inductance (Li) or lumped capacitance (Ci)
greater than 1% of the above values. OR
2. The external circuit contains either only lumped inductance (Li) or lumped capacitance (Ci) in
combination with a cable. OR
3. The inductance and capacitance are distributed as in a cable.
In all other situations e.g. the external circuit contains combined lumped inductance and capacitance, up to
50% of each of the inductance and capacitance values are allowed.
RCI-4100 Display(DISRCI4100)
1. The following parameters are to be taken into account in the installation

Ui = 8 V
Ii = 3 A
Ci = 7.7 µF
Li = 15 µH Maximum inductance of the 10 m cable.
2. The terminations of the integral cable must be terminated in a suitable enclosure offering a degree of
protection not less than IP20.
[18] Essential Health and Safety Requirements

See item 9
+47 22 96 05 50
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IECEx Certificate of Conformity

Display Module Type RCI-4100IS
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IECEx Certificate of Conformity

Model 4120 Power Supply and I2C Barrier
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Data Logging on Robway RCI’s
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Data Logging on RCI Systems
Introduction
The RCI System Logging occurs automatically whenever the driver lifts a load OR
whenever the RCI System detects an error condition on the crane such as moving
outside the load chart. The installer has the option to set the percentage of SWL a load
must reach before the load will be logged. This logging percentage can be set
anywhere between 13% and 110% of SWL.
In addition, the installer can configure three lift counters which can count the number
of lifts performed in three distinct SWL % regions below the logging percentage.
Description of Logging Features

Data Logging is stored in a circular arrangement. That is, when the logs are full and
another log is performed, the oldest log in the logger will be over-written. Each record
stores the following data:
Date Date log was recorded (dd/mm/yyyy)

Time Time log was recorded (hh:mm)
Peak Load Peak load recorded during log cycle
Stable Load Maximum Stable load recorded during log cycle
Safe Working Load SWL at operating position
Percent of SWL Percentage of SWL
Radius Operating Radius
Error Codes 4 digit standard Robway Error Codes
Duty Number Selected Duty number
Winch selected Selected winch
Falls reeved Selected falls
Over-ride state Off / On indicates whether display was in over-
ride
Logging is performed automatically when the percentage of SWL exceeds a threshold

value which is set in Function Codes.
When the logging percentage is not exceeded while lifting a particular load, the lift
occurrence can still be recorded in a lift counter. Three separate lift counters can be
configured to store the number of lifts which occur in a particular SWL % region.
Once again, the exact SWL percentages which will be counted can be configured by
setting the appropriate Function Codes.
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A summary of the logging percentage Function Codes is displayed in the following

table:
Function Code Name Description Default Setting

Low Load Lift counter swl percentage to record 20.0%
Medium Load Lift counter swl percentage to record 40.0%
High Load Lift counter swl percentage to record 65.0%
Logging Percentage swl percentage to log 90.0%
These default settings would give rise to the following logging operation:
Low Load Lift Counter counts the number of lifts which produce a SWL % which
is greater than or equal to 20% but less than 40%.
Medium Load Lift Counter counts the number of lifts which produce a SWL % which
High Load Lift Counter counts the number of lifts which produce a SWL % which
Logger Records full configuration data of any lift which produces
a SWL % which is greater than or equal to 90%
Setting Up the Data Logger

Data logging will occur at all times the display is operational. This includes the cases
when, the over-ride is activated, the display is reporting an error and during the initial
calibration of the system.
For the Logger to operate properly the display must be fully and correctly calibrated.
However, since the logger was recording during calibration it is probably desirable to
erase the logger contents after completing the angle and load calibrations on the RCI
System since the logger would have recorded some invalid information during the
calibration of the sensors.
To erase the data logger contents, simply activate the appropriate Function Code once
calibration is complete (refer to Function Codes list at the rear of the Manual for the
appropriate code).
The operator can access three more Function Codes which control how the actual
logging of loads operates. These three Function Codes are summarised in the
following table
Stable Load Time time during which load must stay stable in order to log
Stable Load Variation load must stay within this variation to be considered stable
Reset Time load must stay below the Low Load Counter threshold for this
time before the log cycle ends
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The first two Function codes in the table are used for determination of a stable load.
When a load is hoisted it is probable that the initial load reading will be greater than
the actual load on the hook because of the "snatching effect". The stable load is
recorded only when these dynamic factors have died down and the load can be
considered to be hanging from the hook in a relatively motion free position.
The "Stable load time" and "Stable load variation" Function codes can be used to
adjust the load recording to minimise the effect of dynamic factors. The load will be
considered stable if the load reading does not change by more than the "Stable load
variation" setting (which is 0.1t by default) for a period of time set by "Stable load
time" (which is 2 seconds by default).
The third Function code, "Reset time," is used for terminating a lift. When the load
causes a SWL % which is less than the logging values (specifically the Low Load Lift
counter percentage), then it is assumed that the driver must be putting the load down
again. In order to ensure that a single load is not logged multiple times because the
SWL % was hovering around the logging threshold, a log cycle will not complete
until the load SWL % remains below the threshold for a certain period of time,
namely of course the "Reset time" (by default the reset time is set for 5 seconds).
Log Cycle Description

Two types of log cycles are possible:
1. Load is lifted inside load chart boundaries (valid SWL is seen at all times).
2. SWL drops to 0 indicating the load chart has been exceeded, sensor error has
occurred or slew error has occurred.
Type 1 Log- Valid SWL cycle

A log cycle is started when:
x the current SWL % (load/swl) exceeds the THRESHOLD (which will be the value
set for the Low Load Lift Counter function Code).
During a log cycle:
x the load is monitored, the peak load seen is continually updated and if no stable
load has been recorded then all other data is recorded against peak load.
x a stable load condition will apply when the load remains within a small variation
range (set by user through F-Code "Stable Load Variation") for a certain period of
time (also an F-Code "Stable Load Time").
x when a stable load is seen, all data (except peak load) are recorded against the
stable load.
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x load monitoring continues, the SWL percentage is continually checked against the
SWL percentage which was stored, if the percentage increases, a new stable load
will be recorded.
A log cycle is completed when:
x the current SWL % drops below the THRESHOLD for a period of time set by the
Reset Time Function Code
OR
x the SWL drops to 0 initiating a Type 2 Log cycle.
In either case, the currently performed log will be stored prior to initiating a new
cycle.
Type 2 Log- Out of Load Chart / Error conditions

A log cycle is started when:
x SWL drops to 0, implying SWL % is unknown but definitely greater than 110%.
In this case the SWL is nominally set to 110% and appears as ">110%" in the
logger print out.
During a log cycle:
x the load is monitored and the peak load seen is continually updated (in log 1).
x the radius is monitored and the max. radius seen is continually updated (in log 2).
A log cycle is completed when:
x SWL becomes > 0 (log 1 AND log 2 are stored and condition for starting a type 1
log is checked).
Hence, if a load is lifted within the load chart a single log is performed. If the boom is
positioned outside of the load chart, any log cycle in progress is stored and a new
cycle begins. During this overload cycle two individual logs will be performed. One
log will record the maximum load reading which is observed and the other will record
the maximum radius which is observed. It is necessary to perform two logs because it
is impossible to know which is a more unsafe condition, a longer radius or a shorter
radius but higher load on the hook.
Stable loads are not monitored during out-of-chart/error logging cycles.
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Example Load Lift
Suppose a driver lifts a load and luffs out. If we assume the SWL % generated at the
edge of the load chart is sufficient to cause a log to record then as soon as the driver
exceeds the maximum radius on the chart, the active log cycle completes and is
written to the logger prior to beginning an "out-of-chart" log cycle.
The out-of-chart cycle continues until the driver luffs the crane back into a safe
condition. As soon as the safe condition is achieved, the out-of-chart logs (one for
max. load and one for max. radius) will be stored to the logger.
Because the crane is now back in a safe condition, a new logging cycle begins. When
the driver finally puts this load down (assuming he does not luff off the chart again)
the normal log cycle completes and another log is written to the logger.
Hence, although the driver has lifted only a single load and luffed it to several
positions, the actual load has been recorded a total of 4 times. This example serves to
illustrate that if the crane is continually working on it's outer radius, the Logger will
fill very quickly.
It should be noted that if motion cut is connected and the display is not in over-ride,
luffing to the out radius limits of the load chart could cause the crane to oscillate as
motion cut activates. In this case many logs may be recorded.
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Example Lift Cycles
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Accessing the Data Logger
When the RCI System is powered on the normal check routines are performed. If
your display has logging enabled then the percentage of the logger which is full is
displayed on start up in the LOAD window. The display will show the prompt
"=LE=" if the logger is completely empty, otherwise the prompt "LXXX" will show
where XXX is the percentage of the logger which is currently filled.
The operator can use two more Function codes for accessing the information stored in
the data logger. These Function codes are used for:
Downloading the data logger records to a PC, and

Erasing the content of the data logger
Downloading Data Logger Information
Downloading of data logger records can be performed at any time by attaching the
cable provided between the RCI System and a standard PC or laptop and selecting the
"Download Log Data" Function Code (refer to Function Codes list at the rear of the
Manual for the appropriate code).
Communication Settings
The download is performed as an ASCII file transfer which means any standard
terminal emulator software (e.g. simterm, procomm, etc.) or the standard Hyper-
Terminal program of Windows (98, XP, etc.) could be used to receive the information
from the RCI System.
Communication Settings for the transfer are:
Baud Rate = 9600

Data Bits =8
Parity = none
Stop Bits =1
Page 92 of 127
MAN1124A
Downloaded Data Format
Each record will be printed in chronological order followed by a summary on the

contents of the data logger. If no records have been stored a message to this extent is
displayed on the RCI calibration window however, the summary information is still
downloaded to the PC.
The summary consists of 6 lines of information as follows:
1. DOWNLOAD PERFORMED (date time)

2. Percentages Changed (date time) ***
3. No. Lifts in range 20% to 40% SWL = xx
6. No. Lifts logged with > 90% SWL = xx
*** Note: Default date if percentages have not been altered from Robway
settings is 01/01/96.
The first line simply states the date and time of when the download was performed.
The second line shows the date and time of when the percentage values for the
counters and/or the logging percentage were last changed. The default date displayed
is the 01/01/96. If the percentages are changed, the new date and time will be stored.
This date and time will be maintained until the values are once again altered or
calibration data is cleared.
The third, forth and fifth lines give counts of the total number of lifts performed in the
specified regions of SWL %. The percentages shown in this table can of course be
changed in Function codes (causing the date in the second line to change as just
discussed).
The sixth line gives a count of the number of full logs which have been performed
and printed.
The records are printed 1 per line with each field in the record separated by a tab
character. This means the resultant file stored on the PC is a tab de-limited text file
which is a suitable format for importing into spreadsheet programs such as Microsoft
Excel.
Generally spreadsheet programs will automatically recognise the file format as a tab
de-limited text file and promptly convert the data into a spread sheet format. In some
cases it may prove necessary to ensure the file is saved with a .txt extension name
which is the standard extension for ASCII text files.
Page 93 of 127
MAN1124A
Downloading of the logger can be performed any number of times without affecting
the contents of the logger. Generally however, after downloading is performed, it is
normally desirable to erase the contents of the logger.
Downloading takes approximately 15 seconds per 100 records.
Erasing Data Logger Information
Erasing of data logger records can be performed at any time by accessing the
Function Code for "Erasing Log Data" (refer to Function Codes list at the rear of the
Manual for the appropriate code).
Erasing the data logger will cause all currently recorded logs to be erased (hence the
information can no longer be downloaded) and it also clears the SWL % counters.
In effect, the logger is now empty, however, the old records in the data logger have
not really been erased, simply the program log counters have been erased. Hence, in
the event that the data logger has been erased but the information has not been saved
it is possible to have the data extracted from the logger by sending the display to
Robway for analysis.
Page 94 of 127
MAN1124A
Errors in Logger Data

On powering the display the contents of the data logger is checked in three separate
operations. In 99% of cases these checks will all pass OK. If however a check fails
the state of the logger is immediately questionable. Where possible the operator is
given the choice of erasing the suspect data, however, in some instances, the logger
will automatically be erased.
If you observe an error and have the option to erase the logger contents, we
recommend you don't immediately erase the logger if there is desired information
stored there, but rather download the data before then erasing.
These errors should not occur except in extenuating circumstances. If you have
trouble with log errors you should immediately report such errors to Robway along
with the pertinent information about your display (display serial number & software
number)
Firstly, the control structure for the data logger is checked. If an error is found in the
control structure for any reason, then the display AUTOMATICALLY ERASES data
logger contents (because future logging is not reliable). If this error occurs the
message:
LOG CONTROL ERR!
RESETTING LOGGER
is displayed in the calibration window. The only way to retrieve any data in the
logger in this case is to send the display to Robway for analysis.
Secondly, the actual data in the logger is checked for errors. In the case that the data
is found to be suspect then the message:
LOG DATA ERROR!
<ENTER> to ERASE
is displayed in the calibration window. In this event the user is prompted as to

whether to erase the logger contents. Ideally the data should be erased since it is not
totally reliable however, the choice is presented so as to give the opportunity to
download the information prior to erasing the data (note erasing the data also clears
the lift counters).
Lastly, the lift counters are checked for errors. Once again, if an error is found the
user has the choice of erasing the counts or ignoring the error.
LOG COUNT ERROR!
<ENTER> to ERASE
If the error is ignored, the count values cannot be relied upon as correct.
Page 95 of 127
MAN1124A
Drawings
Part A: System Components
Page 96 of 127
MAN1124A
3RD ANGLE 150.0 [6 in] 60.0 [2 1/4 in]
Page 97 of 127
3 X WARNING LIGHTS
(GREEN, AMBER, RED)
4 X 16 ALPHA NUMERIC
DISPLAY
10.0 5.0
260.0 [10 1/4 in]

15.0 65.0
4 X 7 SEGMENT LCD
DISPLAYS
MOUNTING HOLE DETAIL
38.1 [1 1/2 in]

OVERIDE KEYSWITCH
4 X Q5.5 [1/4 in]
EARTH LEAD 4 CORE CABLE

15.1 [1/2 in]
DRAWN BY APPROVED BY PART OF ASSY PART No: PROJECT:

REV DATE DESCRIPTION OF CHANGE APPRV'D TOL: X. +/-1
X.X +/-0.2 S. CHAMBERS J. KOVAL DISRCI4100 RCI-4100 DISPLAY
X.XX +/-0.02 - TITLE:
22/05/2008 2/12/2008
A4
DRAFTING STANDARD: AS1100 32 West Thebarton Rd
THEBARTON
DIMENSIONAL DETAIL SHEET
DO NOT SCALE DRAWING SOUTH AUSTRALIA 5031 1 OF 1
ALL DIMENSIONS ARE IN MILLIMETERS
PHONE: +61 8 8238 3500 DRAWING No: FILE No: REV
UNLESS OTHERWISE STATED
web : www.robway.com.au FAX: +61 8 8352 1684
DWG 3798 379801AA.idw 1.0
A
B B
A
A-A ( 1 : 4 )
B-B ( 1 : 4 )
X.X +/-0.2 J.HART EJB110C30 CUFRCI4100
X.XX +/-0.02 TITLE:
2/03/2009
A4
Page 98 of 127

THEBARTON
CUFRCI4100 ENCLOSURE SHEET
MAN1124A
DO NOT SCALE DRAWING SOUTH AUSTRALIA 5031 1OF 3
3992 399201A.idw 1.0
426.5
8.
6
MAN1124A
373
222
Page 99 of 127
330 FIXING CENTERS
373
330 FIXING CENTERS
373.0

X.XX +/-0.02 TITLE:
2/03/2009
A4
THEBARTON
3992 399201A.idw 1.0
X.XX +/-0.02 TITLE:
2/03/2009
A4
Page 100 of 127

THEBARTON
MAN1124A
3992 399201A.idw 1.0
A
MAN1124A
Page 101 of 127
M8
275.0
350.0
305.0 OPENING
16.0
A
250.0 A-A
350.0
305.0 OPENING
Q20.0 10 PLACES
60.0
50.0
200.0
50.0 50.0
50.0 50.0 MATERIAL; STAINLESS STEEL

X.X +/-0.2 johnh ENCI03532S
X.XX +/-0.02 CUSRCI4100 TITLE:
29/01/2009
A4
THEBARTON
CONTROL ENCLOSURE SHEET
ALL DIMENSIONS ARE IN MILLIMETERS PHONE: +61 8 8238 3500 DRAWING No: FILE No: REV
UNLESS OTHERWISE STATED FAX: +61 8 8352 1684
web : www.robway.com.au 3973 ENCM3973.idw A
275.0
Q9.0
375.0
215
X.X +/-0.2 johnh ENCI03532S
X.XX +/-0.02 CUSRCI4100 TITLE:
29/01/2009
A4
Page 102 of 127

THEBARTON
CONTROL ENCLOSURE SHEET
MAN1124A
ALL DIMENSIONS ARE IN MILLIMETERS PHONE: +61 8 8238 3500 DRAWING No: FILE No: REV
3973 ENCM3973.idw A
95.0
MAN1124A
3RD ANGLE
Page 103 of 127
Exd FLAMEPROOF BARRIER GLAND
60.0
ARMOURED CABLE
2 X Q6.0 THRU
Q98.0
89.5

X.X +/-0.2 S. CHAMBERS ANGES4130 Exd ANGLE SENSOR
X.XX +/-0.02 - TITLE:
11/04/2008
A4
THEBARTON
DWG 3800 380001AA.idw 1.0
Parts List
5 ITEM QTY DESCRIPTION DWG No. PART NUMBER
1 1 INTERNAL MOUNTING PLATE DWG3792 PLAM3792
3RD ANGLE
2 1 CLINOMETER ASSEMBLY DWG2559 ASASSY2559
3 1 CLINOMETER INSULATOR DWG2184 INSCLIN2184
4 1 CLINOMETER RETAINING PLATE DWG3794 PLAR3794
5 4 M3 NYLOC NUT - NUTNM3SS
4
2
3
1
X.X +/-0.2 S. CHAMBERS ANGES4130 -
X.XX +/-0.02 - TITLE:
8/04/2008
A4
Page 104 of 127
DRAFTING STANDARD: AS1100 32 West Thebarton Rd HAZARDOUS AREA ANGLE SENSOR

THEBARTON ASSEMBLY DETAIL SHEET
MAN1124A
DWG 3796 379601AA.idw 1.0
Parts List
ITEM QTY DESCRIPTION DWG No. PART NUMBER
5 4 M3 NYLOC NUT - NUTNM3SS
MAN1124A
3RD ANGLE
8 6 1 TERMINAL STRIP MOUNTING DWG3795 PLAM3795
Page 105 of 127
PLATE
7 1 TERMINAL STRIP (3 WAY) - TERB149850
8 2 M3 X 12 PAN HEAD SCREW - SCRM312PSS
9 2 M3 X 30 BRASS SPACER - SPAM330HMF
5
7 MALE/FEMALE
10 2 M3 HEX NUT S/S - NUTHM3SS
6
9 NOTE: APPLY LOCTITE 243 (BLUE) TO ALL SCREW THREADS
10

X.XX +/-0.02 - TITLE:
8/04/2008
HAZARDOUS AREA ANGLE SENSOR A4
DWG 3796 379601AA.idw 1.0
Parts List
ITEM QTY DESCRIPTION DWG No. PART NUMBER
11 1 Exd FLAMEPROOF ENCLOSURE - ENCEXC30
3RD ANGLE
12 2 M4 X 8 CSK SCREW S/S - SCRM48CSS
13 1 FLAMEPROOF Exd BARRIER - GLATWAB1M16
GLAND
14 1 M20 FLAMEPROOF Exd BLANKING - PLUGM20A
PLUG
WIRING DETAIL
12 CLINOMETER WIRES
RED
NOTE:
YELLOW CLINOMETERS REQUIRE SHUNT
13 RESISTORS FOR CORRECT OPERATION.
REFER TO DWG 2559 FOR DETAILS.
BLACK
CRIMP CLINOMETER WIRES
WITH FERRULES.
ORANGE (FER257989) FOR SINGLE WIRE
YELLOW (FERM12) FOR DOUBLE WIRE
11
14
X.XX +/-0.02 - TITLE:
8/04/2008
A4
Page 106 of 127
DRAFTING STANDARD: AS1100 32 West Thebarton Rd HAZARDOUS AREA ANGLE SENSOR

MAN1124A
DWG 3796 379601AA.idw 1.0
MAN1124A
U N CO N
C
T
O
R
P
O
Y
L LED
Page 107 of 127
3RD ANGLE 40
2 X Q9 THRU
ED Q60
LL
RO
4 CORE
SCREENED CABLE
267
NT YP
CO O
C
REV DATE
UN 2
22
40
DESCRIPTION OF CHANGE
12
APPRV'D TOL: X.
X.X
+/-1
+/-0.2
6
DRAWN BY
S. CHAMBERS
45
APPROVED BY
A. CANLAS
PART OF ASSY
-
PART No:
SWISBB5
54
PROJECT:
BB5 ATB SWITCH
X.XX +/-0.02 TITLE: SCALE
19/04/2005 19/04/2005
Page 108 of 127
DO NOT SCALE DRAWING 32 West Thebarton Rd

N/A
ALL DIMENSIONS ARE IN MILLIMETERS THEBARTON
MAN1124A
UNLESS OTHERWISE STATED SOUTH AUSTRALIA 5031 1OF 1
FAX: +61 8 8352 1684
c copyright robway 2005 web : www.robway.com.au DWG 2934 293401AA.idw 1.0
Parts List
MATERIAL FINISH
MILD STEEL HOT DIP GALVANISED
3RD ANGLE
25.0
MAN1124A
12.5
Page 109 of 127
NOTE:
TE:
1. FIT 2 HALVES TOGETHER
TOGETH TO COMPLETE THE
FULLL ASSEMBLY.
ASSEMB
ED 2 X M10 FLAT WASHER

2 X 2mm SPLIT PIN
75.0
125.0
Q2.5
LL 5
25.0
O
12.5
Q10.0
T R 6mm CHAIN LINK - CUT IN HALF
SEAL WELD
GRIND FLUSH 3
N P Y
Q10.5 THRU
CO O
7
7.0
N C
35.0 5.0
U 140.0

X.X +/-0.2 E.R. J. RICH BOBUNI01 UNIVERSAL BOBWEIGHT
1.1 03/07/08 PCR#123 - INCREASE CENTRE DIMS S.C. X.XX +/-0.02 - TITLE:
13/09/1993 11/12/1995
A3
DRAFTING STANDARD: AS1100 32 West Thebarton Rd FABRICATION DETAIL
THEBARTON SHEET
DWG 0946 094601AB.idw 1.1
Parts List
MATERIAL FINISH
25mm MILD STEEL PLATE (PROFILE CUT) HOT
HO DIP GALVANISED
3RD ANGLE 345.0
ED
25.0
300.0
LL
NOTES:
1. CUT
CU 1 X M30 FLAT WASHER IN
HALF AND WELD IN POSITION
SHOWN.
M30
30 WASHER
R 2. WASHER MUST BE AT LEAST 5mm
RO
THICK.
250.0
150.0
R5
R50.0
NT YP
R100.0
CO O
50
5.0 5.0
5.
C
5 5
UN
5 5
400.0
X.X +/-0.2 S. CHAMBERS A. CANLAS BOBWTWHIP WHIP LINE BOBWEIGHT
X.XX +/-0.02 - TITLE:
10/04/2008 14/04/2008
A4
Page 110 of 127

THEBARTON
MACHINING DETAIL SHEET
MAN1124A
DWG 3799 379901AA.idw 1.0
MAN1124A
U N CO N
C
T
O
R
P
O
Y
L LED
Page 111 of 127
MAN1124A
Drawings
Part B.1: Safe Area Crane / Hazardous Area Boom
Part B.2: Hazardous Area Crane & Boom
Page 112 of 127

MAN1124A

Drawings
3DUW%*HQHUDO$UUDQJHPHQW :LULQJ'HWDLOV
3DUW% 6DIH$UHD&UDQH+D]DUGRXV$UHD%RRP

Page 112 of 127

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MAN1124A
MAN1124A
Page 115 of 127

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Page 116 of 127

MAN1124A
MAN1124A
Page 117 of 127

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Page 118 of 127

MAN1124A
MAN1124A
Page 119 of 127

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MAN1124A
Drawings
Part B.2: Hazardous Area Crane & Boom
Page 120 of 127

+$=$5'286$5($ 6$)($5($
=21(([LE

MAN1124A
Page 121 of 127

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Page 122 of 127
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Page 125 of 127

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Page 126 of 127
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MAN1124A
RCI System Crane Configuration Sheets/

Duty Listing/Function Codes
Page 127 of 127

Robway Crane Safety Systems 100419 Config.doc 2009-10-15 VB Page 1 of 3
RCI SYSTEM CONFIGURATION SHEET

Crane Model FAVCO 350RL S/N1614 Chip Number 100419
Function Code List 100419.FCN
SYSTEM TYPE SUPPLIED
DISPLAY MODEL RCI-4100 DATA LOGGING Standard
X Hoist Rope Loadmoment Single Winch X Twin winch Live Mast A-Frame
X Strut Boom Telescopic Other
LOAD CELL POSITION

Dyno Hoist Rope Deadend Pendants Luff Rope Deadend X Pin
Inputs Configuration
Input Description
Input 1 Main Winch Hoist Direction Switch
Input 2 Auxilary Winch Hoist Direction Switch
Input 3 Not used
Input 4 Not used
Input 5 Not used
Input 6 Not used
Input 7 Not used
Input 8 Not used
Outputs
Relay Output Description
RL1 Boom Down Motion Cut
RL2 Hoist up Motion Cut
RL3 Slack Rope Output
Additional Digital Outputs

Output Description
DIO1 Boom-up Motion cut
DIO2 Not used
DIO3 On Board – Open; Off Board – Closed
SPECIAL NOTE
This system has been prepared using information available at time of order and MUST BE VERIFIED on site at
time of commissioning.
ROBWAY MUST BE ADVISED of any changes to the user configurable options carried out on site.
As we have no control or means of verifying the correctness of on site data inputs we accordingly disclaim any
responsibility for malfunctions or accidents arising from incorrectly entered data.
Notifications of changes should be sent to
ROBWAY SAFETY SYSTEMS

Fax: +61-8-8352-1684 Phone: +61-8-8352-6055
PO BOX 23
TORRENSVILLE PLAZA, AUSTRALIA, 5031
Prepared
By VB For Favelle Favco Cranes SDN BHD
Date 2009-10-15
CRANE CONFIGURATION
Supplied Changed To
SWL % for YELLOW light Warning 90.0 % [ F-42 ]
SWL % for Intermittent Audible 90.0 % [ F-43 ]
SWL % for RED light and Continuous Audible 100.0 % [ F-44 ]
SWL % for External Audible 100.0 % [ F-45]
SWL % for motion cut 110.0 % [ F-46 ]
Slew offset ( 3 on fig. 1 ) -0.75 M [ F-47 ]

Negative if foot-pin is behind centre of rotation
Maximum Main Winch Linepull 13.6 T [ F-48 ]
Maximum Falls For Main Winch 2 [ F-49 ]
Main Sheave Radius 0.275 M [ F-50 ]
Maximum Aux. Winch Linepull 4.4 T [ F-51 ]

Maximum Falls For Aux. Winch 1 [ F-52 ]
Aux. Sheave Radius 0.275 M [ F-53 ]
Boom Head Offset 0.7 M [ F-54 ]

Negative if main boom sheave above boom centre line
Foot-pin Offset 0.0 M [ F-55 ]
Negative if foot-pin below boom centre line
Not Used N/A [ F-56 ] TO [ F-62 ]
Main Winch Constant Line Tensioning Threshold -0.40 T [ F-63 ]
Aux Winch Constant Line Tensioning Threshold -0.20 T [ F-64 ]
Stable Load Time 2.0 Secs [ F-65 ]

time during which load must stay stable in order to log
Stable Load Variation 0.2 T [ F-66 ]
amount of load variation allow in a stable load
Reset Time 5.0 Secs [ F-67 ]
time below log threshold before cycle completes
Low Load Lift Counter - SWL percentage to record 20.0 % [ F-68 ]
Medium Load Lift Counter – SWL percentage to record 40.0 % [ F-69 ]
High Load Lift Counter - SWL percentage to record 65.0 % [ F-70 ]
Logging Percentage - Loads logged if SWL % > value 90.0 % [ F-71 ]
Load/Angle Correction - Lowest Angle 0.0 ° [ F-72 ]
Load/Angle Correction - High Angle 90.0 ° [ F-73 ]
Load/Angle Corr – Main Winch Load Error 0.0 T [ F-74 ]
Load/Angle Corr – Aux Winch Load Error 0.0 T [ F-75 ]
Main Winch Rigging SWL 0.0 T [ F-76 ]
Aux. Winch Rigging SWL 0.0 T [ F-77 ]
Not Used NA [ F-78 ]
Metric/ Imperial Units Switching SI-Metric: Lbs-Imperial SI [ F-79 ]
IMPORTANT
check ALL Configuration Values Shown Above For Accuracy Before Operating.
* These values require on-site adjustment as they were not supplied at time of order.
Transducer Gain Default Setting

Transducer 1 Gain 2.0
Transducer 2 Gain 2.0
Crane Dimensions
Refer to configuration sheet for more information
2
6
CL
1
5
Boom Foot Pin

3
1 Slew Offset Horizontal distance between boom foot pin and centre of slew
2 Boom Head Offset Horizontal distance between boom head and centre line of boom
3 Foot Pin Offset Horizontal distance between boom foot pin and centre line of boom
4 Horizontal Offset Horizontal distance between boom foot pin and centre line of A-Frame sheave
5 Vertical Offset Vertical distance between boom foot pin and centre line of A-Frame sheave
6 Boom Tip to Pendant Horizontal distance between the pendant attachment point and the boom tip
Attachment Point
7 Pendant Attachment Point Horizontal distance between the pendant attachment point and the centre line
to Boom Centre Line of the boom
Please note that for LOAD MOMENT systems ALL of the above are required.
For DYNAMOMETER type systems only 1, 2 and 3 are required.
Figure 1
Robway Safety Systems 100419 Duty.DOC 2009-10-15 VB Page 1 of 1
DUTY LISTING TO SUIT FAVCO 350RL S/N: 1614

TWIN WINCH, STRUT BOOM CRANE
Duty Boom Length Jib Details Description

(m) (m)
01 35.8 1.5 ONBOARD DF=1.33

02 35.8 1.5 OFFBOARD SWH=0.50m
03 35.8 1.5 OFFBOARD SWH=1.25m
04 35.8 1.5 OFFBOARD SWH =2.50m
05 35.8 1.5 PERSONAL LIFT: AUX WINCH ONLY
Robway Safety Systems 100419 Function.doc 2009-10-15 VB Page 1 of 3
RCI-4100 CALIBRATION PROCEDURE FOR DYNAMOMETER TYPE

SYSTEMS WITH USER CONFIGURABLE OPTIONS
1. Press and hold SETUP until F-xx appears on top digital display,
( where xx is the code for last calibration function )
2. Use UP/DOWN keys to select function then press ENTER to accept,
3. Use UP/DOWN keys to set new value then press ENTER to accept,
4. Repeat steps 2 and 3 for any other functions if required,
5. Select F-00 or press CANCEL to exit calibration mode.
NOTE
Once in calibration mode you may use CANCEL key to cancel any function.
FUNCTION CODES
F-00 EXIT CALIBRATION MODE
F-01 VIEW CALIBRATED MAIN LOAD
F-02 CALIBRATE LIGHT MAIN LOAD
F-03 CALIBRATE HEAVY MAIN LOAD
F-04 VIEW CALIBRATED AUX LOAD (TWIN WINCH ONLY)
F-05 CALIBRATE LIGHT AUX LOAD (TWIN WINCH ONLY)
F-06 CALIBRATE HEAVY AUX LOAD (TWIN WINCH ONLY)
F-07 VIEW UNCALIBRATED ANGLE INPUT
F-08 VIEW CALIBRATED ANGLE INPUT
F-09 CALIBRATE LOW ANGLE
F-10 CALIBRATE HIGH ANGLE
F-11 NOT USED
F-12 NOT USED
F-13 NOT USED
F-14 NOT USED
WARNING
THE FOLLOWING FUNCTIONS SHOULD ONLY BE USED BY ROBWAY TRAINED PERSONNEL. MISUSE OF
THESE FUNCTIONS MAY CAUSE THE DISPLAY TO FUNCTION INCORRECTLY
F-15 VIEW UNCALIBRATED TRANSDUCER 1 INPUT
F-16 VIEW CALIBRATED TRANSDUCER 1 INPUT
F-17 CALIBRATE LOW END OF TRANSDUCER 1
F-18 CALIBRATE HIGH END OF TRANSDUCER 1
F-19 VIEW UNCALIBRATED TRANSDUCER 2 INPUT (TWIN WINCH ONLY)
F-20 VIEW CALIBRATED TRANSDUCER 2 INPUT (TWIN WINCH ONLY)
F-21 CALIBRATE LOW END OF TRANSDUCER 2 (TWIN WINCH ONLY)
F-22 CALIBRATE HIGH END OF TRANSDUCER 2 (TWIN WINCH ONLY)
F-23 SET GAIN FOR CHANNELS 1 TO 8

CHANNEL 1 GAIN FOR LOAD 1
CHANNEL 2 GAIN FOR LOAD 2
CHANNEL 3 GAIN FOR ANGLE 1
F-24 SET OFFEST FOR CHANNELS 1 TO 8

CHANNEL 1 OFFSET FOR LOAD 1
CHANNEL 2 OFFSET FOR LOAD 2
CHANNEL 3 OFFSET FOR ANGLE 1
F-25 NOT USED
F-26 NOT USED
F-27 NUMBER OF SENSOR SAMPLES TO AVERAGE

F-28 NOT USED
F-29 PERFORM LADEN BOOM RADIUS CORRECTION (TELESCOPIC CRANES ONLY)

F-30 LOAD-CHART VIEW MODE
F-31 VIEW DIGITAL INPUTS
F-32 SET YEAR (WITH OPTIONAL DATALOGGER)
F-33 SET DAY AND MONTH (WITH OPTIONAL DATALOGGER)
F-34 SET TIME (WITH OPTIONAL DATALOGGER)
F-35 DOWNLOAD LOGGER CONTENTS TO PC (9600 8N1) (WITH OPTIONAL DATALOGGER)
F-36 ERASE LOGGER CONTENTS (WITH OPTIONAL DATALOGGER)
F-37 NOT USED

F-38 NOT USED
F-39 NOT USED
F-40 ALTER CALIBRATION DATA
F-41 CLEAR ALL CALIBRATION DATA USE EXTREME CAUTION
F-42 SWL % FOR YELLOW LIGHT WARNING
F-43 SWL % FOR YELLOW LIGHT AND INTERMITTENT AUDIBLE ALARM
F-44 SWL % FOR RED LIGHT AND CONTINUOUS INTERNAL AUDIBLE ALARM
F-45 SWL % FOR CONTINUOUS EXTERNAL AUDIBLE ALARM
F-46 SWL % FOR MOTION-CUT
F-47 SLEW-OFFSET
F-48 MAXIMUM MAIN WINCH LOAD PER FALL
F-49 MAXIMUM FALLS SELECTABLE FOR MAIN WINCH
F-50 MAIN WINCH SHEAVE RADIUS
F-51 MAXIMUM AUX. WINCH LOAD PER FALL (TWIN WINCH ONLY)
F-52 MAXIMUM FALLS SELECTABLE FOR AUX. WINCH (TWIN WINCH ONLY)
F-53 AUX. WINCH SHEAVE RADIUS (TWIN WINCH ONLY)
F-54 PERPENDICULAR DISTANCE FROM CENTRE OF MAIN BOOM SHEAVE TO CENTRE-LINE OF BOOM
Negative if main boom sheave is above the boom centre line
F-55 PERPENDICULAR DISTANCE FROM BOOM FOOT-PIN TO CENTRE-LINE OF BOOM
Negative if boom foot-pin is below the boom centre line
F-56 – F-62 NOT USED
F-63 MAIN WINCH CONSTANT LINE TENSIONING THRESHOLD

F-64 AUX WINCH CONSTANT LINE TENSIONING THRESHOLD
F-65 STABLE LOAD TIME (TIME DURING WHICH LOAD MUST STAY STABLE IN ORDER TO LOG)
(WITH OPTIONAL DATALOGGER)
F-66 STABLE LOAD VARIATION ( LOAD MUST STAY STABLE IN ORDER TO LOG)
F-67 RESET TIME (LOAD MUST STAY BELOW THE LOG THRESHOLDS FOR THIS TIME TO END CYCLE)
F-68 LOW LOAD LIFT COUNTER - SWL PERCENTAGE TO RECORD (WITH OPTIONAL DATALOGGER)
F-69 MEDIUM LOAD LIFT COUNTER - SWL PERCENTAGE TO RECORD (WITH OPTIONAL DATALOGGER)
F-70 HIGH LOAD LIFT COUNTER - SWL PERCENTAGE TO RECORD (WITH OPTIONAL DATALOGGER)
F-71 LOGGING PERCENTAGE - SWL PERCENTAGE TO LOG (WITH OPTIONAL DATALOGGER)
F-72 LOWESET ANGLE CRANE CAN LUFF TO (FOR LOAD / ANGLE CORRECTION)
F-73 HIGHEST ANGLE CRANE CAN LUFF TO (FOR LOAD / ANGLE CORRECTION)
F-74 LOAD / ANGLE CORRECTION - ERROR IN MAIN WINCH LOAD
F-75 LOAD / ANGLE CORRECTION - ERROR IN AUX WINCH LOAD
F-76 MAIN WINCH RIGGING SWL

F-77 AUXILIARY WINCH RIGGING SWL
F-78 NOT USED

F-79 METRIC/ IMPERIAL UNITS SWITCHING SI-METRIC: Lbs-IMPERIAL (Press <ENTER> to switch)
Recommended Gain & Offset Settings in RCI-4100
Load Sensor
1mV/V Offset 500
Gain 520
2mV/V Offset 500

Gain 200
Robway Angle Sensor

(ANGES4140)
Offset 977
Gain 310

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10.

1 SAFE LOAD INDICATOR

FAVCO 350RL S/N: 1614

Favelle Favco Cranes SDN. BHD.

Robway Crane Safety Systems Pty Ltd

Contents Page No.

1. Important Safety Notice ............................................................................................4

2. General Description ..................................................................................................5

RCI-4100IS HRT Pedestal (FFC) Manual Last Ammended: 02/06/2009

Robway Crane Safety Systems Pty Ltd

x IECEx Certificate of Conformity, Display Module Type RCI-

RCI-4100IS HRT Pedestal (FFC) Manual Last Ammended: 02/06/2009

Robway Crane Safety Systems Pty Ltd

1. Important Safety Notice

RCI-4100IS HRT Pedestal (FFC) Manual Last Ammended: 02/06/2009

Robway Crane Safety Systems Pty Ltd

This Manual contains general information, installation, operation, calibration,

x Safe Working Load (SWL),

x Hoist Rope Falls,

x Duty (or Sea-State),

x Time and Date,

x Actual Load as a Percentage of SWL.

RCI-4100IS HRT Pedestal (FFC) Manual Last Ammended: 02/06/2009

Robway Crane Safety Systems Pty Ltd

The RCI-4100IS display also provides the following features:

x Visual and audible alarms on warnings, motion-cut, and two-blocking

x Self-diagnosis and error codes,

x Built-in calibration and fault-finding tools,

x Units conversion (imperial/metric) facility,

x Anti-two-block (overhoist limit) facility,

x Restricted slew zone monitoring – optional feature,

x Wind speed monitoring – optional feature,

x Gross over-moment protection (GOP) – optional feature.

RCI-4100IS HRT Pedestal (FFC) Manual Last Ammended: 02/06/2009

Robway Crane Safety Systems Pty Ltd

3.1. Turning On the RCI-4100IS

The RCI-4100IS can be powered by 9 VDC to 36 VDC supply.

The selected power supply may be permanently connected, however for

3.2. Turning Off the RCI-4100IS

RCI-4100IS HRT Pedestal (FFC) Manual Last Ammended: 02/06/2009

Robway Crane Safety Systems Pty Ltd

3.3. Operating Screen

Winch Select UP/DOWN Buttons

RCI-4100IS HRT Pedestal (FFC) Manual Last Ammended: 02/06/2009

Robway Crane Safety Systems Pty Ltd

3.4. Display Functions

ALPHANUMERIC LCD SCREEN & ALARM LED INDICATORS

The three alarm LED’s (Green-Safe, Amber-Warning & Red-Overload) at the

x Green: 50 to 84%, Amber: 85 to 99%, Red: 100 to 110%

DUTY - shows the current duty (or Sea-state) selected.

FALLS - shows the current parts of line or falls for the

BOOM LENGTH - shows the boom length, in unit selected (feet or

TIME - shows the current local time. The time function is

RCI-4100IS HRT Pedestal (FFC) Manual Last Ammended: 02/06/2009

Robway Crane Safety Systems Pty Ltd

UNITS - shows the current unit (Metric or Imperial)

TARE - when activated by the operator, the load value on

The TARE is an operator-settable function. It allows the operator to TARE out

Using the TARE function

RCI-4100IS HRT Pedestal (FFC) Manual Last Ammended: 02/06/2009

Robway Crane Safety Systems Pty Ltd

7-SEGMENT LCD SCREENS

LOAD - shows the current load in unit selected (kips or

SWL - shows the current maximum safe working load in