Hirschmann PRS 40 EZ Operator's And Service Manual

HIRSCHMANN

PRS 40 EZ

OPERATOR’S / SERVICE MANUAL

P/N 031-300-190-201 Revision A 03/16/2006

Operator’s Manual PRS 40 EZ

NOTICE

Hirschmann, Inc. makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and/or its fitness for a particular purpose.

Hirschmann, Inc. will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing, performance, or use of this manual. This document contains proprietary information, which is protected by copyright, and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Hirschmann, Inc.

Hirschmann, Inc. reserves proprietary rights to all drawings, photos and the data contained therein. The drawings, photos and data are confidential and cannot be used or reproduced without the written consent of Hirschmann, Inc. The drawings and/or photos are subject to technical modification without prior notice.

All information in this document is subject to change without notice.

MANUAL REVISIONS

REV DATE NAME DESCRIPTION

- 02/09/06 SB 06-010

A 03/16/06 SB 06-055

TABLE OF CONTENTS

GENERAL INFORMATION..............................................................................................................1

2 WARNINGS .....................................................................................................................................1

3 FEATURES ......................................................................................................................................2

4 SYSTEM DESCRIPTION.................................................................................................................2

4.1 CONSOLE.......................................................................................................................................2

4.1.1 Liquid Crystal Display ...........................................................................................................................2

4.1.2 Control Identification .............................................................................................................................3

4.2 OPERATION....................................................................................................................................4

4.2.1 MENU STRUCTURE ............................................................................................................................5

4.2.2 Installation.............................................................................................................................................6

5 ANGLE .............................................................................................................................................7

5.1.1 Operation ..............................................................................................................................................7

5.1.2 Limits.....................................................................................................................................................7

5.1.3 Installation / Calibration Hardwired.......................................................................................................8

5.1.4 Calibration.............................................................................................................................................9

5.2 ANGLE .........................................................................................................................................10

6 A2B ................................................................................................................................................12

6.1.1 Operation ............................................................................................................................................12

6.1.2 A2B limit..............................................................................................................................................15

6.1.3 Installation...........................................................................................................................................15

6.1.4 A2B Setup...........................................................................................................................................17

7 WIND..............................................................................................................................................19

7.1.1 Operation ............................................................................................................................................19

7.1.2 LIMITS ................................................................................................................................................20

7.1.3 Installation...........................................................................................................................................20

7.1.4 Wind Setup .........................................................................................................................................21

8 LOADCELL ....................................................................................................................................23

8.1.1 Operation ............................................................................................................................................23

8.1.2 LIMITS ................................................................................................................................................24

8.1.3 Installation...........................................................................................................................................25

8.1.4 Loadcell Setup ....................................................................................................................................26

8.1.5 Loadcell Calibration ............................................................................................................................26

9 LINE RIDER ...................................................................................................................................28

9.1.1 Operation ............................................................................................................................................28

9.1.2 LIMITS ................................................................................................................................................29

9.1.3 Installation...........................................................................................................................................29

9.1.4 Linerider setup ....................................................................................................................................33

9.1.5 Linerider Calibration............................................................................................................................33

10 RADIO MODULE ...........................................................................................................................34

10.1 INSTALLATION...............................................................................................................................34

11 ADDING SENSORS.......................................................................................................................36

12 SERVICE / TROUBLE SHOOTING ...............................................................................................37

12.1 SCREENS .....................................................................................................................................38

12.1.1 To test the outputs: .............................................................................................................................38

12.1.2 To test the inputs: ...............................................................................................................................38

12.1.3 Battery level: .......................................................................................................................................39

12.2 TROUBLESHOOTING......................................................................................................................40

12.3 TROUBLESHOOTING MOISTURE .....................................................................................................41

12.3.1 Water Ingress .....................................................................................................................................41

13 MAINTENANCE .............................................................................................................................42

Operator’s / Service Manual, PRS 40 EZ

13.1 BATTERY REPLACEMENT ........................................................................................................... 42

14 PART NUMBERS...........................................................................................................................43

14.1 CONSOLE ..................................................................................................................................43

14.2 A2B .............................................................................................................................................44

14.3 WIND .........................................................................................................................................46

14.4 ANGLE ..........................................................................................................................................47

14.5 ANTENNA OPTIONS .......................................................................................................................48

14.6 LINERIDER....................................................................................................................................49

14.7 LOADCELL .................................................................................................................................50

General Information

1 GENERAL INFORMATION

The PRS 40 EZ System has been designed to provide indication from various types of sensors, i.e. A2B, Load, Wind and Angle. The A2B system will warn the crane operator of a two-blocking condition of the crane. If a two-blocking condition is approached, the system will warn the operator by sounding an audible alarm, flashing the backlit LCD and locking out those functions which may aggravate the crane's condition, whenever applicable. If the system is set up for load, angle or wind, limits can be set by the user. When these limits are exceeded the system will warn the operator by sounding an audible alarm, flashing the backlit LCD and de-energize the lockout relay. The system relay can be connected to the cranes lockout system. If so, the system will lock out when exceeding any of the user limits.

NOTE:

comes in contact with the boom head. This condition, if not prevented, may cause the wire rope to break, allowing the load to fall. Either raising the load into the boom head, or telescoping the boom out without paying attention to the hoist line can cause a "two- block" condition.

The term "two-block" is a crane term that refers to a condition when the load handling device

2 WARNINGS

The PRS 40 EZ System is an operational aid, which warns a crane operator of approaching two-block conditions, which could cause damage to equipment and personal injury.

This device is not, and must not be a substitute for good, sound operator judgment, experience and use of accepted safe crane operating procedures.

The responsibility for the safe operation of the crane remains with the crane operator who must ensure that all warnings and instructions supplied are fully understood and observed.

Prior to operating the crane, the operator must carefully and thoroughly read and understand the information in this manual to ensure that the operation and limitations of the system and the crane are known.

The system can only work correctly, if all sensors/transmitters have been properly set. For correct setup, the operator has to answer thoroughly and correctly all questions asked during the setup procedure in accordance with the real rigging state of the crane. To prevent material damage and serious or even fatal accidents, the correct adjustment of the system has to be ensured before starting the crane operation.

Always refer to operational instructions and load charts provided by the crane manufacturer for specific crane operation and load limits.

Operator’s / Service Manual, PRS 40 EZ

3 FEATURES

The PRS 40 EZ has the following features:

• Can be hardwired to most PAT sensors.

• Wireless operation option of multiple sensors.

• Easily and clearly shows the operator required information.

• Multi language. The system can be setup to display text in both English and Spanish.

• Multiple limits can be set.

• Minimum of 500 feet LOS.

• Can display in multiple units.

• Built in lockout relay. Rated at 5 amps

• Tare function.

• Low battery indication.

• Expandable

• Direct replacement for the EI33

4 SYSTEM DESCRIPTION

4.1 CONSOLE

The console has 2 functions:

• Accepts inputs from the crane operator (reeving, limits and setup)

• Displays important data and information from the sensors

The operator’s console should be mounted in the operator’s field of vision.

4.1.1 Liquid Crystal Display

The Liquid Crystal Display (LCD) used in the PRS 40 EZ console is a wide temperature-range graphic display with transflective characteristics that give it a high visibility in sunlight and during backlit night operation. Due to the nature of any LCD, it works on the principle of polarization of light. It should be noted that dual polarizations that are at a certain angle to each other can reduce the amount of light up to completely eliminating it if that angle becomes perpendicular. This can have significance if the operator is wearing polarized sunglasses that happen to be perpendicularly polarized in relation to the LCD’s polarization. In this rare case, the operator has to work without sunglasses or find different sunglasses that do not have this characteristic, in order to avoid having the visibility of the display impaired.

The LCD contains an automatic temperature compensation that will adjust the LCD’s contrast according to the surrounding temperature.

System Description

4.1.2 Control Identification

Fig 2: Operator’s Console

Limit LED

LCD

Clear button

Select button

Up Button

Down Button

Button “SCROLL UP”

Button "SCROLL DOWN"

Button "SELECT"

Button "C"

• Use this button to increase values or to scroll up.

• Changes which sensors are displayed and how each is displayed.

• Use this button to decrease values or to scroll down.

• Changes which sensors are displayed and how each is displayed

• Use this button to enter the menu screen and to confirm selections.

• Generally used to back out of a selection and return to the previous

screen.

• Pushing this button for more than 1 second will bypass the control

lever lockout function of the system. Accesses the Tare function

•

Operator’s / Service Manual, PRS 40 EZ

Since button C can deactivate the lockout function of the system, the following instructions must be obeyed:

• The by-pass function shall be used with discretion, as unwarranted use of it to override

the control lever lockout system can result in harm to the crane and danger to property and persons.

• Never use the by-pass function to either overload or operate the crane in a non-

permissible range.

4.2 OPERATION

Upon switching on crane ignition switch, the system starts with an automatic test of the system, of lamps and audible alarm. During the test, the LCD shows the console and system software version. The PRS 40 EZ setup procedure allows the operator to input the sensors being used and the limits for the sensors. The operator must complete the setup procedure for each sensor.

System Description

4.2.1 MENU STRUCTURE

SETUP SETUP CONT'

● REEVING ● SENSORS

● LIMITS

○ ANGLE

MIN NOT INSTALLED

SELECTION HARDWIRED

MAX HIRSCHMANN

SELECTION KRUEGER

○ WINDSPEED

SELECTION

○ LOAD

MAX LOAD HARDWIRED

○ LINERIDER

SELECTION

● CALIBRATIONS

○ ANGLE

ZERO POINT RADIO

○ LOAD 0-POINT ○ WINDSPEED ○ LOAD RANGE

LOADCELL TYPE HARDWIRED

7.5 TON RADIO 10 TON

22.5 TON NOT INSTALLED

○ LINERIDER 0 ○ LINERIDER ADJ

INSTALL / REMOVE ○ ANGLE

RADIO

○ A2B1

NOT INSTALLED

RADIO

○ A2B2

NOT INSTALLED HARDWIRED

NOT INSTALLED

○ LOADCELL

HARDWIRED RADIO

○ LINERIDER

NOT INSTALLED HARDWIRED RADIO

● OPTIONS

○ TEST SEQUENCE ○ LB/MPH OR KG/KPH ○ ENGLISH OR SPANISH ○ CONTRAST ○ ANALOG INPUT ma/volts ○ BATTERY LEVEL

ANGLE A2B1 A2B2 WINDSPEED LOADCELL LINERIDER

Operator’s / Service Manual, PRS 40 EZ

4.2.2 Installation

The console has a mount that allows the console to be swiveled into any direction and to be mounted in a variety of locations and on nearly any surface. Choose a location that is in view and within reach of the operator. If radio sensors are being used, locate in line of site with the sensor. Securely attach the base of the mounting apparatus onto a solid surface. The power supply can be from 12- 24 volt DC. The lockout wire supplies power to operate external solenoids, or relays. The rating of the lockout is 5 amp. An internal fuse protects against overloading this circuit.

Power

Hardwired

Senso

Power cable connections

Angle

5 ANGLE

5.1.1 Operation

When an angle sensor is installed either with radio or hardwired the function of the console is the same. The angle is displayed in tenths of a degree

When other sensors are installed, they can be shown on other screens. These screens can be accessed with the up/down arrows.

5.1.2 Limits

The limits are set by selecting

SETUP/ LIMITS/ ANGLE

There is then the choice to set the minimum angle limit or the maximum angle limit.

To set the limit:

• Select the desired limit to set.

• Move the boom to desired angle.

• Press enter.

The angle limits can be cleared without moving the boom to the desired angle. To clear the angle limit without booming to the angle:

SETUP/ LIMITS/ ANGLE/ MINIMUM

Press and hold the down arrow, . The limits will change to -5 degrees.

SETUP/ LIMITS/ ANGLE/ MAXIMUM

Press and hold the up arrow, . The limits will change to 90 degrees.

Operator’s / Service Manual, PRS 40 EZ

5.1.3 Installation / Calibration Hardwired

Attach the supplied angle sensor mounting plate to the left side of the boom. Note the orientation of the plate from the photo below. If you are going to weld the plate to the boom, remove the angle sensor from the plate. Do not weld near the angle sensor. It will be damaged by welding.

Install the angle sensor to the plate with #6-32 screws and washers.

Clamp the cable with the supplied clamp and #6-32 screw and washers.

Route the cable from the boom to the console and insert the connector. Loop any extra cable length and store in a safe location.

Hardwired (HIRSCHMANN)

This is the setup for the standard Hirschmann angle sensor. This angle sensor has a digital output.

The angle sensor must be previously installed.

Use the setup screens to add the angle sensor to the system.

Select the "HIRSCHMANN" from the following menu.

MENU/ SENSORS/ ANGLE/ HARDWIRED/ HIRSCHMANN

SETUP

● SENSORS

● ANGLE

NOT INSTALLED

● HARDWIRED

● HIRSCHMANN

KRUEGER

RADIO

Angle

Hardwired (Kruger)

Note for older system updates, use the hardwired option. For example if replacing a Krueger AP console and using the existing sensor, select the hardwired option.

Set the internal DIP switch to:

Voltage Angle sensor - SETUP 3

Select the "HARDWIRED" from the following menu.

MENU/ SENSORS/ ANGLE/ HARDWIRED/ KRUEGER

5.1.4 Calibration

Both the radio and the hardwired sensors are calibrated with the same procedure. The angle sensor is pre-calibrated at the factory, but it still must be matched to the boom angle. A level, accurate to +/.2 degrees must be used to set the boom to a known angle.

Go to the menu for calibration of the angle:

MENU/ SETUP/ CALIBRATION/ ANGLE

1. Once the boom angle is determined and the sensor is securely mounted, enter the angle setting screen. This screen is used to match the angle sensor to the angle of the boom.

2. Scroll to the correct angle and press OK.

The calibration and set up of the sensor is then complete.

Operator’s / Service Manual, PRS 40 EZ

5.2 ANGLE

This procedure describes how to install and setup a radio angle transmitter.

CONTACT CRANE MANUFACTURER FOR WELDING INSTRUCTION PRIOR TO WELDING ON

BOOM.

Angle sensor, transmitter, and mounting plate.

The angle sensor will be mounted on the side of boom so as the boom angle changes, the angle sensor can rotate as shown in the 0°(left) and 90° (above) positions.

General information

The angle sensor total range is approximately 105° and the zero point is adjustable in the software in the angle calibration menu. With no software adjustment, the angle range will allow a -15° to 90° range, but if the angle sensor is zeroed at -5° (-5° becomes 0°) your angle range will be -10° to 95°. Therefore, when affixing the mounting plate to the boom, make sure you will be able to get your desired angle range for your application.

Angle

1. Locate an appropriated flat surface area on the boom base section or luffing jib root section. Avoid the installation close to moving parts or parts that could interfere during boom hoist up and down. Lower the boom into position that will allow you to safely install the angle sensor.

Notes: The antenna must point down and not up. Do not install angle sensor on hot mounting plate, temperatures greater than 125°F (52°C) this could damage the angle sensor and/or transmitter.

2. Measure the boom angle by using a digital inclinometer (i.e. smart level) at the area selected in step 1. Align the mounting plate as defined be the decal or so the mounting holes pointing down as shown in the pictures above. Affix the mounting plate onto the area. Clean, prime, and paint the mounting plate if necessary.

3. Remove the angle sensor cover by loosen the four screws in the cover. Check the gasket to insure it is not damaged. Remove the batteries. Align the 4 holes with the mounting plate threaded holes and screw the angle sensor onto the mounting plate by using the four screws supplied in the kit. Attach the antenna to the connector by carefully rotating the antenna clockwise

4. On the console, setup the sensor by using the menu selection: MENU SETUP/SENSORS/ANGLE 1 or 2. In the setup process you will be asked to insert the batteries while the receiver searches for the transmitter. Install batteries correctly as shown on the label in the battery compartment. When the sensor has been found, confirm the angle sensor has been installed. Return angle sensor cover and tighten the four cover screws carefully.

5. On the console, calibrate the angle by using the menu selection: MENU SETUP/SENSORS/ANGLE (1 or 2 as defined above)/ZERO POINT. After making this selection, measure the boom angle by using a digital inclinometer (i.e. smart level), scroll to the correct angle and press OK. The calibration and set up of the sensor is now complete.

6. Check the angle of the main boom at 0°, 40°, 60°, and 70° and compare it with the measure value. It should be ±1°. If it is incorrect, repeat step 5, calibrate the angle sensor again, and verify the actual angle and/or use a different/higher angle (50°) to scroll to and match the angle.

Operator’s / Service Manual, PRS 40 EZ

6 A2B

6.1.1 Operation

When an A2B switch has been installed, the status of the switch is always shown. If other sensors are installed besides the A2B, the A2B status will be shown on the right side of the display.

A2B OK

6.1.1.A PRE-OPERATION INSPECTION

Before operating the crane, the following electrical connections must be checked to ensure that the system is properly connected for the crane configuration.

With even parts of hoisting line, the weight shall be attached to the dead-end line. With odd parts of hoisting line, the weight shall be attached to the line of lowest speed.

A separate A2B weight and transmitter must be used for each hoist that is in use. The Retainer flag, if equipped, must be removed from each switch that is in use. Switches that are not in use should either be removed from the system or must have the retainer flag installed.

Anti-Two-Block Retainers (optional)

Installation of Anti Two-Block Retainer in Locking Position Procedure (see Fig. 1 and 2):

1. Pull the cable out of the switch and bend back parallel to the boom and hold (1).

2. Slide the retainer from left side with its slot over the cable between the crimped stop and the switch (2). Push it firmly straight onto the cable guide of the Anti Two-Block switch (3).

+ 39 hidden pages

Hirschmann PRS 40 EZ Operator's And Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual