PAT DS 150 User Manual

User Manual IK 150 / 0031 e

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50 / 150 / 19_0031E.DOC / 19.03.1997 / Rev. C / rk.

The information in this document is subject to change without notice. PAT makes no warranty of any kind
with regard to this material, including, but not limeted to, the implied warranties of merchantability and fitness
for a particular purpose. PAT shall not be liable for errors contained herein or for identical or consequential
damages in connection with the furnishing, performance, or use of this manual. This document contains
proprietary information which is protected by copyright. All rights reserved. No part of this document may be
photocopied, reproduced, or translated to another language without the prior written consent of PAT.

USER MANUAL

IK 150 / 0031

doc. no. 50 150 19 0031 e

User Manual IK 150 / 0031 e

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50 / 150 / 19_0031E.DOC / 19.03.1997 / Rev. C / rk.

TABLE OF CONTENTS

1 General Information .................................................................................................. 3

2 Warnings..................................................................................................................... 3

3 System Description................................................................................................... 4

3.1 Operating Console ...................................................................................................... 6

4 Control Identification................................................................................................ 7

5 Pre- Operation Inspection and Calibration Verification................................... 12

6 Service and Maintenance....................................................................................... 14

7 Troubleshooting ...................................................................................................... 15

Appendix: Important Notes

User Manual IK 150 / 0031 e

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50 / 150 / 19_0031E.DOC / 19.03.1997 / Rev. C / rk.

1. GENERAL INFORMATION

The PAT DS 150 Load Moment Indicator (LMI) complements the operator's know-how by
providing the information, right in the cab, needed to make the demanding lifts required of
modern cranes.
Using various sensing devices, the PAT DS 150 Load Moment Indicator monitors all crane
functions and provides the operator with a continuous reading of the crane's rated capacity.
The readings continuously change as the crane moves through the motions needed to make
the lift.
The PAT DS 150 Load Moment Indicator also provides the operator with information regard­ing the length of the boom, angle of the boom and jib, working radius, rated load and the total
calculated weight being lifted by the crane.
If non permitted conditions are approached, the PAT DS 150 Load Moment Indicator will warn
the operator by sounding an audible alarm, lighting a warning light and locking out those func­tions that may aggravate the crane´s condition.

2. WARNINGS

The PAT DS 150 Load Moment Indicator (LMI) is an operational aid which warns a crane op­erator of an approaching two blocking condition as well as approaching overload conditions
which could cause damage to equipment and property, and injury to the operator or bystand­ers. This device is not, and should not, be a substitute for good judgement, experience and
accepted safe crane operating procedures. The operator is solely responsible for the safe
operation of the crane and must observe and obey all warnings and instructions supplied by
PAT and the crane manufacturer. Prior to operating a crane equipped with a PAT operational
aid, the operator must carefully and thoroughly read and understand the information in this
manual and the crane manufacturer's manual to insure that the operator knows the operation
and limitations of the operational aid and crane. Proper functioning is dependent on proper
daily inspection and observance of the operating instructions set forth in this manual. We
draw your attention to section 5 of this handbook.

WARNING

The display (1) will only aid the operator when the LMI is properly programmed and the
proper load capacity chart and operating code are selected for the crane configuration
being utilized.
To prevent property damage or serious bodily injury or death to personnel, ensure the
LMI is properly programmed before operating the crane.

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3. SYSTEM DESCRIPTION

The PAT DS 150 load moment indicator consists of a central microprocessor unit, operator's
console and peripheral equipment to register the angles, pressures and hoist limit. The sys­tem operates on the principle of reference/real comparison. The real values resulting from the
force or pressure measurement is compared with the reference data stored in the central
processor memory and evaluated in the microprocessor. When limits are exceeded, an
overload warning signal is generated at the operator's console. At the same time, the danger­ous crane movements, such as hoist up, telescope out and boom down will be stopped.

The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity
and dimensions are stored in memory chips in the central processor unit. This data is the ref­erence information used to calculate the overload conditions.

Boom length and boom angle are registerd by the length/angle sensor, mounted indide the
cable reel which is mounted on the boom. The boom length is measured by the cabel reel ca­ble which also serves as electrical conductor for the anti-two-block switch.

The crane load is measured by pressure transducers attached to the piston and rod side of
the lift cylinders.

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SYSTEM COMPONENTS

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3.1 OPERATING CONSOLE

The console has 2 functions:

• terminal for input of instructions to the system by the crane operator

• display of important data and information

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4. CONTROL IDENTIFICATION

The following list will describe the controls and displays of the DS 150 safe load indicator. The numbers of
the illustration (on page 6) correspond to the numbers in the following list:

(1) LC DISPLAY

The LC DISPLAY will show technical information as well as operating information to the operator.
During crane operation the readout will display radius, boom length, boom angle, height of boom tip,
actual and maximum load. The load moment will also be indicated at the display in form of a bar­graph. In case of system malfunctions the various faults will be indicated via an error code instead of
the tip height display (Described in chapter 7).

(2) BARGRAPH

This indicator displays how much of the crane rated capacity is being used. As the crane is moved
through its various motions, the bargraph will constantly change on the display.
The range is divided into 3 areas:
A green area is the normal working area, the yellow prewarning area shows the remaining portion of
the rated load capacity and the bargraph indicates the approach to the overload condition and the

red area shows that the maximum rated load capacity is exceeded.

NOTE

Operating within the red area is not permitted.

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(3) OPERATING CODE SWITCH

The operating code switch is used to set the load moment indicator (LMI) to the operating configura­tion of the crane.

Caution

The correct setting is of utmost importance for the proper function of the system and the
crane. Therefore only operators who are thoroughly familiar with crane load capacity charts
and the use and operation of the system shall set the operating code switch. To set the op­erating mode, the operator has to adjust the operating code switch to a code number which
is printed in the load chart in accordance with the actual crane configuration.

(4) REEVING SWITCH

The REEVING SWITCH (4) provides the load moment indicator with information regarding the num­ber of falls (parts of line) used to reeve the hook block. The switch has 16 positions which are shown
under the window of the control knob when it is turned. The operator has to set the reeving switch to
the actual number of falls (parts of line) being used.

Caution

The correct setting is of utmost importance for the proper function of the system and the

crane.

(5) ANTI-TWO-BLOCK WARNING LIGHT

The red ANTI-TWO-BLOCK WARNING LIGHT (5) will light up when the anti-two-block limit switch
contacts open, indicating that a two-blocking condition is approaching. At the same time the audible
alarm will sound. The following crane movements will be stopped subsequently: hoist up, telescope
out, boom down.
The term "two block" is a crane term which refers to a condition when the load handling device
comes into contact with the boom head. This condition, if not prevented, may cause the wire rope to
break, allowing the load to fall. Two blocking can be caused by raising the load into the boom head
or lowering the boom without paying out hoist line.

(6) PREWARNING LIGHT

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The yellow LOAD MOMENT PREWARNING LIGHT (6) will light up when the load on the crane is
between 90 and 100 % of the crane rating, indicating that an overload condition is approaching. This
means for the operator to continue his crane operation with extreme caution.

(7) OVERLOAD LIGHT / ALARM SWITCH

This control serves a dual purpose:

• the red warning lamp lights up when the load on the crane is in excess of 100% of the crane rat-

ing, indicating that an overload condition has been reached.

• this button allows the audible alarm to be silenced for 15 seconds.

(8) TARE BUTTON

The TARE BUTTON is used to indicate the net load on the load display (ref. #1). Net load is the ac­tual load, less lifting tackle and hook block. The tare button has to be activated before lifting.
After pushing the TARE BUTTON the display of actual load will be set to zero (taring). and the dis­play shows max. load and net load. Net load display is blinking and set to zero. After lifting a load
the net load display shows the net load (pay load).
The net load display will change to the normal working display when the radius is changed (either by
boom angle or jib angle).
Display errors can be caused by reason of environmental factors such as wind acting upon the
crane and the load.

BOOM ANGLE LIMITS

This system is equipped with presets for boom angle range selection. There are limits for maximum
and minimum boom angle which can be set by the operator as allowed by crane geometry. After re­start the system the limits have to be set new.

(9) SETTING OF BOOM ANGLE LIMIT: MAXIMUM

After pressing this button, the actual boom angle will be stored as maximum boom angle limit. The
LC Display shows the value "MAX xx °". To indicate that the maximum angle limit is activated, the
lamp in the button will light up. Once this angle is reached, the lamp flashes and the buzzer will
sound until the boom is moved back into a permissible angle range.

(10) SETTING OF BOOM ANGLE LIMIT: MINIMUM

After pressing this button, the actual boom angle will be stored as minimum boom angle limit. The LC
Display shows the value "MIN xx °". To indicate that the minimum angle limit is activated, the lamp in
the button will light up. Once this angle is reached, the lamp flashes and the buzzer will sound until
the boom is moved back into a permissible angle range.

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RESET ANGLE LIMITS

To reset the boom angle limits press button (9) and (10) simultaneously. The values for angle limita­tion on the LC Display will be cleared.

(11) ENTER BUTTON "E"

This control has no function.

(12) BY-PASS KEY SWITCH

WARNING

Since this switch deactivates the cut-off function of the LMI system and the anti-two-block
system, the following instructions shall be adhered to:

• the by-pass key should 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 key to either overload or operate the crane in a range not permissi-

ble

The BY-PASS KEY SWITCH (12) can deactivate the cut-off of the LMI or anti-two-block momentarily
to allow the crane operator to override the control lever lockout. It can be operated only by using the
matching key. The spring-loaded by-pass switch has 3 positions which are further described as fol­lows: