PROLEC PME200 User Manual

This guide describes operation of the
PROLEC PME LIFTING AND MACHINE ENVELOPE SAFETY SYSTEM FOR CON-
STRUCTION PLANT
Model covered : PART No. MODEL Ref 0050X0-X00 PME200 - RCI + MEI SYSTEM 0050X0-X00 PME200 - RCC + MEC SYSTEM
Prolec Ltd Telephone +44 (0) 1202 681190 25 Benson Road Fax +44 (0) 1202 677909 Nuffield Industrial Estate E-mail service@prolec.co.uk Poole Dorset BH17 0GB
DURING NORMAL OPERATION THE SAFE WORKING LOAD OF A CRANE SHOULD NOT BE EXCEEDED. THEREFORE THE WARNING OF OVERLOAD SHOULD NOT BE USED AS A NORMAL OPERATING FACILITY. IT SHOULD BE NOTED THAT CERTAIN STATUTORY REQUIREMENTS DO NOT PERMIT THE SAFE WORKING LOAD TO BE EXCEEDED EXCEPT FOR THE PURPOSE OF TESTING.
THIS RATED CAPACITY INDICATOR / CONTROLLER (RCI, RCC) IS NOT SUITABLE FOR USE IN EXPLOSIVE ATMOSPHERES. ADJUSTMENT BY UNAUTHORISED PERSONS WILL INVALIDATE ANY WARRANTY OR CERTIFICATION SUPPLIED. IF A PROBLEM ARISES WHICH CANNOT BE RECTIFIED USING THIS GUIDE, AUTHORISED SERVICE SHOULD BE SOUGHT.
THIS DEVICE IS CERTIFIED TO MEET CURRENT UK & EC SAFETY REGULATIONS FOR LIFTING OPERATIONS.
Any alterations or modifications to machine components which affect this system and any system component failure must be reported to Prolec Ltd or via the machine convertor/ service agreement holder. This manual must be kept with the product and be passed on to any subsequent user of the product. Whilst every effort has been made to ensure the accuracy of the information supplied in this manual, Prolec Ltd cannot be held responsible for any errors or omissions.
This system records data on the machine’s operation.
Manufacturers original instructions.
Table of contents
1 Use of this Document 8
2 Notices 8
3 System Identification 9
4 Operating and Limit Situation Recommendations 10
4.1 MEC Override
5 Operating Instructions 11
5.1 Power Up
5.2 Using the Display
5.3 User Login
10
11
12
13
5.4 Supervisor Login
5.5 Logout
6 Top Menu 15
6.1 Tool Selection Menu (Optional)
6.2 Product Type Selection Menu (Optional)
6.3 PME 2D Digging (Optional)
7 Rated Capacity Indicator / Controller 17
7.1 Introduction
7.2 Operation within the Safe Working Load
7.3 Approach to Overload
14
14
15
16
16
17
18
18
7.4 Stability Indication Overload
19
Continued
Table of contents (continued)
7.4.1 Hydraulic Limit Indication
7.5 Stability Control Overload
7.5.1 Hydraulic Limit Control
7.6 Overload / Hydraulic Limitation Control Override
7.6.1 Soft Override
7.6.2 Master Override Key Switch
7.7 Lift Mode Menu
7.8 Lifting Point Selection
7.9 Duty Selection
7.10 Load Chart Menu
7.11 Lifting Mode - Non Lifting Mode
7.12 Alternative Lifting Mode Screens
20
20
20
21
21
21
22
22
23
24
25
26
8 Envelope Monitoring 27
8.1 Height Limit
8.1.1 Height Limit Menu
8.1.2 Height Limit Setting - Known Height
8.1.3 Height Limit Setting - Using Current Highest Point
8.1.4 Machine Envelope Indicator (MEI) - Height
8.1.5 Machine Envelope Controller (MEC) - Height
8.2 Max Radius Limit
8.2.1 Max Radius Limit Menu
8.2.2 Max Radius Limit Setting - Known Max Radius
28
28
29
30
31
32
33
33
34
8.2.3 Max Radius Limit Setting - Using Current Max Radius
8.2.4 Machine Envelope Indicator (MEI) - Max Radius
8.2.5 Machine Envelope Controller (MEC) - Max Radius
Continued
35
36
37
Table of contents (continued)
8.3 Min Radius Limit
8.3.1 Min Radius Limit Menu
8.3.2 Min Radius Limit Setting - Known Min Radius
8.3.3 Min Radius Limit Setting - Using Current Min Radius
8.3.4 Machine Envelope Indicator (MEI) - Min Radius
8.3.5 Machine Envelope Controller (MEC) - Min Radius
8.4 Low Limit
8.4.1 Low Limit Menu
8.4.2 Low Limit Setting - Known Low Height
8.4.3 Low Limit Setting - Using Current Lowest Point
8.4.4 Machine Envelope Indicator (MEI) - Low
38
38
39
40
41
42
43
43
44
45
46
8.4.5 Machine Envelope Controller (MEC) - Low
9 Warning Messages
9.1 On Screen Messages
9.2 LED and Internal Alarm Warnings
10 Daily checks 49
11 Repair 49
12 Test / Diagnostics 50
121 Relay Function Test
47
48
48
50
12.2 Sensor Data
12.3 Beacon, Beacon, LED and Internal / External Alarm Function Test
Continued
51
51
Table of contents - continued
13 System Information 52
14 Display Settings 52
14.1 Day / Night Mode
14.2 Select Display Machine
14.3 Select Language
14.4 Background Colour
15 User Login 55
15.1 User Login Setup
15.2 Enable / Disable Users
15.3 Add New User
15.4 Edit User Details
53
53
54
54
55
55
56
57
15.5 Select User to Delete
15.6 Edit User Access Code
16 Taking Product out of Operation 59
17 Service and Repair 59
17.1 Maintenance Review 59
18 Definitions / Glossary 60
19 Amendment / Revision Record 61
58
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1 Use of this Document
This user guide is intended for persons familiar with the use of construction plant under­taking lifting operations.
WARNING denotes a risk situation. Caution must be use. Informa­tion about particular risks which may be generated by certain appli­cations and about additional protective measures which are neces­sary for such applications.
HAZARD Actions that can lead to serious injury or death
2 Notices
Adjustment by unauthorised persons will invalidate any warranty or certification supplied. If an error condition is displayed which cannot be rectified using this guide, halt any operation and seek authorised service immediately. Do not continue the operation until the fault has been remedied.
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3 System Identification
The PME system provides two primary safety functions
1. Lifting Stability
2. Machine Envelope Monitoring
Both safety functions are achieved through real time monitoring of some
or all of the machine’s moving parts ( booms, other articulations, turret
etc ) and its environment ( ground pitch and inclination, load etc) and actively determining the safety of the current operation where appropriate limits have been set.
The Lifting Stability function falls into two sub classes
Rated capacity indictors (RCI) warn of potential instability when
the machine is involved in lifting operations. Any motion which
reduces the safe working load will not be inhibited at any time.
Rated capacity controllers (RCC) prevent instability when the ma-
chine is involved in lifting operations. This is achieved by hydraulically stopping unsafe movements of the machine which could cause the machine to tip.
The Machine Envelope Monitoring function has a single class
Machine envelope controllers (MEC) prevent movements that
would bring parts of the machine into hazardous areas, most nota-
bly height restrictions when working under overhead wires.
During operation the indicators on the left are displayed on the screen to clearly identify the function supported by your PME200. Functions may not be available i.e. when in non-lifting mode or when envelope monitoring is switched off, if this is the case a cross will be painted over the relevant function icon. Combinations of these functions may be present, it is essential that the functions of the system installed are identified and understood.
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4 Operating and Hazard Situation Recommendations
Operating Recommendations
When using envelope monitoring:
When setting a slew and or height restriction, make sure any implement attached is
in its least favourable position
Check for correct operation once the restriction or restrictions have been set
Reduce operating speed
Do not move the equipment quickly when close to a restriction
Do not operate the machine in a reckless manor
Do not travel with a restriction set
Reset the slew restriction if the machine is relocated
Hazard Situation Recommendations
In a limit hazard state:
Return the control levers to neutral once a limit has been reached if appropriate
Operate the machine at a slow speed
Do not travel
4.1 MEC Override
The system can optionally be fitted with a master override key switch. Turning the key to the override position will allow normal operation of the hydraulic services regardless of safety status. When the system is in override, the ex­ternal alarm (if fitted) will be active, and the beacon (if fitted) will be off, the
RED LED will flash and an ‘In Override’ message will appear on the display
indicating that the machine limiting is overridden. The override state will auto­matically return to normal operating mode after 30 minutes (default value), regardless of the system status. The master override key switch must be cy­cled to put the system back into override.
The master override key switch should only be used if the safety system is not operational due to a fault and the machine needs to be moved due to its location pre­senting a hazard. The override status is recorded in the system data log. To access the override key switch an anti tamper seal may need to be broken.
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5 Operating Instructions
5.1 Power Up
The PME system automatically powers up when the ignition is switched to on. The in-cab
display 4.3” high resolution LCD display and is controlled with three buttons at each side.
Three status LEDs and an internal alarm provide further indication.
The system will perform a self check at start up:
1. All LEDs will flash, the internal alarm and the external alarm (if fitted) will sound and
the system will perform a self test.
2. Once the self test is complete, a safety warning message will be displayed, pressing
any button activates the operating mode, the GREEN LED will light. Any previous limit or limits set will be enabled.
3. The system is now ready for use unless the user login feature has been enabled,
see section 5.3.
If the RED LED is lit, a fault has been detected, halt any operation, seek authorised service immediately and do not continue operation until the fault has been remedied.
The display is secured to the machine using a flexible ball mounting allowing easy adjust­ment for personal viewing preference.
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5.2 Using the Display
The display is operated by using the buttons adjacent to the function icons. The buttons can open a sub menu, turn a function ON or OFF, set a value, toggle through multiple screens, no one button has a single function. The icon will turn black/purple when the button has been activated. Icons can be assigned for Supervisor use only, to access them enter the supervisor code or use the supervisor key switch (if fitted), see section
5.4. Note that the side view of the machine shown in PME200 is fixed and does not follow the movement of the machine.
Multifunction buttons: The action of the button is indicated by the adjacent icon.
A secondary symbol can appear in the top left corner of an icon, these mean:
The plus symbol indicates a sub menu will be opened if selected.
The cycle symbol indicates that multiple features are available.
The on / off symbols indicate if a feature is ON or OFF. Red is ON and grey is OFF.
Help is available for each button. To access the help, push and hold the icon button for three sec­onds. The help screen can be cleared by pressing any of the six buttons. PME is still actively monitor­ing when displaying help messages, therefore any alarm or warning condition will still be indicated within this feature.
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5.3 User Login
PME may be configured to work with the built-in user list. If so, the system will prompt for a user login pass code after acknowledging the safety warning screen. Select the user name required and the login code screen will appear. Using the Arrow icon buttons, enter a valid pass code. The previous pass code digit will be replaced with a star as the code is entered. Press the Tick icon button to confirm the login pass code. If a valid pass code is entered the system will commence normal opera­tion. Logging out is described in section 5.5
Exit Login
Cancel without change
Moves highlighter to left or Hold to delete digit
Moves highlighter UP
Select highlighted name to open the En­ter Login Code screen below
Moves highlighter DOWN
Increases highlighted digit
Moves highlighter to right
Accept displayed value
Decreases highlighted digit
If an incorrect login code is entered, a failure screen will be displayed. Press the Tick icon button to return to the Select User screen.
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5.4 Supervisor Login
To login as a supervisor, either Login as described in section 5.3, use the supervisor key switch (if fitted) or hold any Exit icon button down for three seconds and enter your code.
Logging out is described in section 5.5 or use the supervisor key switch. Logging in as a supervisor is recorded in the system data log.
Cancel without change
Moves highlighter to left or Hold to delete digit
Accept displayed value
Increases highlighted digit
Moves highlighter to right
Decreases highlighted digit
5.5 Logout
To select the logout screen, hold any Exit icon button down for three seconds. Once log­out has been confirmed, the login screen will be automatically displayed. Press the Cross icon button to stay logged in and return to previous screen.
Cancel without change
Confirm logout
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6 Top Menu
The Top Menu screen allows access to all the system functions. To reveal the icons, if hidden, press any button. To return to the Top Menu from a sub menu press the EXIT button until the Top Menu is displayed. Top Menu button functions:
Limits menu Lifting menu Tool selection Test / Diagnostics Lifting Mode ON and OFF / 2D Digging (Optional) Hide icons
Menu level indicator
Limits Menu
Tool selection
System Type selection
To hide the icons when at the Top Menu, press the EXIT button once more.
6.1 Tool Selection Menu (Optional)
The system can monitor the position of a tool and so be calibrated with one or multiple tools. If more than one tool has been calibrated, they will be manually selected via the Select Tool selection screen shown below. Use the Arrow icon buttons to select the required tool and confirm using the Tick icon button. Example tools are shown in the listing.
Test Diagnostics
Non - lifting mode / 2D Digging mode
Hide icons
Exit without change
Moves highlighter UP
Accept highlighted Tool
Moves highlighter DOWN
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6.2 Product Type Selection Menu (Optional)
This system can be calibrated for multiple Product Types. If more than one Product has been activated, they can be manually selected via the product screen shown below. Use the Arrow icon buttons to select the required prod­uct and confirm using the Tick icon button, the system will restart automati-
cally. Ensure the correct equipment is fitted to the machine when selecting a product. Example products are shown, please refer to the relevant product operator manual for further instructions.
Exit without change
Moves highlighter UP
Accept highlighted system
Moves highlighter DOWN
6.3 PME 2D Digging (Optional)
PME2D offers all the features you’d expect from a 2D guidance product providing accu-
rate and quick grade control in common civil engineering applications. Pre-set profiles allow you to dig to depth or grade to a known profile first time without under/over cutting, saving you time, rework and excess material. Tool addition and measurement, choosing and editing of slopes, cross sections, trenches and simple grading is simple to do all from the display.
Any existing PME system can be upgraded to 2D digging with the addition of simple soft­ware and hardware changes.
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7 Rated Capacity Indicator / Controller
7.1 Introduction
The PME200 RCI / RCC has been designed to meet European requirements for the pro­vision of rated capacity indicators. PME200 ensures that the maximum lifting capacity over the range of a machine working envelope can be utilised. The system will always start up in Lifting Mode. See section 4 for operating advice when using construction plant as a crane. The Lifting Mode feature can be used in conjunction with envelope monitor­ing, see section 8. In this mode, the beacon (if fitted) will indicate that the Lifting Mode functionality is active.
1. Lifting point radius
4. Safe directional indicators
8. Load On Hook
1. Lift point radius is the horizontal distance in metres from the slew centre line to the lifting point.
2. Current lifting duty in use.
3. Current lift point in use.
4. Safe Directional indicators. The triangles on both sides of each piece of equipment and slew arrows indicate if it is safe GREEN, or unsafe RED to move the relevant articulation and direction in that direction under overload envelope limits. A triangle with a red border indicates that the articulation is limited by hydraulic capacity and not by machine stability.
5. RCI / RCC - MEC indicators (see section 3)
6. Maximum Safe Working Load (SWL) for the current lifting point height and radius combination. The value is given in metric tonnes.
7. SWL percentage bar graph indicating the percentage of the current load to the maximum available safe working load.
8. Load on Hook (LOH) shows the current load in tonnes suspended from the current lifting point.
2. Current Duty
7. SWL percentage 5. RCI / RCC indicators
3. Current Lifting point
6. Maximum Safe Working Load
5. MEI / MEC indicators
The SWL as displayed assumes that the load is suspended directly below the lifting point. The weight of the tool or tools, if fitted, (e.g. Bucket , quick hitch etc) are accounted for in the SWL and LOH values if they were taken into consideration when the system was calibrated. The bucket cylinder and control linkage is assumed to be present.
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7.2 Operation within the Safe Working Load
With the Lifting Mode active, the current lifting point radius and the maximum safe working load for that radius are shown.
If the load is less than 95% of the maximum safe working load
The load capacity indicator will be
green
The green LED will be lit
7.3 Approach to Overload
With the Lifting Mode active, if the load is between 95% and 104% of the maximum safe working load the system will warn the machine is
close to the lifting capacity at the current height and radius. The system indicates an approach to overload condition via an internal alarm in conjunction with vis­ual indicators on the display - no motion is cut.
If the load is greater than 95% of the maximum safe working load.
The load capacity indicator will be
amber
The amber LED will be lit
The internal alarm will sound
The message shown here will be
displayed.
In the event of an approach to overload or an overload condition, the lifting
point should only be moved in a direction that increases the safe working
load. See section 4 for further information.
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7.4 Stability Indication Overload
With the Lifting Mode active, if the load is greater than 105% of the maximum safe working load the system will warn the machine is close to the lifting capacity at the current height and radius. The system indicates an overload condition via
internal and external alarms in con­junction with visual indicators on the display ­no motion is cut.
If the load is greater than 105% of the maximum safe working load
The load capacity indicator will be red
The red LED will flash
The internal and external alarm will
sound
The message shown here will be
displayed
Unsafe motion is indicated by RED
arrows, safe motion is indicated by GREEN arrows
7.4.1 Hydraulic Limit Indication
If a particular lift is limited by hydraulic capacity rather than stability, the directional indica­tor on the articulation in question will have a RED border. Hydraulic limitation is more likely to occur at short radii. The system indicates a hydraulic limitation condition via internal and external alarms in conjunction with visual indicators on the display - no mo­tion is cut.
In the event of an approach to overload or an overload condition, the lifting
point should only be moved in a direction that increases the safe working
load. See section 4 for further information.
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7.5 Stability Control Overload
Where an overload condition occurs the machine hydraulics will be locked to pre-
vent any further dangerous movements. Only those movements that allow safer
operation remain active. The radius cannot be increased and the load cannot be
raised. The internal and external alarms will sound in conjunction with visual indi­cators on the display.
If the load is greater than 105% of the maximum safe working load
The load capacity indicator will be red
The red LED will flash
The internal and external alarm will
sound
The message shown here will be
displayed
Motion control of the machine will
operate, motion cut is indicated by RED arrows, safe motion is indicated by GREEN arrows
7.5.1 Hydraulic Limitation Control
The system will cut motion to the appropriate articulation in a hydraulic limit state and in­dicate this via internal and external alarms in conjunction with visual indicators on the dis­play.
Where an overload condition occurs the machine hydraulics will be locked to prevent any further dangerous movements. Only those movements that allow safer operation remain active. The ra­dius cannot be increased and the load cannot be raised.
After three seconds a soft override will become available, see section 7.6.1
In the event of an approach to overload or an overload condition, the lifting
point should only be moved in a direction that increases the safe working
load. See section 4 for further information.
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7.6 Overload / Hydraulic Limitation Control Override
7.6.1 Soft Override
After three seconds a soft override button may replace the Lifting Mode but­ton. If soft override is utilised, the machine hydraulics will be re-enabled. How­ever, the external alarm will stay active, the red LED will flash, and the beacon (if fitted) will switch off. Once the alarm condition has been corrected the RCC will automatically clear the override request and revert to normal operation.
Soft override
7.6.2 Master Override key Switch
The system can optionally be fitted with a key operated Master override switch. Turning the switch to the override
position will allow normal operation of any of the hydraulic services regardless of safety status. When the unit is in override the external alarms will stay active, and the beacon (if fitted) will indicate that the machine is overridden, the red LED will flash and an In Override message will appear on the display. See section 4.1 for further details.
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7.7 Lift Mode Menu
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Lifting point selection
Displays load chart
The Lifting Mode function has various features which may be available if con­figured at installation. The configuration will depend on the operating proce­dures of the machine owner. If only one duty, lifting point and or tool has been calibrated, the relevant icon will not be displayed.
7.8 Lifting Point Selection
Exit to previous screen
The current lifting point is indicated on Lifting Mode screen. The system can be calibrated with just one lifting point for use in any duty. If more than one lifting point has been calibrated, it will be
manually selected via the lifting point selection screen shown be­low. Use the arrow buttons to select the required lifting point and confirm using the TICK button. Example lifting points are shown in the listing.
Exit without change
Multiple lifting points allow different lifting capacities to be achieved, altering the lifting point will not affect the current duty selected (See section 7.9).
Moves highlighter UP
Accept highlighted system
Moves highlighter DOWN
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7.9 Duty Selection
The current duty is indicated on the Lifting Mode screen. The system can be calibrated with just one duty for use throughout 360 degrees of slew, most machines will be calibrated in this way. If more than one duty has been calibrated, it will either be
manually or automatically selected. Manual selection is via the duty selection screen shown below. Use the arrow buttons to select the required duty and confirm using the TICK button. Common duty types are shown in the listing.
Moves highlighter UP
Accept highlighted
Exit without change
system
Moves highlighter DOWN
Multiple duties on tracked machines may be used to allow both 360º and FRONT/REAR lifting arcs for increased lifting capacity. On wheeled machines extra duties could be used for any combination of arc, support blade and stabiliser usage. Altering the duty will not affect the current lifting point selected (See section 7.8).
If automatic duty switching is active, manual duty selection will be disabled. Automatic duty selection can be based on a number of machine features such as slew position, sta­biliser position, telescopic extension position, secondary equipment.
If only one duty has been calibrated this screen will not be accessible.
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7.10 Load Chart Menu
PME can display the load chart for the currently selected lifting duty and lifting point. *If the machine is equipped with a hydrau­lically adjustable boom, both maximum and minimum charts will be available.* Hydraulically adjustable booms allow the machine
to reach the same point in space (i.e. height and radius combina­tion) with a variety of different equipment angles. The minimum loads shown refer to the least favourable angle combination. When load charts are being displayed, machine safety status is still monitored.
Hydraulically limited
Lifting point Radius SWL values
SWL
*Displays maximum load chart
Information bar
Lifting point Height
Duty name and Lifting
point name
Hydraulic limit colour code
ON and OFF
Exit to previous menu
If a particular lift is limited by hydraulic capacity rather than stability, the directional indica­tor on the articulation in question will have a RED border. The maximum load for duties
limited by stability is stated as a percentage of the ‘tipping load’ and in a standard installa-
tion will be 75%.
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7.11 Lifting Mode - Non Lifting Mode
When the machine is not being used for lifting operations it can be put into ‘Non Lifting Mode’ available from the Top Menu screen. When in Non Lifting Mode, the system still monitors all machine activity and safety status but will NOT warn of overload conditions. In this mode, the bea-
con (if fitted) will be off indicating that the Lifting Mode functionality is NOT ac­tive. Lifting mode cannot be activated if the LOH value exceeds a predefined weight. En­velope Limit monitoring will remain active if any limit has been set.
Note Lift Mode button
is not accessible
Lifting Mode ON
Lifting Mode OFF
Lifting mode cannot be activated if the LOH value exceeds the predefined weight, this value defaults to 100kg.
RCI / RCC
ON: when operating with an active limit the indicator will not have a painted on cross on it.
OFF: when operating without limit the indicator will have a cross painted on it.
When in Non Lifting Mode, the screen states NON-LIFTING MODE on the hazard warning tape and a red cross appears in the RCI RCC indicator - lift­ing operations should not be attempted in this state. The beacon (if fitted) will be off.
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7.12 Alternative Lifting Mode Screens
Alterative Lifting Mode screens can be selected from the Display Settings screen (See section 14). The three selectable screens show safe working load, load on hook, lifting point radius and bar graph or
dial indicating the proximity of the current load to the maximum available safe working load. Pressing the EXIT button will hide the icons. Press any button to reveal the icons.
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8 Envelope Monitoring
PME200 can be configured for Machine Envelope Indication (MEI) or Machine Envelope Control (MEC). MEI will give a warning only, MEC will warn, and prevent equipment motion. MEC is achieved by interacting with the machines hydraulics, this allows motion to be cut to any section of equipment that has
reached a restriction but allow other sections to operate unhindered unless they too reach the set restriction. PME200 can monitor the highest, furthest, nearest and lowest part of the machine. When setting a limit, either by entering a known value or by positioning the machine at the de­sired limit, make sure any implement attached is in its least favourable position as the system is unaware of any implement fitted unless listed in Tool Selection, see section 6.1.
Height Limiting
Max Radius Limiting
Low Limiting
MEC MEI
OFF: when operating without limit the indicator will have a cross painted on it.
ON: when operating with an active limit the indicator will not have a cross painted on it.
Care should be taken to test that the limit is set correctly.
Min Radius Limiting
Exit to previous screen
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.1 Height Limit
8.1.1 Height Limit Menu
A height limit can be set by entering a known height or by manu­ally moving the machine to the desired limit.
Turns monitoring
ON and OFF
Enter a value
Current height limit and highest point. Only displayed if a height limit is set.
Set height limit using
Exit to previous menu
current highest part of
equipment
Using the Height Limits Menu, the height limit can be switched ON and OFF (a Confirm Operation screen will be displayed, see sections 8.1.2 to enter a known height and section 8.1.3 for setting the limit by moving the ma­chine.
With a height limit set, the screen will display the current highest point and the current height limit.
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8.1.2 Height Limit Setting - Known Height
A known limit can be entered into the display. This is the vertical height from the ground or base of the ma­chine:
Enter a value
Press the ’Enter a value’ button
Cancel without change
Exit to previous menu
Increases highlighted digit
Moves highlighter to
left/ Hold to delete digit
Accept displayed value
Moves highlighter to right
Decreases highlighted digit
Use the UP and DOWN arrows to increase and decrease the highlighted number. Use the LEFT and RIGHT arrows to move the highlighter to the left and to the right.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.1.3 Height Limit Setting - Using Current Highest Point
Set the limit using the current highest point of the machine. Ensure the tool is off the ground before setting the limit.
Move equipment to required
height limit and press this button
To set the height limit using the machine, move the equipment to the desired maximum height, and
press the ‘current highest point’
button. A confirmation box will appear reporting the height set. Press the TICK button to continue.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.1.4 Machine Envelope Indicator (MEI) - Height
If any of the equipment enters the approach limit* a ‘Close to max height’ mes-
sage will appear, the internal alarm will sound and the amber LED will be lit.
MEI systems will not cut motion to any section of equipment that has reached a limit. This can lead to the a breech of the set limit.
If any of the equipment reaches the height limit, the internal alarm will sound and the RED LED will be lit.
*The approach limit is configurable at point of calibration, check system operation before commencing work.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment reaches the current limit. Always check that the limit activates at the set point. A limit cannot be deactivated when close to or at the limit. Observe the operational limitations given in section 4.
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8.1.5 Machine Envelope Controller (MEC) - Height
If any of the equipment enters the approach limit* a ‘Close to max height’ mes-
sage will appear, the internal alarm will beep and the amber LED will be lit. If any of the equipment reaches the height limit, the appropriate motions will be con­trolled.
MEC systems will cut mo­tion to any section of equipment that has reached a limit but allow other sections to operate unhindered unless they too reach the set limit.
If any of the equipment reaches the height limit, the internal alarm will sound and the RED LED will be lit and the appropriate motions will be controlled.
*The approach limit is configurable at point of calibration, check system operation before commencing work.
See sections 4.1 and 7.6 for hydraulic override details.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment reaches the current limit. Always check that the limit activates at the set point. A limit cannot be deactivated when close to or at the limit. Observe the operational limitations given in section 4.
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8.2 Max Radius Limit
8.2.1 Max Radius Limit Menu
A max radius limit can be set by entering a known radius or by manually moving the machine to the desired limit.
ON and OFF
Turns monitoring
Enter a value
Set max radius limit
using current furthest
part of equipment
Using the Max Radius Limits Menu, the max radius limit can be switched ON and OFF, a max radius limit can be set to a known value, or the max radius limit can be set to the current farthest point. See sections 8.2.2 to enter a known max radius and section 8.2.3 for setting the limit by moving the machine.
Exit to previous menu
Current furthest point. Only displayed if a max radius limit is set.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment reaches the current limit. Always check that the limit activates at the set point. A limit cannot be deactivated when close to or at the limit. Observe the operational limitations given in section 4.
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8.2.2 Max Radius Limit Setting - Known Max Radius
A known limit can be entered into the display. This is the horizontal distance from the slew centre of the machine to the tool pin:
Enter a value
Exit to previous menu
Press the ’Enter a value’ button
Cancel without change
Increases highlighted digit
Moves highlighter to left also moving left beyond
the first digit will insert “0”
Moves highlighter to right
Hold to delete digit
Decreases high-
Accept displayed value
lighted digit
Use the UP and DOWN arrows to increase and decrease the highlighted number. Use the LEFT and RIGHT arrows to move the highlighter to the left and to the right.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment reaches the current limit. Always check that the limit activates at the set point. A limit cannot be deactivated when close to or at the limit. Observe the operational limitations given in section 4.
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8.2.3 Max Radius Limit Setting - Using Current furthest Point
Set the limit using the current furthest point of the machine. Ensure the equipment is off the ground be­fore setting the limit.
Move equipment to required max
radius limit and press this button
To set the max radius limit using the machine, move the equipment to the desired radius, and press
the ‘current farthest point’ button.
A confirmation box will appear re­porting the radius set. Press the TICK button to continue.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment reaches the current limit. Always check that the limit activates at the set point. A limit cannot be deactivated when close to or at the limit. Observe the operational limitations given in section 4.
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8.2.4 Machine Envelope Indicator (MEI) - Max Radius
If any of the equipment enters the approach limit* a ‘Close to max radius’ message will
appear, the internal alarm will sound and the amber LED will be lit.
MEI systems will not cut motion to any section of equipment that has reached a limit. This can lead to the a breech of the set limit.
If any of the equipment reaches the max radius limit, the internal alarm will sound and the RED LED will be lit.
*The approach limit is configurable at point of calibration, check system operation before commencing work.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment reaches the current limit. Always check that the limit activates at the set point. A limit cannot be deactivated when close to or at the limit. Observe the operational limitations given in section 4.
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8.2.5 Machine Envelope Controller (MEC) - Max Radius
If any of the equipment enters the approach limit* a ‘Close to max radius’ mes-
sage will appear, the internal alarm will beep and the amber LED will be lit. If any of the equipment reaches the max radius limit, the appropriate motions will be controlled.
MEC systems will cut mo­tion to any section of equipment that has reached a limit but allow other sections to operate unhindered unless they too reach the set limit.
If any of the equipment reaches the max radius limit, the internal alarm will sound and the RED LED will be lit and the appropriate motions will be controlled.
*The approach limit is configurable at point of calibration, check system operation before commencing work.
See sections 4.1 and 7.6 for hydraulic override details.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.3 Min Radius
8.3.1 Min Radius Limit Menu
A min radius limit can be set by entering a known radius on the keypad or by manually moving the machine to the desired limit.
ON and OFF
Turns monitoring
Enter a value
Set min radius limit us-
ing current nearest
part of equipment
Using the Min Radius Limits Menu, the min radius limit can be switched ON and OFF, see sections 8.3.2 to enter a known min radius and section 8.3.3 for setting the min radius by moving the machine.
Current nearest point. Only displayed if a min radius limit is set.
Exit to previous menu
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.3.2 Min Radius Limit Setting - Known Min Radius
A known limit can be entered into the display. This is the horizontal distance from the slew centre of the machine to the tool pin:
Enter a value
Press the ’Enter a value’ button
Exit to previous menu
Cancel without change
Increases high-
lighted digit Moves highlighter to left also moving left beyond
the first digit will insert “0”
Moves highlighter to
right Hold to delete digit
Decreases high-
Accept displayed value
lighted digit
Use the UP and DOWN arrows to increase and decrease the highlighted number. Use the LEFT and RIGHT arrows to move the highlighter to the left and to the right.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.3.3 Min Radius Limit Setting - using Current nearest Point
Set the limit using the nearest point of the machine. Ensure the equipment is off the ground before set­ting the limit.
Move equipment to required min radius limit and press this button
To set the min radius limit using the machine, move the equip­ment to the desired minimum ra-
dius, and press the ‘current near­est point’ button. A confirmation
box will appear reporting the ra­dius set. Press the TICK button to continue.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.3.4 Machine Envelope Indicator (MEI) - Min Radius
If any of the equipment enters the approach limit* a ‘Close to min radius’ message will
appear, the internal alarm will sound and the amber LED will be lit.
MEI systems will not cut motion to any section of equipment that has reached a limit. This can lead to the a breech of the set limit.
If any of the equipment reaches the min radius limit, the internal alarm will sound and the RED LED will be lit.
*The approach limit is configurable at point of calibration, check system operation before commencing work.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.3.5 Machine Envelope Controller (MEC) - Min Radius
If any of the equipment enters the approach limit* a ‘Close to min radius’ message will
appear, the internal alarm will beep and the amber LED will be lit. If any of the equipment reaches the min radius limit, the appropriate motions will be controlled.
MEC systems will cut mo­tion to any section of equipment that has reached a limit but allow other sections to operate unhindered unless they too reach the set limit.
If any of the equipment reaches the min radius limit, the internal alarm will sound and the RED LED will be lit and the appropriate motions will be controlled.
*The approach limit is configurable at point of calibration, check system operation before commencing work. See sections 4.1 and 7.6 for hydraulic override details.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.4 Low Limits
8.4.1 Low Limit Menu
A low limit can be set by entering a known height on the keypad or by manually moving the machine to the desired limit.
ON and OFF
Set low limit using cur­rent lowest of equip­ment
Turns monitoring
Enter a value
Exit to previous menu
Current lowest point. Only displayed if a Low limit is set.
Using the Low Limits Menu, the low limit can be switched ON and OFF, a low limit can be set to a known value, or the low limit can be set to the current lowest point.
See sections 8.4.2 to enter a known low and section 8.4.3 for setting the limit by moving the machine.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.4.2 Low Limit Setting - Known Low Height
A known limit can be entered into the display. This is the vertical height from the ground or base of the ma­chine:
Enter a value
Press the ’Enter a value’ button
Exit to previous menu
Cancel without change
Increases high-
lighted digit Moves highlighter to left also moving left beyond the first digit will insert
Moves highlighter to right
“0”/ Hold to delete digit
Decreases high-
Accept displayed value
lighted digit
Use the UP and DOWN arrows to increase and decrease the highlighted number. Use the LEFT and RIGHT arrows to move the highlighter to the left and to the right.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.4.3 Low Limit Setting - using Current Lowest Point
Set the limit using the lowest point of the machine.
Move equipment to required low
limit and press this button
To set the low limit using the machine, move the equipment to the desired low height, and
press the ‘current lowest point’
button. A confirmation box will appear reporting the value set. Press the TICK button to con­tinue.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.4.4 Machine Envelope Indicator (MEI) - Low
If any of the equipment enters the approach limit* a ‘Close to min height’ message will ap-
pear, the internal alarm will sound and the amber LED will be lit.
MEI systems will not cut motion to any section of equipment that has reached a limit. This can lead to the a breech of the set limit.
If any of the equipment reaches the low limit, the internal alarm will sound and the RED LED will be lit.
*The approach limit is configurable at point of calibration, check system operation before commencing work.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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8.4.5 Machine Envelope Controller (MEC) - Low
If any of the equipment enters the approach limit* a ‘Close to min height’ message will
appear, the internal alarm will beep and the amber LED will be lit. If any of the equipment reaches the low limit, the appropriate motions will be controlled.
MEC systems will cut mo­tion to any section of equipment that has reached a limit but allow other sections to operate unhindered unless they too reach the set limit.
If any of the equipment reaches the low limit, the internal alarm will sound and the RED LED will be lit and the appropriate motions will be controlled.
*The approach limit is configurable at point of calibration, check system operation before commencing work. See sections 4.1 and 7.6 for hydraulic override details.
Once a limit is set, the internal alarm will sound and the RED LED
will light if the equipment exceeds the current limit. Always check that the current limit activates at the set point. The restriction cannot be de­activated if in the alarm state. Observe the operational limitations given in section 4.
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9 System Messages
9.1 On Screen Messages
Close to max height
Max height reached
Close to max radius
Max radius reached
Close to min radius
Min radius reached
Close to min height
Min height reached
Close to SWL
Overload
Hydraulic Limit
In Override
Highest point of equipment within *0.5m of set limit
Equipment has reached set limit
Furthest point of equipment within *0.5m of set limit
Equipment has reached set limit
Nearest point of equipment within *0.5m of set limit
Equipment has reached set limit
Lowest point of equipment within *0.5m of set limit
Equipment has reached set limit
95 percent of the maximum safe working load
105 percent of the maximum safe working load
Pressure in the lift rams is in excess of 87% of main relief valve pressure
Override has been activated (Soft or master Key)
*The approach limit is configurable at point of calibration, check system operation before commencing work.
PME continuously monitors the presence and condition of the safety controller and sen­sors. If the safety controller or any sensor fails an error message box will appear at the bottom of the display. In the event of a failure, the cab mounted beacon (if fitted) will indi­cate that the system is NOT active, the display red LED will flash and the internal and ex­ternal alarms will sound.
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9.2 LED and Internal Alarm Warnings
The table below shows the state of the three LEDs on the display and the internal alarm with respect to system status.
LED and Internal Alarm status System status
1 Hz
Continuous
8 Hz
Off
Start up
Operational: System OK, no warnings, hazards, or errors
Warning: Approach to overload or envelope limit
Hazard; Overload or an envelope limit reached
Maintenance: Diagnostics access active
Error: PME hardware/software error, or sensor failure
10 Daily Checks
Display - check for damage and correct operation  Safety Controller - check for damage and correct operation  Sensors and sensor cabling - check for damage Cable Connections - check for damage, loose or disconnected connectors Internal / external alarm (if fitted) and beacon (if fitted) functionality
See section 11 for test / diagnosis features.
If an issue is discovered which cannot be rectified using this guide, halt any operation, seek authorised service immediately and do not continue operation until the fault has been remedied.
11 Repair
Once a repair has been carried out and tested, the following must be checked:
Required Checks Section Angles Check 12.2 Relay Check 12.1 Internal / external Alarm, LED and Beacon Check 12.3 Maintenance review 17.1
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12 Test / Diagnostics
The test diagnostics function is available from the main operating screen. This option allows the functionality of the system to be verified, and basic trouble-shooting to be performed. In this mode, the amber LED will flash to indicate that the system is in maintenance mode. The system will continue to
monitor any limits that are active and the Lifting Mode (if active) will continue to monitor machine safety status. Alarm conditions and warnings / controls will be issued as normal.
Relay / LED test
System information
Beacon, Alarms
and LED test
Display options
The image shown is an example only. The exact contents of the sensor list will depend on machine type and PME specification.
Equipment sensor angle
Code protected access to super­visor features
Exit to previous menu
12.1 Relay Function Test
To test the relays and motion cut valves use the blue arrow to highlight the appropriate output. When highlighted no motion for that service should be possible. Input signals are indicated by the LED lamp status.
Operate / show status of feature
Exit to previous menu
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12.2 Sensor Data
Angle values in the Actual column represent the angles of the monitored parts of the machine.
Piston raw = Boom full pressure
Rod raw = Boom rod pressure
Boom Actual = Boom angle
Platform Actual = Slew angle
562200-000, Issue 1.2, December 2015
Arm Actual = Arm angle
Exit to previous menu
12.3 Beacon, LED and Internal / External Alarm Function Test
Press the Beacon icon button with painted cross button to activate the beacon (if fitted)
Press the Beacon icon button to activate the external alarm (if fitted)
Press the Alarm icon button to activate the internal alarm and display LEDs
Press the LED icon button to deactivate the internal alarm and display LEDs
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13 System Information
Information regarding the system can be found from this menu.
Software Version information
LOLER information
License information
Distributor information
14 Display Settings
The display brightness, button click volume, and the displayed machine colour and type can be adjusted from this menu.
Adjust button
click volume
Select day/night mode
Machine information
Exit to previous menu
Alternative Lifting Mode screen se­lection (See section
7.12)
ON and OFF
Select machine colour / type and back-
ground colour
Language selection
Exit to previous menu
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14.1 Day / Night Mode
Select day / night mode:
Day mode ON
Full display brightness
To make viewing the display more comfortable at night, the display brightness can be switched to a
preset ‘night mode’. The system will default to day
mode on power up.
Night mode ON
Reduced display
brightness
14.2 Select Display Machine
Exit without change
An appropriate machine type for the dis­play can be selected from this list.
Moves highlighter UP
Accept highlighted
Moves highlighter DOWN
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14.3 Select Language
Exit without change
An appropriate language type for the display can be selected from this list.
Moves highlighter UP
Accept highlighted language
14.4 Background Colour
Scroll through and accept background
colour
Moves highlighter DOWN
The screen background colour can be altered, use the Background Colour button to scroll through the available colours.
Exit to previous menu
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15 User Login
15.1 User Login Setup
Requires supervisor access rights.
Add new user
Select user to edit
Select user to
delete
15.2 Enable / Disable Users
Requires supervisor access rights
Select / de-select operator all entries
Cancel without change
Select / deselect highlighted entry
Edit user login code
Select user(s) to be displayed on login screen
Exit to previous menu
Edit user login code
Select user(s) to be displayed on login screen
Exit to previous menu
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15.3 Add New User to Login
Requires supervisor access code
Cancel without change
Scroll up though high­lighted digits/ letters
Moves highlighter to
left/ Hold to delete digit
Accept displayed name
Return to previous screen
Cancel without change
Moves highlighter to right
Scroll down though highlighted digits/ letters
Increases highlighted digit
Moves highlighter to right
Decreases highlighted digit
Increases highlighted digit
Moves highlighter to left / Hold to delete digit
Accept displayed code
Moves highlighter to right
Decreases highlighted digit
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15.4 Edit User Details
Requires supervisor access rights.
Cancel without change
Cancel without change
Moves highlighter to
left/ Hold to delete digit
Accept displayed name
Moves highlighter UP
Select highlighted user
Moves highlighter DOWN
Scroll up though high­lighted digits/ letters
Moves highlighter to right
Scroll down though highlighted digits /
letters
Cancel without change
Cancel without change
Moves highlighter to left / Hold to delete digit
Accept displayed code
Moves highlighter UP
Select highlighted Privilege
Moves highlighter DOWN
Increases highlighted digit
Moves highlighter to right
Decreases highlighted digit
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15.5 Select User to Delete
Requires supervisor access rights.
Return to previous
Exit without change
screen
Moves highlighter UP
Delete highlighted user
15.6 Edit User Access Code
Requires supervisor access rights.
Return to previous
Exit without change
screen
Moves highlighter DOWN
Moves highlighter UP
Accept highlighted user
Moves highlighter DOWN
Cancel without change
Moves highlighter to left / Hold to delete digit
Accept displayed value
Increases highlighted digit
Moves highlighter to right
Decreases highlighted digit
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16 Taking Product out of Operation
Prolec Limited is committed to complying with the upcoming European Directive of RoHS (Restriction of Certain Hazardous Substances) and WEEE (Waste from Electrical and Electronic Equipment). PME is sub­ject to the WEEE directive, therefore PME or any component must be returned to Prolec Ltd for correct disposal or recycling. The display and safety controller are fitted with internal batteries and must not be disposed of in landfill.
17 Service and Repair
PME has very few user serviceable parts. The safety controller has internal fuses that, in the event of a blown fuse, can be replaced. The service section describes daily, monthly and yearly checks that must be carried out to ensure safe operation of the system.
17.1 Maintenance Review
Due to nature of the PME system operating environment, changes in usage can occur. Prolec Ltd must be notified of any changes in the pattern of use of the system for consid­eration. Any alterations or modifications to machine components which affect the system must be reported to Prolec Ltd or via the service agreement holder. To aid in the use of PME, all appropriate technical bulletins relating to PME are to be as­sessed and implemented as appropriate. This information is available from Prolec Ltd. Prolec Ltd must be informed of any Prolec system component failure. Be it directly or via the service agreement holder. Technical consultation is available to the user, contact Prolec Ltd or the service agree­ment holder.
Prolec Ltd Telephone +44 (0) 1202 681190
25 Benson Road Fax +44 (0) 1202 677909 Nuffield Industrial Estate Email service@prolec.co.uk
Poole Dorset BH17 0GB
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18 Definitions / Glossary
Definitions of words used to ensure understanding
P/N Part Number Arm Second articulation (stick) Artic Second articulation of a hydraulically adjustable boom (luffing boom, knuckle boom, two piece boom) Attachment Tool fixed to the dipper other than a bucket Angle sensor Sensor detecting current equipment angle Boom First articulation connected to turret Bucket Digging attachment Blade Heavy metal plate on the front of the machine, used for stabil ity and moving material CAN cable Cable connecting system components Counterweight Weight attached to the rear of an excavator to increase digging force and lifting capacity Motion Cut Direct control of component hydraulic service MMI Man Machine Interface (i.e. Display) Pitch Longitudinal base machine angle (fore / aft) Roll Lateral base machine angle (side to side) Power Supply DC supply voltage Pivot pin Point at which the articulations rotate about Ram Hydraulic Cylinder Stabiliser Hydraulically powered arms that can be lowered and raised to increase the stability of the machine Slew restriction Angular slew, virtual wall, multipoint wall Slew limit An adjustable angle or virtual wall setting SC Safety Controller Tracked excavator An excavator fitted with tracks Track Continuous band of treads, metal or rubber covered Turret Section of machine above the undercarriage Undercarriage Section which the tracks/wheels attach too Wheeled excavator An excavator fitted with wheels
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19 Amendment / Revision Record
Issue Number Section / Page Amendment / Revision Description
1.0 N/A Initial Document Release
1.1 N/A Content brought into line with Software Version 1.25.0.0
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Prolec Ltd
25 Benson Road
Nuffield Industrial Estate
BH17 0GB
Tel: +44 (0)1202 681190
E-mail: service@prolec.co.uk
Prolec Ltd® is a member of the James Fisher Group of Companies
Poole
England
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