HIRSCHMANN PRS 40 EZ - RW Sales & Services Ltd.
Contents
1. 42 Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 6 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 LOADCELL2. 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 INSTA
3. 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
4. 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
5. 50 General Information PRS 40 EZ REV A 03 16 06 190201_A 1 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 The term two block is a crane term that refers to a condition when the load handling device 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 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 pe
6. 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
7. If adding a hardwired sensor to the system use the following for the diagrams DIP SWITCH SETTINGS Current Linerider SETUP 1 Kruger Angle sensor SETUP 3 Serial Angle sensor NA Hardwired Wind speed SETUP 4 Hardwired A2B SETUP 4 All Radio sensors NA WIRELESS SOCKET POWER INDICATION RUN INDICATION DIP SWITCH SERVICE trouble shooting PRS 40 EZ REV A 03 16 06 190201_A 37 12 SERVICE TROUBLE SHOOTING Daily maintenance of the system consists of inspecting 1 The electrical wiring connecting the various parts of the system If electrical wiring is damaged it shall be replaced immediately 2 If the insulation is worn on the electrical wiring or cable guides are damaged these parts shall be replaced 3 A damaged or punctured display must be replaced immediately to prevent ingress of water and damage to the internal circuitry Other than correcting the problems identified in the Malfunctions Table and replacing faulty mechanical parts and cables no other repairs shall be made When the PRS40 EZ system is turned on it will show the following screen This screen shows the telephone number of Hirschmann and the software version Make sure the display is working and all the lights come on during this time Listen to the buzzer sound If any of the components above fail please contact your nearest service representative before operating the system Operator s Service Manual PRS 40 EZ PRS 40
8. PRS 40 EZ REV A 03 16 06 190201_A 26 8 1 4 Loadcell Setup In order to use the loadcell the loadcell must first be installed into the system Add the loadcell to the console by pressing HARDWIRED SETUP SENSORS INSTALL REMOVE LOADCELL HARDWIRED RADIO Add the radio loadcell to the console by pressing SETUP SENSORS INSTALL REMOVE LOADCELL RADIO The console will show SEARCHING Remove the batteries from the transmitter Reinstall the batteries into the transmitter The LED on the transmitter will be on for 3 seconds and then start to flash on and off The sensor should now be set up When the transmitter is powered up after batteries removed and replaced the transmitter LED will be on for 3 seconds to indicate the transmitter is setup for a loadcell Press when complete 8 1 4 A LOADCELL RANGE Use the following menu selection as an example to select the correct load cell The following is an example for setting the 7 5 ton load cell SETUP CALIBRATIONS LOAD RANGE LOADCELL TYPE 7 5 TON 8 1 5 Loadcell Calibration ZERO POINT SETTING The load cell being zeroed must be installed and communicating with the console and there should be no load applied to the load cell Use the following menu selection to set the zero point of the load cell SETUP CALIBRATIONS LOAD 0 POINT Press when complete LOADCELL PRS 40 EZ REV A 03 16 06 190201_A 27 8 1 5 A ACCURACY AND TEST REQUIREMENTS Check t
9. 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 PRS 40 EZ REV A 03 16 06 190201_A 10 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 zero
10. When it is desired to use the switch again simply unhook the chain to allow the switch to close The chain must be unhooked before the crane is operated 6 1 3 D Transmitter Switch installation Install the standoff to the boom head using 2 5 16x3 4 HEX bolts The hole pattern for the standoff is the same as that of conventional PAT A2B switches In most cases the standoff can be mounted in the same location as the conventional switch If not replacing an existing switch the proper location would be one that allows the switch to rotate freely without being obstructed by any part of the boom head It should be mounted close to the dead end mounting gusset The switch should normally be mounted on the cab side of the crane A2B PRS 40 EZ REV A 03 16 06 190201_A 17 For jib installations locate the switch close to the jib head Remove the lynch pin from the standoff Slide the A2B switch onto the standoff Replace the lynch pin into the standoff Install the weight and chain onto the A2B switch 6 1 4 A2B Setup HARDWIRED In order to use the A2B the A2B sensor must first be set up on with the console Set the internal DIP switch to A2B sensor SETUP 4 Add the first A2B sensor to the console by pressing SENSORS A2B 1 HARDWIRED Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 18 HARDWIRED A2B WIRING DIAGRAM EXTERNAL RELAY INSTALLED BY CUSTOMER wind PRS 40 EZ REV A
11. 3 Broken Lid An enclosure will only seal correctly if the lid is not bent To check this loosen all screws of the lid take the lid off the box and visually inspect it for deflection If the lid is bent or damaged it needs to be replaced Try to determine what has caused the lid to be bent and eliminate the reason for that Order a new lid through your Hirschmann representative 4 Defective Gasket The gasket underneath the lid seals the unit The gasket needs to be in good condition in order to seal correctly If the gasket is torn brittle or severely bent it needs to be replaced Order a new gasket through your Hirschmann representative Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 42 13 MAINTENANCE The only maintenance required is to change the batteries when required Also check the mounting hardware daily to ensure that there is no damage Replace any damaged parts before operating the crane 13 1 BATTERY REPLACEMENT To replace the batteries remove the 4 screws from the transmitter housing During battery replacement use caution when opening the battery cover and transmitter to avoid damage to the gasket causing moisture ingress which could corrode the batteries and terminals Inspect the gasket surface on the transmitter for nicks or other damages that may prevent the gasket from sealing If it appears to be damaged a replacement gasket should be installed Install 4 fresh batteries into
12. transmitter and battery housing are made of a special polymer that resists damage from impact and will not become brittle even in low temperatures LIMIT LED LCD INDICATION LED H I R SCH MANN A2B XX Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 16 6 1 3 B Transmitter LED The transmitter has an LED on the bottom for diagnostics The LED should be on when in a two block condition or when the weight is lifted The LED will flash rapidly during a 2 block condition and will stop flashing after the switch is in a two block condition for more than 15 seconds The LED will flash randomly approximately every 2 seconds when the switch is transmitting When in sleep mode the LED will not flash When the transmitter is power up batteries removed and replaced the transmitter LED will be on for 1 second to indicate the transmitter is setup for an A2B switch 6 1 3 C Travel position optional Designed into the transmitter plate is a small hole into which a hook can be installed This can be used to fasten the chain This hook is used to open the switch and put it into a permanent 2 block condition This serves 2 functions 1 It extends battery life 2 It prevents the lockouts and alarms from engaging and disengaging due to bounce while traveling The system is in permanent lockout and the system will not function until the chain is unhooked To use the feature attach any part of the chain into the hook
13. up arrow The limits will change to 90 degrees Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 8 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 PRS 40 EZ REV A 03 16 06 190201_A 9 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
14. 0 050 559 1 00 PIN BUSHINGS 2 FOR 40K RADIO LOADCELL 1 ROPE OPTION 5 031 300 050 600 1 00 PIN BUSHINGS 1 3 4 FOR 40 KRADIO LOADCELL OPTION 5 031 300 050 563 1 00 PIN BUSHINGS 1 5 8 FOR 40 KRADIO LOADCELL 7 8 ROPE OPTION 5 031 300 050 604 1 00 PIN BUSHINGS 1 1 2 FOR 40K RADIO LOADCELL Please contact Hirschmann ECS with questions concerning repair or replacement of component 717 263 7655
15. 00 050 480 Mounting pole Anemometer mounting plate 031 300 050 322 031 300 060 586 Pin Transmitter 031 300 050 323 031 300 050 507 Retaining pin Sensor Part Numbers PRS 40 EZ REV A 03 16 06 190201_A 47 14 4 ANGLE 031 300 060 695 Sensor Assy Angle w 25 Cable 031 300 060 592 Sensor Angle w Transmitter 031 300 050 577 Plate Radio Angle Mounting Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 48 14 5 ANTENNA OPTIONS Mount antennas in identical positions and in a direct line between transmitter and receiver ensuring that no obstructions will interfere with the transmission of the radio signal 031 300 050 672 ANTENNA 918 MHz MAGNETICBASE 13ft LONG WIRE FOR CONSOLE 031 300 050 671 ANTENNA 918 MHz FOR TRS05ASSEMBLY 060 576 WHIP ELEMENT FOR CONSOLE 031 300 060 559 ANTENNA ASSY 918 MHz WHIP FORLOAD CELL FOR LOAD SENSOR 031 300 050 688 ANTENNA 918 MHz RCL 90 OTHER SENSOR 031 300 050 535 CONNECTOR SMA RIGHT ANGLE M FREVERSE POLARITY FOR LOAD SENSOR Part Numbers PRS 40 EZ REV A 03 16 06 190201_A 49 14 6 LINERIDER Linerider Please contact Hirschmann ECS with questions concerning repair or replacement of component 717 263 7655 031 300 060 434 Extension cable 031 300 101 178 Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 50 Sensor cable 14 7 LOADCELL 7 5t 15k RADIO LOAD CELL The load
16. 03 16 06 190201_A 19 RADIO In order to use the A2B the A2B transmitter must first be set up to with the console Add the first A2B sensor to the console by pressing SENSORS A2B 1 RADIO The console will show SEARCHING Pull and release the cord of the A2B switch The switch is now setup Add the Second A2B sensor to the console by pressing SENSORS A2B 2 RADIO The console will show SEARCHING Pull and release the cord of the A2B switch The switch is now setup 7 WIND 7 1 1 Operation The wind speed can be shown by itself on the screen or if in combination with other sensors as an additional screen The speed can be shown in miles per hour or kilometers per hour When the wind speed is displayed by itself the peak speed is also shown The peak will be the highest wind speed recorded since the system was started When the system is turned off the peak value will be reset The peak value can also be reset by pressing the button Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 20 7 1 2 LIMITS The system sets the default speed limit to 20 mph The limit can be set to any value The limits are set by selecting SETUP LIMITS WIND Use the up and down arrows to set the desired limit 7 1 3 Installation The sensor is delivered with a bracket support that allows the sensor to stay perpendicular to the ground through the boom angle range CONTACT CRANE MANUFACTURER FOR WELDING IN
17. 2 LIMITS The unit has no default limit set for the load The limits are set by selecting SETUP LIMITS LOAD Use the up and down arrows to set the desired limit Press when complete LOADCELL PRS 40 EZ REV A 03 16 06 190201_A 25 8 1 3 Installation The load cell is installed at the dead end of the wire rope that is being used to lift the load Use the appropriate pins for the type and size of socket block or ball that is being used Note The pin size should have been specified when ordered and should match the existing pin diameter Ensure that the correct pin used is rated for the maximum line pull capacity For the 7 5 ton load cell install the pin so the pin head on the antenna side The pin diameter jaw thickness and jaw opening used to connect to the load cell will effect position of the antenna There is 90 fitting for the antenna P N 031 300 050 535 maybe necessary in some cases Ensure all safety pins are installed properly with washers and bushing to fit the hole diameter and pin length 7 5 ton Installation Install the plate using the 2 1 4 pin so the pin head on the antenna side The plates have a rest button installed to prevent the plates from striking the transmitter on the side of the load cell On rest button should be on the load cell side of the plate Ensure all safety pins are installed properly with washers and bushing to fit the hole diameter and pin length Operator s Service Manual PRS 40 EZ
18. EZ REV A 03 16 06 190201_A 38 12 1 SCREENS Communication error screen When working from the normal operating screen and an error occurs a communication error screen will be displayed temporarily which indicates loss of communication between a sensor and the console This screen shows that there is an error in the communication between the A2B sensor and the console The sensor that is in error is indicated on the bottom line To return to this communication error screen return to the SETUP screen and press At this point you are enabled to scroll through all sensors which are experiencing a communication error by pressing the UP and DOWN arrows 12 1 1 To test the outputs The following outputs can be tested Function lockout Limit LED s Buzzer SETUP gt gt OPTIONS gt gt TEST SEQUENCE Select this option and then press Each of the outputs will be cycled on individually enabling the user to determine if each is functioning correctly 12 1 2 To test the inputs The analog input screen may be used to assist with troubleshooting errors To access this select SETUP gt gt OPTIONS gt gt ANALOG INPUT To change between milliamps and volts use the UP or DOWN arrows while viewing the analog input SERVICE trouble shooting PRS 40 EZ REV A 03 16 06 190201_A 39 12 1 3 Battery level The battery level of each radio sensor can be monitored SETUP gt gt OPTIONS gt gt BATTERY LEVEL Select this o
19. HIRSCHMANN P N 031 300 190 201 Revision A 03 16 2006 PRS 40 EZ OPERATOR S SERVICE MANUAL Operator s Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 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 2006 Hirschmann Inc Chambersburg PA 17201 USA PRS 40 EZ REV A 03 16 06 190201_A 5 TABLE OF CONTENTS 1 GENERAL INFORMATION
20. LL 8 1 1 Operation In order to use the loadcell the loadcell must first be installed into the system See the section on loadcell setup When set up with a load cell the last selected display and configuration will be shown and must only be confirmed if that configuration setup equals the crane s actual configuration Otherwise the reeving must be changed to match the current configuration The load cell can be installed into a single part line configuration or into a multipart line configuration When a multiple parts are used the system multiplies the force from the load cell by the parts of line selected on the console This is why it is imperative that the correct parts of line reeving is selected on the console The correct setting of the reeving is of utmost importance for the proper functioning of the system Therefore only operators who are thoroughly familiar with the operation of the system should perform the setting of the system The system will only measure the load on hook and will not measure the effect of any other attachments Reeving To view the on hook load display the correct reeving must be set Enter Setup screen Select Reeving and press Use the arrows to adjust the reeving setting When complete press Units The load can be displayed in pound or in kilograms To change the units press MENU OPTIONS LB Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 24 8 1
21. LLATION 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
22. STRUCTIONS PRIOR TO WELDING ON BOOM The 1 diameter mounting pole will be affixed to the boom tip at your discretion so that the anemometer sensor is mounted approximately a foot higher than the boom sheaves and will not interfere or be damaged by hoist lines or extension mounting or movement Affix the mounting pole to the boom tip or possibly the length cable anchor pin so the pipe supports the sensor wind PRS 40 EZ REV A 03 16 06 190201_A 21 7 1 4 Wind Setup In order to use the wind sensor the wind sensor must first be set up to with the console HARDWIRED Set the internal DIP switch to Wind speed sensor SETUP 4 Add the wind sensor to the console by pressing SENSORS WIND HARDWIRED HARDWIRED WINDSPEED SENSOR WIRING DIAGRAM EXTERNAL RELAY INSTALLED BY CUSTOMER Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 22 RADIO Add the wind sensor to the console by pressing SENSORS WIND RADIO The console will show SEARCHING Remove the batteries from the transmitter Reinstall the batteries into the transmitter The LED on the transmitter will be on for 3 seconds and then start to flash on and off The sensor should now be set up When the transmitter is powered up after batteries removed and replaced the transmitter LED will be on for 3 seconds to indicate the transmitter is setup for a wind speed sensor LOADCELL PRS 40 EZ REV A 03 16 06 190201_A 23 8 LOADCE
23. 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 PRS 40 EZ REV A 03 16 06 190201_A 5 4 2 1 MENU STRUCTURE SETUP SETUP CONT REEVING SENSORS LIMITS INSTALL REMOVE ANGLE ANGLE MIN NOT INSTALLED SELECTION HARDWIRED MAX HIRSCHMANN SELECTION KRUEGER WINDSPEED RADIO SELECTION A2B1 LOAD NOT INSTALLED MAX LOAD HARDWIRED LINERIDER RADIO SELECTION A2B2 CALIBRATIONS NOT INSTALLED ANGLE HARDWIRED ZERO POINT RADIO LOAD 0 POINT WINDSPEED LOAD RANGE NOT INSTALLED LOADCELL TYPE HARDWIRED 7 5 TON RADIO 10 TON LOADCELL 22 5 TON NOT INSTALLED LINERIDER 0 HARDWIRED LINERIDER ADJ 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 PRS 40 EZ REV A 03 16 06 190201_A 6 4 2 2 Installation The console has a mount that allows the console to be swiveled into any direction and
24. Z REV A 03 16 06 190201_A 31 9 1 3 B LATTICE BOOM MACHINES MAXIMUM 30 Figure 6 Lattice Boom Linerider Installation WARNING CONTACT CRANE MANUFACTURER FOR WELDING INSTRUCTION PRIOR TO WELDING ON BOOM 1 Select a location that the swing arm angle with respect to the boom will not exceed 30 see Figure 6 The linerider should be located as close to the boom tip as possible 2 Construct two base plates Size of base plates will be specific to the lattice structure and your selected location a The first base plate will be attached to the boom with the swing arm bolt affixed to the center of the base plate b The second base plate will be attached to the boom so that it supports the linerider when not in use 3 Affix the swing arm bolt to the center of the first base plate 4 Affix the first base plate to the selected location on the lattice boom 5 Attach the swing arm to the bolt 6 Run the hoist line through the linerider 7 Attach the swing arm to the linerider 8 Ensure freedom of movement side to side 9 Attach the second base plate to the boom so the linerider rubber supports will touch the plate when there is no load 10 Connect linerider electrically with cable provided Note It is recommended that this cable be routed through conduit to the linerider in a way that best protects the cable from damage and secured with tie straps 11 Connect the linerider extension to the console cable at
25. ble to the maximum rated load for line configuration The test load must include the hook block and all rigging 1 Turn unit on 2 Set the reeving to the actual parts of line configured 3 Place hook block or headache ball on the ground so there is no load on the hoist line 4 Press CALIBRATIONS LINERIDER 0 5 Press The display should show 000 LB 6 Pick a known test load as close as possible to the maximum rated load SAE recommends the test load should be accurate to 1 7 Press CALIBRATIONS LINERIDER ADJ 8 Compare the known test load to the displayed load and adjust if necessary using the arrows on the console Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 34 10 RADIO MODULE 10 1 INSTALLATION A receiver module must be installed into the PRS 40 EZ before a radio sensor can be set up or used The following is the procedure for installing the radio module Caution Handle the module with care The module can be damaged by static electricity Take proper precautions by removing any static electricity from your body Do not remove the board from its protective anti static bag until the time of installation 1 Open the PRS 40 by loosening the 4 screws on the console lid 2 Insert p n 101646 radio module into the sockets on the PCB assembly Align the pins and press the radio module into place Make sure that they are correctly aligned and that they are firmly seated The foam wil
26. boom base with the 28ft extension provided NOTE Extra electrical extensions can be ordered if required Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 32 9 1 3 C PRS 40 EZ UPGRADE FROM EI33 NOTE ADDITIONAL CABLE ASSEMBLIES ARE REQUIRED WHEN UPGRADING FROM THE EI33 CONSOLE TO THE PRS 40 EZ SEE BELOW Cable assembly 031 300 060 434 connects to the back of the PRS 40 EZ console and mates with the existing 031 300 101 178 cable assembly which connects to the linerider If additional length is required between the console and linerider cable assemblies of various lengths are available see below PRS 40 EZ HIRSCHMANN Line rider PRS 40 EZ REV A 03 16 06 190201_A 33 9 1 4 Linerider setup Hardwired Set the internal DIP switch to 4 20 mA sensor SETUP 1 Select the HARDWIRED from the following menu SENSORS LINERIDER HARDWIRED 9 1 5 Linerider Calibration The zero point and the gain of the linerider must be set before operation Essential Information The units of measure shall be the same as load chart units Calibration should be completed after installation crane modification or anytime there is an indication of inaccuracy Recommendations for system calibration Use single part line during calibration Note Multiple parts of line are acceptable It only increases the amount of test load recommended Pick a known test load as close as possi
27. cell kit will include item 1 item 2 and one of the optional item 3 ITEM PART NUMBER QTY DESCRIPTION 1 031 300 060 608 1 00 SENSOR ASSY FORCE TRANS 7 5T W RADIO TRANSMITTER 2 031 300 050 064 1 00 HARDWARE COTTER PIN 2 3 8 LG1 8 GRIPPER LENGTH OPTION 3 031 300 100 999 1 00 PIN 1 5 DIAMETER FOR USE W 15T FORCE TRANS OPTION 3 031 300 050 574 1 00 PIN BUSHINGS 1 1 4 FOR 7 5T RADIO LOADCELL OPTION 3 031 300 050 555 1 00 PIN BUSHINGS 1 1 8 FOR 7 5T RADIO LOADCELL 5 8 ROPE OPTION 3 031 300 050 554 1 00 PIN BUSHINGS 1 3 8 FOR 7 5T RADIO LOADCELL 3 4 ROPE OPTION 3 031 300 050 556 1 00 PIN BUSHINGS 1 7 5T RADIOLOADCELL 1 2 ROPE Please contact Hirschmann ECS with questions concerning repair or replacement of component 717 263 7655 Whip Antenna 031 300 050 559 90 antenna fitting 031 300 060 535 Part Numbers PRS 40 EZ REV A 03 16 06 190201_A 51 20t 45k RADIO LOAD CELL The load cell kit will include item 1 item 2 item 3 item 4 and one of the optional item 5 ITEM PART NUMBER QTY DESCRIPTION 1 031 300 060 609 1 00 SENSOR ASSY FORCE TRANS 45K STRAIGHT W TRANSMITTER 2 031 300 060 558 1 00 BRACKET H 20t RADIO LOADCELL 2 050 520 PLATES amp 2 050 573 3 031 300 050 625 2 00 HARDWARE COTTER PIN 3 8 x 3 4 031 300 050 568 1 00 PIN 2 25 FOR 40K RADIO LOADCELL 1 1 8 ROPE OPTION 5 031 300 050 568 1 00 PIN 2 25 FOR 40K RADIO LOADCELL 1 1 8 ROPE OPTION 5 031 30
28. ck switch Release the cable 3 For storage slide the retainer from right side 5 over the Anti Two Block switch until the clips A lock into the holes B Fig 3 Removal of the Anti Two Block Retainer Fig 4 Retainer in Storage Position WIRED APPLICATION After the electrical connections have been checked to insure that the system is properly connected for the crane configuration the following checks shall be made 1 Check the electrical wiring connecting the various parts of the system for physical damage 2 Check the anti two block switches and weights for free movement Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 14 The following tests shall be performed with care to prevent damage to the machine or injury to personnel Proper functioning of the system requires successful completion of these tests before operating the machine If the operator cannot see the load handling device approaching the boom nose he shall have an assistant signal person watch the load handling device The operator shall be prepared to stop the machine immediately should the system not function properly as indicated by flashing the warning symbol sounding the audible alarm and locking the crane movements hoist up telescope out and boom down if lockout is installed Check the anti two block alarm by performing one of the following tests a By manually lifting the weight attached to the anti two block switc
29. ed 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 PRS 40 EZ REV A 03 16 06 190201_A 11 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 sens
30. hat 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 A2B PRS 40 EZ REV A 03 16 06 190201_A 13 Fig 1 Setting of Anti Two Block Retainer in Locking Position Fig 2 Retainer in Locking Position 3 Straighten the cable completely into the slot and release the cable 4 4 Turn the flag of the retainer for best visibility for the operator 5 Removal and Storage of the Anti Two Block Retainer Procedure see Fig 3 and 4 1 Pull the cable out of the switch 1 and bend back parallel to the boom and hold 2 2 Move the retainer down 3 and then left 4 to remove it from the Anti Two Blo
31. he load display by lifting a load of known weight The accuracy of the load indication shall be within the tolerance of SAE J376 refer to complete SAE standard before testing Accuracy The accuracy of the load indicating system is to be such that the indicated load is not less than 100 of the actual load nor more than 110 of the actual load Where the system cannot meet the accuracy criteria at the lower load range conspicuous labeling or signaling is to be provided indicating that these accuracy criteria cannot be met The weight of the load being lifted and all additional equipment such as blocks slings sensors etc also referred to as working load Test Requirements System tests are to be conducted using an appropriate configured crane and specified load rating chart For system calibration three or more test radii or boom angle are to be employed to establish compliance with the accuracy section above Test loads shall be as near as is practical to minimum mean and maximum values within the operating limits One of the following test methods or equivalent is to be used Known Weight Test load to be applied by suspending known weights accurate to 1 If the weights of all additional equipment such as blocks slings sensors etc are included in the test load the total load is to be known to an accuracy of 1 Fixed Anchor Deadman Test load to be applied by hoisting against a fixed anchor or deadman equipped with a means for meas
32. hes When the weight is lifted the audible alarm should sound the anti two block alarm display should flash b Slowly raise the main boom load handling device to create a potential two block condition When the load handling device lifts the weight the audible alarm should sound the anti two block alarm display should flash and the motion of the load handling device should be stopped Lower the load handling device slightly to eliminate this condition c Slowly lower the boom to create a potential two block condition When the load handling device lifts the weight the audible alarm should sound the anti two block display should flash and the boom lowering function should be stopped Lower the load handling device slightly to eliminate this condition If the A2B warning symbol fails to flash and audible alarm does not function as described and the crane movements are not stopped the system is not working properly The malfunction shall be corrected before operating the crane 5 If the crane is equipped with a boom extension repeat the test procedure for the boom extension anti two block switch A2B PRS 40 EZ REV A 03 16 06 190201_A 15 6 1 2 A2B limit When the A2B limit is exceeded the relay will disengage The display will show A2B XX and the red LED will light The audible alarm will sound The limit for the A2B is fixed by the chain length and can not be altered 6 1 3 Installation 6 1 3 A Transmitter Switch The
33. l hold the radio module in place when radio module is installed Inspect the gasket for nicks or other damages Radio Module sockets P N 101646 Radio Module Installed Ensure the pins are correctly aligned and that they are firmly seated sockets Radio Module PRS 40 EZ REV A 03 16 06 190201_A 35 3 Inspect the gasket on the lid for nicks or other damages that may prevent the gasket from sealing If it appears to be damaged a replacement gasket should be installed p n 031 300 050 786 GASKET PRS HOUSING FRONT FACE 4 Reassemble the console ensure the wires are not pinched between the lid and the housing Close housing and tighten the 4 cover screws Make sure that the console lid is completely seated and properly tightened Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 36 11 ADDING SENSORS To add a new sensor Menu SETUP SENSORS This gives the sensor select information screen It shows the status of all hardware Each sensor has several options NOT INSTALLED HARDWIRED RADIO The status of the sensor is indicated with an In the example the sensor is not installed The PRS40 EZ is a very powerful and flexible system To allow for multiple types of sensors a 4 position DIP switch is utilized The DIP switch must be in the proper position for the attached sensor to function properly The DIP switch will be set into the proper position before shipped from the factory
34. n will depend on the type of boom Follow the applicable instructions for a hydraulic or lattice boom LINERIDER GENERAL INFORMATION The linerider is attached to the swing arm mounting bracket as shown in Figure 4 The swing arm assembly has four joints 1 Vertical movement at the attachment point to the linerider 2 Horizontal movement of the swing arm 3 Vertical movement of the swing arm 4 Swivels horizontally around the mounting bolt The mounting bolt secures the swing arm to the machine 1 2 4 3 Figure 4 Linerider and Swing Arm Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 30 9 1 3 A HYDRAULIC BOOM MACHINES Figure 5 Hydraulic Boom Linerider Installation NOTE CONTACT CRANE MANUFACTURER FOR WELDING INSTRUCTION PRIOR TO WELDING ON BOOM 1 Affix the bolt at the tip of the base section on the main boom similar to Figure 5 2 Attach the swing arm to the bolt 3 Run the hoist line through the linerider 4 Attach the swing arm to the linerider 5 Ensure freedom of movement side to side 6 Connect linerider electrically with cable provided Note It is recommended that this cable be routed through conduit to the swing arm in a way that best protects the cable from damage and secured with tie straps 7 Connect the linerider extension to the console cable at boom base with the 28ft extension provided NOTE Extra cable extensions can be ordered if required Line rider PRS 40 E
35. nside any of the housings the source for the water ingress has to be detected and corrected to ensure proper operation There are two major possibilities for the occurrence of excessive moisture inside an enclosure 1 Water ingress 2 Condensation This outline gives instructions for detecting the cause for excessive moisture by using simple troubleshooting methods and how to prevent the moisture ingress from happening again 12 3 1 Water Ingress There are 4 possibilities for water to enter an enclosure 1 Spray Cleaning 2 Missing Loose Screws 3 Broken Lid 4 Defective Gasket It is possible to find out the source of water ingress by going through the following steps and ruling out one possibility after the other until the cause is identified 1 Spray Cleaning The enclosures used for the PRS 40 EZ system are water protected to IP 65 This means protection against the environment such as rain However through the use of spray cleaner at short distances it is possible to force water through the gasket or strain relieves For this reason avoid spraying any components from short distances with spray cleaners Convey this fact to any member of a maintenance crew 2 Missing Loose Screws All screws have to be present and to be equally tight to ensure water protection of the enclosure If there are screws missing replace them If no screw is missing check the tightness If any were loose then open all screws and then re tighten them equally
36. nsor is line of sight to the console Communication error Sensor not installed Install the sensor on the console See adding sensors Communication error Poor communication caused by interference Remove potential interference sources from the area Mount the receiver in a different location Buzzer does not sound Faulty Go into the diagnostics screen for the outputs Verify all outputs are functioning see section 11 If any of the tests fail replace console Crane functions locked out all the time Incorrect wiring Check for power to lockout device Clear all faults Crane functions locked out all the time Communication error See communication error see section 11 Crane functions locked out all the time Fault in receiver module Check for power to lockout device Clear all faults Transmitter LED does not flash Sensor is asleep Change the status of the sensor Pull switch wire rope of A2B Transmitter LED does not flash Batteries dead Replace the batteries SERVICE trouble shooting PRS 40 EZ REV A 03 16 06 190201_A 41 12 3 TROUBLESHOOTING MOISTURE The PRS 40 EZ contains electronic components in various locations such as central unit sensors junction boxes etc These internal components cannot be designed to withstand exposure to moisture over a longer period of time For this reason the housings of the components are water protected according to IP 65 If you find water or moisture i
37. or 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 PRS 40 EZ REV A 03 16 06 190201_A 12 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 t
38. ption and then press Each sensor can be selected individually enabling the user to view the percentage of each sensor s battery level Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 40 12 2 TROUBLESHOOTING After the onboard diagnostics have been performed follow these guidelines All LED s are located inside the receiver box Problem Cause Solution LCD does not light or show characters No power to console Make sure the console is getting power from the crane Check wiring Ensure correct polarity of the power Open console check status of LED s Both the red and green LED s should be on Limit LED s do not light No power to console Make sure the console is getting power from the crane Check wiring Ensure correct polarity of the power Open console check status of LED s Both the red and green LED s should be on Communication error Low battery Verify which sensor is causing the error by looking at the communication error screen see section 11 Replace batteries Communication error Faulty sensor Verify which sensor is causing the error by looking at the communication error screen see section 11 Verify that the transmitting LED on the sensor is blinking Communication error Poor reception Verify which sensor is causing the error by looking at the communication error screen see section 11 Verify that the transmitting LED on the sensor is blinking Verify that the se
39. rsonal 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 PRS 40 EZ REV A 03 16 06 190201_A 2 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 te
40. the proper location and direction as indicated on the battery holder Make sure that the cardboard tube is installed as shown LOOSEN 4 SCREWS INSPECT CONDITION OF GASKET BATTERY DIRECTION LABEL INSTALLED BATTERIES IN CARDBOARD TUBE Software version Battery direction Part Numbers PRS 40 EZ REV A 03 16 06 190201_A 43 14 PART NUMBERS 14 1 CONSOLE 031 300 060 666 PRS 40 EZ w Radio 031 300 060 619 PRS 40 EZ w o Radio 031 300 060 491 Power cable Item Part number Qty Description 1 031 300 060 382 1 Console Accy Mounting Arm W 1 Ball 2 031 300 050 485 3 Screw 10 24 X 5 8 Ph Ph 2 031 300 050 487 3 Washer Sealing 10 2 031 300 050 489 3 Nut 10 24 Lock Nylon Insert 3 031 300 050 523 1 Fuse 5 Amp Auto Mini 4 031 300 050 786 1 Gasket w PRS housing amp front face 2 1 3 101646 Radio Module Assembly 4 Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 44 14 2 A2B 031 300 060 593 Radio A2B transmitter assembly 031 300 060 586 Antenna only Radio A2B transmitter 031 300 050 688 031 300 050 763 Neoprene rubber gasket Part Numbers PRS 40 EZ REV A 03 16 06 190201_A 45 031 002 060 022 Radio A2B switch 031 300 050 295 A2B Mounting standoff 031 300 050 264 A2B mounting plate 031 300 050 272 Lynch pin Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 46 14 3 WIND 031 300 050 321 031 3
41. 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 cable connections Power Hardwired Sensor Angle PRS 40 EZ REV A 03 16 06 190201_A 7 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
42. ture compensation that will adjust the LCD s contrast according to the surrounding temperature System Description PRS 40 EZ REV A 03 16 06 190201_A 3 4 1 2 Control Identification Fig 2 Operator s Console Limit LED LCD Clear button Select button Up Button Down Button Button SCROLL UP Use this button to increase values or to scroll up Changes which sensors are displayed and how each is displayed Button SCROLL DOWN Use this button to decrease values or to scroll down Changes which sensors are displayed and how each is displayed Button SELECT Use this button to enter the menu screen and to confirm selections Button C 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 PRS 40 EZ REV A 03 16 06 190201_A 4 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
43. uring loads accurate to 1 If the weights of all additional equipment such as blocks slings sensors etc are included in the test load the total load is to be known to an accuracy of 1 The system accuracy is to be determined from the following formula Indicated Load x 100 of Load Actual Load Operator s Service Manual PRS 40 EZ PRS 40 EZ REV A 03 16 06 190201_A 28 9 LINE RIDER 9 1 1 Operation In order to use the linerider the linerider must first be installed into the system See the section on linerider setup Reeving To view the on hook load display the correct reeving must be set Enter Setup screen Select Reeving and press Use the arrows to adjust the reeving setting When complete press Units The load can be displayed in pound or in kilograms To change the units press MENU OPTIONS LB Tare A Tare load can be displayed by pressing Pressing this button will zero out the current load display The tare load will be displayed for 120 seconds While in tare function a T will be shown on the display During this time the tare function can be turned off by again pressing Line rider PRS 40 EZ REV A 03 16 06 190201_A 29 9 1 2 LIMITS The unit has no default limit set for the load The limits are set by selecting SETUP LIMITS LINERIDER Use the up and down arrows to set the desired limit Press when complete 9 1 3 Installation The linerider installatio
44. xt 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 tempera
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