PRS 80 Service Manual
Contents
1. C 1 90 Ea i 7 L i E 7 60419 S LK Bee HI Le 902 44 f HA P Ss S YU JA P d ANN af f U AA X AS Ke i fa Ki M HALO A A V S O NO s OY oo s Y NN Woe X Ny Q 0 59 P i e Ns 120 a A i K m e l 9 9 2 A E S SkyAzul Equipment Solutions www skyazul com 301 371 6126 22 Operators Manual PPAT PRS 80 The wiring at the console connection is Pin 1 2 3 4 5 6 Description Power 10 30VDC Ground Lockout NO 2 amp max Lockout NC 2 amp max Lockout common 2amp max Option PRS75 NSULE CUNNECTUR 2 2 RU P 3 3 CKOUT NO 3 4 4 CKOUT NC ss 4 2 5 la g LOCKOUT 1 os E O O 7 7 CONNECTED Se O SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 23 6 3 Adding sensors To add a new sensor Menu SETUP SENSORS This gives the sensor select information screen It shows the status of all hardware In the example below NOT IN means that none of the sensors are installed Sensor status screen Choose the sensor that you wish to install and follow the onscreen instructions which will ask you to remove the pa2. The load cell kit will include item 1 item 2 and one of the optional item 3 ITEM 1 2 OPTION 3 OPTION 3 OPTION 3 OPTION 3 OPTION 3 vr 90 PART NUMBER 031 300 060 608 031 300 050 064 031 300 100 999 031 300 050 574 031 300 050 555 031 300 050 554 031 300 050 556 ntenna fitting 031 300 050 535 SkyAzul Equipment Solutions QTY 1 00 1 00 1 00 1 00 1 00 1 00 1 00 DESCRIPTION SENSOR ASSY FORCE TRANS 7 5T W RADIO TRANSMITTER HARDWARE COTTER PIN 2 3 8 LG1 8 GRIPPER LENGTH PIN 1 5 DIAMETER FOR USE W 15T FORCE TRANS PIN BUSHINGS 1 1 4 FOR 7 5T RADIO LOADCELL PIN BUSHINGS 1 1 8 FOR 7 5T RADIO LOADCELL 5 8 ROPE PIN BUSHINGS 1 3 8 FOR 7 5T RADIO LOADCELL 3 4 ROPE PIN BUSHINGS 1 7 51 RADIOLOADCELL 1 2 ROPE www skyazul com 301 371 6126 44 20t 45k RADIO LOAD CELL Operator s Manual PAT PRS 80 Y 4 Ts b d P d 7 SES AS KH L EE Nl T 1 l i L 4 Y E 4 s Es We l E 163 N 2 N WE g T 7 na DM Va E E D _ A S o 7 3 s gt A z K i 2 291 Es EE 8 5 281 r b
3. Az l EQUIPMENT SOLUTIONS a A f HIRSCHMANN PRS 80 EZ PRS80 EZ INSTALLATION CALIBRATION and SERVICE MANUAL NOTICE SkyAz l 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 SkyAz l 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 SkyAz l SkyAzul 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 SkyAzul The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice s SkyAz l Inc dal 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Fax 301 371 0029 info skyazul com SkyAzul Equipment Solutions www skyazul com 301 371 6126 Operator s Service Manual PAT PRS80 TABLE OF CONTENTS 1l GENERAL INFORMATION E T SE EK lr EE T AP TE PU PO o O 8 E N SEMDE SCRIPTION raso iva 8 a
4. ale Ene ve q s BE e o y eT o O LO A M o O NS e o lt lt O O O oi E CV 5 I o R Ni m m co D o X o O 301 371 6126 www skyazul com SkyAz l Equipment Solutions 46 Radio AZB switch 031 002 060 022 Tu GA BA NS I dig Gta eo t A2B Mounting stud 031 300 050 295 A2B mounting plate 031 300 050 264 Lynch pin 031 300 050 272 SkyAzul Equipment Solutions www skyazul com Operator s Manual PPAT PRS 80 301 371 6126 Service and Maintenance Mounting pole 031 300 050 321 4 Pin Retaining pin 031 300 050 322 031 300 050 323 Anemometer mounting plate 031 300 050 480 ar el um Po Transmitter 031 300 060 586 SkyAzul Equipment Solutions www skyazul com 47 301 371 6126 48 ANGLE Fri HIRSCHMANN Hs l or d Th T E LI LI y Bel L F LI L q feigen gt ptus Le ys Tei i E OMIT RAS LEE 1 Der Fas Lob jun P ja ET m r a i Tt TA pi i AIT u dit d E 3 ier bag ai e wb sl m SR Geh 1 Ces D Tis Formes Lak ER Ier ra Tor 1 Angle sensor with transmitter 031 300 060 592 Mounting plate for angle sensor 031 300 050 577 m Vg wy A ie J i p ud NEL Redesigned mounting plate 031 300 050 577 Direct replacement for above mounting plate SkyAz l Equipment Solutions www skyazul com Operators Manual PPAT PRS 80 301 371 6126 SkyAz l
5. Red LED will flash gt each 2 sec does not flash Replace batteries Replace transmitter error SkyAzul Equipment Solutions www skyazul com 301 371 6126 40 Operators Manual PPAT PRS 80 8 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 8 1 Battery Replacement To replace the batteries remove the 4 screws from the transmitter housing In 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 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 Software version Battery direction SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 41 9 PART NUMBERS m hj HIRSICHMIANIM m n 4 a USE Vater 031 300 060 58 Item Part stame Qty Description PRS80 Console 1 031 300 060 382 1 0 Mounting Arm W 1 Ball 2 024 000 100 095 1 0 Membrane Element 3 031 300
6. 050 223 1 0 Fuse 2 Amp Auto Mini 031 300 060 491 Cable assembly PRS80 Console SkyAz l Equipment Solutions www skyazul com 301 371 6126 42 Operators Manual IPAAN PRS 80 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 031 300 050 671 ANTENNA 918 MHz FOR TRSOSASSEMBLY 060 576 WHIP ELEMENT FOR CONSOLE 031 300 050 672 ANTENNA 918 MHz MAGNETICBASE 13ft LONG WIRE FOR CONSOLE 031 300 050 688 ANTENNA 918 MHz RCL 90 OTHER SENSOR 031 300 060 559 ANTENNA ASSY 918 MHz WHIP FORLOAD CELL FOR LOAD SENSOR 031 300 050 535 CONNECTOR SMA RIGHT ANGLE M FREVERSE POLARITY FOR LOAD SENSOR 031 300 060 596 TRS 05 REPEATER 031 300 060 601 CABLE ASSY 15 2 COND SS 031 300 050 688 ANTENNA 918 MHz RCL 90 20AWG W 12 SKT DEUTSCH SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 43 LOADCELL 7 5t 15k RADIO LOAD CELL C B D 0 79 o J x A i LO i T VA M a s f 2 ge X N P A UN 3 Y G OO Ba a N E NIE pe ie P Sie 4 Nx o f ES e Aa AE cx DH a a Wen N gt 6 f JG 3 148 1 50
7. Operators Manual PPAT PRS 80 Note a prewarning can be set so as to beep the alarm when a limit is approached but not reached This is set with the warning option Menu SETUP SCREEN BEEPER WARNING Enter the value for the limit Use the arrows to change values Use the to change move to the next digit Note the last 2 digits are fixed on the load cell and can not be changed If the system is turned off all setup and limits remain stored When turning the system on again these adjustments can be acknowledged by merely confirming the reeving and pressing the SELECT button provided that the crane configuration has not been modified SkyAz l Eguipment Solutions www skyazul com 301 371 6126 Service and Maintenance 15 9 4 A2B 9 4 1 A2B display When an A2B switch has been installed the status of the switch is always shown There are several options for displaying the status If other sensors are installed besides the A2B the A2B status will be shown as an icon A2B alone A2B with other sensor 9 4 2 AZB limit When the A2B limit is exceeded the relay will disengage The display will flash and show the A2B icon The audible alarm will sound The limit for the A2B is fixed by the chain length and can not be altered A2B warning SkyAzul Equipment Solutions www skyazul com 301 371 6126 16 Operator s Manual PAT PRS 80 5 4 3 Pre Operation Inspection Before operating the crane the following electrical
8. adi 28 6 6 4 Transmitter Switch installation 0 00nna0annannnnnnnnannnennnnnnnnannnsnnnnnnnnnresnrrnnrrnrnrrsnrrnnnrenrrnnrrrsnrrssnrrnnrrnni 29 O ANIN ro eno 30 0 0 AN LE 31 6 8 1 Angle Installation Setup Calbraton 31 6 8 2 Accuracy and Test Requirements ccooccccocncconccconoconncnoncnnnnononnnnonnnnnnonannonnnnnnnnnnnnnnnnnnnnnnannennnnenaninos 34 T SERVICE 7 TROUBLESHOOTING scenic asc iaa 35 n MES erimus cias 36 2 eee eme e uu c o 36 FG WR AA 36 IP MEN TOME nde S A 37 Las 206 Te te CUPU osc iso an nA on 37 fo esi EZz4 89 09 t tal 39 8 MAINTENANCE eseeeeeeseeee nmn ener RR sas t tet etet RR etetett r a nnus 40 9 1 BATTERY REPLACEMENT WEE 40 9 PART NOMBER O stands 41 SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance T 1 GENERAL INFORMATION The PAT Telemetry Receiver 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
9. can only work correctly if all sensors transmitters have been properly set For correct setup the operator has to answer thoroughly and correctly all guestions 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 8 Operators Manual PAT PRS 80 3 FEATURES The PAT Telemetry Receiver has the following features Easily and clearly shows the operator required information Multi language The system can be setup to display text in both English and Spanish Multiple limits can be set Wireless operation Minimum of 500 feet LOS Frequency Hopping Spread Spectrum transceivers Can display in multiple units Built in lockout relay Rated at 2 amps Analog display of of limit on load cells and wind speed Tare function Low battery indication Expandable 4 SYSTEM DESCRIPTION 4 1 Operating Console The console has 2 functions e Accepts inputs from the crane operator reeving limits and setup e 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
10. follows For boom angles 65 deg or more the indicated angle is to be neither greater than the actual boom angle nor more than 2 deg less than the actual boom angle For boom angles less than 65 deg the indicated angle is to be neither greater than the actual boom angle nor more than 3 deg less than the actual boom angle Test Requirements For system calibration three or more test radii or boom angle are to be employed to establish compliance with the accuracy section above Test angles are to be as near as practical to the minimum mean and maximum of the operating range For periodic calibration checks two or more boom angles are to be employed Level the crane to within 0 5 deg in an area that is clear of obstructions so that the boom may be moved from maximum radius minimum boom angle to the minimum radius maximum boom angle For boom angle indicating systems the following test procedure or equivalent is used At each test position the boom angle is measured by an adjustable level protractor or equivalent calibrated means and the measurement compared to the boom angle indicator The adjustable level or protractor must be positioned on a smooth surface of the boom base section parallel with the longitudinal centerline SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 35 7 SERVICE TROUBLESHOOTING Daily maintenance of the Load SYSTEM consists of inspecting 1 The electrical wiring connect
11. 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 PAT Telemetry Receiver System is an operational aid which warns a crane operator of approaching two block conditions which could cause damage to equipment and personal injury This device is not and must not be a substitute for good sound operator judgment experience and use of accepted safe crane operating procedures The responsibility for the safe operation of the crane remains with the crane operator who must ensure that all warnings and instructions supplied are fully understood and observed Prior to operating the crane the operator must carefully and thoroughly read and understand the information in this manual to ensure that the operation and limitations of the system and the crane are known N WARNING The system
12. 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 itis not damaged Remove the batteries Align the 4 holes with the mounting plate threaded holes and screw the angle sensor onto the mounting plate by using the four screws supplied in the kit Attach the antenna to the connector by carefully rotating the antenna clockwise 4 On the console setup the sensor by using the menu selection MENU SETUP SENSORS ANGLE 1 or 2 In the setup process you will be asked to insert the batteries while the receiver searches for the transmitter Install batteries correctly as shown on the label in the battery compartment When the sensor has been found the angle sensor screen will be displayed Inspect the gasket on the battery cover for cuts or other damages install and tighten the four cover screws Ur cc After making this selection measure the boom angle by using a digital inclinometer i e smart level If the angle displayed does not match the measured angle complete the angle calibration next step If the angle displayed matches the measured angle go to step 6 SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 33 5 On the console calibrate th
13. 7 dE E gt S p A FA xm 7 gt p B V Ke Vf d l AD A WES 7 N N ie Ai di AN 4 e ue L Je e G X A NO gd i 5 80 L 11 00 gei The load cell kit will include item 1 item 2 item 3 item 4 and one of the optional item 5 OPTION OPTION OPTION OPTION OPTION ITEM PART NUMBER 1 031 300 060 609 031 300 060 558 2 3 031 300 050 625 4 031 300 050 568 5 031 300 050 568 5 031 300 050 559 5 031 300 050 600 5 031 300 050 563 5 031 300 050 604 QTY 1 00 1 00 2 00 1 00 1 00 1 00 1 00 1 00 1 00 90 antenna fitting 031 300 050 535 SkyAzul Equipment Solutions DESCRIPTION SENSOR ASSY FORCE TRANS 45K STRAIGHT W TRANSMITTER BRACKET H 20t RADIO LOADCELL 2 050 520 PLATES 8 2 050 573 HARDWARE COTTER PIN 3 8 x 3 PIN 2 25 FOR 40K RADIO LOADCELL 1 1 8 ROPE PIN 2 25 FOR 40K RADIO LOADCELL 1 1 8 ROPE PIN BUSHINGS 2 FOR 40K RADIO LOADCELL 1 ROPE PIN BUSHINGS 1 3 4 FOR 40K RADIO LOADCELL PIN BUSHINGS 1 5 8 FOR 40K RADIO LOADCELL 7 8 ROPE PIN BUSHINGS 1 1 2 FOR 40K RADIO LOADCELL Whip Antenna 031 300 060 559 www skyazul com 301 371 6126 45 Service and Maintenance A2B STE DIRE ne x 77 D O 00 0 00 oo ran D0 O C LO LO O o I I E O E C O o o c C oi om D D x O c C Mm D m XI O ZO t gt O c D 0 U D D D See C c E co ated co c
14. Check wiring LCD does not light No power to console or show characters Ensure correct polarity of the power Open console check status of LED s Both the red and green LED s should be on Go into the diagnostics screen for the display Verify all function properly screens are functioning If any of the tests fail replace console Buttons do not Faulty buttons If possible go to the diagnostics screen for the buttons were mu Test the function of each button If any of the buttons fail replace the console Communication Low battery Verify which sensor is causing the error by looking at the error icons on the communication error screen Replace batteries Verify which sensor is causing the error by looking at the error icons on the communication error screen Verify that the LED on the sensor is blinking Communication Poor reception Verify which sensor is causing the error by looking at the icons on the communication error screen Verify that the LED on the sensor is blinking Verify that the sensor is line of sight to the console error Communication Poor communication Remove potential interference sources from the area error caused by Mount the receiver in a different location interference Horn does not Faulty Go into the diagnostics screen for the outputs Verify all If any of the tests fail replace console locked out all the time locked out all the time locked out all the module time Pull switch wire rope
15. Crystal Display The Liquid Crystal Display LCD used in the PAT Telemetry Receiver console is a wide temperature range graphic display with transflective characteristics that give it a high visibility in sunlight and during backlit night operation Due to the nature of any LCD it works on the principle of polarization of light It should be noted that dual polarizations that are at a certain angle to each other can reduce the amount of light up to completely eliminating it if that angle becomes perpendicular This can have significance if the operator is wearing polarized sunglasses that happen to be perpendicularly polarized in relation to the LCD s polarization In this rare case the operator has to work without sunglasses or find different sunglasses that do not have this characteristic in order to avoid having the visibility of the display impaired The LCD contains an automatic temperature compensation that will adjust the LCD s contrast according to the surrounding temperature SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 9 4 1 2 Control Identification This unit contains a display and different controls that are described as follows LCD Clear button fy HIRSCHMANN PRS 80 EZ select button Up Button Down Button S 3 Gm D9 g Fig 2 Operator s Console Button SCROLL UP Button SCROLL DOWN e Use this button to increase values or to scroll up Changes which sensors are di
16. Inc y 200 W Main Street Suite 2A EN Middletown MD 21769 Phone 301 371 6126 EQUIPMENT SOLUTIONS Fax 301 371 0029 www skyazul com info skyazul com
17. T OPERATING CONSOLE sonoridad tinta 8 411 Liguid Crystal DIS DIO zp ho zr ror tna Zo ted re H 8 41 2 Contr l IG SIU i o 9 o OVO LEI OPERA FION oirean is da o rio Sc po an o i or 10 SN WR sp U 11 5 2 MENU SELECTION INSTRUCTIONS ceseee I III nn nn nn nn nn nn 11 A c 12 gal Load EEUU 12 S92 An 13 I PA a 13 A A A 15 sr MEE sel A PA 15 A n RET E ee ee 15 5 4 3 Pre Operation lnspechon o ono so nn ie aaa E a a aa aaa a sns naar asa 16 S VIND P UOH 19 A 19 SEORSUM t s 19 AN AP O 20 o Eu MES te TR c 20 A cCMCMT V 20 6 INSTALLATION AND SETUP siste la ita ri o ri ametur wien 21 Gal CONSOLE d Le Ehl e 21 leed 22 050 ADDING SEN EE 23 DT REPEATER ueno eg 24 A A E e E EA 24 6 5 1 Load cell Installation mE 24 6 5 2 Load Cell Setup and Calibration 001 n00nnn0nnannnannnennnnnnnnennnsnnnsnrrnnrnsnrrsnrrnenrrsnrrnnnrenrrnnrrnnnrrsnrrrrnrrnni 25 6 5 3 Accuracy and Test Requirements vnn nn nn rn r r rr 27 2100922 c APP O tn 28 A ai A E ee eee eee ee 28 0 62 o EE KEE 28 0 6 3 Travel position Optional tret roni Eon A dav ns
18. 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 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 30 Operator s Manual PAT PRS 80 6 7 Wind 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 INSTRUCTIONS PRIOR TO WELDING ON BOOM The mounting pole is 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 It must be installed so that no part of the crane can disrupt the measurement of wind i f F 1 Assembly of parts SkyAz l Eguipment Solutions www skyazul com 301 371 6126 Service and Maintenance 31 6 8 Angle 6 8 1 Angle Installation Setup Calibration This procedure describes how to i
19. and other red LED blinks when the repeater is transmitting a signal 6 5 Load 6 5 1 Load cell 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 25 6 5 2 Load Cell Setup and Calibration The PRS80 console and load cell should be already been setup Howev
20. angle limit To set the limit e Select the desired limit to set e Move the boom to desired angle e 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 4 Press and hold the down arrow SETUP LIMITS ANGLE MAXIMUM Press and hold the up arrow al The limits will change to 90 degrees SkyAz l Eguipment Solutions www skyazul com 301 371 6126 The limits will change to 5 degrees Service and Maintenance 21 6 INSTALLATION AND SETUP 6 1 Console Mounting The console has a mount that allows the console to be swiveled into any direction and to be mounted in a variety of locations and on nearly any surface Choose a location that is in line of site of the sensor and within reach of the operator Securely attach the base of the mounting apparatus onto a solid surface The console has a mount that allows the console to be swiveled into any direction and to be mounted in a variety of locations and on nearly any surface 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 2 amps An internal fuse protects against overloading this circuit Mount the console antenna in a position that is in direct line of the transmitter ensuring that no obstructions will interfere with the transmission of the radio signal
21. art 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 measuring 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 28 Operators Manual PAT PRS 80 66 A2B 6 6 1 Transmitter Switch The transmitter and battery housing are made of a special plastic that resists impact and will not become brittle even in low temperatures LED Travel Hook Option Customer Supplied 6 6 2 Transmitter LED The transmitter has an LED on the bottom for diagnostics The LED should be on when in a two block condition or whe
22. connections must be checked to ensure that the system is properly connected for the crane configuration With even parts of hoisting line the weight shall be attached to the dead end line With odd parts of hoisting line the weight shall be attached to the line of lowest speed A separate A2B weight and transmitter must be used for each hoist that is in use The Retainer flag if eguipped 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 Fig 1 Setting of Anti Two Block Retainer in Locking Fig 2 Retainer in Locking Position 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 17 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 bac
23. e angle by using the menu selection MENU SETUP CALIBRATIONS ANGLE 1 or 2 as defined above ANGLE OFFSET Note Choose sensor to calibrate screen will not be shown if there is only one sensor installed After making this selection measure the boom angle by using a digital inclinometer i e smart level scroll to the correct angle Use the Up or Down arrows to adjust the offset to zero degrees In this example the displayed angle is 2 2 and the measure the boom angle by using a digital inclinometer is 1 2 therefore the down arrow was pressed to adjust the displayed angle to 1 2 Press the select button to enter the adjustment pressing the C button will cancel the adjustment 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 34 Operators Manual PAT PRS 80 6 8 2 Accuracy and Test Requirements Check the angle display by changing the angle of the boom to known angles The accuracy of the angle indication shall be within the tolerance of SAE J375 refer to complete SAE standard before testing Accuracy For Boom Angle Indicating Systems the indication is to be as
24. e 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 9 3 1 Load Display When a load cell has been installed the option is available to display the on hook load The load cell must be installed in the dead end of the load line If additional sensors are installed optional screens can be selected Some showing one of the sensors only and some showing multiple sensors at once The combination of displayed sensors can be selected by pressing the arrow buttons while on the working screen Set the console to match the crane hoist reeving Use the up down arrows to adjust the reeving 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 13 The console will now display the on hook load display REEVING LOAD PERCENT OF LIMIT There are several options for selecting which values are shown on the display and multiple ways in which the data can be di
25. er it maybe necessary to perform the following setup and calibration for maintenance or if you believe the load reading is incorrect Calibration is reguired when a new sensor is added or replaced If the load cell is not already added to the system go to the section on adding sensors Two things must be done to setup a load cell First the type of load cell must be input into the console Second the Zero point of the load cell must be set 6 5 2 A Adding a Sensor Menu selection SETUP SENSORS This gives the sensor select information screen It shows the status of all hardware In the example below NOT IN means that none of the sensors are installed ME nat H P LOAD LORI r d b T I ri 1 T A LA d 11 i pa E ul n i 1 k Sensor status screen Choose the sensor that you wish to install and follow the onscreen instructions which will ask you to remove the paper tap insulating the battery contact or installing the batteries into the transmitter To do this remove the 4 screws from the transmitter housing and remove the paper insulation tag that reads REMOVE BEFORE OPERATION by holding the batteries in place with one hand and removing the tag with the other or insert batteries if not installed If the batteries are already installed pull or disconnect one battery and reinstall to reset transmitter SkyAz l Eguipment Solutions www skyazul com 301 371 6126 26 Operator
26. he anti two block alarm display should flash o 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 o 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 18 Operators Manual PAT PRS 80 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 4 Ifthe crane is equipped with a boom extension repeat the test procedure for the boom extension anti two block switch SkyAz l Eguipment Solutions www skyazul com 301 371 6126 Service and Maintenance 19 5 5 Wind 5 5 1 Display The wind speed can be shown by itself on the screen or if in combination with other sensors as an icon on the bottom of the screen PEAK VALUE CURRENT WIND SPEED UNITS of LIMIT The s
27. in the system First installed A2B switch Second installed AZB switch Load sensor Wind Speed Sensor Reeving SkyAz l Eguipment Solutions www skyazul com 301 371 6126 71 ae GI Si Ze Si Ze 9 2 From the operating screen press Use the up B Service and Maintenance MENU S REEVING LIMIT S SETUP SENSORS A2B 1 A2B2 LOAD 1 LOAD 2 WIND SPD ANGLE 1 ANGLE 2 For each sensor s INSTALL NEW UNINSTALL ENABLE DISABLE CALIBATIONS e LOADCELL 1 e LOADCELL 2 o For each loadcell o ZERO POINT SENSOR TYPE v 7 5 TON MAX v 22 5 TON MAX SCREEN BEEPER UNITS e LBS MPH e KG KPH LANGUAGE PCT BAR IS ON OFF WARNING ARE ON OFF DIAGNOSTICS SCREEN a KEYPAD OUTPUTS ALARM LOG COMM DATA ABOUT Menu Selection Instructions make the selection SkyAzul Equipment Solutions LOW BATTERIES This will only be shown if a low battery condition exists to enter the menu selection O and down to scroll through and high light your selection then press to www skyazul com 11 301 371 6126 12 Operators Manual PPAT PRS 80 5 3 Load 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 eguals 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 lin
28. ing 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 performed by non expert personnel When thePRS80 Telemetry Receiver 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 fails please contact your nearest service representative before operating the system SkyAzul Equipment Solutions www skyazul com 301 371 6126 36 Operators Manual PPAT PRS 80 7 1 Screens Communication error screen This screen shows that there is an error in the communication between the sensor sensors and the console The sensor that is in error is indicated with the icon at the bottom of the screen Inthe example both the load and the A2B 1 are in error Only the sensors that communication error are shown 7 2 Diagnostics There are several diagnostics screens that can be accessed thru the display Howe
29. k parallel to the boom and hold 2 2 Move the retainer down 3 and then left 4 to remove it from the Anti Two Block switch Release the cable A lanyard is supplied to connect flag to A2B mounting plate Fig 3 Removal of the Anti Two Block Retainer 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 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 3 Check the anti two block alarm by performing one of the following tests o By manually lifting the weight attached to the anti two block switches When the weight is lifted the audible alarm should sound t
30. n 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 6 6 3 Travel position optional Designed into the transmitter plate is a small hole into which a hook or hardware can be installed to fasten the chain and put the switch into a permanent 2 block condition This serves 2 functions 1 It extends battery life 2 t prevents the lockouts and alarms from engaging and disengaging due to bounce while traveling During this condition 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 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 29 6 6 4 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
31. nstall and setup a radio angle transmitter CONTACT CRANE MANUFACTURER FOR WELDING INSTRUCTION PRIOR TO WELDING ON BOOM E Anos LED E are nem Fert mut E EE 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 O left and 90 above positions SkyAzul Equipment Solutions www skyazul com 301 371 6126 32 Operators Manual PPAT PRS 80 The angle sensor total range is approximately 105 and the zero point is adjustable in the software in the angle calibration menu With no software adjustment the angle range will allow a 15 to 90 range but if the angle sensor is zeroed at 5 5 becomes 0 your angle range will be 10 to 95 Therefore when affixing the mounting plate to the boom make sure you will be able to get your desired angle range for your application 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 instal 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
32. peed 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 The of limit is shown at the bottom 9 9 2 LIMITS The system sets the default speed limit to 30 mph This is represented in by the bargraph The bargraph shows the of the limit that is set The limit can be set to other values To change the default limit press then select the sensor for the limit that you want to set to confirm the values Use the arrows to change the value Use the Note a prewarning can be set so as to beep the alarm when a limit is approached but not reached This is set with the warning option Menu SETUP SCREEN BEEPER WARNING SkyAz l Eguipment Solutions www skyazul com 301 371 6126 20 Operators Manual PPAT PRS 80 5 6 Angle 5 6 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 6 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
33. per tap insulating the battery contact or installing the paneles is the Tanner To do this remove the 4 screws from the transmitter housing and PAESE TMS uns remove the paper insulation tag that reads REMOVE BEFORE REMOVE BEEOR OPERATION by holding the batteries in place with one hand and pue removing the tag with the other or insert batteries if not installed m Il LOOSEN 4 SCREWS SkyAzul Equipment Solutions www skyazul com 301 371 6126 24 Operators Manual PPAT PRS 80 6 4 Repeater The purpose of the repeater is to reduce the possibility of a communication loss error by receiving the load cell transmitted ID code and re transmitting the same ID code out to the PRS 80 To do this the repeater is positioned at the boom tip up the hoist rope from the load cell and up the boom from the PRS 80 If the load cell does not have a direct line of sight or blocked by a wall structure from the PRS 80 then there is less chance of the signal absorptior interference Power cable connections PIN 1 UB 9 to 30VDC PIN 2 GND The repeater is setup from the factory to repeat signals from the load cells to the PRS 80 receiver PRS 80 can receive both transmissions load cell and repeater and output the load signal to the system computer After switching power on to the repeater from the crane ignition switch the system starts with an automatic test of the repeater board LEDs and electronic components The red power LED should be on
34. s Manual PPAT PRS 80 6 5 2 B Setting Sensor Type 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 Menu SE TUP CALIBRATIONS SENSOR TYPE 6 5 2 C Setting Zero Point 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 as an example to set the zero point of the load cell Menu SETUP CALIBRATIONS ZERO POINT j 1 FT d 1 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 27 6 5 3 Accuracy and Test Requirements Check the 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 ch
35. splayed To change the data that is displayed use the up and down arrows The up arrow cycles thru the available displays These options change for different combinations of sensors lfthe display does not change there is no option available for this combination 5 3 2 Tare Function The tare function is activated by pressing the O button t will flash beside the load display while the tare function is active The tare function is deactivated after 30 seconds if no other buttons are pressed 9 3 3 Limits Load limits can be easily set thru the setup menu When a limit is set the limit may be shown on the bottom portion of the screen What is shown depends on the user preferences he screen can show an Icon representing the sensor for which the limit is set or it can be in the form of an analog bar When a limit Is exceeded the limit icon will flash and the lockout relay will disengage 9 3 3 A SETTING LIMITS To set limit Press E Scroll to select LIMITS Scroll to select your sensor Only installed devices can be selected for limits Two types of limits can be set for the load cell Max linepull and max total load Both will limit the maximum capacity To set the maximum limit of the load select LOADCELL 2 To set a limit on the maximum permissible line pull select LINE PULL 2 from the menu This will give a limit based on the current reeving of the hook block SkyAz l Eguipment Solutions www skyazul com 301 371 6126 14
36. splayed and how each is displayed e Use this button to decrease values or to scroll down A e Changes which sensors are displayed and how each is displayed Button SELECT e Use this button to enter the menu screen and to confirm selections SkyAzul Equipment Solutions www skyazul com 301 371 6126 10 Operators Manual PPAT PRS 80 Button C screen e While pushing this button the control lever lockout function of the system can be deactivated e Accesses the Tare function Since button C can deactivate the lockout function of the system the following instructions must be obeyed C e Generally used to back out of a selection and return to the previous e 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 9 SYSTEM OPERATION Upon switching on crane ignition switch the system starts with an automatic test of the system of lamps and audible alarm During the test the LC display shows the console and system software version The TR 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 On several screens icons are used to represent the sensor Here are the icons used
37. ver it is possible that a malfunction can cause the displays to be inaccessible In this case follow the troubleshooting section of the manual 1 2 1 To Test the Display Menu SETUP DIAGNOSTICS SCREEN Various test screens will be displayed by pressing the button Press to go to the next screen Note any problems in the display SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 37 7 2 2 To Test the buttons Press Menu SETUP DIAGNOSTICS BUTTONS When a button is pressed the corresponding button on the console will invert Press each button one ata time When finished press and hold C 7 2 3 To Test the outputs Press Menu SETUP DIAGNOSTICS OUTPUTS SkyAzul Equipment Solutions www skyazul com 301 371 6126 38 Operators Manual PPAT PRS 80 Arrow to select an output to test Press to test the selected output The state of the output will change when the button is pressed The status indicator text will also change when the button is pressed Indicator LED s RED POWER FLASHING GREEN OK SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service and Maintenance 39 7 3 TROUBLESHOOTING After the onboard diagnostics have been performed follow these guidelines All LED s are located inside the receiver box Problem Cause X Solution Make sure the console is getting power from the crane
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