PROLEC PME 500 Operator's Manual
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PROLEC PME 500 Operator's Manual

Rated capacity indicator, rated capacity controller, machine envelope controller
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562500-000, Issue1.0, May 2013
PME 500
Rated Capacity Indicator,
Rated Capacity Controller,
Machine Envelope Controller
Operators Manual

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Summary of Contents for PROLEC PME 500

  • Page 1 562500-000, Issue1.0, May 2013 PME 500 Rated Capacity Indicator, Rated Capacity Controller, Machine Envelope Controller Operators Manual...
  • Page 3 Any alterations or modifications to machine components which affect this system and any system component failure must be reported to Prolec Ltd or via the machine convertor/ service agreement holder. This manual must be kept with the product and be passed on to any subsequent user of the product.

  • Page 4: Table Of Contents

    Table of contents Use of this Document Notices System Identification Operating and Restriction Situation Recommendations 4.1 MEC Override Operating Instructions 5.1 Power Up 5.2 Using the Display 5.3 User Login 5.4 User Logout Top Menu 6.1 Tool Selection Menu Rated Capacity Indicator / Controller 7.1 Introduction 7.2 Operation within the Safe Working Load 7.3 Approach to Overload...
  • Page 5 Table of contents (continued) 7.6 Overload / Hydraulic Limitation Control Override 7.6.1 Soft Override 7.6.2 Master Override Key Switch 7.7 Lift Mode Menu 7.8 Lifting Point Selection 7.9 Lifting Duties 7.10 Load Chart Menu 7.11 Safe Working Area Indication 7.12 Lifting Mode - Non Lifting Mode 7.13 Alternative Lifting Mode Screens Envelope Monitoring 8.1 Height Limit...
  • Page 6 Table of contents (continued) 8.3.2 Min Radius Limit Setting - Known Radius 8.3.3 Min Radius Limit Setting - Using Current nearest Point 8.3.4 Machine Envelope Controller (MEC) - Min Radius 8.4 Low Limit 8.4.1 Low Limits Menu 8.4.2 Low Limit Setting - Known Radius 8.4.3 Low Limit Setting - Using Current Lowest Point 8.4.4...
  • Page 7 Table of contents (continued) Test / Diagnostics 12.1 Relay Function Test 12.2 Slew Angle 12.3 Beacon, LED Alarm Function Test System Information Display Settings 14.1 Day / Night Mode 14.2 Select Display Machine 14.3 Select Safe Working Area Indication 14.4 Select Language User Login 15.1 User Login Setup 15.2 Add New User to Login...

  • Page 8: Use Of This Document

    562500-000, Issue1.0, May 2013 Use of this Document This user guide is intended for persons familiar with the use of construction plant under- taking lifting operations. WARNING denotes information about particular risks which may be generated by certain applications, by using certain fittings, and about additional protective measures which are necessary for such applications.

  • Page 9: System Identification

    562500-000, Issue1.0, May 2013 System Identification The PME system provides two primary safety functions Lifting Stability Machine Envelope Monitoring Both safety functions are achieved through real time monitoring some or all of the machine’s moving parts ( booms, other articulations, turret etc ) and its environment ( ground pitch and inclination, load etc) and actively determining the safety of the current operation where appropri- ate limits have been set.

  • Page 10: Operating And Restriction Situation Recommendations

    562500-000, Issue1.0, May 2013 Operating and Hazard Situation Recommendations Operating Recommendations When operating the machine as a When using envelope monitoring: crane:   When setting a slew restriction, Ensure Lift Mode is selected dur- make sure any implement attached ing lifting operations ...

  • Page 11: Operating Instructions

    562500-000, Issue1.0, May 2013 Operating Instructions 5.1 Power Up The PME system automatically powers up when the machines ignition is switched on. The in-cab unit incorporates a 4.3” high resolution LCD display and is controlled with three buttons at each side. Three status LEDs and an internal alarm provide further infor- mation.

  • Page 12: Using The Display

    562500-000, Issue1.0, May 2013 5.2 Using the Display The display is operated by using the buttons adjacent to a function icon. The buttons can open a sub menu, turn a function ON or OFF, set a value, toggle through multiple screens, no one button has a single function.

  • Page 13: User Login

    562500-000, Issue1.0, May 2013 5.3 User Login If PME has been configured to work with the built-in user list, the system will prompt for a user login pass code. Select the user name required and the login code screen will ap- pear.

  • Page 14: User Logout

    562500-000, Issue1.0, May 2013 5.4 User Logout If a user is logged in as the current user, they can select the logout screen by holding an exit key down for three seconds. Cancel to stay Confirm logout logged in Once logout has been confirmed the login screen will be automatically displayed. Press the CROSS button to stay logged in, the screen will return to that previously shown.

  • Page 15: Tool Selection Menu

    562500-000, Issue1.0, May 2013 6.1 Tool Selection Menu The system can monitor the position of a tool and so be calibrated with, one or multiple tools. If more than one tool has been calibrated, it will be manually selected via the Select tool selection screen shown below. Use the arrow but- tons to select the required tool and confirm using the TICK button.

  • Page 16: Rated Capacity Indicator / Controller

    562500-000, Issue1.0, May 2013 Rated Capacity Indicator / Controller 7.1 Introduction The PME500 RCI/RCC has been designed to meet European requirements for the provi- sion of rated capacity indicators. PME500 ensures that the maximum lifting capacity over the range of a machine working envelope can be utilised. The system will always start up in Lifting Mode.

  • Page 17: Operation Within The Safe Working Load

    562500-000, Issue1.0, May 2013 7.2 Operation within the Safe Working Load With the Lifting Mode active, the current lifting point radius and the maximum safe working load for that radius are shown. If the load is less than 95% of the maximum safe working load ...

  • Page 18: Stability Indication Overload

    562500-000, Issue1.0, May 2013 7.4 Stability Indication Overload The system indicates an overload condition via internal and external alarms only - no motion is cut. If the load is greater than 105% of the maximum safe working load  The load capacity indicator will be red ...

  • Page 19: Stability Control Overload

    562500-000, Issue1.0, May 2013 7.5 Stability Control Overload Where an overload condition occurs the machine hydraulics will be locked to pre- vent any further dangerous movements. Only those movements that allow safer operation remain active. The radius cannot be increased and the load cannot be raised.

  • Page 20: Overload / Hydraulic Limitation Control Override

    562500-000, Issue1.0, May 2013 7.6 Overload / Hydraulic Limitation Control Override 7.6.1 Soft Override After three seconds a soft override button will replace the Lifting Mode button. If soft override is utilised, the machine hydraulics will be re-enabled. However, the external alarm will stay active, the red LED will flash, and the beacon (if fitted) will switch off.

  • Page 21: Lift Mode Menu

    562500-000, Issue1.0, May 2013 7.7 Lift Mode Menu The Lifting Mode function has various features which may be available if con- figured at installation. The configuration will depend on the operating proce- dures of the machine owner. If only one duty, lifting point and or tool has been calibrated, the relevant icon will not be displayed.

  • Page 22: Lifting Duties

    562500-000, Issue1.0, May 2013 7.9 Lifting Duties The current duty is indicated on the Lifting Mode screen. The system can be calibrated with just one duty for use throughout 360 degrees of slew, most machines will be cali- brated in this way. If more than one duty has been calibrated, it will either be selected by slew angle or auto- matically selected using a switch or other input.

  • Page 23: Load Chart Menu

    562500-000, Issue1.0, May 2013 7.10 Load Chart Menu PME can display the load chart for the currently selected lifting duty and lifting point. *If the machine is equipped with a hydrauli- cally adjustable boom, both maximum and minimum charts will be available.

  • Page 24: Safe Working Area Indication

    562500-000, Issue1.0, May 2013 7.11 Safe Working Area Indication Safe working area indication displays the where a load can be safely moved using the plan view. It can be turned on and off in Displays Setting screen 4. (See section 7.8, 14.2) With Safe Working Indication ON: The Green area indicates the safe zone The Hatched area indicates the hazard...

  • Page 25: Lifting Mode - Non Lifting Mode

    562500-000, Issue1.0, May 2013 7.12 Lifting Mode - Non Lifting Mode When the machine is not being used for lifting operations it can be put into ‘Non Lifting Mode’ available from the Top Menu screen. When in Non Lifting Mode, the system still monitors all machine activity and safety status but will NOT warn of overload conditions.

  • Page 26: Alternative Lifting Mode Screens

    562500-000, Issue1.0, May 2013 7.13 Alternative Lifting Mode Screens Alterative Lifting Mode screens can be selected from the Display Settings screen (See section 13). The three selectable screens show safe working load, load on hook, lifting point radius and bar graph or dial indicating the proximity of the current load to the maximum available safe working load.

  • Page 27: Envelope Monitoring

    562500-000, Issue1.0, May 2013 Envelope Monitoring PME500 is configured for Machine Envelope Control (MEC) only. MEC will warn and prevent equipment motion. MEC is achieved by interacting with the machines hydraulics, this allows motion to be cut to any section of equipment that has reached a restriction but allow other sections to operate unhindered unless they too reach the set restriction.

  • Page 28: Height Limit

    562500-000, Issue1.0, May 2013 8.1 Height Limit 8.1.2 Height Limit Menu A height limit can be set by entering a known height on the key- pad or by manually moving the machine to the desired limit. Current highest point. Only displayed if a height limit is set.
  • Page 29 562500-000, Issue1.0, May 2013 8.1.2 Height Limit Setting - Known Height A known limit can be entered into the display: Enter a value Exit to previous menu Press the ’Enter a value’ button Cancel without change Increases highlighted digit Moves highlighter to right / Moves highlighter to left / Hold to delete digit Hold to delete digit...
  • Page 30 562500-000, Issue1.0, May 2013 8.1.3 Height Limit Setting - Using Current Highest Point Move equipment to required height limit and press this button To set the height limit using the machine, move the equipment to the desired maximum height, and press the ‘current highest point’...
  • Page 31 562500-000, Issue1.0, May 2013 8.1.4 Machine Envelope Controller (MEC) - Height If any of the equipment enters the approach limit* an ‘Approaching max height’ message will appear, the internal alarm will beep and the amber LED will be lit. If any of the equipment reaches the height limit, the appropriate motions will be controlled.

  • Page 32: Max Radius Limit

    562500-000, Issue1.0, May 2013 8.2.1 Max Radius Limit 8.2.1 Max Radius Limit Menu A max radius limit can be set by entering a known radius on the keypad or by manually moving the machine to the desired limit. Switches max radius monitoring and OFF Current furthest point.
  • Page 33 562500-000, Issue1.0, May 2013 8.2.2 Max Radius Limit Setting - Known Radius A known limit can be entered into the display: Enter a value Exit to previous menu Press the ’Enter a value’ button Cancel without change Increases highlighted digit Moves highlighter to right / Moves highlighter to left / Hold to delete digit...
  • Page 34 562500-000, Issue1.0, May 2013 8.2.3 Max Radius Limit Setting - Using Current furthest Point Move equipment to required max radius limit and press this button To set the max radius limit using the machine, move the equipment to the desired radius, and press the ‘current farthest point’...
  • Page 35 562500-000, Issue1.0, May 2013 8.2.4 Machine Envelope Controller (MEC) - Max Radius If any of the equipment enters the approach limit* an ‘Approaching max radius’ message will appear, the internal alarm will beep and the amber LED will be lit. If any of the equipment reaches the max radius limit, the appropriate motions will be controlled.
  • Page 36 562500-000, Issue1.0, May 2013 8.3 Min Radius 8.3.1 Min Radius Limit Menu A min radius limit can be set by entering a known radius on the keypad or by manually moving the machine to the desired limit. Switches min radius monitoring and OFF Enter a height...
  • Page 37 562500-000, Issue1.0, May 2013 8.3.2 Min Radius Limit Setting - Known Min Radius A known min radius can be entered into the display: Enter a value Exit to previous menu Press the ’Enter a value’ button Cancel without change Increases highlighted digit Moves highlighter to right / Moves highlighter to left / Hold to delete digit...
  • Page 38 562500-000, Issue1.0, May 2013 8.3.3 Min Radius Limit Setting - Using Current nearest Point Move equipment to required min radius limit and press this button To set the min radius limit using the machine, move the equipment to the desired minimum radius, and press the ‘current nearest point’...
  • Page 39 562500-000, Issue1.0, May 2013 8.3.4 Machine Envelope Controller (MEC) - Min Radius If any of the equipment enters the approach limit* an ‘Approaching min radius’ message will appear, the internal alarm will beep and the amber LED will be lit. If any of the equipment reaches the min radius limit, the appropriate motions will be controlled.

  • Page 40: Low Limit

    562500-000, Issue1.0, May 2013 8.4 Low Limits 8.4.1 Low Limit Menu A low limit can be set by entering a known height on the keypad or by manually moving the machine to the desired limit. Switches low monitoring and OFF Enter a value Set low limit using current Exit to previous menu...
  • Page 41 562500-000, Issue1.0, May 2013 8.4.2 Low Limit Setting - Known Low Menu A known low limit can be entered into the display: Enter a value Exit to previous menu Press the ’Enter a value’ button Cancel without change Increases highlighted digit Moves highlighter to right / Moves highlighter to left / Hold to delete digit...
  • Page 42 562500-000, Issue1.0, May 2013 8.4.3 Low Limit Setting - using Current Low Move equipment to required low limit and press this button To set the low limit using the machine, move the equipment to the desired low height, and press the ‘current lowest point’ button.
  • Page 43 562500-000, Issue1.0, May 2013 8.4.4 Machine Envelope Controller (MEC) - Low If any of the equipment enters the approach limit* an ‘Approaching min height’ message will appear, the internal alarm will beep and the amber LED will be lit. If any of the equipment reaches the low limit, the appropriate motions will be con- trolled.

  • Page 44: Slew Limits Menu

    562500-000, Issue1.0, May 2013 8.5 Slew Limits Menus Slew restriction can be set by manually moving the machine to the desired limit. Slew limits screen shown here. Do not travel once a slew limit has been set. Select Slew Switches slew monitoring restriction type and OFF Current hazard zone...
  • Page 45 562500-000, Issue1.0, May 2013 8.5.1 Angular Slew Limit Setting - using Current Slew Angle Select angular slew limiting, follow the on screen in- structions. Do not travel once a slew limit has been set. Set to angle Press this button to start the setup procedure Step by step instructional banner Step One...
  • Page 46 562500-000, Issue1.0, May 2013 Step three Move to the right slew limit, press any button to set the left limit. Another marker will be placed here Slew left restriction marker Step four Press any button to complete. The hatched hazard zone will be shown on the main screen. Check the limits are working as required.
  • Page 47 562500-000, Issue1.0, May 2013 8.5.2 Virtual Wall Limit Setting - using Virtual Wall Select single vertical wall limiting, follow the on screen instructions. Do not travel once a slew limit has been set. Set to Virtual Wall Press this button to start the setup procedure Step by step instructional banner Step One...
  • Page 48 562500-000, Issue1.0, May 2013 Step three Move the equipment away from the limit and press any button to complete. The hatched hazard zone will be shown on the main screen. Check the limit is working as required. Safe Directional indicators. The triangles Safe Directional indicators.
  • Page 49 562500-000, Issue1.0, May 2013 8.5.3 Twin Virtual Wall Limit Setting - using Twin Virtual Walls Select twin vertical wall limiting, follow the on screen instructions. Do not travel once a slew limit has been set. Set to twin Virtual Wall Press this button to start the setup procedure Step by step instructional banner...
  • Page 50 562500-000, Issue1.0, May 2013 Step four Move the dipper to the other end of the SECOND virtual wall, press any button. A marker will be placed here. Step four Move the equipment away from the limit and press any button to complete. The hatched hazard zones will be shown on the main screen.
  • Page 51 562500-000, Issue1.0, May 2013 8.5.4 Multipoint Envelope Restriction- using Multipoint Wall Select multipoint envelope restriction, follow the on screen instructions. Do not travel once a slew limit has been set. Set to multipoint Any number of points can be used, four are shown in the example below.
  • Page 52 562500-000, Issue1.0, May 2013 Step four Confirm if another position is needed, the tick is selected in this example Step five Move the end of the dipper to the FORTH point of the box, press any button. A marker will be placed here.
  • Page 53 562500-000, Issue1.0, May 2013 The hatched hazard zones will be shown on the main screen. Check the limits are working as required. Safe Directional indicators. The triangles indicate if it is safe GREEN, or unsafe RED to movement a particular articulation. Safe Directional indicators.
  • Page 54 562500-000, Issue1.0, May 2013 8.5.5 Machine Envelope Controller (MEC) - Slew and Virtual Wall If the equipment enters the approach limit* an ‘Approaching slew limit’ message will appear, the internal alarm will beep and the amber LED will be lit. MEC systems will cut mo- tion to any section of equipment that has...

  • Page 55: System Messages

    562500-000, Issue1.0, May 2013 System Messages 9.1 On Screen Messages Highest point of equipment within *0.5m of set limit Approaching max height Equipment has reached/exceeded set limit Maximum height exceeded Furthest point of equipment within *0.5m of set limit Approaching max radius Maximum radius exceeded Equipment has reached/exceeded set limit Approaching min radius...

  • Page 56: Led And Internal Alarm Warnings

    562500-000, Issue1.0, May 2013 9.2 LED and Internal Alarm Warnings The table below shows the state of the three LEDs on the display and the internal alarm with respect to system status. LED and Internal Alarm status System status Start up, Power Down Operational: System OK, no warnings, hazards, or errors Warning: Approach to overload or envelope limit 1 Hz...

  • Page 57: Test / Diagnostics

    562500-000, Issue1.0, May 2013 12 Test / Diagnostics The system test function is available from the main operating screen. This option allows the functionality of the system to be verified, and basic trouble- shooting to be performed. In this mode, the amber LED will flash to indicate that the system is in maintenance mode.

  • Page 58: Slew Angle

    562500-000, Issue1.0, May 2013 12.2 Slew Angle Boom = Slew angle Arm = Slew angle Platform = Slew angle Exit to previous menu 12.3 Beacon, LED Alarm Function Test Press the Beacon button to activate the alarm Press the Alarm button to activate the LEDs Press the Alarm...

  • Page 59: System Information

    562500-000, Issue1.0, May 2013 13 System Information Information regarding the system can be found from this menu. LOLER information Software Version Machine information License information Distributor information Exit to previous menu 14 Display Settings The display brightness, button click volume, and the displayed machine colour and type can be adjusted from this menu.

  • Page 60: Day / Night Mode

    562500-000, Issue1.0, May 2013 14.1 Day / Night Mode To make viewing the display more comfortable at night, the display brightness can be switched to a preset ‘night mode’. The system will default to day mode on power up. Select day / night mode: Day mode ON Night mode ON Full display brightness...

  • Page 61: Select Safe Working Area Indication

    562500-000, Issue1.0, May 2013 14.3 Select Safe Working Area Indication Safe working area indication displays the where a load can be safely moved using the plan view. It can be turned on and off in Displays Setting screen 4. (See section 7.8, 7.11) Switches safe working area indicator and OFF...

  • Page 62: Select Language

    562500-000, Issue1.0, May 2013 14.4 Select Language An appropriate machine type for the display can be selected from this list. Moves highlighter UP Accept highlighted Exit without change language Moves highlighter DOWN 15 User Login 15.1 User Login Setup Requires supervisor access rights. Add new user Edit user login code Select user(s) to be dis-...

  • Page 63: Add New User To Login

    562500-000, Issue1.0, May 2013 15.2 Add New User to Login Requires supervisor access code Scroll up though high- Toggle to / from keyboard lighted digits/ letters Moves highlighter to left Moves highlighter to right Scroll down though high- Accept displayed name lighted digits/ letters Highlight cross and press tick to cancel without...

  • Page 64: Edit User Details

    562500-000, Issue1.0, May 2013 15.3 Edit User Details Requires supervisor access rights. Moves highlighter UP Cancel without change Select highlighted user Moves highlighter DOWN Scroll up though high- Toggle to / from keyboard lighted digits/ letters Moves highlighter to right Moves highlighter to left Scroll down though high- Accept displayed name...

  • Page 65: Select User To Delete

    562500-000, Issue1.0, May 2013 15.4 Select User to Delete Requires supervisor access rights. Moves highlighter UP Exit without change Delete highlighted Moves highlighter DOWN 15.5 Edit User Access Code Requires supervisor access rights. Moves highlighter UP Exit without change Accept highlighted user Moves highlighter DOWN Cancel without change Increases highlighted digit...

  • Page 66: Edit User Access Code

    17.1 Maintenance Review Due to nature of the PME system operating environment, changes in usage can occur. Prolec Ltd must be notified of any changes in the pattern of use of the system for consid- eration. Any alterations or modifications to machine components which affect the system must be reported to Prolec Ltd or via the service agreement holder.

  • Page 67: Definitions / Glossary

    562500-000, Issue1.0, May 2013 18 Definitions / Glossary Definitions of words used to ensure understanding Part Number Boom First articulation connected to turret Second articulation Artic Second articulation of a hydraulically adjustable boom (luffing boom, knuckle boom, two piece boom) Turret Section of machine above the undercarriage Undercarriage...
  • Page 69 562500-000, Issue1.0, May 2013 Prolec Ltd 25 Benson Road Nuffield Industrial Estate Poole England BH17 0GB Tel: +44 (0)1202 681190 E-mail: service@prolec.co.uk Prolec Ltd® is a James Fisher Company...

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