1. Manuals
  2. Brands
  3. SkyAzúl Manuals
  4. Construction Equipment
  5. PRS40 EZ
  6. Installation, calibration, and service manual

SkyAzúl PRS40 EZ Installation, Calibration, And Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
SIGALARM
MODEL 210
PRS40 EZ
INSTALLATION, CALIBRATION & SERVICE MANUAL

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PRS40 EZ and is the answer not in the manual?

Questions and answers

Summary of Contents for SkyAzúl PRS40 EZ

  • Page 1 SIGALARM MODEL 210 PRS40 EZ INSTALLATION, CALIBRATION & SERVICE MANUAL...
  • Page 3 NOTICE SkyAzúl 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. SkyAzúl 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.
  • Page 4 SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION......................1 WARNINGS .............................1 FEATURES ............................2 SYSTEM DESCRIPTION.........................2 4.1 C ............................2 ONSOLE 4.1.1 Liquid Crystal Display ...........................2 4.1.2 Control Identification ..........................3 4.2 O ............................4 PERATION 4.2.1 MENU STRUCTURE ..........................5 4.2.2 Installation.............................6 ANGLE .............................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 A...
  • Page 6 Operator’s / Service Manual, PRS 40 EZ 13.1 ......................42 ATTERY EPLACEMENT PART NUMBERS...........................43 14.1 CONSOLE ..........................43 14.2 A2B .............................44 14.3 WIND ............................46 14.4 ............................47 ANGLE 14.5 A ........................48 NTENNA OPTIONS 14.6 L ............................49 INERIDER 14.7 LOADCELL ..........................50 SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

  • Page 7: General Information

    General Information 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.

  • Page 8: Features

    Operator’s / Service Manual, PRS 40 EZ 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. •...

  • Page 9: Control Identification

    System Description 4.1.2 Control Identification Fig 2: Operator’s Console Limit LED 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"...

  • Page 10: Operation

    Operator’s / Service Manual, PRS 40 EZ 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.

  • Page 11: Menu Structure

    System Description 4.2.1 MENU STRUCTURE SETUP SETUP CONT' ● REEVING ● SENSORS ● LIMITS INSTALL / REMOVE ○ ANGLE ○ ANGLE NOT INSTALLED SELECTION HARDWIRED HIRSCHMANN SELECTION KRUEGER ○ WINDSPEED RADIO ○ A2B1 SELECTION ○ LOAD NOT INSTALLED MAX LOAD HARDWIRED ○...

  • Page 12: Installation

    Operator’s / Service Manual, PRS 40 EZ 4.2.2 Installation 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 view and within reach of the operator. If radio sensors are being used, locate in line of site with the sensor.

  • Page 13: Angle

    Angle 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.

  • Page 14: Installation / Calibration Hardwired

    Operator’s / Service Manual, PRS 40 EZ 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.

  • Page 15: Calibration

    Angle 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 Select the "HARDWIRED"...

  • Page 16: Angle

    Operator’s / Service Manual, PRS 40 EZ 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°...
  • Page 17 Angle 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.

  • Page 18: A2B

    Operator’s / Service Manual, PRS 40 EZ 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...
  • Page 19 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). Removal and Storage of the Anti Two-Block Retainer Procedure (see Fig.
  • Page 20 Operator’s / Service Manual, PRS 40 EZ 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.

  • Page 21: A2B Limit

    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.
  • Page 22 Operator’s / Service Manual, PRS 40 EZ 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.

  • Page 23: A2B Setup

    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.
  • Page 24 Operator’s / Service Manual, PRS 40 EZ HARDWIRED A2B WIRING DIAGRAM (EXTERNAL RELAY INSTALLED BY CUSTOMER) SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

  • Page 25: Wind

    wind 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.

  • Page 26: Limits

    Operator’s / Service Manual, PRS 40 EZ 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.

  • Page 27: Wind Setup

    wind 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.
  • Page 28 Operator’s / Service Manual, PRS 40 EZ 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.

  • Page 29: Loadcell

    LOADCELL LOADCELL 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.

  • Page 30: Limits

    Operator’s / Service Manual, PRS 40 EZ 8.1.2 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. SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

  • Page 31: Installation

    LOADCELL 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.

  • Page 32: Loadcell Setup

    Operator’s / Service Manual, PRS 40 EZ 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.
  • Page 33 LOADCELL 8.1.5.A 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.

  • Page 34: Line Rider

    Operator’s / Service Manual, PRS 40 EZ 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.

  • Page 35: Limits

    Line rider 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 installation will depend on the type of boom. Follow the applicable instructions for a hydraulic or lattice boom.
  • Page 36 Operator’s / Service Manual, PRS 40 EZ 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.
  • Page 37 Line rider 9.1.3.B LATTICE BOOM MACHINES 30┐ MAXI MUM 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).
  • Page 38 Operator’s / Service Manual, PRS 40 EZ 9.1.3.C PRS 40 EZ UPGRADE FROM EI33 HIRSCHMANN PRS 40 EZ 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.

  • Page 39: Linerider Setup

    Line rider 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: •...

  • Page 40: Radio Module

    Operator’s / Service Manual, PRS 40 EZ 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.
  • Page 41 Radio Module 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.

  • Page 42: Adding Sensors

    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.

  • Page 43: Service / Trouble Shooting

    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.

  • Page 44: Screens

    Operator’s / Service Manual, PRS 40 EZ 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.

  • Page 45: Battery Level

    SERVICE / trouble shooting 12.1.3 Battery level: The battery level of each radio sensor can be monitored. SETUP >> OPTIONS BATTERY LEVEL. >> Select this option and then press . Each sensor can be selected individually, enabling the user to view the percentage of each sensor’s battery level. SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

  • Page 46: Troubleshooting

    Operator’s / Service Manual, PRS 40 EZ 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 No power to Make sure the console is getting power from the crane. show characters.

  • Page 47: Troubleshooting Moisture

    SERVICE / trouble shooting 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.

  • Page 48: Maintenance

    Operator’s / Service Manual, PRS 40 EZ 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.

  • Page 49: Part Numbers

    Part Numbers PART NUMBERS 14.1 CONSOLE 101646 Radio Module Assembly 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 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.

  • Page 50: A2B

    Operator’s / Service Manual, PRS 40 EZ 14.2 031-300-060-593 Radio A2B transmitter assembly 031-300-060-586 Antenna only Radio A2B transmitter 031-300-050-688 031-300-050-763 Neoprene rubber gasket SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...
  • Page 51 Part Numbers 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 SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

  • Page 52: Wind

    Operator’s / Service Manual, PRS 40 EZ 14.3 WIND 031-300-050-321 031-300-050-480 Mounting pole Anemometer mounting plate 031-300-050-322 031-300-060-586 Transmitter 031-300-050-323 031-300-050-507 Retaining pin Sensor SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

  • Page 53: Angle

    Part Numbers 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 SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

  • Page 54: Antenna Options

    Operator’s / Service Manual, PRS 40 EZ 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. 031-300-050-671 ANTENNA, 918 MHz FOR TRS05ASSEMBLY 060-576 WHIP ELEMENT 031-300-050-672 ANTENNA, 918 FOR CONSOLE...

  • Page 55: Linerider

    Part Numbers 14.6 LINERIDER Linerider * Please contact SkyAzul with questions concerning repair or replacement of component. (301) 371-6126 031-300-060-434 Extension cable 031-300-101-178 SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

  • Page 56: Loadcell

    Operator’s / Service Manual, PRS 40 EZ Sensor cable 14.7 LOADCELL 7.5t (15k) RADIO LOAD CELL The load cell kit will include item 1, item 2, and one of the optional item 3. ITEM PART NUMBER DESCRIPTION 031-300-060-608 1.00 SENSOR ASSY, FORCE TRANS. 7.5T W/RADIO TRANSMITTER 031-300-050-064 1.00 HARDWARE, COTTER PIN 2 3/8"...
  • Page 57 Part Numbers 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 DESCRIPTION SENSOR ASSY, FORCE TRANS. 45K STRAIGHT 031-300-060-609 1.00 W/TRANSMITTER BRACKET, H 20t RADIO LOADCELL 2-050-520 PLATES &...
  • Page 59 SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...
  • Page 60 SkyAzúl, Inc. 16 Walnut Street Middletown, MD 21769 Phone 301-371-6126 Fax 301-371-0029 www.skyazul.com info@skyazul.com SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

Table of Contents