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Hirschmann PRS 80, Operators & Service Manual

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Hirschmann PRS 80 Operators & Service Manual Download Page 39

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 

Solution 

LCD does not light 
or show characters.  

No power to console 

Make sure the console is getting power from the crane. 
Check wiring. 
Ensure correct polarity of the power. 
Open console, check status of LED's.  Both the red and 
green LED's should be on. 

LCD does not 
function properly 

Faulty LCD 

Go into the diagnostics screen for the display.  Verify all 
screens are functioning. 
If any of the tests fail, replace console 

Buttons do not 
work 

Faulty buttons 

If possible, go to the diagnostics screen for the buttons.  
Test the function of each button.   
If any of the buttons fail, replace the console. 

Communication 
error 

Low battery 

Verify which sensor is causing the error by looking at the 
icons on the communication error screen.      
Replace batteries.  

Communication 
error 

Faulty sensor 

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.  

Communication 
error 

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. 

Communication 
error 

Sensor not installed. 

Install the sensor on the console.  See adding sensors 

Communication 
error 

Poor communication 
caused by 
interference. 

Remove potential interference sources from the area. 
Mount the receiver in a different location. 
 

Horn does not 
sound 

Faulty 

Go into the diagnostics screen for the outputs.  Verify all 
outputs are functioning. 
If any of the tests fail, replace console. 

Crane functions 
locked out all the 
time 

Incorrect wiring 

Check for power to lockout device. 
 

Crane functions 
locked out all the 
time 

Communication error. 

See communication error. 

Crane functions 
locked out all the 
time 

Fault in receiver 
module. 

Check relay output voltage on wire number 3. 
 

Transmitter LED 
does not flash 

Sensor is asleep. 

Pull switch wire rope. Red LED will flash ~each 2 sec. 
Replace batteries. 
Replace transmitter. 

 

 

© Hirschmann PRS80 REV. D 11/08/10 

190183_D.DOC 

Summary of Contents for PRS 80

Page 1: ...www hirschmann com P N 031 300 190 183 Rev D 11 08 10 PRS 80 OPERATOR S SERVICE MANUAL ...

Page 2: ......

Page 3: ...ts are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Hirschmann Hirschmann reserves proprietary rights to all drawings photos and the data contained therein The drawings photos and data are confidential and cannot be used or reproduced without the written consent of Hirschmann The drawings and or photos are su...

Page 4: ......

Page 5: ... 1 Operation 20 5 6 2 Limits 20 6 INSTALLATION AND SETUP 21 6 1 CONSOLE MOUNTING 21 6 2 WIRING 22 6 3 ADDING SENSORS 23 6 4 REPEATER 24 6 5 LOAD 24 6 5 1 Load cell Installation 24 6 5 2 Load Cell Setup and Calibration 25 6 5 3 Accuracy and Test Requirements 27 6 6 A2B 28 6 6 1 Transmitter Switch 28 6 6 2 Transmitter LED 28 6 6 3 Travel position optional 28 6 6 4 Transmitter Switch installation 29 ...

Page 6: ......

Page 7: ...ion 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 responsi...

Page 8: ... 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...

Page 9: ...tton 5 Down Button Button SCROLL UP Use this button to increase values or to scroll up Changes which sensors are displayed and how each is displayed Button SCROLL DOWN Use this button to decrease values or to scroll down Changes which sensors are displayed and how each is displayed Button SELECT Use this button to enter the menu screen and to confirm selections Hirschmann PRS80 REV D 11 08 10 1901...

Page 10: ...rsons Never use the by pass function to either overload or operate the crane in a non permissible range 5 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...

Page 11: ... 5 TON MAX SCREEN BEEPER UNITS LBS MPH KG KPH LANGUAGE PCT BAR IS ON OFF WARNING ARE ON OFF DIAGNOSTICS SCREEN KEYPAD OUTPUTS ALARM LOG COMM DATA LOW BATTERIES This will only be shown if a low battery condition exists ABOUT 5 2 Menu Selection Instructions From the operating screen press to enter the menu selection Use the up and down to scroll through and high light your selection then press to ma...

Page 12: ...s 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...

Page 13: ...sed 5 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 The 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...

Page 14: ...ws 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 Hirschma...

Page 15: ...her sensors are installed besides the A2B the A2B status will be shown as an icon A2B alone A2B with other sensor 5 4 2 A2B 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 Hirschmann PRS80 REV D 11 08 10 190183_D DOC ...

Page 16: ...re 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 switc...

Page 17: ...proaching 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 p...

Page 18: ...bol 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 If the crane is equipped with a boom extension repeat the test procedure for the boom extension anti two block switch Hirschmann PRS80 REV C 09 26 05 190183_D DOC ...

Page 19: ...he peak value will be reset The peak value can also be reset by pressing the button The of limit is shown at the bottom 5 5 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 U...

Page 20: ...electing SETUP LIMITS ANGLE There is then the choice to set the minimum angle limit or the maximum angle limit To set the limit Select the desired limit to set Move the boom to desired angle Press enter The angle limits can be cleared without moving the boom to the desired angle To clear the angle limit without booming to the angle SETUP LIMITS ANGLE MINIMUM Press and hold the down arrow The limit...

Page 21: ...ce 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 posi...

Page 22: ...0 22 6 2 Wiring The wiring at the console connection is Pin Description 1 Power 10 30VDC 2 Ground 3 Lockout NO 2 amp max 4 Lockout NC 2 amp max 5 Lockout common 2 amp max 6 Option Hirschmann PRS80 REV C 09 26 05 190183_D DOC ...

Page 23: ...u 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 inse...

Page 24: ...ing 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...

Page 25: ...ection 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 paper tap insulating the battery contact or installing the batteries into the transmitte...

Page 26: ... 7 5 ton load cell Menu SETUP 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 Hirschmann PRS80 REV C 09 26 05 190183_D DOC ...

Page 27: ...cified load rating chart For system calibration three or more test radii or boom angle are to be employed to establish compliance with the accuracy section above Test loads shall be as near as is practical to minimum mean and maximum values within the operating limits One of the following test methods or equivalent is to be used Known Weight Test load to be applied by suspending known weights accu...

Page 28: ...s 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 It prevents the lockouts and alarms from engaging and disengaging du...

Page 29: ...g switch the proper location would be one that allows the switch to rotate freely without being obstructed by any part of the boom head It should be mounted close to the dead end mounting gusset The switch should normally be mounted on the cab side of the crane For jib installations locate the switch close to the jib head Remove the lynch pin from the standoff Slide the A2B switch onto the standof...

Page 30: ...xed 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 measur...

Page 31: ...he side of the boom as shown below figures A and B The sensor must be installed so that as the boom angle increases the angle sensor rotates in a clockwise direction If the sensor rotates in a counter clockwise direction you will receive a negative boom angle indication Figure C Angle sensor transmitter and mounting plate Figure B Angle senor mounting shown at 80 sensor can reach 90 Figure A Angle...

Page 32: ...ting holes pointing down as shown in the pictures above Affix the mounting plate onto the area Clean prime and paint the mounting plate if necessary 3 Remove the angle sensor cover by loosen the four screws in the cover Check the gasket to insure it is not damaged Remove the batteries Align the 4 holes with the mounting plate threaded holes and screw the angle sensor onto the mounting plate by usi...

Page 33: ...s 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 ...

Page 34: ... 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 rad...

Page 35: ...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 dis...

Page 36: ...ly the sensors that communication error are shown 7 2 Diagnostics There are several diagnostics screens that can be accessed thru the display However it is possible that a malfunction can cause the displays to be inaccessible In this case follow the troubleshooting section of the manual 7 2 1 To Test the Display Menu SETUP DIAGNOSTICS SCREEN Various test screens will be displayed by pressing the b...

Page 37: ...P DIAGNOSTICS BUTTONS When a button is pressed the corresponding button on the console will invert Press each button one at a time When finished press and hold C 7 2 3 To Test the outputs Press Menu SETUP DIAGNOSTICS OUTPUTS Hirschmann PRS80 REV D 11 08 10 190183_D DOC ...

Page 38: ...est 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 Hirschmann PRS80 REV C 09 26 05 190183_D DOC ...

Page 39: ...ing at the icons on the communication error screen Verify that the LED on the sensor is blinking Communication error 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 Communication error Sensor not installed Install the sensor on the c...

Page 40: ...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...

Page 41: ...PRS80 Console Item Part number Qty Description 1 031 300 060 382 1 0 Mounting Arm W 1 Ball 2 024 000 100 095 1 0 Membrane Element 3 031 300 050 223 1 0 Fuse 2 Amp Auto Mini 3 2 1 031 300 060 491 Cable assembly PRS80 Console Hirschmann PRS80 REV D 11 08 10 190183_D DOC ...

Page 42: ... CONSOLE 031 300 050 671 ANTENNA 918 MHz FOR TRS05ASSEMBLY 060 576 WHIP ELEMENT FOR CONSOLE 031 300 060 559 ANTENNA ASSY 918 MHz WHIP FORLOAD CELL FOR LOAD SENSOR 031 300 050 688 ANTENNA 918 MHz RCL 90 OTHER SENSOR 031 300 050 535 CONNECTOR SMA RIGHT ANGLE M FREVERSE POLARITY FOR LOAD SENSOR 031 300 060 596 TRS 05 REPEATER 031 300 050 688 ANTENNA 918 MHz RCL 90 031 300 060 601 CABLE ASSY 15 2 COND...

Page 43: ...PER LENGTH OPTION 3 031 300 100 999 1 00 PIN 1 5 DIAMETER FOR USE W 15T FORCE TRANS OPTION 3 031 300 050 574 1 00 PIN BUSHINGS 1 1 4 FOR 7 5T RADIO LOADCELL OPTION 3 031 300 050 555 1 00 PIN BUSHINGS 1 1 8 FOR 7 5T RADIO LOADCELL 5 8 ROPE OPTION 3 031 300 050 554 1 00 PIN BUSHINGS 1 3 8 FOR 7 5T RADIO LOADCELL 3 4 ROPE OPTION 3 031 300 050 556 1 00 PIN BUSHINGS 1 7 5T RADIOLOADCELL 1 2 ROPE Whip A...

Page 44: ...TTER PIN 3 8 x 3 4 031 300 050 568 1 00 PIN 2 25 FOR 40K RADIO LOADCELL 1 1 8 ROPE OPTION 5 031 300 050 568 1 00 PIN 2 25 FOR 40K RADIO LOADCELL 1 1 8 ROPE OPTION 5 031 300 050 559 1 00 PIN BUSHINGS 2 FOR 40K RADIO LOADCELL 1 ROPE OPTION 5 031 300 050 600 1 00 PIN BUSHINGS 1 3 4 FOR 40K RADIO LOADCELL OPTION 5 031 300 050 563 1 00 PIN BUSHINGS 1 5 8 FOR 40K RADIO LOADCELL 7 8 ROPE OPTION 5 031 300...

Page 45: ... transmitter assembly with antenna 031 300 060 593 Radio A2B transmitter Antenna only 031 300 060 586 031 300 050 688 Card board battery tube Neoprene rubber gasket 031 300 050 536 031 300 050 763 Hirschmann PRS80 REV D 11 08 10 190183_D DOC ...

Page 46: ...Operator s Manual PRS 80 46 Radio A2B switch 031 002 060 022 A2B Mounting stud 031 300 050 295 A2B mounting plate 031 300 050 264 Lynch pin 031 300 050 272 Hirschmann PRS80 REV C 09 26 05 190183_D DOC ...

Page 47: ...Maintenance 47 WIND Mounting pole 031 300 050 321 Pin Retaining pin 031 300 050 322 031 300 050 323 Anemometer mounting plate 031 300 050 480 Transmitter 031 300 060 586 Hirschmann PRS80 REV D 11 08 10 190183_D DOC ...

Page 48: ...schmann PRS80 REV C 09 26 05 190183_D DOC 48 ANGLE Angle sensor with transmitter 031 300 060 592 Mounting plate for angle sensor 031 300 050 577 Redesigned mounting plate 031 300 050 577 Direct replacement for above mounting plate ...

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