James Fisher Prolec PME100 User manual

 2022 Prolec Limited
User manual
PME100 / 105
Machine envelope controller
Document Reference: 562100-000
Issue 1.3 January 2022

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This guide describes operation of the
PROLEC PME ENVELOPE SAFETY SYSTEM FOR CONSTRUCTION PLANT
Model covered:
PART No.
MODEL Ref
PME100H/E/C
PME
1
05
H/E
PME100 - MEC SYSTEM
PME
1
0
5
-
MEC SYSTEM
Prolec supports a nationwide dealer network. Warranty claims, service work, technical information and
spare parts are available by contacting:
James Fisher Prolec Ltd
25 Benson Road
Nuffield Industrial Estate
Poole Dorset BH17 0GB
Telephone [phone]
E-mail [email protected].uk
THIS ENVELOPE SAFETY SYSTEM IS NOT SUITABLE FOR USE IN EXPLOSIVE ATMOSPHERES.
ADJUSTMENT BY UNAUTHORISED PERSONS WILL INVALIDATE ANY WARRANTY OR
CERTIFICATION SUPPLIED. IF A PROBLEM ARISES WHICH CANNOT BE RECTIFIED USING THIS
GUIDE, AUTHORISED SERVICE SHOULD BE SOUGHT.
THIS DEVICE IS CERTIFIED TO MEET CURRENT UK & EC SAFETY REGULATIONS FOR LIFTING
OPERATIONS.
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.
Whilst every effort has been made to ensure the accuracy of the information supplied in this manual,
Prolec Ltd cannot be held responsible for any errors or omissions.
This system records data on the machine’s operation.
Manufacturers original instructions.

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Contents
1. Use of this Document................................................................................................................. 5
2. Notices ........................................................................................................................................ 5
3. System Identification ................................................................................................................. 6
4. Operating, and Hazard Situation, Recommendations .............................................................. 7
4.1. MEC Override .................................................................................................................... 8
5. Operating Instructions ............................................................................................................... 9
5.1. Power Up ........................................................................................................................... 9
5.2. Using the Display ............................................................................................................. 11
5.3. User Login ....................................................................................................................... 12
5.4. Supervisor Login .............................................................................................................. 13
5.5. User Logout ..................................................................................................................... 13
6. Top Menu .................................................................................................................................. 14
6.1. Tool Selection Menu (Optional) ........................................................................................ 14
6.2. Product Type Selection Menu (Optional) ......................................................................... 15
7. Envelope Monitoring ................................................................................................................ 16
7.1. Height Limit ...................................................................................................................... 17
7.1.1. Height Limit Menu ........................................................................................................... 17
7.1.2. Height Limit Setting - Known Height ................................................................................ 18
7.1.3. Height Limit Setting - Using Current Highest Point .......................................................... 19
7.1.4. Machine Envelope Controller (MEC) - Height .................................................................. 20
7.2. Max Radius Limit ............................................................................................................. 21
7.2.1. Max Radius Limit Menu ................................................................................................... 21
7.2.2. Max Radius Limit Setting - Known Max Radius ............................................................... 22
7.2.3. Max Radius Limit Setting - Using Current furthest Point .................................................. 23
7.2.4. Machine Envelope Controller (MEC) - Max Radius .......................................................... 24
7.3. Min Radius....................................................................................................................... 25
7.3.1. Min Radius Limit Menu .................................................................................................... 25
7.3.2. Min Radius Limit Setting - Known Min Radius ................................................................. 26
7.3.3. Min Radius Limit Setting - Using Current nearest Point ................................................... 27
7.3.4. Machine Envelope Controller (MEC) - Min Radius ........................................................... 28
7.4. Low Limits........................................................................................................................ 29
7.4.1. Low Limit Menu ............................................................................................................... 29
7.4.2. Low Limit Setting - Known Low Height ............................................................................ 30
7.4.3. Low Limit Setting - Using Current Low ............................................................................. 31
7.4.4. Machine Envelope Controller (MEC) – Low ..................................................................... 32
7.1. Limit Control Override ...................................................................................................... 33

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7.1.1. Soft Override ................................................................................................................... 33
7.1.2. Master Override key Switch ............................................................................................. 33
8. System Messages .................................................................................................................... 34
8.1. On Screen Safety Messages ........................................................................................... 34
8.2. On Screen Component Error Messages .......................................................................... 35
8.3. LED and Internal Alarm Warnings .................................................................................... 36
9. Daily Checks ............................................................................................................................. 36
10. Repair .................................................................................................................................... 36
11. Test / Diagnostics ................................................................................................................. 37
11.1. Relay Function Test ..................................................................................................... 37
11.1.1. Valve Function Test ......................................................................................................... 38
11.2. Sensor Data ................................................................................................................. 39
11.3. Beacon, LED and Internal / External Alarm Function Test ............................................ 39
12. System Information .............................................................................................................. 40
13. Display Settings .................................................................................................................... 40
13.1. Day / Night Mode ......................................................................................................... 41
13.2. Select Display Machine ................................................................................................ 41
13.3. Select Language .......................................................................................................... 42
13.4. Background colour ....................................................................................................... 42
14. User Login ............................................................................................................................. 43
14.1. User Login Setup ......................................................................................................... 43
14.2. Enable / Disable Users ................................................................................................. 43
14.3. Add New User to Login ................................................................................................ 44
14.4. Edit User Details .......................................................................................................... 45
14.5. Select User to Delete ................................................................................................... 46
14.6. Edit User Access Code ................................................................................................ 46
15. Taking Product out of Operation ......................................................................................... 47
16. Service and Repair................................................................................................................ 47
16.1. Maintenance Review .................................................................................................... 47
17. Definitions / Glossary ........................................................................................................... 48
18. Amendment / Revision Record ............................................................................................ 49

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1. Use of this Document
This user guide is intended for persons familiar with the use of construction plant undertaking
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.
HAZARD Actions that can lead to serious injury or death
2. Notices
Adjustment by unauthorised persons will invalidate any warranty or
certification supplied. If an error condition is displayed which cannot be
rectified using this guide, STOP any operation, seek authorised service
immediately, and do not continue the operation until the fault has been
remedied.

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3. System Identification
The PME system provides an envelope safety function
All safety functions are achieved through real time monitoring of 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 appropriate limits have been set.
The Machine Envelope Monitoring function has a single class
 Machine Envelope Controllers (MEC) prevent movements that would
bring parts of the machine into hazardous areas, for example, height
restrictions when working under overhead wires. This is achieved by
hydraulically controlling unsafe movements of the machine.
 MEC equipped systems may include Height Limiting and or Slew
Limiting.
During operation, indicators are displayed on the screen to clearly identify the
function supported by your PME100/105. Functions may not be available i.e.
when envelope monitoring is switched off, if this is the case a cross will be
painted over the function icon.

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4. Operating, and Hazard Situation, Recommendations
Operating Recommendations
When using envelope monitoring:
 When setting height or slew restrictions,
make sure any implement/tool attached is
in its least favourable position
 Check for correct operation once the
restriction has been set
 Reduce operating speed
 Do not move the equipment quickly when
close to a restriction
 Do not operate the machine in a reckless
manner
 Do not travel with a restriction set
 Reset the slew restriction if the machine is
relocated
Hazard Situation Recommendations
In a limit hazard state:
 Return the control levers to neutral once a
limit has been reached, if appropriate
 Operate the machine at a slow speed
 Do not travel

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4.1. MEC Override
The system can optionally be fitted with a key operated master override
switch. To access the master override switch, a tamper detection device
must be broken and the operation of this switch will be automatically logged.
Turning the switch to the override position will allow normal operation of any
of the hydraulic services regardless of safety status. When the system is in
override:
 the external alarm (if fitted) will be active
 the beacon (if fitted) will be off
 the RED LED will flash
 an ‘In Override’ message will appear on the display indicating that the
machine limiting is overridden.
The override state will automatically return to normal operating mode after 30
minutes (default value), regardless of the system status. The master override
key switch must be cycled to put the system back into override.
The master override key switch should only be used if the system is not
operational due to a fault and the machine needs to be moved due to its
location presenting a hazard.

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5. Operating Instructions
5.1. Power Up
The PME system automatically powers up when
the machine ignition is switched on. The in-cab
display 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 information. The display is
secured to the machine using a flexible ball
mounting allowing easy adjustment for personal
viewing preference.
1. On starting up, the system will perform a self test. All LEDs will flash; the internal display
alarm and the external alarm (if fitted) will sound momentarily.
2. The operator will be asked to review the system’s safety features.
(Note: older system types may not display this screen – skip to step 4 if it does not appear)
Individual safety features may be disabled or re-enabled, if appropriate for the current job
and work site. For example, if the work site has no overhead hazards, the operator may
disable the height limiter function.
 Each safety feature is initially set/enabled as it was set before the last power-down.
 The operator is responsible for verifying that the safety features are enabled
appropriately for the job/work site.
 If the height limiter function is enabled, the operator is responsible for checking that the
movement limits are correctly configured:
 See section 7.1 for configuring Height Limits

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 If the system is fitted with a supervisor key switch (see section 5.4), this key must be
turned to the SET position to disable/enable the Height Limiter function.
 If a safety function is unavailable – for example due to a system or sensor fault – this
will be made apparent to the operator from this screen.
3. The operator must press Start to:
 Confirm that the safety features are set as required for the job/work site;
 Confirm that any unavailable safety features are understood, and not required for
the job/work site.
Pressing Start activates the operating mode, at which point the GREEN LED will light.
4. The system can be configured to only allow access via a User Login code and will prompt
for a code to be entered before use (see section 5.3 for further details).
If the RED LED is lit, a fault has been detected, halt any operation,
seek authorised service immediately and do not continue operation
until the fault has been remedied.

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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 and toggle through multiple screens. No one
button has a single function. The button icon will turn black/purple when the button has been
activated. Icons can be assigned for Supervisor use only, to access them enter the supervisor
code or use the supervisor key switch (if fitted), see section 5.4. Note that the side view of the
machine shown in PME100/105 is fixed and does not follow the movement of the machine.
A secondary symbol can appear in the top left corner of an icon, these mean:
The plus symbol indicates a sub menu will be opened if selected.
The cycle symbol indicates that multiple features are available.
The on/off symbols indicate if a feature is ON or OFF. Red is ON and grey is OFF.
Help is available for each button. To access help, push
and hold the relevant button for three seconds. The help
screen can be cleared by pressing any button. PME is still
active when displaying help messages; alarms or warning
conditions will be indicated, as appropriate.
Multifunction buttons:
The action of the button is
indicated by the adjacent
icon.

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5.3. User Login
PME may be configured to work with a built-in user list. If so, the system will prompt for a user
login pass code after acknowledging the Confirm Safety Features screen. Select the user name
required and the login code screen will appear.
Using the arrow buttons enter a valid pass code. The previous pass code digits will be replaced
with a star as the code is entered. Press the GREEN TICK button to confirm the login pass code.
If a valid pass code is entered the system will commence normal operation.
If an incorrect login code is entered, a failure screen will be displayed. Press the GREEN TICK
button to return to the Select User screen.
Logging out is described in section 5.5.
Increases highlighted
digit
Decreases highlighted
digit
Accept displayed
value
Cancel without
change
Moves highlighter to
right
Moves highlighter to
left / Hold to delete
digit
Moves highlighter UP
Select highlighted
name to open the
Enter Login Code
screen below
Moves highlighter
DOWN
Exit Login

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5.4. Supervisor Login
To login as a supervisor, either Login as described in section 5.3,
use the supervisor key switch (if fitted) or hold any Exit icon button
down for three seconds and enter your code.
Logging out is described in section 5.5 or use the supervisor key
switch. Logging in as a supervisor is recorded in the system data
log.
Supervisor SET position is intended for set-up of envelope limiting
functions only. The keyswitch must be returned to the LIMIT
position for normal operation.
5.5. User Logout
If a user is logged in, they can select the logout screen by holding an exit key button down for
three seconds.
Once log off has been confirmed, the login screen will be automatically displayed.
Press the RED CROSS button to stay logged in, the screen will return to that previously shown.
Confirm logout
Cancel to stay
logged in
Increases highlighted
digit
Decreases highlighted
digit
Accept displayed
value
Cancel without
change
Moves highlighter to
right
Moves highlighter to
left / Hold to delete
digit

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6. Top Menu
The Top Menu screen allows access to all the system functions:
 Limits menu
 Lifting menu
 Tool selection / System Type (Optional)
 Test Diagnostics
If the icons are hidden, press any button to reveal. To return to the Top Menu from a sub menu
press the “Hide Icons”/EXIT button until the Top Menu is displayed.
To hide the icons when at the Top Menu, press the “Hide
icons” button once more.
6.1. Tool Selection Menu (Optional)
The system can monitor the position of a tool or multiple tools. If more than one
tool has been calibrated, they must be manually selected via the example Select
Tool selection screen shown below. Use the Arrow icon buttons to select the
required tool and confirm using the Tick icon button.
2D Digging
Tool selection
Menu level indicator
System Type
selection
Hide icons
Test Diagnostics
Limits Menu
Accept highlighted
Tool
Moves highlighter
DOWN
Moves highlighter UP
Exit without change

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6.2. Product Type Selection Menu (Optional)
This system can be configured for multiple Product Types. If more than one Product
is available, they can be manually selected via the product screen shown below.
Use the Arrow icon buttons to select the required product and confirm using the Tick
icon button, the system will restart automatically. Ensure the correct equipment is
fitted to the machine when selecting a product. Example products are shown, please
refer to the relevant product operator manual for further instructions.
Moves highlighter UP
Exit without change
Accept highlighted
system
Moves highlighter
DOWN

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7. Envelope Monitoring
PME100/105 is configured for Machine Envelope Control (MEC). MEC
will warn and prevent equipment motion. MEC is achieved by interacting
with the machine’s 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.
PME 105 only — the MEC device may reduce the speed of motion to a section of equipment if it is
approaching (but has not yet reached) a restriction.
The motion being slowed will be indicated by an amber arrow.
When setting a limit, either by entering a known value or by positioning the machine at the desired limit,
ensure any tool attached is in its least favourable position — as the system is unaware of any tool unless
listed in Tool Selection. See section 6.1.
PME100/105 can monitor the highest, furthest, nearest, lowest part of the machine and slew angle, taking
into consideration the counterweight when used with a virtual wall type restriction.
MEC
OFF: when operating without limit the indicator will show a cross.
ON: when operating with an active limit the indicator will not show a cross.
Care should be taken to test that the limit or limits are set correctly.
Once a limit is set, the internal alarm will sound and the RED LED will
light if the equipment exceeds the current limit. Always check that the
current limit activates at the set point. The restriction cannot be
deactivated if in the alarm state. Observe the operational limitations
given in section 4.
Exit to previous screen
Height Limiting
Max Radius Limiting
Low Limiting
Slew Limiting
Min Radius Limiting

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7.1. Height Limit
7.1.1. Height Limit Menu
A height limit can be set by entering a known height on the keypad or by
manually moving the machine to the desired limit.
Using the height Limits Menu, the height limit can be
switched ON and OFF. A “Confirm Operation” screen will be
displayed, see sections 7.1.2 to enter a known height and
section 7.1.3 for setting the limit by moving the machine.
With a height limit set, the screen will normally display the current highest point value. To display the
current limit value, exit to the full screen and hold any button for three seconds, the value will then turn
blue indicating it is the current limit value.
Exit to previous menu
Set height limit using
current highest part of
equipment
Enter a value
Current height limit and highest point.
Only displayed if a height limit is set.
Turns Monitoring
ON
and OFF

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7.1.2. Height Limit Setting - Known Height
A known limit can be entered into the display. This is the
vertical height from the ground or base of the machine.
Step One: Press the ’Enter a limit value’ button.
Step Two: Use the UP and DOWN Arrow buttons to increase and decrease the highlighted number. Use
the LEFT and RIGHT Arrow buttons to move the highlighter to the left and to the right. Set a limit and
press Green TICK to accept:
Once a limit is set, the internal alarm will sound and the RED LED will
light if the equipment exceeds the current limit. Always check that the
current limit activates at the set point. The restriction cannot be
deactivated if in the alarm state. Observe the operational limitations
given in section 4.
Increases highlighted
digit
Decreases highlighted
digit
Accept
displayed
value
Cancel without
change
Moves highlighter to
right
Moves highlighter to
left / Hold to delete
digit
Enter a limit value
Exit to previous

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7.1.3. Height Limit Setting - Using Current Highest Point
Set the limit using the current highest point of the machine.
Ensure the tool is off the ground before setting the limit.
Step One: Move the equipment to the required height limit and press the ‘Set using highest point of
equipment’ button.
Step Two: Check the limit and press Green TICK to accept.
If you attempt to set a height limit below the current machine height, an
error will be shown. Move the machine to be lower than the desired
height, and then try again.
Once a limit is set, the internal alarm will sound and the RED LED will
light if the equipment exceeds the current limit. Always check that the
current limit activates at the set point. The restriction cannot be
deactivated if in the alarm state. Observe the operational limitations
given in section 4.
Height limit shown
here
Exit without change
Accept the value
shown
Move equipment to
required height limit
and press this button

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7.1.4. Machine Envelope Controller (MEC) - Height
If any of the equipment enters the approach limit* a ‘Close to 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.
PME 105 only — if the equipment is nearing the limit, but has not yet reached it, the appropriate
motions will be slowed progressively until the limit is reached.
MEC systems will cut motion to any
section of equipment that has
reached a limit but allow other
sections to operate unhindered
unless they too reach the set limit.
*The approach limit is configurable at point of calibration, check system operation before commencing
work.
See sections 4.1 and 7.1 for hydraulic override details.
Once a limit is set, the internal alarm will sound and the RED LED will
light if the equipment exceeds the current limit. Always check that the
current limit activates at the set point. The restriction cannot be
deactivated if in the alarm state. Observe the operational limitations
given in section
4
.