PAT America DS 350 User manual

www.patamerica.com PAT America, Inc.
RATED CAPACITY LIMITER
DS 350 / 1334 GRAPHIC
for Lattice Boom Cranes
OPERATOR'S MANUAL
P/N 031-300-190-072, Rev. D, 04/12/02

Operator's Manual DS 350 / 1334
© PAT Rev. D 04/12/02 CSH 190072_d.DOC
NOTICE
The information in this document is subject to change without notice.
PAT makes no warranty of any kind with regard to this material, including, but not limited to the implied
warranties of merchantability and fitness for a particular purpose.
PAT shall 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. All rights are reserved.
No part of this document may be photocopied, reproduced, or translated to another language without the
prior written consent of PAT.
MANUAL REVISIONS
REV DATE NAME DESCRIPTION
C 06/29/01 CSH ECN 01-155
D 04/12/02 CSH ECN 02-133
© 1999 PAT GmbH, D-76275 Ettlingen / Germany © 1999 PAT America, Chambersburg, PA 17201, USA

Operator's Manual DS 350 / 1334
© PAT Rev. D 04/12/02 CSH 190072_d.DOC
TABLE OF CONTENTS
1GENERAL INFORMATION ................................................................................. 1
2WARNINGS .................................................................................................... 1
3SYSTEM DESCRIPTION .................................................................................... 2
3.1 SYSTEM FUNCTION .................................................................................................... 3
3.2 OPERATING CONSOLE ................................................................................................. 3
3.3 CONTROL IDENTIFICATION ............................................................................................ 4
4CONFIGURATION SETUP................................................................................ 10
4.1 RCL SETUP PROCEDURE ............................................................................................ 10
4.2 HOIST-IN-USE QUICK SELECTION .................................................................................. 16
4.3 CRAWLER POSITION QUICK SELECTION .......................................................................... 17
5OPERATION.................................................................................................. 18
5.1 LIMIT SETTING....................................................................................................... 21
5.1.1 Radius Limitation ............................................................................................ 22
5.1.2 Tip Height Limitation ....................................................................................... 24
5.1.3 Boom Angle Limitation..................................................................................... 26
5.1.4 Slewing Angle Limitation / Virtual Wall Definition ................................................ 28
5.2 INFO CRANE CONFIGURATION ..................................................................................... 38
5.3 DISPLAY CONTRAST CONTROL .................................................................................... 39
6PRE-OPERATION INSPECTION AND CALIBRATION VERIFICATION ...................... 40
7SERVICE AND MAINTENANCE ........................................................................ 44
8TROUBLESHOOTING...................................................................................... 45
APPENDIX A: DETAILED SYMBOL EXPLANATION OF BOOM EXTENSIONS ......................................... 47
APPENDIX B: DETAILED SYMBOL EXPLANATION OF COUNTER WEIGHT OPTIONS................................ 48

General Information
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1GENERAL INFORMATION
The PAT Rated Capacity Limiter (RCL) DS 350 has been designed to provide the crane operator with the
essential information required to operate the machine within its design parameters.
Using different sensing devices, the Rated Capacity Limiter monitors various crane functions and provides
the operator with a continuous reading of the crane’s capacity. The readings continuously change as the
crane moves through the motions needed to make the lift.
The RCL provides the operator with information regarding the angle of the boom, working radius, rated
load and the total calculated weight being lifted by the crane.
If non permitted conditions are approached, the DS 350 Rated Capacity Limiter will warn the operator by
sounding an audible alarm, lighting a warning light and locking out those functions that may aggravate the
crane’s condition.
2WARNINGS
The RCL is an operational aid that warns a crane operator of approaching overload conditions and of over
hoist conditions that could cause damage to equipment and personnel.
The device is not, and shall not, be a substitute for good operator judgment, experience and use of
accepted safe crane operating procedures.
The responsibility for the safe crane operation shall remain with the crane operator who shall 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 he knows the operation and limitations of indicator and crane.
Proper functioning depends upon proper daily inspection and observance of the operating instructions set
forth in this manual. Refer to Section 6. Pre-Operation Inspection and Calibration Verification of this
handbook.
The RCL can only work correctly, if all adjustments have been properly set. For correct adjustment, the
operator has to answer thoroughly and correctly all questions 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 RCL has to be ensured before starting the crane
operation.

Operator's Manual DS 350 / 1334
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3SYSTEM DESCRIPTION
The PAT Rated Capacity Limiter DS 350 consists of a central microprocessor unit, operating console,
angle sensor, line riders, and anti-two block switches.
The system operates on the principle of reference/real comparison. The real value, resulting from the load
measurement is compared with the reference data, stored in the central processor memory and evaluated
in the microprocessor. When limits are reached, an overload warning signal is generated at the operator’s
console. At the same time, the aggravating crane movements, such as hoist up and boom down, will be
stopped.
The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity and
dimensions are stored in memory chips in the central processor unit. This data is the reference information
used to calculate the operating conditions.
The boom angle is measured by the angle sensor, mounted in the boom base. The cable reel cable serves
as an electrical conductor for the anti two-block switches and line rider signals.
The hoist load is measured by line riders mounted on top of the boom, close to the tip.
The interactive user guidance considerably simplifies the input of operating modes as well as the setting of
geometry limit values.
Fig. 1: Components of the RCL system PAT DS 350
1. Operator’s Console
2. Central Unit
3. Cable Reel
4. Boom Angle Sensor
5. Junction Box
6. Line rider (Tensiometer)
7. A2B Switch

System Description
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3.1 System Function
Upon switching on, the system starts with an automatic test of the RCL system,
of lamps and audible alarm. During the test, the LC display shows the initial
logo.
If the system was turned off for more than two hours, the setup configuration
has to be entered after the system test. (⇒chapter 4)
First, the operating mode is determined by an interactive step-by-step
interrogation of the rigging states.
Next is the interactive input of the reeving.
Now the LC display shows in symbols all inputs and awaits acknowledgment or
canceling.
Upon acknowledgment of the inputs the system is ready for operation.
3.2 Operating Console
The console has 3 functions:
•inputs by the crane operator (operating mode, reeving)
•input of geometry limit values and signalization of exceeded limit values
•display of important data and information
The operator’s console is mounted in the crane’s cab in the operator’s field of vision. For a better
identification of displays and operating elements, they are continuously backlit during operation.

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3.3 Control Identification
This unit contains a display and different controls which are described as follows:
Fig 2: Operator’s Console

System Description
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1. LC Display Area
2. Load Moment Limit Light
3. Load Moment Prewarning Light
4. Alarm Light “Anti-Two-Block”
5. By-Pass Warning Light
6. Button “Alarm Stop”
7. Button and Control Light “TARE”
8. Button and Control Light “LIMITS”
9. Button and Control Light “SELECT
OPERATION MODE”
10. Button and Control Light "INFO"
11. Button and Control Light
"CONTROL"
12. Audible Alarm
13. By-Pass Key Switch
14. Button and Control Light "By-Pass
Anti-Two-Block"
15. Button and Control Light "By-Pass
LMI Kick-out function"
F1. Button "Function 1"
F2. Button "Function 2"
F3. Button "Function 3"
F4. Button "Function 4"
1
LC-Display
The LC display visualizes graphical symbols, texts and numerical values.
Depending on the selected operating mode (setup, limit mode or RCL
representation), the corresponding information is indicated on the display.
Please refer to the description of the different operating modes for the

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signification of the individual elements.
Rated Capacity Limit Light
The red RATED CAPACITY LIMIT LIGHT (2) warns the operator that a rated
load condition has been reached. It lights up when the load on the crane
reaches the crane load capacity. The audible alarm also sounds when this
condition has been reached.
The following crane movements will be stopped concurrently:
−hoist up
−telescope out
−boom down
Rated Capacity Prewarning Light
The yellow RATED CAPACITY PRE-WARNING LIGHT (3) will light up when the
load on the crane reaches the defined prewarning area, thus indicating that an
overload condition is approaching.
This means for the operator to continue his crane operation with extreme
caution.
Alarm Light “Anti-2-Block”
The red “Anti Two-Block Alarm Light” (4) lights up when the anti-two-block
limit switch contacts open, indicating that a two-blocking condition is
approaching. At the same time the audible alarm will sound.
The following crane movements will be stopped subsequently: hoist up and
boom down (depending on your machine).
By-Pass Key Warning Light
The red BY-PASS WARNING LIGHT (5) flashes to indicate that the kick-out
function of the A2B / RCL system is deactivated.
Button and Control Light “Alarm Stop”
This ALARM STOP BUTTON (6) allows the audible alarm to be silenced for
approximately 15 seconds by pressing this button. Reference ⇒“Audible
Alarm” (12).
Button and Control Light “Tare”
The button “TARE” (7) is used to indicate the “Net load” on the LC Display (1).
Net load is the present load, less lifting tackle and hook block. The Tare Button
(7) has to be activated before lifting.

System Description
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After pushing the “Tare Button” (7) the load display is set to zero (taring) and
the control light lights up. After lifting a load the display shows the net load
(pay load).
The net load display will change to the actual load display when the boom
radius is changed (either by angle or length).
Button "LIMITS"
Button to start the function "program limit values".
For the proceeding please refer to ⇒chapter 5.1.
Button "SELECT"
Button to start the function "set operating mode".
For the proceeding please refer to ⇒chapter 4.1.
The correct setting is of utmost importance for the proper function of the system and the
crane. Therefore only operators who are thoroughly familiar with use and operation of the
system shall set this button.
Button "INFO"
Button to start the function "information crane configuration"
Please refer to ⇒chapter 5.2.

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Button "CONTROL"
Button to start additional functions.
Please refer to ⇒chapter 5.3.
Audible Alarm
The AUDIBLE ALARM (12), sounds during the following conditions:
•overload condition
•approaching two-block condition
•preset limits reached
•malfunction of the RCL system
•operating error
The alarm can be temporarily silenced by pushing the button “Alarm Stop” (6).
Key Switch
•The anti-two-block switch kick-out function is deactivated when the KEY
SWITCH (13) is turned to position "B" and the “By-pass A2B” button (14) is
pushed.
or
•The RCL kick-out function is deactivated when the KEY SWITCH (13) is
turned to position "B" and the “By-pass RCL” button (15) is pushed.
KEY SWITCH (13) can be operated only by using the matching key.
Since button (14) and (15) deactivate the kick-out function of the RCL system / the anti two-
block 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.
•Never use the by-pass function to either overload or operate the crane in a non-permissible
range.

System Description
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Button "By-pass A2B"
This button can be operated only if key switch (13) is turned to position B.
While pushing this button, the kick-out function of the anti-two-block switch is
deactivated.
The By-Pass Warning Light (5) flashes to indicate that the kick-out function is
deactivated.
Button "By-pass RCL"
This button can be operated only if key switch (13) is turned to position B.
While pushing this button, the control lever lockout function of the RCL is
deactivated.
The By-Pass Warning Light (5) flashes to indicate that the kick-out function is
deactivated.

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4CONFIGURATION SETUP
The RCL setup procedure allows the operator to input the crane configuration using interactive displays.
The operator must complete the setup procedure for the Rated Capacity Limiter system if the system has
been turned off for more than two hours or the crane operation configuration has been changed.
4.1 RCL Setup Procedure
...starts: •manually at each modification of the crane configuration by pressing
key (9) "SEL"
...is operated: •by answering the different questions using functional keys F1...F4 in
accordance with the actual configuration of the crane.
...is cancelled: •any time by pressing again key (9) "SEL". The system, however, is
only ready for operation, if the procedure has been completed and the
selections have been confirmed.
If the system is turned off, all adjustments remain stored. When turning on again the system these
adjustments can be acknowledged by merely pressing one key (provided that the crane configuration has
not been modified!).
During the programming procedure the Rated Capacity Prewarning Light (3) and the Rated Capacity Limit
Light (2) will light up and the aggravating crane movements will be interrupted.
Note:
If a configuration is selected which is not available, the display will indicate error code E04. In this case,
the procedure has to be repeated with valid values!
The correct setting is of utmost importance for the proper functioning of the system and the crane.
Therefore, only operators who are thoroughly familiar with the crane and the operation of the system
should execute the setting of the system according to the operating configuration of the crane.
The RCL programming procedure consists of the following steps:
•setting the boom type configuration
•setting the counterweight configuration
•specify boom / setting the hoist configuration and reevings
•selecting the pick point
•confirmation of the programming procedure
For easy operation, the computer guides the operator through the procedure step by step. (interactive
operation)

Configuration Setup 11
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Definition of the Displayed Symbols:
The following illustrations define the symbols appearing on the display during the setup procedure.
Not all symbols will be shown, depending on the crane type and the answers to the questions.
•Setting the boom type configuration
main boom / nose operation
fixed jib operation
luffing jib operation
if main boom/nose operation or jib operation selected:*
tube boom type
angular boom type
* this selection screen only appears, if both boom types are available on
this crane
main boom tip extension hammerhead hammerhead
tip extension
fixed jib luffing jib luffing jib +fixed jib
For detailed symbol explanation of extensions, please refer to Appendix A in this manual.

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•Setting the crawler / counterweight configuration
Retracted crawlers
Extended crawlers
•Setting the counterweight configuration
Depending on the model of your crane and counterweight
options, please refer to Appendix B in this manual for
detailed symbol explanation of counterweight.
decrease counterweight
increase counterweight
confirm counterweight
OR
increase counterweight
confirm counterweight
decrease counterweight
increase counterweight
confirm counterweight

Configuration Setup 13
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decrease counterweight
increase counterweight
confirm counterweight
with additional lower counterweight
without additional lower counterweight
•Specify boom / jib lengths (example luffing jib):
Select luffing jib length:
decrease luffing jib length
increase luffing jib length
confirm luffing jib length selection
Select main boom
length:
increase main boom length
decrease main boom length
confirm main boom length
selection

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•Setting the hoist configuration and reeving (example luffing jib)
The hoist selection can be made from 3 hoists, but only 2 hoists drum can be selected for one
configruation.
Set front hoist drum
pick point:
select pick point 1
select pick point 2
no use of front hoist drum
Select front hoist
reeving:
decrease reeving
increase reeving
confirm reeving
Set 3rd hoist drum pick
point:
select pick point 1
select pick point 2
no use of 3rd hoist drum
Select 3rd hoist reeving:
decrease reeving
increase reeving
confirm reeving
Once you have set the pick-points, you can switch between them by selecting which hoist drum
is in use:
•Select hoist-in-use (example luffing jib)
Hoist-in-use selection:
use pick point 1 as defined above
use pick point 2 as defined above
Under each pick point that you had set, you will find a symbol of the crane with the
corresponding hoist drum filled in black.