PAT America EI65 User manual

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PAT America,
Inc
www.
p
atamerica.com
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LENGTH-ANGLE-RADIUS-LOAD
INDICATING SYSTEM
!
EI65/0005
!
!
!
!
!
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SERVICE MANUAL
!
P/N 031-300-190-007, Rev.B, 03/8/02

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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 herein 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 prior
consent of PAT.
© 1999 PAT America, Chambersburg, PA 17201, USA

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Table of Contents
1 GENERAL INFORMATION ............................................1
REFERENCE: ............................................................ 1
SYSTEM MALFUNCTION: ................................................... 1
SYSTEM DESCRIPTION: ................................................... 1
2 WARNINGS .......................................................2
3 TROUBLESHOOOTING USING THE ANALOG VALUES SCREEN ................3
4 TROUBLESHOOTING FLOW CHARTS ....................................4
4.1 GENERAL FLOW CHART ................................................... 4
4.2 NO DISPLAY ........................................................... 5
4.3 ANTI TWO BLOCK PROBLEM................................................ 6
4.4 ANGLE READING PROBLEM ................................................ 8
4.5 LENGTH READING PROBLEM ............................................... 9
4.6 LOAD READING PROBLEM ................................................ 11
5 ERROR CODE TABLE ..............................................13
6 SYSTEM DRAWINGS ...............................................14
Connection Board 056-065-300-002 Designations: ....................... 14
6.1 DRAWING 1. SYSTEM WIRING DIAGRAM (REFER TO INSTALLLATION
MANUAL 031-300-190-008) ............................................. 14
6.2 DRAWING 2. CONNECTION BOARD LAYOUT ................................... 15
6.3 DRAWING 3. MAIN BOARD LAYOUT ......................................... 15
6.4 DRAWING 4, ANGLE SENSOR CIRCUIT ...................................... 16
6.5 DRAWING 5, LENGTH SENSOR CIRCUIT ..................................... 17
6.6 DRAWING 6, LINERIDER CIRCUIT......................................... 18
6.7 DRAWING 7, LINERIDER SUPPLY VOLTAGES ................................. 19
6.8 DRAWING 8, CONSOLE PARTS LIST ........................................ 20

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1 GENERAL INFORMATION
The purpose of this service manual is to provide additional information to
assist a service or maintenance person in identifying malfunctions or
system problems with the PAT System. A digital voltmeter and regular
maintenance and service tools will be required to troubleshoot the system.
Note: Knowledge of how to use a digital voltmeter is assumed.
REFERENCE:
Operator’s Manual 056-065-190-005
Calibration Manual 031-300-190-009
Installation Manual 031-300-190-008
SYSTEM MALFUNCTION:
In case of a malfunction of the system, an error code
which identifies the system malfunction will be
displayed in the reeving portion of the display. The
error codes are listed in Section 4, Error Codes. The
table identifies various faults that can occur with
the EI65, explain each fault, and describe the action, which shall be taken
to correct the fault.
Faults within the electronic microprocessor shall be repaired by factory
trained service personnel. When these faults occur, contact your authorized
dealer or service organization.
If the operator identifies a possible problem in the system, perform the
pre-operation inspection Section 5 in the Operator’s Manual 056-065-190-005
to define the problem.
SYSTEM DESCRIPTION:
The PAT Length-Angle-Radius-Load Indicator System EI65 has been designed to
provide the crane operator with the essential information required to
enable the machine to be used within its design parameters. The EI65 System
indicates the length and angle of the boom, tip height, working radius and
the total weight being lifted by the crane. Using the various sensors and
the limits set by the operator, the EI65 System warns the crane operator of
certain approaching hazardous conditions which could occur during the
operation of his crane.
WARNING
Always refer to operational instructions and load charts provided by the crane
manufacturer for specific crane operation and load limits.
MB 115.0 J1 85.0

J2 50.0 0J 15.0
E71

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2 WARNINGS
x!The EI65 is an operational aid, which warns a crane operator of certain
approaching hazardous conditions, which could cause damage to equipment
and personnel.
x!The device is not, and shall not be, a substitute for good operator
judgment, experience and use of accepted safe crane operating
procedures.
x!The responsibility for the safe operation of the crane shall remain with
the crane operator who shall ensure that all warnings and instructions
supplied are fully understood and observed.
x!Prior to operating the crane, the operator must carefully and thoroughly
read and understand the information in the operator’s manual to ensure
that he/she knows the operation and limitations of the indicating system
and crane.

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3 TROUBLESHOOOTING USING THE ANALOG VALUES SCREEN
For a sensor error or problem with a sensor, look at the output voltage of
the linerider and angle sensors and compare the reading with the following:
Angle sensor 1.875 at 0q, 2.5 at 45q, or 3.125 at 90q
Linerider under no load is 0 to 15mV not to exceed 2500 mV.
To access the analog output screen use the following procedure.
1. Power up the system. The screen will display EI 65/10 software version
and date.
2. To start calibration, within 5 seconds of powering up, simultaneously
press the ‘‘OK’’ and ‘‘SELECT’’ buttons. Hold these buttons (approximately
15 seconds) until the screen changes to ‘‘CALIB. PASSWORD’’. If these
buttons are not pressed and held, the screen changes to the existing
operating configuration. Refer to Operator’s section in this manual.
3. Enter the calibration password ‘‘0815’’. Use the ‘‘UP’’ and ‘‘DOWN’’
buttons to select the number and the ‘‘OK’’ button to confirm each entry.
Enter 0 -- OK, 8 -- OK, 1 -- OK, 5 - OK
4. Scrole to the ANALOG VALUES screen by pressing the ‘‘UP’’ or ‘‘DOWN’’
arrows, pressing ‘‘OK’’ to select and show the following screen.
All Analog input voltages (shown in millivolts), received from the sensors
will be displayed here as described below. The minimum values are show in
the screen pictured.
FORCE 1 and FORCE 2
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ANGLE 1 and ANGLE 2
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4 TROUBLESHOOTING FLOW CHARTS
This section explains how to handle a problem that may arise with the EI65,
PAT Load Indicator System. The procedures are easy to follow and are given
in flowcharts on the following pages. Start with the general flowchart
below that will guide you to one of the detailed flowcharts shown in this
section. Section 5 contains the necessary drawings needed for
troubleshooting.
4.1 GENERAL FLOW CHART
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Do NOT select Default in of section 4.4 or all other calibration data will be lost,
and you will have to complete the entire calibration procedure.
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5 ERROR CODE TABLE
Error
code
Reason Action
11 Operating data in the buffered
RAM
Turn on the system again
and adjust operating data
21 Crane parameters in the serial
EPROM incorrect
Re-calibrate the system
31 Wrong EPROM programming or EPROM
defective
Exchange EPROM
51 Short circuit min layer device
term 11&12
Check minimum layer device
52 Cable break min layer device term
11&12
Check minimum layer device
53 Short circuit A2B -switch - 2
term 13&14
Check anti-two block
system
54 Cable break A2B -switch - 2 term
13&14
Check anti-two block
system
55 Short circuit A2B -switch - 1
term 9&10
Check anti-two block
system
56 Cable break A2B -switch - 1 term
9&10
Check anti-two block
system
x61 Load on the main hoist hook too
big
Reduce load on main hoist
x63 Load on the auxiliary hoist hook
too big
Reduce load on aux. hoist
x71 Limit Length - Main - Boom - Max. Decrease length limit
x72 Limit Length - Main - Boom - Min. Increase length limit
x73 Limit WG - Main - Boom - Max. Decrease main boom angle
x74 Limit WG - Main - Boom - Min. Increase main boom angle
x75 Limit Boom height - Max. Decrease main boom angle
x76 Limit Boom height - Min. Increase main boom angle
x77 Limit Working radius - Max. Increase main boom angle
x78 Limit Working radius - Min. Decrease main boom angle
81 ADC-Measuring value KMD1 too big Check zero point in
linerider
82 ADC-Measuring value KMD1 too low Check zero point in
linerider
83 ADC-Measuring value KMD2 too big Check zero point in
linerider
84 ADC-Measuring value KMD2 too low Check zero point in
linerider
91 ADC-Measuring value LG1 too big Check main length sensor
circuit
92 ADC-Measuring value LG1 too low Check main length sensor
circuit
93 ADC-Measuring value WG1 too big Check main angle sensor
circuit
94 ADC-Measuring value WG1 too low Check main angle sensor
circuit
95 ADC-Measuring value WG2 too big Check luffing angle sensor
circuit
96 ADC-Measuring value WG2 too low Check luffing angle sensor
circuit

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x!Limit set by the operator refer to Operator’s Manual, Section 4.3.
Activating and Setting Preset Limits