PROLEC EA Heightmaster + Manual

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Prolec Ltd., 25 Benson Road, Nuffield Industrial Estate, Poole, Dorset, England BH17 0GB
EA Heightmaster +
Operators Guide

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This guide describes operation of the
PROLEC EA HEIGHTMASTER+
Model covered : MODEL NAME EA HEIGHTMASTER+
INTRODUCED JANUARY 2009
PART No 002146-000
Prolec supports a nationwide network of fully trained service engineers. Warranty claims, service work, technical
information and spare parts are available by contacting :
Prolec Ltd Telephone [phone]
25 Benson Road Fax [phone]
Nuffield Industrial Estate E-mail [email protected]
Poole Dorset BH17 0GB
Manufacturers original instructions

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Section Subject Page
1.0 System Description 6
1.1 RCI 6
1.2 Height Limiting 7
1.3.0 MIN Radius Limiting (Cab Protection) 9
1.3.1 Dual Redundancy Bucket System (Optional) 10
2.0 System Components 11
3.0 System Operation 13
3.1 Power On 13
3.2 Initialisation 13
3.3 Key Switch Positions 13
3.4 Key Switch in RCI Position 14
3.5 Key Switch in VARIABLE ADJUST Position 15
4.0 Key Switch in 3.7m and 4.6m positions - Fixed Height Limits 16
5.0 Functions of the RCI Key Switch Position 17
5.1 Time/ Date Mode 17
5.2 Rated Capacity Indicator Mode 18
5.3 Dig Depth Monitoring Mode 19
5.4 Change Duty Mode 21

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Section Subject Page
6.0 Functions of the VARIABLE ADJUST Key Switch Position 22
6.1.0 Setting the height limit at an operator derived equipment position 22
6.1.1 Setting the Height Limit to a Known Height 24
6.1.2 Switching OFF Height Monitoring 26
6.1.3 Variable Height Limit Active Indicators 27
6.2 No Protection Transport Mode 28
6.3.0 MIN Radius Limiting (Cab Protection) 29
6.3.1 Selecting the MIN Radius limits (Bucket or Attachment) (Cab Protection) 29
6.3.2 MIN Radius Limiting (Cab Protection) Dual redundancy Bucket System 30
7.0 Variable Height Limit - Key Switch in Variable Existing Setting Position 31
8.0 Height Alarm Conditions 32
9.0 System Test 33
10.0 Error Conditions 36

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1.0 System Description
EA Heightmaster+ provides a Rated Capacity Indicator (RCI), Height Limiting, Cab Protection, Dig Depth Monitoring and a Transpor-
tation mode for use on monoboom and triple articulated machines.
The system will allow the use of telescopic sections along with secondary booms and arms giving real time height measurements
with automatic/ manual duty switching.
A keyswitch is supplied allowing quick access to functions along with locking the system into certain modes.
Motion control is standard on the EA Heightmaster+ allowing motion to be cut to the boom, artic and arm for Height Limiting and Cab
Protection.
1.1 RCI
EA Heightmaster+ RCI mode displays the current maximum
safe working load (SWL) in tonnes. In RCI mode, the top line
of the display shows the current bucket pin radius and the
maximum safe working load at that radius. The bar graph on
the lower line will indicate the proximity of the current load to
the maximum available safe working load. The system
indicates an approach to overload and an overload condition
via internal and external alarms along with visual indicators on
the display.
To calculate the SWL, the radius of the bucket pin (Or Lifting
point) and the pressure within the boom lifting rams are used.
Radius
Pressure

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1.2 Height Limiting
The EA Heightmaster+ provides accurate monitoring of height and will alarm and cut motion at a user definable height or by selecting
one of the two predefined height limits of 3.7 and 4.6 m. These are indicated on a lamp bar. EA Heightmaster + uses a COMBI BOX
(see section 2.0) which allows the system to interface with hydraulic solenoid valves on the pilot control circuits to physically prevent
the height limit from being exceeded. The system is suitable for monoboom or triple articulation excavators and those with telescopic
Height Limit
Excavator operates uninhibited under
the set height limit.
When the excavator equipment reaches the
set height limit, the visual and audible alarms
will activate and the corresponding equipment
motion will be cut, halting further movement
into the height limit.
Raising of the Boom, artic or Arm
will be cut depending upon which
section is at the height limit.
The EA Heightmaster+ :
Lamp Bar
1. Allows the machine to work under restricted areas.
2. Can control the machine equipment motion to prevent
access into the restricted area.
3. Provides the user with a clear display of the
equipment height and of alarm conditions.
4. Allows the height limit to be
set from the safety of the cab.

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1.2 Height Limiting - Continued
The EA Heightmaster+ system calculates the height of each articulation at it‟s pivot pin and can take into account any part of the
articulation which extends above the pivot pin.
Guide to equipment pin positions used to determine height
Artic = Artic Pin
Arm = Arm Pin
Bucket = Bucket Pin
R = Residual height
Artic
Arm
Bucket
R
R
R

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1.3 MIN Radius Limiting (Cab Protection)
The Min Radius Limit limits the bucket pin from entering one of two predefined minimum radii. EA Heightmaster + uses a COMBI BOX
(see section 2.0) which allows the system to interface with hydraulic solenoid valves on the pilot control circuits to physically prevent
the Min Radius Limit from being exceeded. The Min Radii Limits are stored in the memory each time it is set. When the system is
switched on, the last Min Radius Limit selected will become operative. The yellow LED on the display is lit when the bucket radius is
selected and the green LED is lit when the attachment radius is selected. This function cannot be cancelled or adjusted by the opera-
tor. True Height and radius are given with telescopic section equipped machines.
1. Constantly monitors the bucket pivot pin radius
The EA Heightmaster+ :
3. Provides the user with a clear display of alarm conditions.
2. Motion is cut to prevent equipment from entering excluded zones
4. Allows two preset Min Radii Limits (Bucket and Attachment) to be
set from the safety of the cab via a key switch.
Attachment MIN Radius Limit
Bucket MIN Radius Limit

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Excavator operates
uninhibited outside
of the set Minimum
Radius Limits.
1.3.1 Dual Redundancy Bucket System (Optional)
As an option, EA Heightmaster + can monitor the position of the bucket / attachment (Bucket shown in example) and automatically ad-
just the current Cab Protection Limit by a preset distance. There are two states, crowded in and crowded out. This allows the bucket
pivot pin to come in closer to the cab if the bucket is crowded out.
When the bucket pivot pin reaches the set radius limit, depending on the attitude of the bucket, it will either cause
the visual and audible alarms will activate and the corresponding equipment motion to be cut at the inner limit or the
outer limit.
Bucket MIN Radius Limit
with the bucket crowded in
Bucket MIN Radius Limit
with the bucket crowded out

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AS7 BUCKET SENSOR***
The EA Heightmaster+ uses CAN2.0B communication technology. A single cable run connects all the system components. Power from an
ignition switched source is connected to the LCD/Computer. All the cables have 6-way screw type connectors. These have a common pin-out,
and are polarised, allowing any cable to be plugged into any device or sensor without causing damage.
*Telescopic sections only **Triple articulation machines only –secondary boom sensor ***Additional arm sensor labelled bucket angle sensor
2.0 System Components
COMPUTER / DISPLAY
COMBI BOX AS7 BOOM/ PRESSURE SENSOR
AS7 ARTIC SENSOR **
AS7 ARM SENSOR
4 Way Analogue Interface *
REELING DRUM SENSOR *
TERMINATOR
LAMP BAR

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Cab mounted combined Computer/LCD display unit with lamp bar. Rear mounting
plate carries sockets for connection to DC power, lamp bar and the CAN system.
AS7 boom angle/ pressure sensor (or primary boom sensor on hydraulically
adjustable booms). This sensor is usually mounted on the OFFSIDE of the boom. The
sensor is connected to the Combi Box and to either the arm sensor on monoboom
machines, or the secondary boom sensor on hydraulically adjustable booms.
[OPTIONAL] Secondary boom angle sensor (AS7 Artic sensor) for hydraulically
adjustable booms. This sensor is usually mounted on the OFFSIDE of the secondary
boom. The sensor is connected to the primary boom sensor and arm sensor.
AS7 Arm/ Bucket [OPTIONAL] angle sensor usually mounted on the NEARSIDE of
the arm near the pivot pin. The sensor is connected to the boom sensor. The bucket
sensor is fitted to any extra arms that are supplied with the machine. This sensor has
a special „Terminator‟ plug fitted. This is required for correct system operation.
4 way Combi Box provides the interface to solenoid valves which control the motion of
the machine equipment.
[OPTIONAL] Reeling drum only fitted to telescopic booms. This can be mounted on
the side or top at the base of the boom. The reel will extend and retract with the
boom.
2.0 System Components - Continued
[OPTIONAL] 4-way Interface box. This is fitted to machines with telescopic section. It
will be located in an appropriate location in the CAN line near to the reeling drum.

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3.1 Power On
EA Heightmaster+will only operate when it is switched on.
To activate the EA Heightmaster+turn the key switch to any position other than OFF. The
System title and software version will be momentarily displayed before proceeding to the
selected mode. See section 3.3.
3.2 Initialisation
Once activated, EA Heightmaster+ will perform an initialisation procedure. This will take three to four seconds, during which time all sensors
and auxiliary components are checked for correct operation. If all checks are successfully completed, operation will commence. The next
screen displayed is dependant on the position of the key switch. If problems are detected during initialisation, relevant warning message(s) will
be issued.
See section 10 for further information on error conditions.
RCI
With the key switch in the RCI position, RCI mode
and duty selection can be accessed. See section
3.4 for further details.
LW5 MK2: EA+
VER : X.XX
3.0 System Operation
Variable Existing Setting
With the key switch in the Variable Existing
Setting position, the variable height monitoring will
be activated. See section 6.0 for further details.
3.7m and 4.6m Fixed
Height
With the key switch in the 3.7m or 4.6m position, the
predefined height limits are selected. See section 4.0 for
further details.
Variable Adjust
With the key switch in the Variable Adjust position, three
functions can be accessed; variable height limit setting ,
selecting minimum radius limits and No Protection
Transport Mode. See section 3.5 for further details.
See section for more information.
3.3 key Switch Positions

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3.4 Key Switch in RCI Position
Pressing the MODE button will cycle the EA Heightmaster+ through the four available operational modes as shown below with the key
in the RCI position.
09:47 01/03/09
H: 0 C:0
*TIME/DATE MODE See Section 5.1
Press [ENTER] to
Change DUTIES
*CHANGE DUTY MODE See Section 5.4
DEPTH MONITOR MODE See Section 5.3
DEPTH = 0.00m
DATUM = 0.00m
RCI MODE See Section 5.2
Rad 6.17m 1.45t
1% swl
* Optional, may not be activated at installation.

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*TRANSPORT MODE See Section 6.2
NO PROTECTION
TRANSPORT MODE
SET HEIGHT LIMIT MODE See Section 6.1
Press [ENTER] to
set height limit
3.5 Key Switch in VARIABLE ADJUST Position
Pressing the MODE button will cycle the EA Heightmaster+ through the two possible operational modes as shown below with the key in
the VARIABLE ADJUST position. Additionally, pressing the Cab Set button below the key switch allows access to select the preset
minimum radius limits.
* Optional, may not be activated at installation.
MINIMUM RADIUS SELECTION MODE See Section 6.3
ATTACH1 (5.00m)
[ENTER] NEXT

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Current duty
4.0 Key Switch in 3.7m and 4.6m positions - Fixed Height Limits
With the Key switch in either the 3.7m or 4.6m positions, the screen displays the following information for each position. Also, the 3.7m
or the 4.6m lamp will be lit. The system will alarm and motion will be cut if the either preset height limit is reached. If the variable height
limit has been previously set, it will be deactivated and the VAR lamp will no longer be illuminated.
KEY SWITCH IN 3.7m POSITION
Height : 2.94m
1Hgt : ON 3.66m
KEY SWITCH IN 4.6m POSITION
Height : 2.94m
1Hgt : ON 4.57m
Measurement of highest equipment point*
Height monitoring status
Measurement of highest equipment point*
Height monitoring status
All heights are referred to equipment pins plus, and where applicable
will include the residual height –Triple articulation machine shown in
the example
Current duty
Set height limit value
Set height limit value

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In this mode the system will display the current time, date and Height and Cab Limit monitoring status. *This mode is optional and
may not have been activated at installation.
09:47 01/03/09
H: 0 C:1
5.1 Time/ Date Mode
Date shown here
Time shown here
5.0 Functions of the RCI Key Switch Position

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5.2 Rated Capacity Indicator Mode
In the RCI MODE the top line will display the current bucket pin radius and the maximum safe working load at that radius. The bar
graph on the lower line will indicate the proximity of the current load to the maximum available safe working load. Approach to SWL and
OVERLOAD are indicated by audible and visual indicators.
SWL is the maximum load that can be
lifted at the currently displayed radius.
SWL is shown in TONNES
Radius is the horizontal distance
between the slew centre of the
machine and the bucket pin
(Lifting point), and is displayed in
metres.
The bar graph shows the
percentage of the maximum lifting
capacity currently being utilised.
The more „bars‟ shown, the
greater the load suspended.
The number to the left of the lower
line is the DUTY number. Unless
multi-duty operation is available,
this value will be 1.
If the load suspended is between
102.5% and 110.0% of the SWL
both the amber SWL and the red
OVERLOAD indicators will light, and the
alarm will sound. The bar graph will be at
the end of its scale.
If the load suspended is between
92.5% and 97.5% of the SWL
the amber SWL indicator will light, and the
internal alarm will sound. The bar graph
will be almost at the end of its scale.
The SWL as displayed assumes that the load is
suspended directly below the bucket pin. The
weight of the bucket, if fitted, and any lifting
devices, (e.g. a quick hitch) must be deducted
from this value. The bucket cylinder and control
linkage is assumed to be present.
Rad 6.17m 1.45t
1% swl

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B. Dig to the required depth using the DEPTH
value on the top line (remembering that the
bucket must be in the attitude described above to
measure accurately). In this example the
basement depth is 2.00m (or -2.00m below the
initial DATUM). NOTE: because the current
depth is BELOW the current DATUM, the „TOO
LOW‟ internal alarm will sound.
A. Position the bucket on the ground at the start
of the excavation, with the bucket in the attitude
shown in the diagram. Correct depth will only be
displayed when measurements are taken with the
bucket in this attitude. This is because EA
Heightmaster+ does not have a bucket angle
sensor. Press ENTER to set the datum at this
elevation. At this point the DEPTH value will
change to 0.00, and the new DATUM will become
the current ground level.
C. Place the bucket (in the attitude described in 1) in the bottom of the
trench at the target depth, and press the ENTER button to re-reference the
system. The current DEPTH will change to 0.00m (i.e. the distance to the
target datum), and DATUM will change to -2.00m (i.e. target depth). The
system is now fully referenced and ready for use.
5.3 Dig Depth Monitoring Mode
As the EA Heightmaster + system has equipment-mounted angle sensors, it has the capability to measure bucket tooth depth.
Although a bucket angle sensor is not a standard feature, careful operation and control of bucket attitude can produce accurate
trenching and basement excavations. Use the MODE button to scroll through the options until the display shown below appears. The
operation sequence described here gives an example of how the system can be used.
DEPTH = 0.00m
DATUM = 0.34m
DEPTH = 0.00m
DATUM = - 2.00m
DEPTH = - 2.00m
DATUM = 0.34m

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D. The basement/trench can now be extended at will. To extend,
move the machine to the new position, place the bucket at the base
of the initial excavation, and press the ENTER button to re-reference
the position. The excavation can now be continued without the need
to watch the display. When the correct depth is achieved (or
exceeded) the „TOO LOW‟ internal alarm will sound. As the system
has been referenced to the bottom of the initial excavation (and not
to the track base of the machine) the position/height of the actual
excavator is not important.
5.3 Dig Depth Monitoring Mode - Continued