PROLEC PME200 User manual

This guide describes operation of the
PROLEC PME LIFTING AND MACHINE ENVELOPE SAFETY SYSTEM FOR CON-
STRUCTION PLANT
Model covered : PART No. MODEL Ref
0050X0-X00 PME200 - RCI + MEI SYSTEM
0050X0-X00 PME200 - RCC + MEC SYSTEM
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
DURING NORMAL OPERATION THE SAFE WORKING LOAD OF A CRANE SHOULD
NOT BE EXCEEDED. THEREFORE THE WARNING OF OVERLOAD SHOULD NOT
BE USED AS A NORMAL OPERATING FACILITY. IT SHOULD BE NOTED THAT
CERTAIN STATUTORY REQUIREMENTS DO NOT PERMIT THE SAFE WORKING
LOAD TO BE EXCEEDED EXCEPT FOR THE PURPOSE OF TESTING.
THIS RATED CAPACITY INDICATOR / CONTROLLER (RCI, RCC) 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.

Table of contents
1Use of this Document 8
2Notices 8
3 System Identification 9
4 Operating and Limit Situation Recommendations 10
4.1 MEC Override 10
5Operating Instructions 11
5.1 Power Up 11
5.2 Using the Display 12
5.3 User Login 13
5.4 Supervisor Login 14
5.5 Logout 14
6Top Menu 15
6.1 Tool Selection Menu (Optional) 15
6.2 Product Type Selection Menu (Optional) 16
6.3 PME 2D Digging (Optional) 16
7Rated Capacity Indicator / Controller 17
7.1 Introduction 17
7.2 Operation within the Safe Working Load 18
7.3 Approach to Overload 18
7.4 Stability Indication Overload 19
Continued

Table of contents (continued)
7.4.1 Hydraulic Limit Indication 20
7.5 Stability Control Overload 20
7.5.1 Hydraulic Limit Control 20
7.6 Overload / Hydraulic Limitation Control Override 21
7.6.1 Soft Override 21
7.6.2 Master Override Key Switch 21
7.7 Lift Mode Menu 22
7.8 Lifting Point Selection 22
7.9 Duty Selection 23
7.10 Load Chart Menu 24
7.11 Lifting Mode - Non Lifting Mode 25
7.12 Alternative Lifting Mode Screens 26
8Envelope Monitoring 27
8.1 Height Limit 28
8.1.1 Height Limit Menu 28
8.1.2 Height Limit Setting - Known Height 29
8.1.3 Height Limit Setting - Using Current Highest Point 30
8.1.4 Machine Envelope Indicator (MEI) - Height 31
8.1.5 Machine Envelope Controller (MEC) - Height 32
8.2 Max Radius Limit 33
8.2.1 Max Radius Limit Menu 33
8.2.2 Max Radius Limit Setting - Known Max Radius 34
8.2.3 Max Radius Limit Setting - Using Current Max Radius 35
8.2.4 Machine Envelope Indicator (MEI) - Max Radius 36
8.2.5 Machine Envelope Controller (MEC) - Max Radius 37
Continued

Table of contents (continued)
8.3 Min Radius Limit 38
8.3.1 Min Radius Limit Menu 38
8.3.2 Min Radius Limit Setting - Known Min Radius 39
8.3.3 Min Radius Limit Setting - Using Current Min Radius 40
8.3.4 Machine Envelope Indicator (MEI) - Min Radius 41
8.3.5 Machine Envelope Controller (MEC) - Min Radius 42
8.4 Low Limit 43
8.4.1 Low Limit Menu 43
8.4.2 Low Limit Setting - Known Low Height 44
8.4.3 Low Limit Setting - Using Current Lowest Point 45
8.4.4 Machine Envelope Indicator (MEI) - Low 46
8.4.5 Machine Envelope Controller (MEC) - Low 47
9Warning Messages
9.1 On Screen Messages 48
9.2 LED and Internal Alarm Warnings 48
10 Daily checks 49
11 Repair 49
12 Test / Diagnostics 50
121 Relay Function Test 50
12.2 Sensor Data 51
12.3 Beacon, Beacon, LED and Internal / External Alarm Function Test 51
Continued

Table of contents - continued
13 System Information 52
14 Display Settings 52
14.1 Day / Night Mode 53
14.2 Select Display Machine 53
14.3 Select Language 54
14.4 Background Colour 54
15 User Login 55
15.1 User Login Setup 55
15.2 Enable / Disable Users 55
15.3 Add New User 56
15.4 Edit User Details 57
15.5 Select User to Delete 58
15.6 Edit User Access Code 58
16 Taking Product out of Operation 59
17 Service and Repair 59
17.1 Maintenance Review 59
18 Definitions / Glossary 60
19 Amendment / Revision Record 61

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1 Use of this Document
This user guide is intended for persons familiar with the use of construction plant under-
taking lifting operations.
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, halt any operation and seek authorised service
immediately. Do not continue the operation until the fault has been
remedied.
WARNING denotes a risk situation. Caution must be use. Informa-
tion about particular risks which may be generated by certain appli-
cations and about additional protective measures which are neces-
sary for such applications.
HAZARD Actions that can lead to serious injury or death

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3 System Identification
The PME system provides two primary safety functions
1. Lifting Stability
2. Machine Envelope Monitoring
Both 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 Lifting Stability function falls into two sub classes
 Rated capacity indictors (RCI) warn of potential instability when
the machine is involved in lifting operations. Any motion which
reduces the safe working load will not be inhibited at any time.
 Rated capacity controllers (RCC) prevent instability when the ma-
chine is involved in lifting operations. This is achieved by
hydraulically stopping unsafe movements of the machine which
could cause the machine to tip.
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, most nota-
bly height restrictions when working under overhead wires.
During operation the indicators on the left are displayed on the screen
to clearly identify the function supported by your PME200. Functions
may not be available i.e. when in non-lifting mode or when envelope
monitoring is switched off, if this is the case a cross will be painted over
the relevant function icon.
Combinations of these functions may be present, it is essential that the
functions of the system installed are identified and understood.

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4 Operating and Hazard Situation Recommendations
4.1 MEC Override
The system can optionally be fitted with a master override key switch. Turning
the key to the override position will allow normal operation of the hydraulic
services regardless of safety status. When the system is in override, the ex-
ternal alarm (if fitted) will be active, and the beacon (if fitted) will be off, the
RED LED will flash and an ‘In Override’ message will appear on the display
indicating that the machine limiting is overridden. The override state will auto-
matically return to normal operating mode after 30 minutes (default value),
regardless of the system status. The master override key switch must be cy-
cled to put the system back into override.
The master override key switch should only be used if the safety system is
not operational due to a fault and the machine needs to be moved due to its location pre-
senting a hazard. The override status is recorded in the system data log. To access the
override key switch an anti tamper seal may need to be broken.
Operating Recommendations
When using envelope monitoring:
 When setting a slew and or height restriction, make sure any implement attached is
in its least favourable position
 Check for correct operation once the restriction or restrictions have been set
 Reduce operating speed
 Do not move the equipment quickly when close to a restriction
 Do not operate the machine in a reckless manor
 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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5 Operating Instructions
5.1 Power Up
The PME system automatically powers up when the ignition is switched to on. The in-cab
display 4.3” high resolution LCD display and is controlled with three buttons at each side.
Three status LEDs and an internal alarm provide further indication.
The system will perform a self check at start up:
1. All LEDs will flash, the internal alarm and the external alarm (if fitted) will sound and
the system will perform a self test.
2. Once the self test is complete, a safety warning message will be displayed, pressing
any button activates the operating mode, the GREEN LED will light. Any previous
limit or limits set will be enabled.
3. The system is now ready for use unless the user login feature has been enabled,
see section 5.3.
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.
The display is secured to the machine using a flexible ball mounting allowing easy adjust-
ment for personal viewing preference.

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5.2 Using the Display
The display is operated by using the buttons adjacent to the function icons. The buttons
can open a sub menu, turn a function ON or OFF, set a value, toggle through multiple
screens, no one button has a single function. The 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 PME200 is fixed and does not follow
the movement of the machine.
Help is available for each button. To access the
help, push and hold the icon button for three sec-
onds. The help screen can be cleared by pressing
any of the six buttons. PME is still actively monitor-
ing when displaying help messages, therefore any
alarm or warning condition will still be indicated
within this feature.
Multifunction buttons:
The action of the button is
indicated by the adjacent
icon.
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.

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

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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.
5.5 Logout
To select the logout screen, hold any Exit icon button down for three seconds. Once log-
out has been confirmed, the login screen will be automatically displayed. Press the Cross
icon button to stay logged in and return to previous screen.
Confirm logout
Decreases highlighted
digit
Moves highlighter to
right
Increases highlighted
digit
Moves highlighter to
left or Hold to delete
digit
Cancel without change
Accept displayed value
Cancel without change

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

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6.2 Product Type Selection Menu (Optional)
This system can be calibrated for multiple Product Types. If more than one
Product has been activated, they can be manually selected via the product
screen shown below. Use the Arrow icon buttons to select the required prod-
uct and confirm using the Tick icon button, the system will restart automati-
cally. 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.
6.3 PME 2D Digging (Optional)
PME2D offers all the features you’d expect from a 2D guidance product providing accu-
rate and quick grade control in common civil engineering applications. Pre-set profiles
allow you to dig to depth or grade to a known profile first time without under/over cutting,
saving you time, rework and excess material. Tool addition and measurement, choosing
and editing of slopes, cross sections, trenches and simple grading is simple to do all from
the display.
Any existing PME system can be upgraded to 2D digging with the addition of simple soft-
ware and hardware changes.
Moves highlighter UP
Exit without change Accept highlighted
system
Moves highlighter
DOWN

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7 Rated Capacity Indicator / Controller
7.1 Introduction
The PME200 RCI / RCC has been designed to meet European requirements for the pro-
vision of rated capacity indicators. PME200 ensures that the maximum lifting capacity
over the range of a machine working envelope can be utilised. The system will always
start up in Lifting Mode. See section 4 for operating advice when using construction plant
as a crane. The Lifting Mode feature can be used in conjunction with envelope monitor-
ing, see section 8. In this mode, the beacon (if fitted) will indicate that the Lifting Mode
functionality is active.
1. Lift point radius is the horizontal distance in metres from the slew centre line to the
lifting point.
2. Current lifting duty in use.
3. Current lift point in use.
4. Safe Directional indicators. The triangles on both sides of each piece of equipment
and slew arrows indicate if it is safe GREEN, or unsafe RED to move the relevant
articulation and direction in that direction under overload envelope limits. A triangle
with a red border indicates that the articulation is limited by hydraulic capacity and
not by machine stability.
5. RCI / RCC - MEC indicators (see section 3)
6. Maximum Safe Working Load (SWL) for the current lifting point height and radius
combination. The value is given in metric tonnes.
7. SWL percentage bar graph indicating the percentage of the current load to the
maximum available safe working load.
8. Load on Hook (LOH) shows the current load in tonnes suspended from the current
lifting point.
The SWL as displayed assumes that the load is suspended directly below the
lifting point. The weight of the tool or tools, if fitted, (e.g. Bucket , quick hitch etc)
are accounted for in the SWL and LOH values if they were taken into consideration
when the system was calibrated. The bucket cylinder and control linkage is
assumed to be present.
2. Current Duty
8. Load On Hook
7. SWL percentage5. RCI / RCC indicators
4. Safe directional
indicators
5. MEI / MEC
indicators
1. Lifting point radius
3. Current Lifting point
6. Maximum Safe
Working Load

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7.2 Operation within the Safe Working Load
With the Lifting Mode active, the current lifting point radius and the
maximum safe working load for that radius are shown.
7.3 Approach to Overload
With the Lifting Mode active, if the load is between 95% and 104% of
the maximum safe working load the system will warn the machine is
close to the lifting capacity at the current height and radius. The system
indicates an approach to overload condition via an internal alarm in conjunction with vis-
ual indicators on the display - no motion is cut.
In the event of an approach to overload or an overload condition, the lifting
point should only be moved in a direction that increases the safe working
load. See section 4 for further information.
If the load is greater than 95% of the
maximum safe working load.
 The load capacity indicator will be
amber
 The amber LED will be lit
 The internal alarm will sound
 The message shown here will be
displayed.
If the load is less than 95% of the
maximum safe working load
 The load capacity indicator will be
green
 The green LED will be lit

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7.4 Stability Indication Overload
With the Lifting Mode active, if the load is greater than 105% of the maximum
safe working load the system will warn the machine is close to the lifting capacity
at the current height and radius. The system indicates an overload condition via
internal and external alarms in con-
junction with visual indicators on the display -
no motion is cut.
7.4.1 Hydraulic Limit Indication
If a particular lift is limited by hydraulic capacity rather than stability, the directional indica-
tor on the articulation in question will have a RED border. Hydraulic limitation is more
likely to occur at short radii. The system indicates a hydraulic limitation condition via
internal and external alarms in conjunction with visual indicators on the display - no mo-
tion is cut.
If the load is greater than 105% of the
maximum safe working load
 The load capacity indicator will be red
 The red LED will flash
 The internal and external alarm will
sound
 The message shown here will be
displayed
 Unsafe motion is indicated by RED
arrows, safe motion is indicated by
GREEN arrows
In the event of an approach to overload or an overload condition, the lifting
point should only be moved in a direction that increases the safe working
load. See section 4 for further information.

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7.5 Stability Control Overload
Where an overload condition occurs the machine hydraulics will be locked to pre-
vent any further dangerous movements. Only those movements that allow safer
operation remain active. The radius cannot be increased and the load cannot be
raised. The internal and external alarms will sound in conjunction with visual indi-
cators on the display.
7.5.1 Hydraulic Limitation Control
The system will cut motion to the appropriate articulation in a hydraulic limit state and in-
dicate this via internal and external alarms in conjunction with visual indicators on the dis-
play.
Where an overload condition occurs the machine
hydraulics will be locked to prevent any further
dangerous movements. Only those movements
that allow safer operation remain active. The ra-
dius cannot be increased and the load cannot be
raised.
After three seconds a soft override will become available, see section 7.6.1
If the load is greater than 105% of the
maximum safe working load
 The load capacity indicator will be red
 The red LED will flash
 The internal and external alarm will
sound
 The message shown here will be
displayed
 Motion control of the machine will
operate, motion cut is indicated by
RED arrows, safe motion is indicated
by GREEN arrows
In the event of an approach to overload or an overload condition, the lifting
point should only be moved in a direction that increases the safe working
load. See section 4 for further information.