tower crane concise_manual_stt200

STT200 CONCISE MANUAL

- 1 - EURC1.0.1.ENG

TOWER CRANE STT200 CONCISE MANUAL

- 2 - EURC1.0.1.ENG

- 3 - EURC1.0.1.ENG

- 4 - EURC1.0.1.ENG

- 5 - EURC1.0.1.ENG

STT2

00 C

ON

CISE

MA

NU

AL

- 6

- EU

RC

1.0.

1.EN

G

- 7

-

EUR

C1.

0.EN

G

-8- EURC1.0.ENG

PREFACE

Dear Customer

Jinlong Europe, a revolutionary evolution!

Reliability, quality, safety, and high technology are the success of Yongmao�s topless tower cranes all over the world.

In Europe all our cranes are CE approved. This is the result of a constant technological research.

The absence of tie-bars allows an optimized erection (quicker and safer).

The use of small sized mobile cranes saves air space. The best solution for installation in job sites next to airports or in the city with several cranes in use and interfering working areas.

Because of our relentless efforts to improve our products, technical updates are from time to time necessary. Therefore, the technical data in this manual are subject to change without warning.

Topless tower cranes, a revolutionary evolution.

Jinlong Europe

Zandvoorstraat 10/6 2800 Mechelen, Belgium

Tel: ++ 32/15 28 54 54 � Fax: ++32/15 20 96 80

Jinlong Europe UK & Ireland

Unit 14 The Enterprise Centre, Cranborne Road, Potters Bar EN6 3DQ Hertfordshire� U.K.

Tel: ++ 44/ 1707 600 199 � Fax: ++44/ 1707 600 188

-9- EURC1.0.ENG

CONTENTS

CHAPTER 1. TECHNICAL DATA........................................................................................... 111

1.1. SPECIFICATIONS.........................................................................................................................................12 1.1.1. MAST 2X2M L68A1.................................................................................................................................12 1.1.2. MAST 2X2 M � L68A1 � CHASSIS 6 X 6 M ............................................................................................12 1.1.3 MAST 1,6 X 1,6 M � S15 � CHASSIS 4,5 X 4,5 M.....................................................................................15

1.2. PREPARING THE CONSTRUCTION SITE ................................................................................................17 1.2.1. SPACE REQUIREMENTS FOR ASSEMBLY............................................................................................17

1.2.1.1. INTRODUCTION...............................................................................................................................17 1.2.1.2. DIMENSIONS....................................................................................................................................18

1.3. CONCRETE FOUNDATION FOR FOUNDATION ANCHORS..................................................................20 1.3.1. PREPARATION.........................................................................................................................................20 1.3.2. SOIL PRESSURE AND CHOICE OF CONCRETE BLOCKS ON FIXING ANGLES................................21

1.3.2.1. STANDARD CONFIGURATION .......................................................................................................21 1.3.3. DIMENSIONAL FEATURES OF THE FOUNDATION ANCHORS ..........................................................26 1.3.4. INSTALLING THE FOUNDATION ANCHORS .......................................................................................27

1.4. CENTRAL BALLAST....................................................................................................................................29 1.4.1. INTRODUCTION .....................................................................................................................................29 1.4.2. CENTRAL BALLAST DETAILS ..............................................................................................................31

1.5. COUNTER-JIB BALLAST ............................................................................................................................33 1.5.1. INTRODUCTION .....................................................................................................................................33 1.5.2 DIMENSION OF COUNTER-JIB BALLAST.............................................................................................34

1.6. RE-REEVING (SEE FIG. 2.4.4.2.3-1).............................................................................................................41 1.6.1. FROM DUAL REEVING TO SINGLE REEVING....................................................................................41 1.6.2. FROM SINGLE REEVING TO DUAL REEVING.....................................................................................43

CHAPTER 2. WINCH UNIT ......................................................................................................45

2.1. EXPLANATION OF THE SYMBOLS...........................................................................................................46

2.2. COMPOSITION OF THE WINCH UNIT .....................................................................................................46

2.3. OPERATING PRINCIPLE.............................................................................................................................47

2.4. PARTS AND MAINTENANCE......................................................................................................................48 2.4.1. PROGRAMMABLE PLC CONTROLLER ................................................................................................48 2.4.2. FREQUENCY CONVERTER....................................................................................................................49

2.4.2.1. DIGITAL ACTUATOR USE DIRECTIONS........................................................................................49 2.4.2.2. OPERATING FUNCTIONS................................................................................................................50

-10- EURC1.0.ENG

CHAPTER 3. SLEWING MECHANISM...................................................................................57

3.1. EXPLANATION OF THE SYMBOLS...........................................................................................................58 3.1.1. DESCRIPTION .........................................................................................................................................58

3.2. SLEWING UNIT.............................................................................................................................................59 3.2.1. DESCRIPTION .........................................................................................................................................59 3.2.2. OPERATION.............................................................................................................................................60 3.2.3. RTC SCHEMATIC DIAGRAM .................................................................................................................62

3.3. MALFUNCTIONS..........................................................................................................................................64

3.4. SLEW BRAKE................................................................................................................................................66 3.4.1. RELEASING THE BRAKE MANUALLY (SEE FIG. 3-4-1)......................................................................66 3.4.2. ELECTRICALLY CONTROLLED WEATHERVANING ...........................................................................69

3.4.2.1. DESCRIPTION...................................................................................................................................69 3.4.2.2. OPERATING PRINCIPLE ..................................................................................................................69

3.4.3. SLEWING BRAKE MAINTENACE .........................................................................................................70 3.4.4. WIRING DIAGRAM (ZIE FIG. 5.4.4-1) ....................................................................................................71

CHAPTER 4. TROLLEY WINCH ..............................................................................................72

4.1. EXPLANATION OF SYMBOLS....................................................................................................................73

4.2. COMPOSITION OF THE TROLLEY WINCH UNIT..................................................................................74

4.3. TROLLEY BRAKE ........................................................................................................................................76 4.3.1. DESCRIPTION (SEE FIG. 6.3.1-1) ............................................................................................................76

4.4. WIRING DIAGRAM ......................................................................................................................................78


-11- EURC1.0.ENG

CHAPTER 1. TECHNICAL DATA


12

1.1. SPECIFICATIONS

1.1.1. MAST 2X2M L68A1 1.1.2. MAST 2X2 m � L68A1 � CHASSIS 6 X 6 m

Fig.1.1.1-a

3.0t

4.3t

3.7t

2.7t50m

40m

44m

54m

60m

62.0m

12t 3.6m

16.2m

30m

6.0t

5.2t

34m

2.2t

3.0m

3.8m


13

Table 1.1.1-a

Fig.1.1.2a

R Fall R(max

) m

C(max) t

20 25 30 34 40 44 50 54 60

IV 14.20 12.0 7.94 6.34 4.76 4.03 3.22 2.80 2.30 2.04 1.70 60 II 25.80 6.0 6.00 6.00 5.05 4.37 3.61 3.22 2.76 2.51 2.20

IV 14.80 12.0 8.37 6.69 5.05 4.29 3.44 3.00 2.48 2.20 54 II 27.30 6.0 6.00 6.00 5.39 4.67 3.87 3.46 2.97 2.70

IV 14.90 12.0 8.43 6.75 5.09 4.32 3.46 3.02 2.50 50

II 27.60 6.0 6.00 6.00 5.46 4.73 3.91 3.50 3.00 IV 15.40 12.0 8.79 7.05 5.34 4.54 3.65 3.20

44 II 28.90 6.0 6.00 6.00 5.75 4.99 4.14 3.70 IV 15.70 12.0 9.02 7.25 5.51 4.70 3.80

40 II 29.90 6.0 6.00 6.00 5.98 5.18 4.30 IV 15.60 12.0 8.96 7.22 5.50 4.70

34 II 30.00 6.0 6.00 6.00 6.00 5.20 IV 15.50 12.0 9.16 7.56 6.00

30 II 30.00 6.0 6.00 6.00 6.00

H

197. 4mH

616263

17

123456789

1213141516

1011

484950

17

123456789

1213141516

1011

393837

17

123456789

1213141516

1011

252627

17

123456789

1213141516

1011

17

123456789

1213141516

1011

3m

117m

153m

81m 81m

45m45m45m

59. 4m

89. 4m

125. 4m

161. 4m

H

H

H

2423

2726252423

2726252423

2726252423

3536

3938373635

3938373635

47

5049484746

6059

51

7.5m

22.93

H(m)

2x2m

17

1516

53.4

56.4

59.4H(m)

1213

11

10

44.4

38.4

41.4

47.4

32.4

26.4

23.4

29.4

8

5

67

9 35.4

14 50.4

7.5m

3m12

.4m

20.4

17.4

11.4

14.4

43

12

0.15

m

7.5m

3m

2x2m

6mx6m

10

1211

13

1514

16

F2 F3F1

L68G

21

L68G

21

L68B1

L68B1

58.9

61.9

52.9

55.9

46.9

937.9

40.9

43.9

76 31.9

34.9

4 25.9

28.95

8

49.9

216.9

19.9

1L68A1

L68A1

L68G22


14

Table 1.1.2-a

F2 129t 161t F1 87.5t 130t F3 84t 121t 102t

107t In service Out of service Crane weight without load

or ballast with longest jib and at maximum height.

Crane mechanism specifications

Table 1.1.2-3

Speed/ Hoist weight Name Code

m/min t m/min t Rope capacity Motor

kW

55LFV30 0�44

0�53 0�88

6.0 4.8 1.2

0�22 0�27 0�44

12.0 9.6 2.4

580m >580m* 55

Hoisting

70RCS30 0�40 0�80

6.0 3.0

0�20 0�40

12.0 6.0

550m >550m* 51.5

Trolleying DTC120 0→68 m/min 120N.m

RTC290 0�0.8 rpm 2x 145N.m Slewing

YMD100 0�0.8 rpm 2x10.5 Traveling RT 12.5-25m/min 4x2.6/5.2

* Please consult us


15

1.1.3 MAST 1,6 x 1,6 m � S15 � CHASSIS 4,5 x 4,5 m

Fig. 1.1.2-1

Table 1.1.2-2


16

Table 1.1.2a

F2 129t 161t F1 81.2t 61t F3 84t 121t 102T

107T In service Out of service Craneweight without load

or ballast with longest jib and maximum height.

Crane mechanism specifications

Table 1.1.3a

Speed / Hoist weight Name Code

m/min t m/min t Rope capacity Motor

kW

55LFV30 0�44

0�53 0�88

6.0 4.8 1.2

0�22 0�27 0�44

12.0 9.6 2.4

580m >580m* 55

Hoisting

70RCS30 0�40 0�80

6.0 3.0

0�20 0�40

12.0 6.0

550m >550m* 51.5

Trollying DTC120 0→68 m/min 120N.m

RTC290 0�0.8 rpm 2x 145N.m Slewing

YMD100 0�0.8 rpm 2x10.5 Travelling RT 12.5-25m/min 4x2.6/5.2

* Please consult us


17

1.2. PREPARING THE CONSTRUCTION SITE 1.2.1. SPACE REQUIREMENTS FOR ASSEMBLY 1.2.1.1. INTRODUCTION This brochure provides the dimensions of the space requirements

for the crane.

They consist of two sets:

- The entire crane with indication of the most important

dimensions.

- The crane is shown in three parts:

− Foundation anchors and undercarriage

− Mast composition

− Range and jib length

Based on the provided dimensions, you can prepare the assembly of the crane. ATTENTION: The provided dimensions do not take account of sagging

under load or any manufacturing tolerances.


18

1.2.1.2. DIMENSIONS 1.2.1.2.1. Total crane

Fig.1.2.1-1

5 2. 0x2. 0x3. 0m1

2. 1m16. 2m 60. 0m

2. 0x2. 0x3. 0m

6x6m

20 18 17 12 11109

7

13 14 16 15

2

3

4

6

8

19


19

N° Name N° Name

1 Foundation anchor 11 Slewing mechanism

2 Brace strut 12 Tower head

3 Central ballast (untercarriage) 13 Jib

4 Bogie 14 Trolley mechanism

5 Mast section 15 Trolley

6 Mast section 16 Hook assembly

7 Telescoping cage 17 Counter jib

8 Telescoping mechanism 18 Hoist mechanism

9 Lower slewing 19 Electric control system

10 Upper slewing 20 Counterweight


20

1.3. CONCRETE FOUNDATION FOR FOUNDATION ANCHORS 1.3.1. PREPARATION TO BE PREPARED BY THE CLIENT:

The concrete foundation of the foundation anchors must be executed on basis of

the parameters in Table 1.3.2.1.

ATTENTION: The listed parameters are minimum values to be observed,

taking account of the stability requirements of the crane.

Please contact us in case of deviating conditions1.

1 Jinlong Europe � Zandvoorstraat 10/6 � 2800 Mechelen � Belgium - Tel: ++ 32/ 15 28 54 54 � Fax: ++32/ 15 20 96 80 and � Jinlong Europe UK & Ireland � Unit 14 The Enterprise Centre, Cranborne Road, Potters Bar � EN6 3DQ Hertfordshire � U.K. Tel: ++ 44/ 1707 600 199 � Fax: ++44/ 1707 600 188


21

h

lb

eFg

FvFh

Mv

1.3.2. SOIL PRESSURE AND CHOICE OF CONCRETE BLOCKS ON FIXING ANGLES. 1.3.2.1. STANDARD CONFIGURATION

Mv： Over turning moment(kNm)

Fv： Crane weight(kN) Fh： Horizontal force(kN)

L： Jib length(m) n： Mast section n° (stationary) YM: Types of concrete blocks Fg： Concrete block weight ES： In service HS： Out of service

e： Offset(m) b： Dimension of concrete blocks(m)

pB： Soil pressure(kN/m2) [pB]： Admissible soil pressure(kN/m2)

Table 1.3.1-1

H n R=60 Es Hs

Mv 2824 3756

Fh 35 145 59.4 17

Fv 912 812

Table 1.3.1-2 H n YM101N YM126N YM142N YM169N

Fg 1010 1260 1420 1690

pB 341 181 218 159

b 5.60 6.25 5.90 6.45 59.4 17

h 1.35 1.35 1.70 1.70

3b

FFhFMe

gv

hv ≤+

⋅+=

[ ]BgvB p

blFF

p ≤+

=3

)(2

3b

FFhFMe

gv

hv ≤+

⋅+=


22

M101N

L=560cm；I=560cm；H=135cm；V=42m3

2 33HA25x625 ( e=17)

2 33HA25x625 ( e=17)

135 70

555

555

1 33HA25x625 ( e=17)

1 33HA25x625 ( e=17)

560

560

55520 20

555

280

130

11x11HA16x155 ( e=51)3


23

M126N

L=625cm；I=625cm；H=135cm；V=53m3

625

D: 2. 4

625

7013

5

1 52HA25x690 ( e=12)

2 52HA25x690 ( e=12)

201 52HA25x680 ( e=12)

2 52HA25x680 ( e=12)

2020620

20620

20610

20610

20

3 14x14=196HA16 ( e=48)

20

130


24

M142N

L=590cm；I=590cm；H=170cm；V=59m3

590

D: 2. 4

170

70

620

20

20 20

620

2 38HA25x655 ( e=15. 5)

1 38HA25x655 ( e=15. 5)20

202 38HA25x645 ( e=15. 5)

1 38HA25x645 ( e=15. 5)59

0

58520

585

20 20

3 12x12=144HA16x190 ( e=46. 5)

130


25

M169N

L=645cm；I=645cm；H=170cm；V=71m3

170

70

20640

20

2 55HA25x710 ( e=12)

1 55HA25x710 ( e=12)

6401 55HA20x700 ( e=11. 8)

2 55HA20x700 ( e=11. 8)20

20

645

D: 2. 4

64020

20

3 13x13=169HA20x190 ( e=47)

645

20640

20

165


26

1.3.3. DIMENSIONAL FEATURES OF THE FOUNDATION ANCHORS

The foundation anchors are placed symmetrically in the foundation block and

are to form a 2-by-2 m square, based on the dimensions of the mast to be

erected (see Fig. 1.3.3-1).

The distance between the topside of the mounting plate and the topside of the

foundation block must be 150 mm.

Fig.1.3.3-1

ATTENTION: Cutting or reducing the reinforcement in the foundation is

prohibited.

2000

Earthing

600

600

150

2000


27

1.3.4. INSTALLING THE FOUNDATION ANCHORS The foundation anchors are mounted by means of:

− 4 foundation anchors and 8 associated pins − 1 foundation framework and 8 associated pins − 1 standard mast section − 1 plumb line or measuring device

- Check the framework for any deformation during transport. The difference between respectively the diagonals and the bearing surface heights may be at the most 2 mm.

- Install the foundation anchor on the reinforcement and adjust by means of filling plates.

- Check perpendicularity in both directions after assembly of the lower mast section on the framework. Adjust if necessary.

- Pour the concrete block and wait until it is completely hardened before removing the mast section and the framework


28

150

Plumb line

Standard section

2 Pins in each corner

Perpendicular

4 Fixing angles

2 Pins in each corner

Fig.1.3.4-1

Mast section

Perpendicular


29

1.4. CENTRAL BALLAST 1.4.1. INTRODUCTION The central ballast consists of reinforced concrete blocks symmetrically placed on the undercarriage for the chassis. The blocks are marked with the letters C or D. Required minimum soil pressure: 2.0 kg/cm2 (200kN/m2). The central ballast must be composed according to the table below (taking account of the mast composition). The ballast is to be supplied by the client in accordance with Fig. 1.4.2-1, 1.4.2-2. - CHASSIS L68A1

CP HUH NR ND LD 2+1+1 13.4m 3 6C+6D 31.8t 2+2+1 14.4m 3 6C+6D 31.8t 2+3+1 17.4m 3 6C+6D 31.8t 2+4+1 20.4m 3 6C+6D 31.8t 2+5+1 23.4m 3 6C+6D 31.8t 2+6+1 26.4m 3 6C+6D 31.8t 2+7+1 29.4m 3 6C+6D 31.8t 2+8+1 32.4m 3 6C+6D 31.8t 2+9+1 35.4m 3 6C+6D 31.8t

2+10+1 38.4m 3 6C+6D 31.8t 2+11+1 41.4m 3 6C+6D 31.8t 2+12+1 44.4m 3 6C+6D 31.8t 2+13+1 47.4m 4 8C+8D 42.4t 2+14+1 50.4m 6 12C+12D 63.6t 2+15+1 53.4m 7 14C+14D 74.2t 2+16+1 56.4m 8 16C+16D 84.8t 2+17+1 59.4m 10 20C+20D 106.0t

CP: Mast composition

HUH: Hook height

NR: Number of layers

ND: Number of blocks

LD: Ballast obtained

DC CD


30

- TYPE YZ48X

B blok A blok A blok A blok A blok A blok A blok

CP HUH NR ND LD 2+1+1 13.9m 7 6A+1B 70.2t 2+2+1 19.4m 7 6A+1B 70.2t 2+3+1 23.9m 7 6A+1B 70.2t 2+4+1 29.4m 7 6A+1B 70.2t 2+5+1 34.9m 7 6A+1B 70.2t 2+6+1 40.4m 7 6A+1B 70.2t 2+7+1 45.9m 7 6A+1B 70.2t


31

R20

115

(※)

250

450

900

420

750

100500

1 2

150

7501500

3

250

4

540

R10R30

R30

220

1

2

220

1.4.2. CENTRAL BALLAST DETAILS

C

Fig. 1.4.2-2

All dimensions tolerances: ±1cm

Rep : Serial No. & ： Diameter N ： Quantity Lu ： Unit length cm Lt ： Total length cm Form： Form M ： Material

REP & mm N L.u L.t Form M

1 40 2 50 100 2 10 8 90 720 ※

3 10 4 220 880 4 10 3 160 480

Q23

5-B

Reinforced concrete

P：2800kg D：2.3


32

R20

115

(※)

220

450

900

420

750

100500

1

150

250

500

2

1500

3

R10R30

R30

220

1

2

250

4

750

540

500

D

Fig. 1.4.2-2

All dimensions tolerances: ±1cm

Rep ： Serial No. φ ： Diameter N ： Quantity L．u ： Unit length cm L．t ： Total length cm Form ： Form M ： Material

REP & mm N L.u L.t Form M

1 40 2 50 100 2 10 8 90 720 ※

3 10 4 220 880

4 10 3 160 480

Q23

5-B

Reinforced concrete

P：2500kg D：2.3

All authorized dimensions +/- 1 cm

Pos: Reference & Diameter in mm

N Number

Lu Length in cm

Lt Total length in cm

Form Reinforcement type

M Material


33

1.5. COUNTER-JIB BALLAST 1.5.1. INTRODUCTION

The counter-jib ballast consists of various reinforced concrete blocks A, B or

C. The counter-jib ballast is governed by the length of the jib. These blocks are

suspended one by one at the rear of the counter-jib.

The ballast is to be supplied by the client in accordance with Fig. 1.5.2-1.

During installation, care must be taken to ensure that they cannot be chipped or

become loose while operating the crane.

Composition and structural dimensions are dealt with in point 5.2.

The admissible tolerance is 500

+ kg per block. To allow for concrete density

changes, alter dimension X to bring the blocks within the indicated tolerance.

We recommend weighing the concrete blocks and marking their weight with

paint on a visible side of the block.


34

1.5.2 DIMENSION OF COUNTER-JIB BALLAST

Length of jib 30 34 40 44 50 54 60

Length of counter jib 16.2 16.2 16.2 16.2 16.2 16.2 16.2

Blocks 2A+B+C 3A 3A+C 3A+B 4A 4A+C 4A+B During working

and telescoping weight（kg） 11000 12000 13000 14000 16000 17000 18000

Block type Density (t/m3) Weight(kg) Tolerance

A 2.4 4000 ±1%

B 2.4 2000 ±2%

C 2.4 1000 ±2%

The dimension and parameter of counterweight see the following counterweight drawing in details.


35


36


37

T 742719-1 4000 kg


38

T 742719-2 2000 kg


39

T 742719-3 1000 kg


40


41

1.6. RE-REEVING (SEE FIG. 2.4.4.2.3-1) 1.6.1. From dual reeving to single reeving

- Bring the trolley against the jib foot and fasten it.

- Lower the hoist hook down to the ground (vertical position).

- Remove the connecting pin (8), connecting arm (5) and single hook block (4).

- Reinstall the connecting pin (8) on the single hook block and secure it with cotter pins.

- Fig.2.4.4.2.3-1

8

9

4 3

5


42

Hoist the single hook block (4) against the trolley (jib) (see Fig. 2.4.4.2.3.1-2).

- Remove the trolley connection pin (8) between both trolleys (1) and (2).

- When the trolley (2) is being run out, both trolleys become separated.

- Reinstall the connecting pin (8) and cotter pins (9) on the rear trolley.

- This concludes the transition from dual (4-rope) reeving to single (2-rope) reeving.

Fig.2.4.4.2.3-2

ATTENTION:

- If operating a significant amount of time with single reeving, the following periodic maintenance must be performed.

- Convert to dual reeving; let the trolley run a few times over the entire jib length while veering and hoisting the load hook over the entire hoisting height.

- Revert to single (2-rope) reeving

8

9

1 2

4


43

1.6.2. From single reeving to dual reeving

- Bring the front trolley (2) against the rear trolley (1) (opposite the jib foot).

- Press the switch button on the operating panel.

- Connect both trolleys with the connecting pin (8) and secure it with the cotter pins (9).

- Lower the single hook block (4) down to the ground.

- Connect both hook blocks (4 and 3) by means of the fittings (8, 9 and 10) (see Fig. 2-5-10).

- This concludes the transition from single to dual reeving.

Fig.2.4.4.2.3.1

8

9

2

4

3

6


44

ATTENTION:

- Working in single reeving configuration with cranes installed above freestanding mast height.

- The crane is designed to work with single reeving up to the maximum freestanding height.

- In case of higher heights, an imbalance can occur. Please contact us on this. In that case, the hook blocks must be ballasted, which will lead to diminished hoisting capacities.

- The traveling wheel (nylon wheel) of the trolley must be replaced every two year.


45

CHAPTER 2. WINCH UNIT


46

2.1. EXPLANATION OF THE SYMBOLS LFV (EX. 90LFV60) 2.2. COMPOSITION OF THE WINCH UNIT The LFV winch unit consists of the following components: See Fig. 4.2-1

Fig. 4.2-1 - Frequency controlled driving motor (1) - Brake mechanism (2) - Gear box (3) - Hoisting drum (4) - Limiter (5) - Motor ventilator (6) - Support frame [chassis] (7)

Speed code, D for high speed motor Load capacity of single wire Frequency controlled Motor power in kW


47

2.3. OPERATING PRINCIPLE

The LFV frequency controlled system allows conversion of the 3-phase supply (through an AC transformer) to a frequency controlled supply voltage. Schematic electric diagram:

XL Joystick PLC Programmable controller Lfa Brake PG Converter LM Hoisting motor frequency-converter


48

2.4. PARTS AND MAINTENANCE 2.4.1. PROGRAMMABLE PLC CONTROLLER

The PLC must be checked regularly for proper operation.

Part Description Parameter

Supply voltage PLC voltage L.N: AC 220V

Control panel Dust-free ambient temperature and humidity

0°C~55°C 30% ~ 85% RH

I/O voltage Operating voltage Input/output voltage DC24V

Connecting conditions

Actual connecting parameters

Battery backup

Replace the batteries regularly +/- 3 year

Failure message: ERR: fire because of low battery backup voltage. ATTENTION: The battery must be replaced within 1 month.


49

2.4.2. FREQUENCY CONVERTER

Connect the frequency converter CIMR-G7A to the vector

controller connection according to the wiring diagram.

2.4.2.1. DIGITAL ACTUATOR USE DIRECTIONS. The following shows the name and function of the key.

Drive Mode Indicators FWD: Lit when there is a forward run

command input REV: Lit when there is a reverse run

command input SEQ: Lit when the run command from

the control circuit terminal is enabled.

REF: Lit when the frequency reference from control circuit terminals A1and A2 is enabled.

ALARM: Lit when an error or alarm has occurred.

Data Display Displays monitor data, constant numbers, and settings. Mode Display (Displayed at upper left of data display.) DRIVE: Lit in Drive Mode. ADV: Lit in Advanced Programming

Mode. VERIFY: Lit in Verify Mode. Keys Execute operations such as setting user constants: monitoring, jogging, and auto tuning.

Name and function for digital actuator


50

NOTE: When disconnecting the power, actuator discharge can take several minutes. During that period, there is a risk of electrocution when touching the components or the wiring.


51

2.4.2.2. OPERATING FUNCTIONS General:

Key Name Function

LOCAL/REMOTE Key .Switches between operation via the Operator (LOCAL)and control circuit terminal operation(REMOTE).This Key can be enabled or disabled by setting user constant 02-01

MENU Key Selects menu items (modes )

ESC Key Returns to the status before the DATA/ENTER

Key was pressed

JOG Key Enables jog operation when the Inverter is

being operated from the Digital Operator.

FWD/REV Key

Selects the rotation direction of the motor when the Inverter is being operated from the Digital Operator

Shift/RESET Key

Sets the number of digits for user constant settings. Also acts as the Reset Key when a fault has occurred.

Increment Key

Selects menu items sets user constant numbers, and increments set values. Used to move to the next item or data.

Decrement Key

Selects menu items sets user constant numbers, and increments set values. Used to move to the previous item or data.

DATA/ENTER Key

Pressed to enter menu items, user constants, and set values. Also used to switch from one display to another.

RUN Key Starts the Inverter operation when the Inverter is

being controlled by the Digital Operator.

STOP Key

Stops Inverter operation. This Key can be enabled or disabled when operating from the control circuit terminal by setting user constant o2-02.


52

Indicator light on the left or the RUN, STOP key, the indicator light operating condition is light up, glitter and crush out. DB (incipient excitation) RUN key is glitter and STOP key is light up.

The following showing about the indicator light showing or RUN

key and STOP key operating

Indicator light and showing The parameter set and converter adjusted in the factory. The

setting code ensures that system could run right, stably and safely.

Customer can operate by joysticks and the digital actuator is for

repairing, checking and setting the parameter. Therefore, the

customer could operate at actuator instead of open the electric

control box during system is normal.

Monitor malfunction and maintenance for frequency converter


53

Monitor malfunction and maintenance for frequency converter

Display Explanation Cause Solution

UV1 Main Circuit Under voltage

1. An open-phase occurred with the input power supply

2. A momentary power loss occurred

3. The wiring terminals for the input power supply are loose.

4. The voltage fluctuations in the input power supply are too large.

Reset the fault after correcting its cause

1. The deceleration time is too short and the regenerative energy from the motor is too large.

Increase the deceleration time or connect a braking resistor (or Braking Resistor Unit). Alternatively, enable (set to 1) the stall prevention selection during deceleration (L3-04).

2. The regenerative energy when an overshoot occurs after acceleration is completed is too large

In vector control, enable (set to 1) the over voltage inhibit selection (L3-11)

OV Main Circuit Over voltage

3. The power supply voltage is too high.

Decrease the voltage so it�s within specifications.

OC Over current

A short-circuit or ground fault occurred at the Inverter output. (A short or ground fault can be caused by motor burn damage, worn insulation, or a damaged cable.)

The load is too large or the acceleration / deceleration time is too short.

A special-purpose motor or motor with a capacity too

Reset the fault after correcting its cause.


54


large for the Inverter is being used.

A magnetic switch was switched at the Inverter output.

GF Ground Fault

A ground fault occurred at the Inverter output. (A ground fault can be caused by motor burn damage, worn insulation, or a damaged cable.)


UV2 Control Power Fault

1. Try turning the power supply off and on.

2. Replace the Inverter if the fault continues to occur.

PF Main Circuit Voltage Fault

1. An open-phase occurred in the input power supply.

2. A momentary power loss occurred.

3. The wiring terminals for the input power supply are loose.

4. The voltage fluctuations in the input power supply are too large.

5. The voltage balance between phases is bad.

Reset the fault after correcting its cause

1. There is a broken wire in the output cable

2. There is a broken wire in the motor winding.

3. The output terminals are loose


LF Output Open-phase

The motor being used has a capacity less than 5% of the Inverter�s maximum motor capacity

Check the motor and Inverter capacity


55


The ambient temperature is too high. Install a cooling unit

There is a heat source nearby

Remove the heat source

OH Cooling Fin Overheating

The Inverter�s cooling fan has stopped

Replace the cooling fan (Contact our sale representative)

The load is too heavy. The acceleration time, deceleration time, and cycle time are too short.

Check the size of the load and the length of the acceleration, deceleration, and cycle times.

The V/f characteristics voltage is too high.

Check the V/f characteristics.

OL1 Motor Overload

The Motor Rated Current (E2-01) is incorrect.

Check the Motor Rated Current (E2-01)

The load is too heavy. The acceleration time, deceleration time and cycle time are too short.

Check the size of the load and the length of the acceleration, deceleration, and cycle times

The V/f characteristics voltage is too high.

Check the V/f characteristics.

OL2 Inverter Overload

The Inverter capacity is too low.

Replace the Inverter with one that has a larger capacity.

Overshooting/Undershooting are occurring Adjust the gain again

The reference speed is too high

Check the reference circuit and reference gain

OS Over speed

The settings in F1-08and F1-09 aren�t appropriate

Check the settings in F1-08 and F1-09

There is a break in the PG wiring

Fix the broken/disconnected wiring

The PG is wired incorrectly Fix the wiring

PGO PG Disconnection Detected

Power isn�t being supplied to the PG

Supply power to the PG properly


56


—

Check for open circuit when using brake (motor)

The load is too heavy Reduce the load

The acceleration time and deceleration time are too short

Lengthen the acceleration time and deceleration time

The load is locked Check the mechanical system

The settings in F1-10and F1-11

Check the settings in F1-10 and F1-11

DEV Excessive Speed Deviation

— Check for open circuit when using brake (motor)

— Try turning the power supply off and on again CPF02 Base block

circuit error The control circuit is damaged

Replace the Inverter

— Try turning the power supply off and pm again CPF03 EEPROM

error The control circuit is damaged Replace the Inverter

— Try turning the power supply off and on again CPF04

CPU internal A/D converter error The control circuit is

damaged Replace the Inverter

— Try turning the power supply off and on again CPF05

CPU external A/D converter error The control circuit is

damaged Replace the Inverter

The Option Card is not connected properly

Turn off the power and insert the Card again CPF06

Option Card connection error The Inverter or Option Card

is faulty Replace the Option Card or the Inverter

NOTE: User needn�t alter setting, otherwise bring any change could influence running normally.


57


Up impulse/ under impulse Adjust gain

Appointed speed too high Adjust appointed return circuit and gain OS Over speed

F1-08, F1-09 setting error Confirm the setting value

Wire of PG broken Connecting broken wire

PG connecting error Correct wiring PGO Wire of PG broken

PG without supply Supply normally

Overload Reduce load

Accelerating time too long Prolong accelerating time

Speed of load is locking state Check winch

DEV Deviation of speed too

F1-10, F1-11 setting error Confirm setting value

OPR Digital actuator contacting not good

Check signal PG disturbance Confirm actuator input

CPF02 Base electrode locking not good

Controlling return circuit broken

Regulate supply ON/OFF Replace the converter

CPF03 Not good Controlling return circuit broken

Regulate supply ON/OFF

CPF04 Controlling return circuit broken


CPF05 Controlling return circuit broken


Selection card connecting error Supply OFF, insert card

CPF06 PG-B2 connecting not good Selection card broken Replace card

NOTE: User needn�t alter setting, otherwise bring any change could influence running normally.


58

CHAPTER 3. SLEWING MECHANISM


59

3.1. EXPLANATION OF THE SYMBOLS: R T C (ex. RTC435)

3.1.1. DESCRIPTION:

Select the slewing speed suitable for the required movement. Gradually increase or decrease the slewing speed. Slow down gradually instead of stopping the load abruptly with the slew brake.

The slew brake may only be used to position the jib during hoisting at wind speeds < 13 m/s (46 km/h).

Avoid simultaneous slewing and hoisting to prevent damage to the hoist rope (rope twisting risk).

Couple (Nm) Eddy current Voltage timing Slewing mechanism


60

3.2. SLEWING UNIT 3.2.1. DESCRIPTION

The RTC slewing unit consists of:

- Motor with squirrel-cage armature turning at constant speed in the desired direction.

- Electrodynamics coupling/brake to perform the speed changes.

- A gearwheel in which the clutch engages directly on the slewing ring.

- Safety brakes mounted on the electrodynamics coupling/brake.

- Techno-dynamo, for speed control.

- Slewing limiter.

- The crane can be put in weathervaning both manually and electrically.


61

3.2.2. OPERATION

- Make the motor run in the desired direction.

- The brake releases.

- The electrodynamics brake inductor is supplied with direct current.

- An amperage change in the inductor produces a speed change. In that way, the desired speed can be obtained by means of the control box.

At Standstill:

- The power supply to the motor is switched off, power is supplied to the inductor of the electrodynamics brake and the jib is brought to a stop;

- The safety brake only locks when, in case of necessity, the operator presses the slewing brake button (XRFS).

ATTENTION: Stopping the jib by counter-slewing is prohibited.

At the end of the workday, the jib must be placed in weathervaning.


62

1. Motor

2. Gearbox

3. Weathervaning mechanism

4. Slewing ring

5. Limit switch

6. Eddy current brake

Fig. 5.2.2-1

5

4

2

6

3

1


63

3.2.3. RTC SCHEMATIC DIAGRAM

Functional diagram Name RP: Potentiometer IC: Signal amplifier Operation: The control signal of the potentiometer RP (slewing

mechanism RTC) is converted through the amplifier IC to a single and three-phase AC-voltage that directly controls the driving motor.

The slewing direction is controlled through a separate signal.

IC

IC

IC

IC

－V

Contactor clockwiseContactor counterclockwise

Adjustable 3-

phase AC-

Voltage feedback

RP

+ V


64

Wiring diagram

RMRD

RG

RDi A

B

C

AC48V

RR


65

3.3. MALFUNCTIONS

- The slewing mechanism is provided with an electronic control device that:

- Controls slewing acceleration and deceleration - Prevents changing of the slewing direction by a control

error

- If a malfunction occurs, working with the crane must be stopped and its cause must be eliminated.

Table 5.3-1

Operation Normal Abnormal

Slewing movement from �0� position on joystick

Slewing starts gradually up to its maximum speed

Slewing starts abruptly. The tower deforms

Slewing movement towards �0� position

The slewing movement slows down and stops after 7-10 seconds

Slewing stops instantly. The tower deforms

Shunt bridging Free slewing Slewing stops suddenly.


66

NOTE: These malfunctions can have the following causes:

- Incorrect connection of the 380VAC/48VAC power upply; excessive voltage fluctuations.

- Potentiometer and joystick are not compatible or are incorrectly adjusted with reference to the resistance O-R/2.

- Check if the inverter is intact and operates properly within the parameters.

- Check the connections of each part for damage and/or improper tightening.

- Check if the control box still works within the given parameters.


67

3.4. SLEW BRAKE

3.4.1. RELEASING THE BRAKE MANUALLY (SEE FIG. 3-4-1)

1) Weathervaning:

Engage the manual brake lever (1), according to movement A.

When the button (2) is pushed, the clamp (3) comes under the brake lever (1).

Release the manual brake lever (1) to let it rest on the clamp (3) and lock it.

Release the pushbutton (2). There may be no clearance at the brake lever (1). Adjust if necessary.

When putting in weathervaning is complete, the slewing mechanism must rotate freely.

2) Locking of the weathervaning:

Set the manual brake lever upright (1), according to movement A.

The clamp (3) releases by the spring (4) action.

Release the manual brake lever (1).

When weathervaning locking is complete, the slewing mechanism should be locked.

ATTENTION: Locking of the weathervaning can jeopardize crane stability in case of high wind speeds.


68

Fig. 3-4-1

4

3

A

1

2


69

1. Brake coupled

3）Operating principle

Fig. 5.4.1-2 REMARK: �E� is the brake clearance. This value must lie between

0.8 mm and 1.2 mm. Adjust if necessary.

2. Brake released E


70

1. Brake coupled

3.4.2. ELECTRICALLY CONTROLLED WEATHERVANING

3.4.2.1. DESCRIPTION:

The electromagnetic brake becomes coupled when the current is cut. It has its own independent power supply.

3.4.2.2. OPERATING PRINCIPLE

Fig. 5.4.2.2

REMARK: �E� is the brake clearance. This value must be at least 0.8 mm and at the most 1.2 mm. If not within these values, adjust brake clearance.

2. Brake released

E


71

3.4.3. SLEW BRAKE MAINTENANCE

Fig. 5.4.3

- Intermediate maintenance

Maintenance must be performed if:

- Insufficient braking moment is generated because of wear or damage of the brake disc (friction disc).

- The control lamp no longer lights up.

- Programmed maintenance Every 200 hours or every month.

- Check air slot and brake torque, as well as the condition of the brake linings. Replace before they are completely worn.

- Check for presence of foreign matter between the brake linings (cement, sand, grease, etc.)

ATTENTION: The brakes must free from dust and foreign matter

(such as cement, sand, grease, etc.).


72


73

7～9

HVeM

HVeM

8

1～9、11～16H

R 1～4

31

2 4

7

5、6

6

5

RRa

19～22

47、48、49、46

9

11～14

LFa11 12

15、16

G1Fa

1314

15

16

F

RM

RM

3.4.4. WIRING DIAGRAM (see fig. 5.4.4-1)

Fig. 5.4.4-1

terminal terminal

Terminal strip for the connecting box of slewing

(R panel)


74

CHAPTER 4. TROLLEY WINCH


75

4.1. EXPLANATION OF SYMBOLS

D T C (EX. DTC55)

Remark: The trolley speed must be selected according to

the distance to be run. Increase and decrease speeds gradually

Couple Voltage regulator, brake Voltage regulator Trolley winch


76

4.2. COMPOSITION OF THE TROLLEY WINCH UNIT The DTC trolley winch unit consists of the following components (see Fig. 6.2-1):

- Rope drum - Gearbox - Electric squirrel-cage motor - Electromagnetic brake - Disk brake

Three speeds are available: MV: Low speed, realized by a combination of actuation of

the electromagnetic brake and running of the motor at lower voltage (230 -260 V).

PV1: Medium speed, realized by partial actuation of the

electromagnetic brake and control of the motor voltage (380 V).

PV2: High speed; the motor is run at its rated voltage (380

V) without excitation of the electromagnetic brake. The disk brake of the trolley winch unit is of the regular closed type (i.e. release through voltage control). Normal brake clearance is 0,8 � 1,2 mm. The brake clearance is set in an identical way as for the slewing motor. The brake torque is set by a spring screw Fig. 6.2-1 item 14.


77

Fig. 4.2-1 1. Outer support plate

2. Connecting rod

3. Drum and gear housing

4. Limit switch pin

5. Inner support plate

6. Limit switch, model DXZ-4/FW

7. Motor brake field excitation voltage DC-20 V

8. Motor, synch rev. 1500 rpm

9. Motor brake field excitation voltage DC-20 V

10. Protection cover locknut

11. Manual brake release lever

12. Fixing nut

13. Screw M8 for disc brake

14. Brake pressure adjusting spring.

15. Brake disc locknut

16. Protection

17. Spindle connection

18. Bearing type 80212

19. Transmission axle

20. Gear coupling, speed ratio r = 30.36

21. Bearing type 60209

22. Sealing ring 23. Trolley rope clamp

19 18

1

23

42 3

1516 14 13

12865 7 119 10

17

22

21 20


78

4.3. TROLLEY BRAKE 4.3.1. Description (SEE FIG. 6.3.1-1): The electromagnetic brake starts operating as soon as the power supply is cut. Brake clearance in the active range is automatically adjusted.

1. Operating principle

Fig. 6.3.1-1 Brakes:

When the current is cut, the electromagnetic attractive force disappears. The brake spring (2) pushes the pressure disc (6) back on the brake disc (5). This closes the brake. The brake is of the regular, closed type.

Releasing the brake:

When the excitation coils (1) is energized, the pressure disc (6) is attracted and the brake pressure spring (2) is pressed in. By this, the brake discs open up.

Brake clearance:

Normal brake clearance is 0.8 to 1.2 mm. Check the brake clearance for soiling (oil - grease).

Brake moment adjustment:

The brake moment was factory-set

1. excitation coil 2. Spring 3. Brake yoke nut4. Movable plate5. Brake plate 6. Pressure disc 7. Brake lining 8. Screw 9. Cover E Brake


79

Releasing the brake manually: The brake can be released manually by loosening the brake yoke (3).

PROGRAMMED MAINTENANCE

- Every 200 hours once a month:

- Check brake clearance and brake moment, as well as the condition of the brake discs. Brake clearance is to be 0.8 � 1.2 mm.

- Attention: replace brake discs before they are completely worn.

- Check if there is any foreign matter in the brake and if it is free from oil and grease.

ATTENTION: The brake must immediately be inspected if:

- It does not work properly - It is overheating - Abnormal vibrations are noticed - Braking torque is insufficient


80

4.4. WIRING DIAGRAM

XD

GV

XD

Ar

XD

GV

XD

PVX

DPV

XD

AV

PD DA

V

SD DFa

DA

r

DM

V

DG

V

DPV

1

DM

V1

DPV

0档

RXDAr

SDAv SDM0

RDMr RXDAv

SDAr

SD

DPv 1 S

1 SDPv

Engaged when energized

Holding position

Disengaged in de-energized condition


81

tower crane concise_manual_stt200

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