Shenxi ZLP250 Manual de usuario

SHENXI Temporarily Installed

Suspended Access Equipment

OPERATION MANUAL

For Shenxi ZLP250

Temporarily Installed Suspended Platform

INSTALLATION OPERATION

MAINTENANCE

TEL.:86-510-88215261 Fax: 86-510-88700937

Website: www.shenxi.com E-mail: [email protected]

SHENXI MACHINERY CO., LTD.

P.R CHINA

NOTE: READ OPERATION INSTRUCTIONS CAREFULLY

BEFORE OPERATING TEMPORARILY INSTALLED

SUSPENDED ACCESS EQUIPMENT

Content

1. Brief Description ......................................................................................................................1

2. Main Parameters......................................................................................................................1

3. Main Structure and Operation Principle...............................................................................2

3.1 Suspension Platform ...........................................................................................................2

3.2 Suspension Mechanism.......................................................................................................2

3.3 Hoist....................................................................................................................................4

3.4 Safety Lock.........................................................................................................................4

3.5 Electric Control System ......................................................................................................5

3.6 Steel Rope...........................................................................................................................6

4. Installations andAdjustment..................................................................................................7

4.1 The Preparation before Installation.....................................................................................7

4.2 Installation of Suspension Mechanism................................................................................7

4.3 Installation of Hoists, Safety Locks and Electric Control Box ...........................................8

4.4 Connection Between Suspended Platform and Suspension Mechanism.............................8

4.5 Special Notice.....................................................................................................................8

5. Operation..................................................................................................................................9

5.1 Checking andAdjusting after Installation...........................................................................9

5.2 Operation Procedure .........................................................................................................10

5.3 Safety Operation Regulations ...........................................................................................14

6. Common Failures and Troubleshooting...............................................................................16

7. Maintenance............................................................................................................................17

7.1 Daily Maintenance............................................................................................................17

7.2 Daily Check.......................................................................................................................18

7.3 Check Periodically............................................................................................................18

8. Storage, Packing and Transportation...................................................................................19

9. Documents and Tool...............................................................................................................19

9.1 Documents attached..........................................................................................................19

9.2 Tools..................................................................................................................................19

10. Attached Table and Figure ....................................................................................................19

Operation Instructions for ZLP250 Temporarily Installed Suspended Access Equipment

1. Brief Description

ZLP series temporarily installed suspended access equipment is ideal equipment

for building facade construction, decoration, cleaning and maintenance. And it is also

widely used in façade building, glass cleaning and installing, elevator installing, ship

building and repairing, or in other works such as big-size tank, bridge, embankment

and chimney.

It is easy for operation, flexible for moving, reliable in safety. Besides, it is not

necessary to build scaffolding in the construction, the efficiency will be promoted and

the cost will be reduced. Therefore, ZLP series versatile knock-down platforms

provides workers safer, easier and more efficient platform access.

ZLP series temporarily installed suspended access equipments conform to the

national standard GB19155-2003.

2. Main Parameters

Model description

Z L P 250

Main parameter or rated capacity (kg)

Identity Symbol: P --- Climb Type

Suspended Platform

Decoration machinery

Table 1: Main Parameters for ZLP250

Item

Parameters

Rated capacity

250kg

Rated speed

8-10 m/min

Platform length

1.2m

Steel rope

4Χ31SW+Fc-8.3

Hoist

Hoist model

LTD6.3

Rated lifting force

6.3KN

Motor

Model

YEJ90L-4

Power

1.5 KW

Voltage

AC380V

Speed

1420 r/m

Brake force moment

15 Nm

Safety lock

Configuration

Centrifugal type

Permission force of impact

30 KN

Locking Cable Distance

＜100mm

Locking Cable Speed

≥22m/min

Suspension

mechanism

Front beam overhang

1.3m-1.5m

Height adjustment

1.27m -1.83 m

Operation Instructions for ZLP250 Temporarily Installed Suspended Access Equipment

Weight

Lifting part (including

hoist, safety lock and

electric control system)

Steel Platform

180kg

Suspension mechanism

115kg

Counter weight

400kg

3. Main Structure and Operation Principle

3.1Suspended Platform

ZLP250 platform consists of the components as following:

Figure 1: Suspended Platform

Operation Instructions for ZLP250 Temporarily Installed Suspended Access Equipment

3.2Suspension Mechanism

The suspension mechanism is the heavy-duty steel frame structure fixed on the

top of the building as the supporting equipment. It is mobile, adaptable and easy to

erect and dismantle.

3.1.1 The suspension mechanism (see figure 2 as below) consists of front beam (1),

middle beam (4), rear beam (5), front base (2), rear base (6), upper column (8),

tommy bar (3), counter weight (7) and reinforce steel rope (9) etc. The tommy bar is

mounted on the front and rear base; the front and rear beams will be fixed through the

tommy bar, the middle beam is fixed between the front and rear beam. The upper

column is mounted on the tommy bar for fixing the reinforced steel rope and counter

weight will be placed on the rear base. For details of structure, see attached figure 1:

suspension mechanism.

Figure 2: Suspension Mechanism

1. Front beam 2. Front base 3. Tommy bar 4. Middle beam

5. Rear beam 6. Rear base 7. Counter weight 8. Upper column

9. Reinforcing steel rope 10. Turnbuckle

3.1.2 The configuration of the suspension mechanism shall meet the following

formula:

a*F * bG

n------- Safety coefficient against overturning;

G------ Weight of counter weight in kg;

a------- Front beam overhang in m;

F------- Total weight in Kg of the platform, hoists, electric control system,

safety lock, steel rope and rated load, plus wind pressure;

b------- Distance in m between the front base and rear base.

The permissible load should be adjusted according to the height, front beam

overhang, distance between the front base and rear base and other variables (see table

2 next page).

Operation Instructions for ZLP250 Temporarily Installed Suspended Access Equipment

3.3 Hoist

The hoist is the powered unit for the platform with the climbing structure.

3.3.1 The hoist for ZLP250 is model LTD6.3. It consists of electromagnetic brake

motor, centrifugal speed limiter and dual speed reduction system and “α”

cable-guiding system (For details of structure, see attached figure 4 and attached

figure 5). The hoist is driven by the electromagnetic brake three-phase asynchronous

motor through the worm gear and a pair of reduced gears. The suspended platform

will be moved upward and downward with the movement of the hoist.

3.3.2 The hoist is provided with automatic rope feeding function and operators just

need to insert steel rope into the inlet of the hoist (see figure 3 as below).

3.3.3 The electromagnetic brake of hoist motor is able to be auto-engaged to produce

braking torque that stops and supports the suspended platform. In the event of power

failure or emergency, the manual descending device can be used to prompt the

suspended platform to slide downwards at even speed (see figure 3 as below).

Figure 3: LTD5 Hoist Figure 4: LSL30 Safety Lock

3.4 Safety Lock

The LSL30 safety lock is the safety-protecting device for the suspended platform.

When the working steel rope is broken suddenly, the safety lock will be actuated to

lock the safety steel rope to prevent the suspended platform from falling down.

The working principle: The safety wire rope goes through the rope inlet hole to

the space between the pressing wheel and the block rotation disc. When the platform

goes down, the steel wire rope drives the wheels to move in the opposite direction by

the friction power. There is block on the rotation disc. When the lowering speed is

over the regulated value, the centrifugal force of the block will overcome the pressing

force of the spring. Then the components will be touched and as a result , the wire

Operation Instructions for ZLP250 Temporarily Installed Suspended Access Equipment

rope locking system will start to work and will make the locking block is locked on

the safety wire rope. The suspended platform will stop lowering.

3.5 Electric Control System

The electric control box is used to control the working of the suspended platform. The main

components are installed on the insulation board. On the box door, there is power indicator light,

start button, emergency stop button. On the bottom of the electric box, there is power supply,

handle switch, power board and the hoist connection plug. (See figure 6 as below).

1 2

图9 电气箱示意图

Figure 5: Electric Control System

The electric control box is used for the control of the up and down movement of

the suspended platform. The main elements are mounted onto an isolated plate and the

universal switch, power indicator light, starting button and emergency stop button are

fixed on the panel.

3.5.1 The schematic diagram and wiring diagram see attached figure 4 and attached 5.

3.5.2 The main electric elements see table 3 next page.

Table 3: List of Electric Elements

Code

Name

Code

Name

KM1,2,3

AC contactor

Power indicator light

QF1

Power leakage breaker

SL1

Limit switch

(or travel switch)

QF2

Miniature circuit

breaker

XPI

10-core plug

Control transformer

XP2

5-core plug

Thermal overload relay

Alarm bell

Operation Instructions for ZLP250 Temporarily Installed Suspended Access Equipment

SB1

Starting button

Electromagnetic brake

SB2,3

Control button

Fuse

STP

Emergency stop button

Power board

Rectifier for brake

Power indicator light

3.5.3 The principle of electric control is as below:

The principle of electric control is as below:

Press start button----Start the contactor (KM1) ---The power indicator light

starts---Press the control button---Main contactors (KM2, KM3) work:

Main contact point closes--- Thermal overload relay ---The motor

electrifies and works --- The platform lifts or lowers

Normal close contact opens---Contact is closed

Normal open contact closes---Electromagnetic brake works

Press emergency stop button---Starting contactor loses power supply--- cut main

power supply and controlling power supply ---platform stops

Upper limit switch works

Starting contactor loses power supply--- Cut main power supply and

Controlling power supply ---platform stops; Alarm bell rings

(If the upper limit switch bumps the limit block and works, only after the suspended

platform is lowered, the start button and control button can be pressed.)

(If power failure happens, it needs to pull upwards the handle release switch to make

the suspended platform lower down to the ground.)

3.6 Steel Rope

3.6.1 The steel rope used in hoists for the equipment is special galvanized steel rope,

diameter is 8.3mm, rated strength is 1960Mpa, breaking force is over 53kN.

3.6.2 The maintenance and inspection of steel rope

The steel rope should be kept and maintained in a proper way to prevent

corrosion and pollution, and the steel ropes should be regularly inspected for

deformation and breakage. The rejection of steel rope is as per the specification of

GB5972.

3.6.3 Special notice:

The steel rope must be the steel rope designated by our company.

The steel rope should be replaced in any one of the situations below:

a. The loosening, twisting, untwisting, or any other deformation and distortion.

b. The steel rope should be rejected when the rope breaking number within the range

Operation Instructions for ZLP250 Temporarily Installed Suspended Access Equipment

of ab spacing reaches 5 (see figure 6 as below). When any corrosion or abrasion

on the surface of steel rope, the standard for rejection is reduced further. The

percentage of reduction is that the maximum allowable breaking numbers 5 times

the percentage of the corrosion or abrasion on the surface of steel rope to make

deduction.

Figure 6: Steel Rope

c. Obvious corrosion on the steel rope, that is, the concave pit on the surface and the

steel rope is loose.

d. The nominal diameter of steel rope is reduced by 6%, even if there is no twist

breakage.

e. When the abrasion of outer rim of steel rope up to 40% of diameter.

f. The damage or accumulation incurred by the heat or electric arc.

4. Installations and Adjustment

4.1 The Preparation before Installation

Prior to installation, please check up the number of parts as shown in the packing

list. Check the condition of each and all the parts and components.

4.2 Installation of Suspension Mechanism

See attached figure 1: suspension mechanism and use the special installing tool

─pinch bar if necessary.

4.2.1 Insert the tommy bars into the front base and rear base respectively. Adjust the

height of the tommy bars and tighten the bolts to form the front base and rear base.

(The height of which should be adjusted with the 1.44~2.14m range according to the

height of parapet).

4.2.2 Lead the front and rear beams into sleeve on front or rear base, position the

middle beam between the front and rear beams and tighten the bolts and nuts.

4.2.3 Mount the working steel rope and safety steel rope onto the coupling sleeve of

the front beam. Make sure that the ends of the ropes must be clamped well (see

section

4.2.4 Adjust the front beam overhang and fix the upper column with tommy bar with

the bolts and make sure that it is not askew.

4.2.5 Adjust the distance between the front and rear bases. Adjust the three beams to

make sure that the three beams should be in the same straight line. Care must be taken

that the height different between the three beams must not larger than 10 cm.

Moreover, it is only allowed that the front is higher than the rear.

Operation Instructions for ZLP250 Temporarily Installed Suspended Access Equipment

4.2.6 Fix the coupling sleeve on the tommy bar of the rear base. Lead one end of the

reinforcing steel rope (7m long) into the coupling sleeve of front beam and tighten the

rope clamp. Lead the reinforcing steel rope to the rope sheave on upper column and

the other end through the hole of the close side of the turnbuckle, tighten the rope

clamp. Adjust the screw bar of the turnbuckle and tighten the reinforcing steel rope to

raise one end of front beam about 3cm.

4.2.7 Place the suspension mechanism to its working position with the reach of front

hanger plate out of the working wall space about 60cm. The distance between two

front hanger plates of suspension mechanism should be the same as the length of the

suspended platform.

4.2.8 Place the counter weight onto the poles of the rear holder and fix them with

bolts and slowly release the steel ropes.

4.3 Installation of Hoists, Safety Locks and Electric Control Box

4.3.1 Fix the hoists on the hoist-mounting frame with pins and M10 bolts: insert the

pin into the hole at the low end of the hoist and at the mount frame, insert the M10

bolt into the two holes at the high end of the hoist and at the mount frame (see figure8

next page).

4.3.2 Install safety lock on the bracket of the hoist-mounting frame and tighten with

bolts. Fix the limit switch onto the right position of the safety lock.

4.3.3 Install and hang the electric control box in the middle of high balustrade of the

suspended platform.

4.3.4 Insert motor plug and handle switch plug into the power socket of the electric

control box. Power plug should be inserted and power cable should be connected

based on three-phase five-wire system.

4.4 Connection between Suspended Platform and Suspension

Mechanism

4.4.1 Rope passing of the hoist

Turn the universal switch to the side where the hoist is prepared for rope passing.

Insert the working steel rope into the inlet of the hoist after passing between the

limiting wheel and the roller of safety lock. And then press the upward button, the

hoist will wind automatically to finish the rope passing and positioning of steel rope.

4.4.2 Rope passing of the safety lock

Make the suspended platform rise up until the arm of the safety lock cannot be

rose, and then insert the safety steel rope into upper inlet of safety lock.

4.4.3 Place heavy hammer: After the complete of the connection of the safety steel

rope, hang the heavy hammer onto the other end of the ropes.

4.5 Special Notice

4.5.1 The suggested front beam overhang should be 1.3 m; the suggested distance

between the front and rear should be 4.6 m. The counter weight should be placed on

the two rear beams on the average basis and fixed with the bolts.

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