PM530-C TOWER CRANE SAFETY MONITORING SYSTEM

User Manual

Xi'an Fosow Electronic Technology Development Co., Ltd.

Product Manual Statement

This manual is the intellectual product of Xi'an Fosow Electronic Technology
Development Co., Ltd. (hereinafter referred to as Fosow Electronics), without the
prior written permission of Fosow Electronics, all the contents of the relevant user
manual affiliated to the product may not be reproduced, transmitted, transcribed or
stored into the retrieval system or translated into other languages in any form.

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 Fosow Electronics reserves the right to change the hardware and software
specifications contained in the user manual at any time without prior notice. Every
effort has been made by the Company to ensure the accuracy and integrity of the
information contained in the user manual. If you find any errors or omissions, please
report to the Company, and we are deeply grateful.
This product is composed of related accessories studied and developed by Fosow
Electronics, and it can only develop its functions after all accessories have been
installed completely and correctly. Any technicians not from Fosow Electronics or any
personnel without the authorization and permission of Fosow Electronics may not
disassemble or replace with other accessories by themselves, and the Company shall
not assume any responsibility and obligation to damage of the product component or
the system which cannot run properly due to human causes.

Product Safety Instructions

1. Be sure to read the safety instruction carefully and please keep the manual
properly for future reference.
2. Please keep all equipment of the product dry.
3. All equipment of the product are installed at high altitude, please follow the
operation procedure during the installment, and be sure to take security measures to
ensure the safety.
4. Please install the power cord, signal cable and others at the place not being
trampled, torn or worn, do not stack anything on the power cord.
5. Please cut off the power when inserting and extracting any plug socket
contacts.
6. Please note all cautions and warnings mentioned in the manual.
7. No any waterproof devices are installed for the host and display screen
equipment of the product which are easy to be heated in operation, therefore, be sure
to install the equipment in ventilated and dry surroundings firmly, neither shall any
liquid be led into the groove of the host nor the cooling window of the display be
blocked. Otherwise, serious damages or electrical shocks will be caused.

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 8. If any of the following situations occur, please contact the professionals:
(1) Any power cord or plug is damaged
(2) Liquid has penetrated into the equipment
(3) The system cannot work properly or users cannot make the system work
properly under the guidance of the manual
(4) The equipment drops or is damaged.
(5) The equipment has any obvious damaged signs
9. The product is an electronic product, so please handle gently in installation
and transportation, do not throw it heavily. Please place it far from strong electrical
interference when in store.
10. Please do not attempt to repair, improper wiring can cause a short circuit, if
so, irreparable damages to the machine may occur. Do not open the power box, or it
may cause dangers.
11. During the process of using the system, users shall follow the user manual,
do not place any liquid container on the master controller; do not let hard objects
touch the monitor, to prevent the monitor from being destroyed.

Product Installment and Maintenance Instructions

The product is auxiliary safety equipment to prevent any dangers to the tower
crane operation. The Company shall not assume any responsibilities to any accidents
due to human violations of tower crane operators
The product is specific equipment in the industry, any installations,
commissioning or demolitions of the product carried out by the personnel, who are
not either the technicians of Fosow Electronics or the ones authorized by Fosow
Electronics, shall be prohibited, the Company shall not assume any responsibilities for
any loses caused by operations without permission;
The maintenance for the operation safety testing and controlling equipment of the
product must be carried out every quarter for the normal operation;
Some accessories of the product are consumables (e.g. loaded nylon wheel), so
the tower crane driver is required to take the routine inspection every day before

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starting the operation; at the same time, regular inspections shall be carried out
according to the requirements of the maintenance;
When the tower crane safety monitoring system has been moved to other sites
along with the tower crane, it shall be only used after the re-commissioning by
qualified technicians. The Company shall not assume any responsibilities for any
consequences resulting from directly use without prior re-commissioning.

Explanations of Terms
Height:
Vertical distance between the hook location and calibrated reference plane
Amplitude:
Horizontal distance between the rotation center and trolley center
Calibration:
The process to correspond the status of sensors to the actual status of the tower crane
Load percentage
The ratio between the actual lifting weight of the tower crane and the maximum
lifting weight at the rate
Torque percentage:
The ratio between the actual lighting weight of tower crane and rated lifting weight
Limit:
Alarm control before all mechanisms of the tower crane reach the limited position, to
prevent safety accidents caused by operational errors.
Duty cycle:
The process that the crane begins to lift an object until it can lift the next object.
Safety tips
1. Musts of safety
 This product is the auxiliary safety monitoring equipment to prevent dangerous
tower crane operations. The Company shall not assume any responsibilities for
accidents caused by violation operations and unprofessional operations of tower
crane operators.
 To ensure proper collision alarms of the system, please ensure that tower cranes

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 that have collision relations are installed with safety monitoring systems which
communication data is mutually compatible (To ensure effective use of the
functions provided by the system, it is recommended to use the same type of
product provided by the Company).
 Be sure to carefully read through this manual, and please keep this manual
properly for retrieval.
 The installations of all equipments of this product belong to high-altitude
operations. During installation, it must be carried out in strict accordance with the
operating procedures, and safety measures must be provided to ensure safety.
 Before plugging in or pulling out equipment interfaces or accessory contacts,
please cut off power supply first.
 In case of equipment failures, request for repair timely. Do not arbitrarily open or
repair, consequences caused by arbitrary open and related responsibilities shall be
borne by the responsible party.
 If the following occurs during installation, contact the manufacturer or your
dealer for handling:
(1) The power cords or the plugs are damaged
(2) Liquid permeates into the equipment
(3) The equipment does not work properly, or the user can not make it work properly
by following the guide of this manual
(4) The equipment falls or hurts
(5) The equipment has obvious signs of breakage
2. Definition of safety signs
Descriptions about “Dangerous”, “Note” and “Important” signs in the Instruction:

Appearing in the Instruction to warn users serious damages to the product or

even personal injuries may be caused if do not operate in accordance with the
requirements.

Appearing in the Instruction to remind users moderate damages to the product

or other damages to property may be caused if do not operate in accordance with the
requirements.

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 Appearing in the Instruction to prompt users to be sure to comply with and pay
special attention.
3. Safety precautions
A. Logistics handling

1. This product is of electronic products, gently handle during transportation, or the

system is likely to be damaged.
2. Do not store the system in humid environments for a long term, the system shall be
stored away from strong electrical environments, or the function of the system will be
affected.
B. Installation

1. Do not install the system on flammable objects to avoid the risk of fires.
2. Do not arbitrarily remove the monitoring system, data or communication cables,
any opening of the monitoring system may cause the system can not work properly.
3. Do not use the monitoring system with damaged enclosure and missing parts,
otherwise the system will not play its role, and there is the danger of electric shock.
4. The installation and maintenance of the product belong to high-altitude operations,
to ensure the safety of installation personnel, shut down the tower crane power, during
the installation and maintenance process, hot-line work by staff is strictly prohibited.
5. To prevent falling objects during installation, be sure to turn tower cranes to
non-key operation areas.
6. Prevent liquid from immersing into the system when the system is in use, otherwise
it will cause the system working improperly, and there is the danger of electric shock.
7. Wiring work must be carried out by qualified personnel to avoid electric shock
hazards.
8. Before accessing the system power supply cables, make sure tat the main power of
tower cranes is cut off.

1. Install in strict accordance with the specification of the user manual.

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2. Power supply connections must be reliably grounded.
3. The system can not be disassembled arbitrarily, or it is not warranted during the
warranty period.
4. Lifting operations are strictly prohibited during the installation and maintenance
process of the product.
5. The system can only be used normally after proper installation and debugging.
6. Please place the equipment connecting lines at places free from trample, avulsion,
abrasion and extrusion to prevent short circuit or open circuit of cables.
C. Use of the system

1. After energized, do not touch the terminals of the monitoring system,

otherwise, there is the risk of damages to the monitoring system and the risk of
electric shock.
2. The monitoring system exchanges the operating status information of tower cranes
through real-time communications, when safety monitoring system of one unit or
several units of tower crane group is closed, drivers shall carry out operations in strict
accordance with actual situation at scene. Otherwise, there may be risk of collision.
3. The system provides a three-dimensional collision alarm protection, please timely
contact technical personnel to modify parameters when the relative height of tower
cranes changes, otherwise, there will be false alarms or risk of collision.

1. If the system has faults during the use procedure, please contact professionals
for timely maintenance.
2. Please check the set parameters before running, or there is the risk of damage to the
monitoring system.
3. Do not use wet hands to operate the monitoring system, or there is the risk of
damage to the monitoring system.
4. Do not drop screws, washers and foreign objects like metal inside the monitoring
system, or there is the risk of damage to the monitoring system.
5. To ensure the normal use of the equipment, operate in strict accordance with the
operating instruction, ensure the cooling and drying of the monitor, the host and
GPRS equipment, securely mount them. Prevent hard objects from hitting the monitor
to avoid damages to the monitor; prevent liquid from infiltrating into the gap between

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the host and the monitor, liquid intrusion can cause serious damages to the equipment.
D. Maintenance

1. If users find that the system has errors during the use procedure, the system
must be debugged again.
2. When tower cranes transfer site or the lifting speed changes, the system must be
debugged again.
3. Maintenance operations must be performed when the main power is disconnected,
otherwise there may be the risk of damages to the monitoring system and the risk of
electric shock.
4. Parts must be replaced by professionals. It is strictly prohibited to leave wire joints
or metal objects in the monitoring system, otherwise there may be the risk of damages
to the monitoring system, the risk of electric shock or fires.
5. Do not arbitrarily transform the monitoring system, or there may be the risk of
damages to the monitoring system and personnel safety hazards.

1. After the monitoring system is replaced, parameter modification must be

carried out, or the monitoring system may work improperly.
2. It is strictly prohibited to plug in or pull out sensor connectors or data connecting
cables during the operating process of the system, or it may result in system failures,
and there may be the risk of damages to monitoring system and risk of electric shock.
3. Please check the system components daily before starting up.

目 录

本手册型号适用（以打 √ 为准）......................................................................... 错误！未定义书签。

手册版本说明..............................................................................................................错误！未定义书签。

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声明.............................................................................................................................. 错误！未定义书签。
关于手册......................................................................................................................错误！未定义书签。
安全使用提示..............................................................................................................错误！未定义书签。
简介.............................................................................................................................. 错误！未定义书签。
1、概述................................................................................................................................................ 10
1.1 功 能..................................................................................................................................... 10
1.2 配置....................................................................................................................................... 11
1.3 技术参数............................................................................................................................... 11
2、安装................................................................................................................错误！未定义书签。
2.1 原理.......................................................................................................错误！未定义书签。
2.2 部件....................................................................................................................................... 12
2.3 系统传感器接口定义...........................................................................................................14
2.4 继电器输出定义（非 PLC 控制塔机适用）...................................................................... 15
2.5 电源.......................................................................................................错误！未定义书签。
2.6 注意事项................................................................................................错误！未定义书签。
2.7 指示操作区域说明............................................................................... 错误！未定义书签。
3、使用说明........................................................................................................................................ 15
3.1 登陆步骤指南........................................................................................错误！未定义书签。
3.2 设置界面................................................................................................错误！未定义书签。
3.3 设置界面详细介绍.............................................................................. 错误！未定义书签。
编后语..........................................................................................................................错误！未定义书签。

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1、Overview

This product is a electronic torque limiter which for the mainstream of the 63 M - 200 - t t. m.

characteristics of tower crane is designed.Both can be used in the PLC control tower crane, also

can used for tower crane controlled not by the PLC(relay output control).Simplified operation,

compact integration design, volume compared with similar products 60% reduction, reduce the

occupied space ； Focusing on tower crane safety 3 big core functionality: force and torque, the

overload warning and alarm, data record;A new circuit design, optimization of components,

prolong the service life of equipment at least 3 years!

1.1 Function

Real-time detection and display of operational status for the tower crane,

Force, Torque, amplitude, height limit;

Support sound and light alarm

Wind speed early-warning and alarm

PLC output controlor (tower crane controlled by the PLC)

8 relay output control (for tower crane controlled not by the PLC)

“black box”real-time data records and records download

Sensor anomaly and not-in-position detection

Wire rope 2/3/4/6 conversion

Transformation in both English and Chinese

Transformation in the Metric System and the British system

U-disk update the program

U-disk import the load table

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 1.2 configuration

HMI Dynamic real-time display and recording of tower crane operating status

Load sensor Lifting weight, moment testing anddangerous status control

Basic Luffing sensor Car amplitude detection and dangerousstatus control

configuration
Relay module 8 relay output control

Height sensor Lifting height detection and dangerous status control

Anemometer Surrounding wind detection anddangerous status alarm

1.3 technical parameters

NO. Project name Detailed indicators note

HMI adopts 7-inch ，
1 HMI 320X240resolution ratio ， Shell
using aluminum material
2 operating temperature -20℃~70℃
3 storage temperature -30℃~80℃
4 level of protection IP65 Dustproof and waterproof
5 Voltage fluctuation resistant ability 18V~60V DC The power range
6 Camera Tether level ±45° vertical ±40°
7 visual effect Sunlight Readable
8 shock resistance According to the GB12602-2009
Lightning
9 ±4KV
Surge
electrostatic Contact discharge±8KV
10
discharge air discharge±15KV
Electromagnetic
conducted
11 compatibility According to the GB/T28554-2012
interference
electromagnetic
12 According to the GB/T28554-2012
emission
13 EMI According to the GB/T28554-2012
14 According to the GB GB12602-2009 GB/T28554-2012）
15 Signal Type voltage signal：0~5V current signal：4~20mA
16 weight sampling、display 10m
17 Detection of Luffing sampling、display 16m
18 display Height sampling、display 20m
19 Anemometer sampling、display With extended interface

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2. Installation
2.1 principles

HMI interface is used for the input of system sensor signals,the output of relay control signals and

tower crane real-time operating status display. System principle diagram is shown in Figure 2.1

Figure 2.1 System principle diagram

2.2 components

2.2.1 all-in-one machine

Figure 2.2all-in-one machine structure size

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2.2.2 Stroke limiter
Amplitude and height sensors use stroke limiters, which structural dimension is
shown in Figure 2.3.

Figure 2.3 Stroke limiter structure size

2.2.3 Anemometer

Anemometer using pulse signal to output, and its structure size below：

Figure 2.4 Structure size of anemometer

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 2.2.4 Angle sensor （Apply to luffing tower crane）

Angle sensor using gravity pendulum principle, its structure size below:

Figure 2.5 Angle sensor structure size

2.2.5 weight sensor

Because the sensor is not a common component pin, for structural aspects related information,
please call our offices.

2.3 Definition of system interface

Number of
Sensor name 1 2 3 4 5
interface pins
4-core positive-plug Power Ground Signal
Load sensor Signal A ---
aviation connector supply wire B
3-core positive-plug Power Ground
Height sensor Signal ----- ---
aviation connector supply wire
3-core positive-plug Power Ground
Luffing sensor Signal ----- ---
aviation connector supply wire
3-core positive-plug Power Ground
Wind speed sensor Signal ----- ---
aviation connector supply wire
Power
Relay Communication RS485
5-core positive-plug Power supply RS485
interface Ground RS485
aviation connector supply Ground +
（not PLC control） wire
wire
PLC Communication 5-core positive-plug RS485
Ground wire RS232_RX RS232_TX RS485
interface（PLC control） aviation connector +
2-core positive-plug
power supply + — ----- ----- ---
aviation connector

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 2.4 Relay output definition(for tower crane controlled not by the PLC)

Relay output using green connectors connection with tower crane control circuit，Function in the

following table：

Set the numerical size rule:

Output torque control points：Y1<Y2<Y3；Tonnage/speed control output point：Y4<Y5<Y6.

Name of the
NO. Action condition Line no.
output signal
Actual lifting torque is greater than the rated lifting moment of
output torque 90% (80%) then output the control signal, less than 80% of the set
Y1 1,2
control points 1 value then reset;can adjust,The range is 0-90%,When leaving the
factory, luffing tower is 90%,the other is 80%.
Actual lifting torque is greater than the rated lifting moment of
output torque
Y2 105% then output the control signal, less than 80% of the set value 3,4
control points 2
then reset;can adjust,The range is 0-105%,Factory default 105%
Actual lifting torque is greater than the rated lifting moment of
output torque
Y3 110% then output the control signal, less than 80% of the set value 5,6
control points 3
then reset;can adjust,The range is 0-110%,Factory default 110%
Tonnage/speed Actual weight to the rated lifting weight x % ,then output control
Y4 control output signal;can adjust,The range is 0-100%;Less than 80% of the set 7,8
point 1 percentage then signal reset
Tonnage/speed Actual weight to the rated lifting weight x % ,then output control
Y5 control output signal;can adjust,The range is 0-100%;Less than 80% of the set 9,10
point 2 percentage then signal reset
Tonnage/speed Actual weight to the rated lifting weight x % ,then output control
Y6 control output signal;can adjust,The range is 0-100%;Less than 80% of the set 11,12
point 3 percentage then signal reset
Y7 reserved - 13,14
Y8 reserved - 15,16

2.5 Power supply

The main box of the system is AC220V power input.

2.6Indicating operating area
The system voltage shall have ground wires! ! !
All connections between systems shall be reliably connected, otherwise it will cause
system abnormalities! !

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2.7Status indicator light area

Alarm indicator light, when there is alarm state system, The light is on.

Warning lights, when there is alert system, The light is on.

Running lights, when the system is running, The light is on.

The key area

main menu，To be able to return at the next higher level interface；

Move the cursor position；

confirm，Able to enter the next level interface.

3、Equipment use
Admin login：
The first step：

Equipment after electrify, appear "show interface ” ， press ， Into the

"management" of landing interface；this interface have SN NO.，Software version，

Hardware version.
The second step：

In the "management" of landing interface，press and press at same

time， then loosen frist and loosen second ， so can Into the "main menu
interface".

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 show interface management" of landing interface

Notice：
if 30 s are not operating equipment, the system will automatically return to the
management of landing interface, log in again in accordance with the above method.
3.1 HMI introduction

This menu contains：Parameter setting,system setting,fall select,bypass,radius

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calibration,height calibration,load calibration,load table config,system upgrade,record
download.
3.2 Introduction of operation interface
3.2.1 Parameter setting：

The interface of the main set radius , height, load, torque alarm parameters.

Icon is introduced：

radius height

load torque

radius to slow down inward radius to stop inward

radius to slow down outside radius to stop outside

height to stop downward height to slow down upward

height to stop upward height to slow down downward

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 distance for Rotary center to arm the root

height of tower crane Rated lifting weight

load 1 load 2

load 3 torque of percentage 1

torque of percentage 2 torque of percentage 3

Wind speed warning Wind speed alarm

3.2.2 System settings：

Set the following under this menu: system time, screen brightness,Chinese-English
shift.

system time The screen brightness Chinese-English shift

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3.2.3 Fall select：press can transform

.
3.2.5 Amplitude calibrations：
Amplitude calibrations，Using two points calibration method，Keep the amplitude
value and actual value of tower crane is in line ,Simply enter the current actual
amplitude.
Specific operation process for amplitude calibration: after adjusted the car to a
measurable value, maintain the same position, after the voltage of the first point is
stable, fill in the current amplitude value, click on “OK”; then after adjusted the car to
another measurable value, keep the same position, after the voltage of the second
point is stable, fill in the current amplitude value, after clicked on “OK”, the system
will automatically calculate the values of K and B, and prompt “amplitude calibration
success.”

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3.2.6 Height calibrations：
Height calibrations，Using two points calibration method，Keep the Height value
and actual value of tower crane is in line ,Simply enter the current actual Height .
Specific operation process for height calibration: adjust the hook and place it
vertically on the ground, after the voltage of the first point is stable, fill in 0, click on
“OK”, then lift the hook to the highest point, after the voltage of the second point is
stable, fill in the current height value, after clicked on “OK”, the system will
automatically calculate the values of K and B, and prompt “height calibration
success”.

Notice：
Height calibration takes the ground as 0 reference point, and ground is still the 0
reference in tower lifting operations)

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3.2.7 load calibrations：
load calibrations，Using three points calibration method，Keep the load value and
actual value of tower crane is in line ,Simply enter the current actual load.
Specific operation process for load calibration：In the first place in the condition
of empty hook, waiting for the first point voltage stability ,then fill in the current
lifting value: 0 t.Next, lifting a standard weight, waiting for the second point voltage
stability , fill in the weight value of the standard weight, you can press "save" to
complete the calibration at this time. If you need to continue to the third point
calibration, you need to lifting a heavier weight, after the third point voltage stability
and fill in the weight weight value,press "save" to complete the calibration,the system
will automatically prompt“load calibration success”.

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 3.3.7 The PLC output control interface：(for tower crane controlled not by the PLC)

Click “ ” button to open or close the output control

Open the output control, connecting the PLC,hold down hold down again

at the same time，loosen first and loosen next，then can enter into the PLC

control interface.connection is equal to the equipment no truncation signal

output;Truncation is equal to the output of the corresponding truncation signal.

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 3.3.8 Load table configuration：
viewing the current load list information.

3.3.9 Record download：

Tower crane black box is the interface for recording the real-time data of tower crane
operating status, insert U-disk into the corresponding USB hole on the main box,
black box records can be downloaded, including work records, operate
records,overload records.

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3.3.10 Load table import
Named “ImportChart” for load table folder,Put in the file ImportChart to U-disk
root directory,Then U-disk inserted into the USB interface,In the interface table, click
import load table,Can complete!
3.2.11 System upgrade：

Insert U disk into corresponding USB hole on the main box, System can be upgrate：
The upgrade method：
the program file of the host shall be named “PM530C.bin”, placed in the root
directory of U-disk, then insert U-disk into the host USB port, after clicked on Check
Update, version information appears,Only version different circumstances can be
normal to upgrade, then click on Download.After system upgrade,Must have a look at
the version number is correct.

Notice：
If there is any accident in the process of upgrading, which leads to the system was
unable to complete the upgrade, please do not disassemble the equipment, please
contact our technical staff for processing!

Additional Words
In case of doubt in the same version of English and Chinese, please refer to Chinese

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instructions; Due to constantly update products of our company, if there are any
differences with the equipment, please give priority to with equipment
Thanks!

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