CONTROL AND DISPLAY

DEVICE FOR TOWER CRANES

MOVEMENTS - V.2.0

ERREDILIFT ENGINEERING SRL - Via Meuccio Ruini 74 - 42124 Reggio Emilia (RE)
1.0 INTRODUCTION

The solution proposed includes a display for effectively showing the characteristic data of
the crane system: load height, trolley position, jib angle, weight of the lifted load,
transportable weight, percentage of the transported weight with respect to the
transportable weight, wind speed and temperature. Moreover in the last few months we
have studied the possibility of adding a black box to the system so the product can be
marketed also in those sectors where this specification is required. All data are displayed
on one single 5.7” or 7” colour touch-screen. When developing the product, special
attention was paid to the complete interoperability of both the fitter and user with the
system. After selecting one of the six possible languages, the user can view all
characteristic system data. Using a dedicated password, the fitter can access the control
system and configure sensor calibration which is immediate and performed entirely inside
the control cab.
Data acquisition and system control are both centralised in one single device, a
programmable controller. The display and control system technology relies on
Telemecanique components.

When the following unit is installed in the cab, the display shows the following information
to the operator:

• load weight
• transportable weight
• crane features
• wind speed and relevant alarms (yellow, red, acoustic)
• temperature
• man-machine dialogue in 6 languages (Italian, Spanish, German, French, English,
Russian).

Installation of a black box with the following features can also be requested:

• measurements of the load cycles divided into 4 ranges

0-25%
25-50%
50-75%
75-100%

• download of the load cycle log via USB media

• measurement of the work hours divided by each manoeuvre

• trolley distance - lifting – slewing

• recording wind peaks greater than 65 Km/h, overloads and temperature below -20°C

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As an option the following can be fitted:

• measurement of the slewing angle (upon request areas that can be programmed
to limit the radius of action of the crane jib can be fitted)

• hook height

• electronic bogie

• display of the measurements made by the control unit on the radio control

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2.0 PROGRAMMING THE CONTROL UNIT

2.1 SELECTION OF THE MAN-MACHINE DIALOGUE LANGUAGE

When the system is switched on the operator panel shows the following page:

Press the SETUP button to select the man-machine dialogue language. By pressing
SETUP the operator gains access to a menu that allows him to access the three sub
menus of the system:

1) Language

2) Crane set-up

3) Black Box

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Below is the screen page that appears by pressing the SETUP key on the initial page.

Press the LANGUAGE button to access a menu where the language can be selected. The
following screen page will appear on the display:

Press the button of the language wanted (RUSSIAN, ITALIAN, ENGLISH, GERMAN or
FRENCH) for the operator dialogue panel. Press the SETUP button to go back to the
previous menu and configure the display.

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2.2 CALIBRATION OF THE TROLLEY POSITION ON THE JIB

Below is the screen page that appears by pressing the SETUP key on the initial page.

Press SETUP on the main page of the Touch screen. By pressing SETUP on the initial
page the following screen page is displayed, then press CRANE SETUP.

The system now asks the operator to enter the password. To do this the operator must
PRESS on the green frame, which shows 0 if the system is active; by pressing that button
a keypad is displayed on the panel and the password can be entered.

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The default password is 1234. After entering the password, press ENTER to confirm the
entered values. If the password has been entered correctly, no error message is displayed
on the panel, otherwise the incorrect password message is displayed after pressing
ENTER; enter the correct password as explained previously. After entering the password
correctly press OK to access the CRANE SETUP menu.

Press NEXT to access the trolley position calibration menu.

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Observe the following procedure for correct calibration of the trolley position measurement:

1 Move the trolley back to the minimim radius, stop at 20 cm before placing the
wheels on the counterjib trolley housing brackets, then set the value of 3.2 m by
pressing“ 3-2-0” and “ENTER”.

2 Press “RESET” to store the set value.

3 Wait 6 second after the first RESET

4 Now move the trolley to the tip and stop 40 cm before the stop buffers. After the tip
has been reached, press "JIB LENGTH” and set, for example, 60 m by entering “6-
0-0-0”, then press “ENTER”.

5 Press “RESET” to store the set value.

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2.3 HOOK HEIGHT CALIBRATION PROCEDURE

Below is the screen page that appears by pressing the SETUP key on the initial page.

Press SETUP on the main page of the Touch screen. By pressing SETUP on the initial
page the following screen page is displayed, then press CRANE SETUP.

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The system now asks the operator to enter the password. To do this the operator must
PRESS on the green frame, which shows 0 if the system is active; by pressing that button
a keypad is displayed on the panel and the password can be entered.

The default password is 1234. After entering the password, press ENTER to confirm the
entered values. If the password has been entered correctly, no error message is displayed
on the panel, otherwise the incorrect password message is displayed after pressing
ENTER; enter the correct password as explained previously. After entering the password
correctly press OK to access the CRANE SETUP menu.

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Press “NEXT” twice to access the “CRANE SETUP – HOOK HEIGHT CALIBRATION”
menu

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Observe the following procedure for correct calibration of the HOOK HEIGHT position
measurement:

1 Configure the two-rope system

2 “DISTANCE OF THE JIB FROM THE BLOCK” indicates the distance from the
trolley roller sliding surface to the hook centre.
3 Press “0” to set the value that normally ranges between 1.7 a 2.0 m; this value
varies depending on how the ascent and descent limit switches were calibrated.
4 Enter “1-7-0” to set the value of 1.7m and press “ENTER” to confirm
5 Press “RESET” to store the set value.
6 Wait 6 second after the first RESET
7 Now move the block to the descent end-of-stroke position, minimum distance
from the ground and Press “CRANE HEIGHT”.
8 The value that will be set on this section is used to define the maximum height of
the hook. Press “BACK”.
9 Press “HOMEPAGE”; once the work screen page is displayed, move the block
upwards and downwards to check that the correct radius values are displayed.
10 Please note that:the four-rope hook height is automatically calibrated after
completing the two-rope calibration.

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2.4 CALIBRATING THE LOAD CELL

Before proceeding with the steps for calibrating the load cell, some technical explanations
are necessary. The system can be equipped with one or two load cells depending on the
functions the weighing system has to perform. If the measurement of the lifted weight has
to be used only as a parameter to be displayed, there will be one load cell in the system; if
the weighting measurement is used for controlling the lifted weight as well, there will be
two load cells in the system. The first load cell will be used as the main weighing cell while
the second cell will have to monitor that the first cell works correctly. Please note that both
the first and the second cell need to be calibrated but the system is designed so that both
cells are calibrated at the same time, i.e. when you calibrate the first cell, the second one
is calibrated automatically.

2.4.1 LOAD CELL CALIBRATION PROCEDURE

Below is the screen page that appears by pressing the SETUP key on the initial page.

Press SETUP on the main page of the Touch screen. By pressing SETUP on the initial
page the following screen page is displayed, then press CRANE SETUP.

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The system now asks the operator to enter the password. To do this the operator must
PRESS on the green frame, which shows 0 if the system is active; by pressing that button
a keypad is displayed on the panel and the password can be entered.

The default password is 1234. After entering the password, press ENTER to confirm the
entered values. If the password has been entered correctly, no error message is displayed
on the panel, otherwise the incorrect password message is displayed after pressing
ENTER; enter the correct password as explained previously. After entering the password
correctly press OK to access the CRANE SETUP menu.

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Press “NEXT” three times to access the “LOAD CELL CALIBRATION” menu. Cell
calibration is used to set the correct weight and must be performed with both the two-rope
and four-rope (if fitted) pulls.

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Observe the following procedure for correct calibration of the weight measurement:

1 Move the block to the ground, unloading any chains hooked up to the hook if
required.
2 Press “RESET” on “CALIBRATION OF -0 – TWO-ROPE PULL”.
3 Hook up a known weight which must be no less than 1000 kg, and press on the
frame showing the weight beside the writing “KNOWN TWO ROPE PULL
WEIGHT”
4 Enter the weight and press “ENTER”
5 Press “RESET” to confirm.
6 Change the type of pull, prepare the block with a “FOUR-ROPE PULL”
7 Move the block to the ground, unloading any chains hooked up to the hook if
required.
8 Press “RESET” on “CALIBRATION OF - 0 – FOUR-ROPE PULL”.
9 Hook up a known weight which must be no less than 1000 kg, and press on the
frame showing the weight beside the writing “KNOWN FOUR-ROPE PULL
WEIGHT”
10 Enter the weight and press “ENTER”
11 Press “RESET” to confirm.
12 Go back to the “HOMEPAGE” to check the correct measurement.

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2.4.2 ELECTRONIC MAX LOAD AND HOISTING SPEED LIMITER

The "electronic max load and hoisting speed limiter " is calibrated to limit the speed
according to the lifted load.

Press “NEXT” four times to access the “ELECTRONIC BOGIE CALIBRATION” menu

Observe the following procedure for correct calibration of the electronic boogie:

1 Medium speed limitation (4° speed limitation); press the weight value box and
set the weight as specified in the load-speed chart in the instruction handbook.

2 To limit the fast speed (5° speed limitation), press the icon [button figure] and
enter the maximum admitted weight as specified in the load-curve chart in the
instruction handbook.

3 In the case of 4-speed winches, the medium speed corresponds to the third
whereas the fast speed corresponds to the fourth.

4 In the case of 5-speed winches, the medium speed corresponds to the fourth
whereas the fast speed corresponds to the fifth.

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3.0 BLACK BOX

The need for monitoring machine working hours, work cycles and use of the crane under
hazardous conditions resulted in the need for developing a software inside the PLC
capable of storing all the above-mentioned events. The system that was developed is a
sort of black box capable of recording events and creating a log. Hence the system
envisages:

1 calculation of working hours for each operation (trolley, hoisting, slewing);

2 calculation of the working cycles, divided into 4 areas.
3 recording of the wind peaks above 65 km/h
4 recording of the temperature decrease below -20°C
5 recording of the overloads above 115% of the maximum liftable load
6 download of the working cycle log from the operator panel on a USB media
7 software for converting the data downloaded on the pen drive from .dat format to
txt format (this allows the data to be read using MS Excel or any other programme
that opens txt files),

an update of data concerning the working cycles, work hours, wind peaks, temperature
decrease and overloads can be visualized on the operator panel on the relevant
pages under the black box section.

When the system is switched on the operator panel shows the following page.

Just press the SETUP button on the main page of the operator panel to access the black
box.

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Another page opens, giving three possible choice; press BLACK BOX to proceed.

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3.1 WORKING HOURS

The page displayed after pressing the WORKING HOURS button is the following;

The following page of the operator panel shows 3 boxes with the actual operating hours for
the three motors used for operating the trolley, lifting and slewing.

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3.2 MACHINE CYCLES

Press MACHINE CYCLES to display the page showing the updates for the crane loading
cycles.

The first box (1) shows the number of loading cycles ranging between 0 and 25% of the
maximum load; the second box (2) shows the number of loading cycles ranging between
25% and 50% of the maximum load; the third box (3) shows the number of loading cycles
ranging between 50% and 75% of the maximum load and the fourth box (4) shows the
number of loading cycles ranging between 75% and 100% of the maximum load. Box (5)
shows the count of the loading cycles above 115% of the maximum load.
If the >115% box is pressed, a window appears where the operator can see when the
maximum load was performed.

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The following data can be displayed by moving on this window using the arrows:

• DATE: Date of the overload

• TIME: start time
• STATUS: Status of the overload
• RTN : it is the time when theload was placed (system returned to normal
conditions).

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3.3 HISTORIAN ALLARMS WIND

The system can display the force of the wind, record the wind peaks above 65 km/h and
show the following data on a chart:

• DATE: date of the wind peak

• TIME: start time
• STATUS: status of the wind peak
• RTN: time when the wind reduced its blowing force

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3.4 HISTORIAN ALLARMS TEMPERATURE

The system can display the external temperature, save the event (temperature decrease
below -20°C) and show the following data on a chart:

• DATE: date when the temperature dropped below -20°C

• TIME: start time
• STATUS: status of the temperature decrease (on or off)
• RTN: time when the temperature went back above -20°C

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3.5 HISTORICAL OPERATIONS

The system can display the historical operation, save the event (trolley in, trolley near,
lifting up, lifting down, rotation left, rotation right) and show the following data on a chart:

• DATE: date when the start operation

• MESSAGE: type of operation (trolley in, trolley near, lifting up, lifting down,
rotation left, rotation right)
• TIME: start time
• STATUS: status of the operation
• RTN: time when the operation is in stop

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3.6 HISTORICAL SENSORY BREAKDOWNS

The system can display the historical sensory breakdowns, save the event (failure sensor
trolley, failure anemometer, failure load cell, failure encoder rotation) and show the
following data on a chart:

• DATE: date when start sensory breakdowns

• MESSAGE: type of sensory breakdowns (failure sensor trolley, failure
anemometer, failure load cell, failure encoder rotation)
• TIME: start time failure
• STATUS: status of the failure
• RTN: time when the failure is in stop

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3.7 USE CRANE

Just press the USE CRANE button on the black box page of the operator panel to access
the use crane menu.

Press “DAILY” access in this page:

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Press “GLOBAL” access in this page:

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4.0 DATA DOWNLOAD

As stated previously, the system is able to implement the data log. At this stage a short
description is provided explaining how to download this log onto a USB device. First, go
back to the following screen page of the operator panel.

2 The second step is to press the “SAVE ALL FILE ON DEVICE CF CARD” button
on the operator panel to transfer the data into the cf card drive.

3 When the operation is completed, when finish lamp download in progress

4 The third step is to press the “SAVE ALL FILE ON DEVICE USB” button on the
operator panel to transfer the data into the usb pen

The USB pen drive has a 1Gb capacity which is enough space one year of working
cycles.

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5.0 TECHNICAL CHARACTERISTICS
5.1 Technical characteristics of the visualization system

This section of the manual specifies the technical characteristics, functions and selection
criteria for the elements of the display system.

Touch -screen display

the touch-screen panel allows for the man-machine dialogue and its main functions are:

• Displaying animated graphic layouts, representations to scale of a tower crane that

performs. The actual movements given by the operator and a constant update of
the crane 's characteristic data
• Displaying and indicating alarm statuses
• Control, using dynamic or static function keys
• Log register of the alarms and load cycles of the crane
• Changing the man-machine dialogue language

Based on the information provided, the operator must perform actions to properly operate
the machine and system without jeopardising safety or availability. It is therefore
indispensable that the interface and dialogue function design quality ensures that the
operator has control in complete safety whatever the circumstances.

The touch-screen panel was chosen since it fully meets this requirement. The evaluation
criteria that led to this choice were:

• Size of the screen; it had to be large enough to display the movements and
dynamic data of the crane.
• Colour display: the alarms are displayed in a better way and the operator can
intervene more quickly
• A memory device is fitted, which is necessary to store the causes of the alarms and
save the values if log data display trends need to be managed
• Compatibility with the PLC
• The panel can be installed in any type of industrial or non-industrial environment
thanks to the high temperature resistance range and compliance with the standards
and certifications. (IEC, UL, CSA, TUV, CE)

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Main characteristics :

• Compliance with the following standards: EN 61131-2, IEC 60068, IEC 600-2-27,
UL508, CSA C22-2 no.14
• Product type approval: CE, CSA, TUV
• Operating temperature: -20°C….50°C
• Relative humidity: 10…90%
• Altitude: <2000m
• Front protection rating: IP65 according to IEC605929
• Rear protection rating: IP20 according to IEC 60529
• Impact resistance: according to IEC 60068-2-27
• Vibrations: according to IEC 60068-2-6, 10…57 Hz at 0.075 mm;
• Electromagnetic interference: according to IEC 61000-4-3, 10 V/m;
• Electric interference: according to IEC-4-4, level 3.

Mechanical characteristics :

• Assembling and fixing: built-in, fixing with 4 screws, assembly on a 1.6….10 mm

thick panel
• Enclosure material: polycarbonate alloy / polyethylene terephthalate

Electrical specifications :

• supply voltage: 24vdc

• power supply limits: 19.2…28.8v
• starting current: < 30 a
• consumption: 28w
• LCD screen:

• type: TFT colour

• colour: 4056 colours, 64 with flashing;
• resolution: 640x480 pixel (VGA)
• size (width x height): 7.4’’ (149.8 x 112.3)
• touch area: film, 32 x 24 cells
• backlighting (duration): 50000 hours at 25°C in continuous operation
• adjustments: 4-level brightness, with touch-screen keypad

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5.2 PLC TWIDO

A programmable controller is an electronic device specialized in managing and controlling

processes in real time. It runs a series of instructions stored in the memory as a
programme. The fundamental features are:

• It can be connected directly to the sensors and pre-actuators via industrial

inputs and outputs
• It is designed to work in industrial environments that are particularly subject to highly
variable temperatures, vibrations, supply voltage microinterruptions and industrial
disturbances.

TECHNICAL CHARACTERISTICS OF THE TWIDO PLC MAIN CHARACTERISTICS:

• Operating temperature: 0°C….55°C

• Relative humidity: 30…95%, without condensation
• Altitude: <2000m
• Protection rating: IP20
• Impact resistance: 147 m/s^2 for 11 ms

BUFFER BATTERY:

• Stored elements: Internal RAM: internal variables, internal bits and words, timers,
counters, shift registers, etc.
• Type of battery: lithium battery, not interchangeable
• Autonomy: about 30 days at 25°C after charging the battery completely
• Charge time: approx. 15 hours
• Duration: 10 years

POWER SUPPLY:

• Rated voltage: 24 VDC

• Limit voltage: 20.4….26.4 VDC
• Absorbed power: 19W
• Integrated protection: via internal fuse

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5.3 AIR SPEED METER WITH INTEGRATED ALARM INDICATORS

The instrument used for measuring the horizontal component of the wind speed is the
three-cup-type impeller, which allows the physical movement of the wind to be converted
into a pulse train that is read by a PLC input. Moreover, two lamp indicators and a buzzer
are fitted inside the air speed meter. The first lamp indicator is a series of highly luminous
yellow LED’s that turn on blinking when wind speed reaches 50 km/h. The second lamp
indicator is a series of highly luminous red LED’s that turn on with a steady light when wind
speed reaches 70 km/h. A highly audible sound alarm is connected to the switching on of
the yellow and red lamps. The air speed meter can be fixed to the crane with magnets or
flanges for maximum installation simplicity.

Technical characteristics of the anemomter

Main characteristics :

• Power supply: 48/115/230/400 VAC

• Consumption: 6VA (0.5 in stand-by)
• Operating temperature: from -20°C to 60°C
• Protection rating: IP65
• Dimensions: 195x150x270 mm
• Sound power: 115dB
• Yellow light intensity: >100cd
• Red light intensity: >80cd
• Magnet fixing force: >80Kg
• Measurable speed: from 0 to 200Km/h

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5.4 INCREMENTAL ENCODER FOR MEASURING THE POSITIONS OF THE ROPES
AND TROLLEY

Technical characteristics:

Base: Aluminium
Cover: Painted steel
Weight: 80g
Shaft: 4-dia. stainless steel
Max rad/ass load: 2Kg
Bearing life: 1.5 x 10^9 revs
Shock resistance: 50G x 11ms
Vibration resistance: 12 G (10Hz – 2000Hz)
Power supply: 5…24V
Operating temperature: -10 – 70°C
No. of pulses per revolution: 100/1024
Max frequency: 180 Hz
Max consumption: 60 mA
Light source: LED with over 100000 h of life

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 ERREDILIFT ENGINEERING SRL
Via Meuccio Ruini 74
42124 Reggio Emilia - RE -
Italy

INFO
 +39.0522.1872655
 +39.0522.1872656
S.A.T.

 +39.0522.1872655

info@eng-co.com
www.eng-co.com

Edition 2011 - Rev.00