Catalogue 1. Safety rules for use. 2. Characteristics and purpose... 3. Major technical parameters... 4. Introduction to structure of suspended access equipment. 5. Electric control system... 6. Installation, adjustment and application... 7. Common troubles and troubleshooting... 8. Emergency treatment of construction... 9 . Regular inspection, maintenance and repair ... 10. Standard for scrap of main structural members and wearing parts ...41 11. Main wearing parts list...... 12. Packaging and transport... 13. Appendix...1. Safety Rules for use of suspended access equipment The suspended access equipment is a manned mechanism for works at heights; therefore, it is compulsory to abide by the safety rules when using it for construction. 1.1 Safety rules for environment 1.1.1 The building or the top of construction where will support the suspended mechanism must have a bearing strength more than 1500kg/m®. If the suspended mechanism is supported by the embedded rhember on top, the safety coefficient of the embedded member must not be less than 3. 1.1.2 The power supply for the suspended access equipment is the grounding power of S80V with 3-phase 5-wire (if there is special request, please operate accordingly). 41.1.3 It is prohibited to use the suspended access equipment within a range, keeping 10mtrs away from the high voltage line. 1.1.4 It Is prohibited to hoist the suspended access equipment for operation under rainstorm, thunderstorm, dense fog, heavy snow or the atrocious weather with a wind speed over 10.80m/s (equal to force-six gale). 1.1.5 If there is the road or passage under the works limit, it must design the warning line or safety passage beneath the suspended access equipment, as well as the conspicuous warning sign and assign the safety supervisor. 1.1.6 If must clear all kinds of prominence or barriers away from the work range of suspended access equipment; the fixed prominence or comer must be available a conspicuous warning sign; in the process of construction, it is prohibited to open the ‘out-swinging window. 4.1.7 When working at night, there must be available the sufficient lighting on the {construction site, it must provide a clear vision and bright environment; the intensity of illumination must be more than 150LX; besides, the warning signal lamp must be available additionally. 1.1.8 When working under the rainy day, snow day, or other corrosive environmen, it must take protective measures, i.e.: damp-proof, water-proof and corrosion-proot measures for operator, safety device, electrical box, steel wire rope and life rope. 1.2 Safety rules of operator 1.2.1 The operator of the suspended access equipment must have te. n trained, with the related qualification certificate; the suspended access equipment must be only operated by the given person; no other persons without being trained or authority of controlling officer are allowed to operate. 1.2.2 The operator must wear safety helmet and safety belt when working, the self-locking buckle on the safety belt must be fastened independently, and fixed on the life rope that is tied on the top of building or structural member (the top end of the life rope is not allowed to fix on the suspended mechanism). 1.2.3 Any operators who drinks, bears a great strain or have abnormal mood are not allowed to operate the suspended access equipment. 1.2.4 The suspended access equipment hoisted by dual machines must be operated by two or more operators; it is prohibited to operate by a single person. 1.2.5 The operator is not allowed to wear the shoes with hard or plastic sole, or slippers and other shoes inclining to slip when working. During the operation, it is Prohibited to use the ladder, bench, wooden stool and other tools for climbing in the Tange of suspension platform, or design or place the hoisting devices out of the suspension platform.1.2.6 The operator must access into the suspended access equipment on ground, no accession into the suspended access equipment from the window in air is allowed. It is absolutely prohibited to access into the suspension platform from another one when itis suspended. 1.3 Safety rules for use 1.8.1 The suspended access equipment that is installed newly, repaired completely, unused for one year or ceased in suspension for more than 2 months must be inspected according to the safety requirements, and it must be only allowed to release for use after being confirmed to meet the given requirements and condition. 1.3.2 The minimal distance between the suspended access equipments that are installed adjacently must be over 0.5mtrs. 1.8.3 The suspended access equipment must be inspected according to the daily inspection requirement on a frequency of each day, and run without load to confirm it is in anormal condition. After a day's work finishes, it must be maintained according to the daily requirement. 1.3.4 The load of the suspended access equipment must keep balance as much as possible, no overload is allowed. When it works normally, the working load must be less than 80% of the rated load. The suspended access equipment is prohibited to run with full load or be used frequently to hoist as the hoisting machine or transport tool. 1.3.5 It must keep the steel wire rope vertical when the suspension platform runs. The steel wire rope is not allowed to bend, plump up or have mortar or other foreign matters. During the hoist, it is prohibited to use safety lock for braking or construction activity, 1.3.6 When construction activity finishes or staying over night, the suspension 3platiorm must be at the lowest position and fixed reliably, 1.3.7 On the construction site, it is prohibited to use the suspended access equipment or steel wire rope as the arc start for welding or connection's loop. When using the suspended access equipment for gas welding, it is prohibited to place oxygen or ethyne bottle or other explosive substances within the range of suspension platform. 1.8.8 During the normal working period of the suspended access equipment, it must perform a regular inspection and maintenance according to the given requirements. 1.3.9 When repairing or replacing the electric components, it must shut power supply off firstly. When the suspended access equipment is repaired, it must abide by the ground repair rule and be performed by the exclusive designated full-time personnel. It is prohibited to repair or replace the components of the suspended access equipment by the non-designated personnel without authority or perform the operation in air. When it is necessary to make the inspection in air, the repairér must take reliable safety measures firstly. 1.8.10 If it is found any errors, deformations, tear and wear, corrosion, damage or abnormal condition when the suspended access equipment is used or inspected, it must only allow the full-time personnel to repair or replace the damaged components; afterwards, it can only be allowed to release for reuse when it is inspected to meet the given condition. It is prohibit to run the suspended access equipment with any hidden troubles or defectives.2. Characieristics and purpose of suspended access equipment “Zhenda” brand ZLP series temporarily installed suspended access equipment is a suspended manned facility for work at heights by relying on a movable platform driven by motor, designed to suspend along the vertical surface of building by steel wire ropes through the suspension mechanism placed at the top of building. It is a kind of non-regular suspended access equipment. The suspended access equipment is featured in strong construction adaptability, higher construction height, less occupation of construction land, high construction efficiency, easy erection, less labor need and etc. The main purposes of the suspended access equipment are: 2.1 Exterior wall construction and decoration of high-rise building, installation of panel wall and structural members of exterior wall. 2.2 Repair, maintenance and cleansing of exterior wall of high-rise building. 2.3 Construction, inspection, repair and maintenance of large project, for instance: chimney, dam, bridge and head frame. 2.4 Welding, cleansing and oi-painting of large ship. 2.5 Fabrication and installation of bulletin board on buildings at heights.3. Major technical parameters Table 1 Type ‘ZLP630 ZLP800 | 630 ( including the | 800 ¢ including the Rated load eee | *2 | weight of personnel ) | weight of personnel > speed m/min 9.90.5 8.2205 Dimension of platform 4 lenissidtaheiin mm | (2000x8)x690x1180 | (2500x3)x690x1180 Suspension | Protusion of font Beam | mm 1300 1300 | 1800-1800 (adjustable | 1300-1800 ¢ adjustable Mechanism | Height of Front B i etghtof Front Beam | mm | cistanoe 200) distance 200) Type | LTD6.3 LTD8.0 Quantity | piece 2 2 Type ‘YEJ9OL-4 ‘YEJ@OL-4 Hoist Power kw 18 18 Motor | Voltage v 380 380 | Rotati cater | efmin 1400 1400 Speed Brake Torque | Nm | 16 Type us@20 Ls@20 Satety Lock | Quantity piece 2 2 ; : Allowable Impulsive [| - a Force | Suspension Piatiorm | kg 310 386 | Hoist kg 0x2 | 4x2 Safety Lock kg 5.5x2 | 5.5x2 i - saat 320 ( no-including Weight | Sus Mechanism | k 388 ig uuspension Mechanism | kg ome cao Electric Control Box | kg 15 18 The Whole Machine | kg 756 908 Counterweight Kg 900 (25x36pes) 1000 (25x40p¢s) | ween ipa 4xS1Fi#PP-08 3 Break | 4xS1Fi+PP-O8 6 Break si yr Strength 251800N Strength 270000N PowerCabie Type B2S2ASYCS | 8x2.5+2x1 5YO-S Note: The whole machine weight is no-including counter weight, wire rope and power cable.4. Introduction to structure of suspended access equipment The whole suspended access equipment is consisted of the suspension mechanism, suspension platform, hoist, safety lock, working wire rope, safety wire rope, electric control box and electric control system and ete (See Figure 1). 1. Suspension mechanism 2. Counter weight 3. Height of suspended mechanism 4. Front Beam Overhang 5. Upper limit stopper 6. Working wire rope 7. Safety wire rope 8. Safety lock 9. Hoist 10. Heavy hammer 11. Suspension platform 12. Electric contro! box Figure 1 Structural diagram of the suspended access equipment In order to transport and handle easily, the suspended access equipment will be delivered in a form of unassembled parts from the factory, and then will be assembled only when all components arrive in the construction site.4.1 Suspension platform The suspension platform is a suspended closed frame device with the safety guards around, designed to carry the operating staff, tools and materials for work at heights. The suspension platform is of steel or aluminium structure. The suspension platform is consisted of three basic segments and two erection frames for hoists at both ends. Where each segment is consisted of the balustrade at the front and rear, as well as the base, The front balustrade (closing to the working surface) is 0.9m high, the rear balustrade 1.2m high. The multiple basic segments and the erection frame for hoists at both ends form a closed frame platform. The basic length is 1m, 2m and 2.5m; the finished available length is 1m, 2.5m, 3m, 3.5m, 4m, 4.5m, 5m and so on. The maximal length of ZLP630 type platform is not more than 6m, ZLP800 type platform not more than 7.5m. 4.2 Suspension mechanism The suspension mechanism is a device designed on the top of building to suspend the suspension platform by steel wire ropes. The suspension mechanism is consisted of two suspension brackets with same structure, assembled in pairs. The suspension bracket of ZLP630 type and ZLP800 type suspended access equipment is consisted of the front base, rear base, tommy bar, upper column, front beam, middle beam, rear beam, reinforced wire rope and counter weight. Where the middle beam is installed in the front and rear beam; the distance between the front and rear base can be adjusted by changing the position of installation hole of connecting bolt, with an adjusting range 2-4m, adjusting space 0.2m. The front and rear beam is installed on the front and rear base through the tommy bar; the distance from the beam to the grouind can be adjusted by changing the position of installation hole of connecting bolt between the tommy bar, front and rear base, with an adjustingrange 1.3-1.8m, adjusting space 0.1m, itis an adjustable suspension bracket. The groupware of the reinforced wire rope is connected with both ends of the front and rear beam through the turnbuckle, coupling sleeve and the upper column. The whole rigidity of the suspension bracket can be improved by tightening the wire rope through the turnbuckle. 4.3 Hoists The suspended access equipment is provided two LTD6.3 hoists with power of 1.5kw (ZLP630 type) or LTD8.0 hoists with power of 1.8kw (ZLP800 type), which are installed in the erection frames of hoists at both ends of the suspension platform. The hoist is the power facility to drive the suspension platform to move up and down (Figure 2). 5 1 4 1. Hoist body 2. Electrical box 3. Cable of motor 4. Control cable 5, Handle for falling 6. Motor 7.working wire rope Figure 2 Hoist The lift motor is the S-phase asynchronous motor with the electromagnetic brake, where the normal close type DC electromagnetic brake is installed on the upper end 9of the main shaft of the motor. When power supply is switched on, the armature iron releases from the friction plate under the action of electromagnetic force, which will guarantee the motor to run normally; when power supply is switched off, the armature iron keeps closed with the friction plate under the action of spring force, which will brake the motor immediately; the use of the self-lock of motor can prevent the suspension platform from falling down caused by overload. The electromagnetic brake has a semi-circular release device, the descending handle is inserted into the release device through the kidney-shape handle hole at the upper of the cover of motor; when lifting the handle upwardly, it can open the brake manually. The suspension platform can realize its manual fall under the force of self-gravity. At the joint of the shaft end of motor and the input end of the reducing mechanism inside the box, the centrifugal reducing mechanism is installed, which is used to prevent the suspension platform from falling down sharply caused by stall speed when it makes free fall. ‘The reducing mechanism inside the box is consisted of the worm wheel, worm gear and 2-class sub-speed reducing transmission system of intemal gears. The working wire rope shall encircle the dovetail groove at the outer end of the inner gear disc in “qt” form after entering into the body (See Figure 2). When the motor drives the inner gear disc to turn with different directions, under the action of the friction force formed between the wire rope and dovetail groove, the hoist and suspension platform will move up and down along the wire rope. 4.4 Safety lock The suspended access equipment is provided two LSG20 safety locks, installed respectively in the bracket at the upper of the erection frame for the hoists at both ends of the suspension platform. LSG20 safety lock is the skew-free safety lock; it is actually the device to prevent the 10suspension platform from falling down by locking the safety wire rops automatically when the suspension platform tilts caused by the broken working wire rope or fall of ‘one end of the suspension platform. The safety lock is only to clamp the rope automatically by the swing arm and rope-locking mechanism; it is a kind of the normal close lock. When it works normally, the scroll wheel on the swing arm will lit the swing arm under the force of the working wire rope, which will then cause the rope-locking mechanism to unfasten, and make the safety lock under an unlocked condition. At this time, the safety wire rope can access into the safety lock easily. When the working wire rope breaks or the suspension platform tilts (at certain angle), the pressure at the scroll wheel on the swing arm caused by the working wire rope will disappear, which will make the swing arm fall to the original locking position, and cause the rope-locking mechanism to clutch and clamp the safety wire rope completely, and thus the safety lock will realize the automatic look on rope. Angle adjustment of safety lock rope (Figure 3): Mastral viernes (CPEs Hl stay wire \ wot] go) @ ‘wre rope re Figure 3 Schematic diagram of angle adjustment for locking rope 4.4.1 Unfasten the nets between the soroll wheel and connection plate; 4.4.2 Increase or reduce the locking angle of safety lock according to the indicated direction; "14.4.3 Tighten the nuts between the scroll wheel and connection plate; 4.4.4 Adjust the rope-locking angle formed with the horizon to 4° —5° 4.5 Working wire rope and safety wire rope The working wire rope will be used to suspend and lift the suspension platform after entering and encircling the hoists; it is actually the carrier of the suspension platform for movement. The safety wire rope will only play a role to prevent the suspension platform from falling or tilting by being clamped by the safety lock when the working wire rope breaks or the suspended access equipment becomes tilted, which will then guarantee the operating staff in safe. The working wire rope and safety wire rope are the main components to support the load of the suspended access equipment, therefore, the wire rope that will be used must meet the given requirement. Preferably, the working wire rope and the safety wire rope should be the zinc-plated one (it must be ©8.3-4x31Fi+PP for ZLP630 type, ©8.6-4x31Fi+PP for ZLP800 type) with features of high strength and rust-proof capability. In order to prevent the rope damp from loosening and enter into the hoists and safety lock easily, after the wanted length for the wire rope is cut, its both ends must be treated specially; whereas the input end shall be polished into a warhead-like shape after being welded. 4.6 Power cable The power cable is connected between the power supply and electrical box; it is actually the conductor to transmit the electric energy to the suspension platform. The power cable is the 3x2.5+2x1.5 cables with 5-core and rubber sheath, where 3 cables with 2.5mm? core wires are used to connect with 380V 3-phase power supply, 2 cables with 1.5mm? core wires are used to connect with the zero line and earthing cable. 125. Electric control system The electric control system of the suspended access equipment is controlled intently by the electrical box, featuring in convenient operation, safety and reliability ‘The hoist of the suspension platform is controlled by the extention cords control switch and control buttons on the electrical box, which are easy to access for operate at any directions. The electric control system is designed the electrical leakage protection device, emergency stop brake, limit brake, warning ring, limit load control and other various automatic protection device. It is safe and reliable. eR BREE ¢ oe Control principle diagram of electric appliance6. Installation, adjustment and application of the suspended access equipment 6.1 Schematic diagram for installation of the suspension mechanism(Figure 4) 2 1. Front beam 2. Front base 3. Front tommy bar (adjusting stand) 4.upper column —_5. Middle beam 6. Reinforced wire rope 7. Rear beam 8. Rear tommy bar (adjusting stand) 9. Rear base 10. Counter weight Figure 4. Schematic diagram for installation of the suspension mechanism 6.1.1 Installation 6.1.1.1 Insert the tommy bars into the front base and rear base respectively. Adjust 14the height of the tommy bars and tighten the bolts to form the front base and rear base. 6.1.4.2 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. 6.1.1.3 Mount the working wire rope and safety wire rope onto the coupling sleeve of the front beam. Make sure that the ends of the ropes must be clamped well, and then, put the stopper onto the safety wire rope at the proper position. ( Make sure that the ends of wire ropes must be Ferrules well, and then, put the clamps onto safety wire rope at proper position. ) 6.1.1.4 Adjust the front beam overhang and fix the upper column with tommy bar with the bolts and make sure that it is not askew. 6.1.1.5 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. 6.1.1.6 Fix the coupling sleeve on the tommy bar of the rear base. Lead one end of the reinforced wire rope into the coupling sleeve of front beam and tighten the rope clamp(See Figure 5). Lead the reinforced wire 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 turbuckle and tighten the reinforced wire rope to raise one end of front beam about 3 cm. 6.1.1.7 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. 156.1.1.8 Place the counter weight onto the poles of the rear holder and fix them with bolts and slowly release the wire ropes. 6.1.2 adjustment and precautions 6.1.2.1 The installation ground must be horizontal. The place where is sloped shall be leveled up by wood plate; if the installation surface is water-proof and heat insulated, it must place the wood plate with thickness of 2.5~3.0om beneath the front and rear base to prevent It from being damaged. 6.1.2.2 Adjust the height of the front adjusting stand of the suspension bracket and make the bottom side of the front beam higher than the parapet wall (or other barriers). 6.1.2.3 The rated adjusting range of the protrusion at the front beam is 0.3~1.5m. If it exceeds the rated protrusion length, it must take reliable measures and reduce the rated working load, and then be allowed to use after the department in charge consents. 6.1.2.4 Under the allowable condition, the distance between the front and rear base must be kept maximal as much as possible. 6.1.2.5 The distance between two brackets must be adjusted to the one that distance between the protruding ends of the front beam is more 3~Som than the length of the suspension platform. 6.1.2.6 When tightening the reinforced wire rope, it must keep the front beam tumed up 3~5om, which will then produce prestressing and improve the rigidity of the front beam. 6.1.2.7 When installing the wire rope, the quantity of the rope clamp must not be less 16than 3 pieces, and the U-shape opening is designed at the side of the tail end of the wire rope, keeping same direction. The rope clamp must clamp the hoisting points in tums. (See Figure 5). When the nut of the rope clamp is tightened, it must keep the clamp of the wire rope at 1/2~1/3 diameter. 6.1.2.8 When placing the wire rope vertically, it must coll and place the wire rope on the floor, with one end to be fixed on the top end of the suspension protrusion of the suspension mechanism, the other end to be placed downward slowly along the wall after it comes out. It Is prohibited to throw the wire rope in coil. After the wire rope is released completely, it must separate and hold the rope knot carefully; the excessive wire rope on the ground must be coiled and bound carefully. It is not allowed to place on the ground untied (See Figure 6). 6.1.2.9 Each clump weight is 25kgs; When loading the clump weight, it must follow up Table 2-1 and 2-2 for the two kinds of the suspended access equipment respectively. No modification is allowed to make freely. B. Installation location of rope clamp Figure 5 Quantity, distance and installation location of rope clamp 71. Front beam 2, Front base 3. Tommy bar (adjusting stand) 4, Middle beam 5. Rear beam 6. Coulpling sleeve 7. Rear base 8.Counter weight. Upper column 10. Reinforced wire rope 11. Tightening the spiral buckle (tumbuckle) Figure 6 Schematic diagram for counter weight of suspension mechanism The quantity of counter weight is subject to the table 2-1 and 2-2, After the quantity of the counter weight is defined, it can place the counter weight symmetrically on the 4 Installation posts at the rear base. Table 2-1 Weight reference table for loading the counter weight for ZLP630 suspended access equipmentExtension | Maximal Distance between the front and Loading counter length of the | working load rear bracket b (mm) | weight frontbeam | W2(kg) | Length of wire | Length of steel | Weight | Quantity a (mm) rope <100m | rope <200m | G (kg) | (pieces) 700 630 22000 22200 900 36 900 630 22600 2800 900 36 1100 630 23000 23200 900 36 1300 630 | 4000 4000 900 36 1500 500 | 23800 23800 1000 40 1700 400 >3600 | : 1200 | 48 Table 2-2 Weight reference table for loading the counter weight for ZLP800 suspended access equipment Extension | Maximal | Distance between the front and | Loading counter length of the | working load rear bracket b (mm) | weight frontbeam | wetkg) | Length of wre | Length of size! | Weight | Quantity a (mm) | rope <100m | rope <200m | @ (kg) | (pieces) 700 soo | >2000 >2200 i000 | 40 900 800 22600 22800 | 1000 | 40 | 1100 800 3000 3200 to00 | 40 1300 goo | 4000 4000 i000 | 40 1500 600 >3800 23800 1100 44 | 1700 500 23600 = 1200 48 196.2 Installation of the suspension platform The suspension platiorm must be installed at the wall approaching to the ground of the suspension mechanism on the top. 6.2.1 Installation sequence (See Figure 7 and 8). Low Balustrade | Low Balustrade Erection frame pl |_,| Erection frame of hoists Floor panel Floor panel of hoists ¥ f High Balustradd | High Balustrade Figure 7 Installation sequence of suspension platform 6.2.1 Installation 6.2.1.1 Put the bottom plate flat on the ground, mount the balustrade and place the bolts and nuts in position without tightening them for the time being. 6.2.1.2 Install 4 caster wheels on the hoist-mounting frame of at the ends of suspended platform, place the bolts and nuts in position without tightening them for the time being. 6.2.1.3 Check each part to make sure everything is correct. 6.2.1.4 Tighten the bolis connecting the balustrades and floor panel, as well as the bolts connecting the balustrades together. Tighten the bolts connecting the balustrades and the hoist-mounting frame. 206.2.2 adjustment and precautions 6.2.2.1 It must select the flat ground as the installation surface. 6.2.2.2 The joint of the basic segment must be flush, the whole platform's frame must be straight after being pre-tightened, no obvious distortion is allowed 6.2.2.3 When installing the hoists at both ends, it must keep the bracket of the safety lock toward the outside of the platform. 6.2.2.4 Atter installing, it should tighten all connecting bolts well. 62.2.5 The specitication of bolts must meet the standardized dimension specified by Figure 8 for the bolt, with the flat cushion is added. 3 4. Bracket 2. Erection frame of hoists 3. Caster whee! 4, Floor panel 5. Bolt M10X70 6. High Balustrade 7. Bolt M12X120 8, LowBalustrade 9, Bolt M12X120 10. Bolt M12X140 Figure 8 Schematic diagram for installation of suspension platform 6.3 Installation of safety lock and hoists ‘The safety lock and the hoists should be installed respectively at the safety lock’s bracket and hoists’s support of the erection frame of the hoists at both ends of the 24suspension platform (See Figure 9). When installing the safety lock, it must keep the scroll wheel of swing arm toward the inner side of the platform. —Electrical Control Box ge = Limiting Device Safety Lock 4 Figure 9 Schematic diagram for installation location of hoists and safety lock The hoists is installed inside the suspension platform. When making the installation, it must move the hoists into the suspension platform, keeping the dented rectangular frame at the back the hoists aiming to the support of the hoists, and then insert the pin roll, lock by the pin lock; afterwards, fix the hoists onto the horizontal pole of installation frame, Alternatively, it can also put the working wire rope into the hoists, and jog the ascending button to lift the hoists into the suspension platform for installation. If the latter method is used, it must level up the rope outlet of the hoists to empty, and then draw the wire rope off from the outlet carefully by hand so as to Prevent the rope head from impacting the ground. 226.4 Installation of electrical box ‘The electrical box is installed on the rear (high) balustrade in the middle of the suspension platform, with the door of electrical box towards its inner side. Two lifting pieces are used to fix the electrical box onto the handrail of the column plate. After the electrical box is installed and fixed well, it must place the plugrin unit of the power cable, motor cable and control switch cable into the corresponding socket beneath, When inserting the plug-in unit into the socket, it must aim to the location of base pin, and then push with average force. No sharp force or violent operation is allowed: otherwise it will damage the plug-in unit. All plug-in units said above are not allowed to operate when power supply is switched on. Descending bution Right Romote cable Figure 10 Diagram for plug-in unit’s position 6.5 Power up and inspection Betore and after switching on the power supply, it must make a careful inspection. Any unconformities must be corrected immediately. itis only allowed to start and adjust the suspended access equipment when each item meets the given requirement wall. 236.5.1. Inspection and requirement before switching on the power supply 6.5.1.1 The power supply must be of 380V, with 3-phase. The place where the power cable will be connected and come across must be fixed reliably; the socket of the power supply can not bear the weight of cable directly 6.5.1.2 The top suspension mechanism must be installed correctly, placed stably and fixed reliably; its connecting bolts must be tightened; the counter-balancing mass must be installed reliably, and the balance weight must meet the given requirement. 6.5.1.3 The rope buckle’s holder at the joint of wire rope must be installed correctly, with screws tightened reliably. 6.5.1.4 The vertical suspended wire rope must be separated, no tangle, twist and bend is allowed. 6.5.1.5 The hoists, safety lock and suspension platform must be installed correctly, connected reliably, and the connecting bolts must be tightened well, the structural members at the joint must be free of deformation or crack. 6.5.1.6 The plug-in unit of cable must be inserted well, no loosening is allowed; The buckle must be locked tightly, 6.5.1.7 The screws to connect the wirings inside the electrical box must be tightened completely. 6.5.1.8 The vertical construction surface of the suspended access equipment must be free of conspicuous protrusion or other barriers. 246.5.2 Inspection and requirement after switching on the power supply. 6.5.2.1 Closing the switch inside the electrical box, the indicator lamp for power will be on, the electric system will be powered up. 6.5.2.2 Placing the alteration switch to the left position, jogging the operation switches on the door of electrical box, i. the ascending and descending button respectively, the left hoists must run clockwisely and anticlockwisely. 6.5.2.3 Placing the alternation switch to the right position, jogging the operation switches on the door of electrical box, i.e. the ascending and descending button respectively, the right hoists must run clockwisely and anticlockwisely. 6.5.2.4 Placing the alternation switch to the middle position, jogging the operation switches on the door of electrical box, i.e.: the ascending and descending button respectively, the left and right hoists shall run clockwisely and anticlockwisely simultaneously. 65.2.8 Placing the alternation switch to the middle position, start the left and right hoists, and then press the emergency button at the door of electrical box (red), the motor shall stop running. Turn the emergency button to reset, and then keep on going to start. 6.5.2.6 Placing the alternation switch to the middle position, start the left and right hoists, and then press the contact head of the upper limit's switch of each travel, the alarm ring shall send alarm, meanwhile the motor shall stop running. Release the contact head, it can keep on going to start. 256.6 Installation of heavy punch The heavy hammer is fixed beneath the wire rope, used to strain and keep wire rope stable, prevent the suspension platform from producing impact on its normal operation causing by pulling up the wire rope whilst lifting. Under the special condition, it plays the role to make it stop. When installing the heavy hammer, it should clamp the bottom end of the wire rope by iwo semi-collet, and keep it away 5~Gem from the ground, and then tighten it onto the wire rope by bolts. 6.7 Official. inspection and adjustment of the suspended access equipment before use After the suspended access equipment is installed, it must check if each component meets the given installation requirement or not carefully before putting it into use officially; if necessary, it can make the adjustment accordingly. As per the steps for Inspection and adjustment, please see as follows: 6.7.1 Placing the altemation switch of the electrical box to the middle position, pressing the ascending button to lift the suspension platform to a place away 0.5m approximately from the ground, and then check if the suspension platform keeps horizontal. If it tts obviously, it should turn the alternation switch to the high (or low) end, and then press down the descending (or ascending) button to make the high end of the suspension platform descend or the low end to ascend, till the suspension platform becomes level. Afterwards, place the altemation switch to the middle position. 6.7.2 Keeping pressing down the ascending button, the suspension platform shall be lifted to a place away 6~8m from the ground. After a while, pressing down the descending button, it will then descend the suspension platform to a place away 0.5m 26approximately from the ground; keeping it at the place for a while, and then making it down to the ground. Perform a careful inspection during this process 6.7.2.1 If the hoists has abnormal sound; 6.7.2.2 If the both ends of the suspension platform keep horizontal or become sloped; 6.7.2.3 If it can stop immediately when the ascending or descending stops, if it skids during the period. 6.7.3 By using the method said above, it can lift the suspension platform to a place away 3m from the ground, and then stop it at this place; at this time, lift the manual ball-ike handle for descending into the rectangular hole of the cover of the motor of the hoists at both ends simultaneously, switch on the electromagnetic brake by hand, and then make the suspension platform free fall under the force of its self-gravity, release the handle when it is 0.6m approximately away from the ground; keep the suspension platform stay for a while, lift the handle to descend the suspension platform to the ground. The check that is made in the process of descending, i.e. 6.7.3.1 if the manual descending process goes on stably and smoothly; 6.7.3.2 if it keeps descending when the manual fall stops; 6.7.3.3 If the manual falling handle occurs stall speed (the normal falling speed is less than or equal to 13.5m/min). The inspection described by 2# and 3$ above can be repeated when necessary. If the hoists sends abnormal sound, or produces large noise, or the motor becomes too hot, produces smoke or burnt flavor, or the suspension platform becomes tilted obviously, or the suspension platform keeps on falling even it is stopped or the manual fall handle is blocked, normally it is the reason caused by the large or small gap of electromagnetic brake or the unequal distance between the electromagnetic brake of the hoists at both ends. Under such condition, it must stop the machine immediately. Down the suspension platform to the ground manually, check and adjust the gap 27between the electromagnetic brakes. Under the normal condition, the gap between the bottom of the brake and the armature iron, i.e. the release gap between the armature iron and the friction plate, 5=0.5~0.6 mm (See Figure 11); and the distance around must be even, the gap between the electromagnetic brakes of the hoists at both ends must be same. When making adjustment, it should Fastening screws unfasten the 3 fastening screws Friction platé. anticlockwisely, and then twist the Armat \ supporting screws to adjust the gap; iron 0.5~0.6mm, when the supporting screw tums anticlockwisely, the gap will become Supporting screw —~4 less; otherwise it will become large. Adjust it to the required gap, and then tighten the screws solidly. Figure 11 Schematic diameter for gap adjustment of brake After the gap Is adjusted, it must perform the inspection said above again. When all meet the given requirement, cover the motor well. If the gap is adjusted to the one meeting the given requirement, but the hoists produces still the abnormal noise, it must stop and open the hoists to check the assembly condition of components and if any components are damaged. If yes, the damaged components must be repaired, and then it will be allowed for further use. If it is found that the manual falling handle occurring stall speed, it means that the centrifugal speed reducer at the input end of the hoists's motor is broken; if so, it should stop the manual falling immediately. Start the motor to down it to the ground and then repair or replace the centrifugal speed reducer; afterwards, inspect if it meets the given requirement. 286.7.4 Placing the alternation switch of the electrical box in the middle, and then pressing the ascending button to lift the suspension platform to a place away 2.6m approximately from the ground. Under such condition, placing the alternation switch to the left, then pressing the descending button to check if the safety locks at the left and right side of the suspension platform locks the safety wire rope well within an angle of 8 when the platform tilts; and then pressing the ascending button to reset the platform to a horizontal position; placing the alternation switch of electrical box to the right, then pressing the ascending button to check if the safety lock at the right side of the suspension platiorm locks the safety wire rope well within an angle of 8° when the platform tits. 6.7.5 Lifting the suspension platform to a maximal construction position, and then perform the inspection to see if the wire ropes at both ends unfasten, bend, tangle or break; if it meets the scrap standard, the new wire rope must be replaced correspondingly. 6.8 Installation of limit stop Lift and stop the suspension platform at the desired construction site, the contact head of the upper travel switch of the safety lock shall have a distance more than 1.5m from the end point of the front beam at the suspension mechanism; at this moment, clamp and fix the limit stop onto the safety wire rope, and keep the limit stop pressing down the contact head of the travel switch; under such condition, the alarm ring shall send alarm, the ascending circuit shall shut off the power supply. Pressing down the descending button, the suspension platform shall down to the ground. 6.9 After the installation, adjustment and inspection for acceptance completes, it can only allow to put into use officially. When the suspended access equipment is used, it must abide by the safety rule strictly, and no frequent jogging is allowed; when it is necessary to jog the equipment, 29the time interval must be over 1 second. Under a normal condition, it is prohibited to use the suspended access equipment as @ crane or transport tool for delivering the construction materials and litters. It is prohibited to use the equipment frequently for lifting and keep it under the continuous operation condition for a long time. 307. Common troubles and troubleshooting Table 3 No. | Feature of troubles | ‘Main reason | Troubleshooting method | | |The connecting line of the travel| Connect the connecting | switch is loosened. . | tine of the travet switch, | | | | The operation button is damaged. Repair or replace the operation button (or operation switch) ne ee Te at aa becomes unfastened cand or replace the 4 | platform can not be started ‘The time interval for jogging is too |The time interval for short. jogging must be more than 1 second. ‘The emergency switch is not reset. | Turn and tighten the switch to make it reset. ‘The fuse inside the electrical box Is | Replace the fuse. | broken. ’ Heres venti | The gap between the electromagnetic | Adust the gap or replace ae brake of motor is too large. the friction plate. | | The gap between the electromagnetic | Adjust and make the gap | | | brakes of motor at both ends is not| at both ends become | | |The suspension | equal. | equal. | platform becomes | | | 3 | tited obviously at a | One end of stee! sire rope skids. | Solve the troubles | short travel. | according to oF. | | The rotation difference between two | Inspect and replace the | motors is too large. | motor. | The manual falling | 4 [Randle of the | The centifugal speed reducer at the | Replace the centrifugal suspension platform | motor end is failed to work. | speed limiter has stall speed. | “The contactor inside the electrical box | Clean the oll from the The suspension | can not come of. surface of the contactor or 5 | Platform keeps going replace the contactor. ‘whilst the control | The operation button is damaged or | Repair or replace the button is released. _| falled to reset. operation button (or operation switch) The suspension Clean the oll from the 6 | platiorm can not fall oe the electrical bOX a. tace of the contactor or down after being lifted; replace the contactor. 34or can not lift after being descended. The hoists sends abnormal noise, the motor becomes over hot, or the motor products smoke and burnt flavor. The gap between the motor and electromagnetic brake is too less. ‘The friction plates of the motor’s brake are worn unevenly. The semiconductor's rectifier inside the electrical box is damaged. The mechanical members inside the hoists is worn. ‘Adjust the gap. Replace the friction plate. Replace the rectifier. Inspect and replace the wearing components. The suspension platform can not be lifted even the motor is The transmission components inside the hoists are damaged. The semiconductor's rectifier inside Inspect and replace the damaged component. Replace the rectifier. switched on; | : damaged. Ba eetmnes the hole | th eet box is damags nds the abnormal fi ‘The rope's trolley or wire rope inside | Replace or replace the noise and the motor ; : ci the hoists is worn. tope's trolley and wire becomes overheat. | rope. The surface of the wire rope is| Clean the wire rope. The suspension | contaminated by cil. | platform falls down | whilst keeping stil; or | The gap between the motor and the | Adjust the gap or replace 2 | becomes unstable | electromagnetic brake is too large. _| the friction plate. whilst fiting, or the | wire rope skids | The bottom end of the working wire | Add the heavy hammer at sometimes. rope is not loaded the belance weight. | the bottom end of the | working wire rope. fy The rope collets are worn. Check and replace the | | The wire rope sts ae | 10 |when safety lock) the gurface of the wire rope is clamps the ope. | contaninated by ol. Clean he wie rope, The wire rope| The wire rope produces different | Replace the wire rope. 41 | unfastens wrinkles or| stress after becoming worn and torn. deforms | Tne suspension wie | T2, Teliy oF The wire ropes | Replace the wire rope ineufcient ga. |f0P8 is tom and worn | oui d | sucky 274 | the wire rope skids. Inspect and solve the | abnormally. problems according to 94. | 328. Emergency treatment of construction During the construction, if some special conditions happen, it must keep calm, and take corresponding measures accordingly, for instance: 8.1 Power failure During the construction, if the power supply is shut down suddenly, it should shut off the power switch of the electrical box to prevent accident when power is on; this power switch can be only closed when power transmission notice is received, and put into use for continuous work after making inspection. If it needs to make It return to the ground when power supply is shut off, It should lift the manual fall handles of the hoists’s motor at both ends simultaneously, it will make the suspension platform free fall to the ground. 8.2 The suspension platform keeps moving after releasing the buttons during the ascending or ascending process. During the ascending or descending, if the suspension platform keeps moving after releasing the button, it should press down the red emergency switch on the door of the electrical box immediately to stop the suspension platform; afterwards, it must shut off the power switch of the electrical box. Under such condition, it can then check the contactor’s condition, clean the surface of contactor; If it can work normally after the contactor is pressed down manually, it can close the power supply and turn the emergency switch to reset, If the troubles can not be solved timely, it must shut off the power supply, and descend the suspension platform to the ground for repair by manual method. 8.3 The suspension platform locks the rope automatically since it becomes tilted. During the ascending or descending, or one end of the manual fall handle becomes 33tilted, the safety lock will jock the rope automatically; at this moment, it must stop the equipment immediately, and then turn the alternation switch on the electrical box to the low end of the platform; afterwards, press down the ascending button to lift the low end of the suspension platform to the horizontal position, at this moment, the safety lock shall resume to its unlocking condition automatically, Down the suspension platform to the ground, check and adjust the gap between the electromagnetic brakes Inside the hoists at both ends to meet the given requirement; or check the rotation difference of the motors at both ends, if the difference is obvious, it should replace the motor immediately. 8.4 The working wire rope is blocked inside the hoists since the unfastened and tangled rope or damaged components of the hoists. If the working wire rope is blocked inside the hoists, it must stop the machine immediately; it is prohibited to solve the trouble by lifting frequently. Under the condition to keep an absolute safety, it should evacuate all operating staff within the working range of the suspension platform, and send the qualified maintenance personnel for repair. If so, it should firstly encircle the safety wire rope onto the installation frame of the hoists at both ends, and fasten the two ends of the rope tightly by rope buckles; and then loosen the 2 protection rings of the scroll wheel of the swing arm of the safety lock (See Figure 3), keep the working wire rope separating from the scroll wheel, which will make the safety locks at both ends under the rope-locking condition. After the measures said above are taken, it can then remove the hoists for inspection, and get back the wire rope that is blocked. When necessary, it can cut the wire rope under trouble and open the cover of the hoists for inspection, and then take the wire rope inside carefully. Simultaneously, the new wire rope can be replaced at the corresponding position of the suspension mechanism, and then make it strained after going into the hoists, with the working wire rope in the wheel's groove of the safety lock’s swing arm; put the protection ring, and then open the safety lock, lift the suspension platform by 0.5m roughly, take away the rope buckle at the safety wire rope, and finally place the safety wire rope at the vertical position, down the 34suspension platform to the ground, After making strict inspection on the hoists, it can be then allowed for further use. 8.5 When the working wire rope breaks. If the working steel wire at one end of the suspension platform is broken, the suspension platform shall become tilted; at a certain angle, the safety lock shall close up automatically, which will then lock the suspension platform onto the safety wire rope. At this moment, the operating staff inside the suspension platform must keep calm. It is prohibited to run fast or jump within the range of suspension platform, meanwhile, it must be treated by following up the emergency measures for solving the problems when the working wire rope is blocked inside the hoists. 359. Regular inspection, maintenance and repair of suspended access equipment In order to guarantee the construction of the suspended access equipment in safe, it must establish the regular inspection, maintenance and repair system incorporated by the operating staff and the related professional personnel, and then keep the equipment in a good condition. 9.1 Safety inspection ‘The suspended access equipment that is installed newly, repaired completely, unused for one year or ceased in suspension for more than 2 months must be inspected for acceptance by the trained professional personnel before use. The inspection for acceptance mainly involves in the following contents, i.e. 9.1.1 If the main bearing members (suspension platform, suspension mechanism) deforms permanently or the welding line has crack; 9.1.2 If the fasteners at the joint the structural members unfasten or loosen; 9.1.3 If the suspension mechanism is installed reliably and stably, balance weight meets the given requirement or not; 9.1.4 If the wire rope rusts seriously, rope strand becomes unfastened, tangled or broken; if the wire rope clamps correctly and reliably; 9.1.5 If the electric control system acts normally, safety device has crack or not; 6.1.6 If the safety lock actions flexibly, the function of locking and unlocking normal or not; 9.1.7 If the movement for ascending or descending (including the manual fall handle) is normal or not, the gap between the electromagnetic brake meets the given requirement or not; 2.1.8 If the moving paris action normally or if it is blocked, sends abnormal sound, the motor becomes overheat, produces smoke or burnt flavor; 9.1.9 If the reduction gearbox and transmission device is injected or replaced the lubrication oil as per the given requirement; 369.1.10 If the limit stopper and heavy hammer for the wire rope is added according to the given requirement. 9.2 Daily inspection Each day when starting the construction, the suspended access equipment must be inspected by the operating staff, the related record must be kept well; additionally, it must make the evaluation on equipment's condition and furnish the handling solutions. The daily inspection shall be performed in accordance with the specification of Table 4 (user can refer to the copy of this table). 9.3 Periodic inspection When the suspended access equipment is used for a while, it must make a periodic inspection, and keep the corresponding record well. Daily checklist of the suspended access equipment Table 4 Equipment No. Inspector: Date: Year Month Date tems | Mark Description Inspection sequence record 1fets[4[slel7 Damage or not (floss, burr, break, | press, loosen) | Wire rope Having mortar or other foreign | | matters | | = _| Rust or not %&__| Damage or not (break or corrosion) Life rope if the self-buckle of the safety rope * works flexibly ye [if the clump weight Is lost or | damaged. | i If the swing arm's beam frame is eas | | jon ibe ioe 7 connected reliably. mechanism | If the orientation of the suspension mechanism is reliably. > _| Ifthe handrail is loosened or not. 37Suspension] , | If the bottom plate is damaged or platform skidproot _| Ife suspension platform is tted or not. | Satety ook | % |" te action Keeps telibie and | sensitive or not. | ge_| Ifthe action of switch keeps normal i} or not. _| ifthe plus, socket and incieator lamp Electric works normally; system | | ifthe cable is damaged or not. l T | ifthe nameplate ofthe electric device | is In good condition or not. | Limit % if the action keeps reliably and } stopper sensitive. | if the connection between the hoists | i land the suspension platform is fixed; Hoist | * Tit there Is crack, deformation, abnormal sound and vibration. Lift the suspension platform to a Operation |, | place away 2-sm from the ground test for 2-3 times, and then check if it | runs normally | Note | Evaluation and solution Note: in the column “Record”, “O” represents the perfect; "X" represents troubles or errors. ‘The inspection on the holsts and operation test must be performed after the previous items are inspected and the Rectification and Reform measures are taken. if there are troubles for the items under inspection, it must perform as per the following methods and give the comments for solution, ie.: With “e* signal, it means rectification that will be made Immediately; With *a" signal, it means the rectification that will be made within a given limit; With “w® signal, it means it will scrap as per the given standard. 9.3.1 Each two weeks for use or reuse after it ceases for use for one month must give a full inspection on the wire rope to see if it is corroded, worn and ton, broken, unfastened or bent; if it meets the scrap standard, it must be scraped for replacement. 9.3.2 Each two months for work, it must give a full inspection as per the related safety 38inspection requirement, including the inspection on the friction plates of the electromagnetic brake and cable. 9.8.8 Each six months for work, it must give a test on the safety lock; if user has no the corresponding capability, it can be tested by the manufacturer, 9.3.4 Each six months for work, the hoists must be disassembled for inspection by the professional personnel; any wom and torn parts are found must be replaced immediately. 9.3.5 Each six months for work, it must check and inspect the reliability of the electric component and connecting line of each electric system. 9.4 Maintenance and repair When the suspended access equipment is used, it must be offered the daily maintenance and repair specially. Any failures or abnormal conditions are found must be repaired immediately. The repair work shall be only done by the qualified person. The daily maintenance and repair work includes: 9.4.1 When each day's work finishes, clean the suspension platform, wire rope and suspension mechanism; clear all litters, coating, mortar and other foreign matters at the outside. 9.4.2 The suspended access equipment (especially the electric system) must be given the waterproof and damp-proof measures so as to prevent short circuit. 9.4.3 The excessive wire rope on the ground must be coiled and tied well, After the suspended access equipment is ceased for use or disassembled, it must coil all cables and ropes, disassemble and place the structural members and connecting parts in order. All of which must be kept well so as to prevent mould ness, corrosion, deformation and lose. 9.4.4 After each use, the self-locking hook of the safety rope must be injected the 39rust-proof oil at the spring, which can keep it move flexible. 9.4.5 After the reduction gearbox and transmission device Is used for the first 3 months, the lubrication oil for both of them must be replaced completely; in the future, all of them must be added the lubrication oll each month; and each 6 months, it must replace the lubrication oil completely. 9.4.6 The moving sections of the safety lock must add the lubrication oil each month. 9.4.7 The electric circuit, component and the joint of the cables must keep dry, clean and free of oil contamination. 9.4.8 During the safety, daily and periodic inspection and operation, any failures, errors, wearing or abnormal condition is found, it must stop the equipment immediately, and then repaired by the professional staff. It is prohibited to use the suspended access equipment with defectives or troubles. 9.4.9 If the bearing structural members and wearing parts meet the scrap standard, all of them can be scraped for replacement. 9.4.10 It should establish a file for the equipment and keep all records well. 4010. Standard for scrap of main structural members and wearing parts 10.1 The main bearing members of the suspended access equipment, i.e.: the suspension mechanism and suspension platform must be scraped immediately under the following conditions, i. 10.1.1 The whole piece can not keep stable, have no way to repair, and must be scraped. 10.1.2 The one deformed permanently could not be repaired, and must be scraped. 10.1.3 Some structural members deformed permanently could not be repaired, and the surface corrosion or wearing depth exceeds 10% of the original member, the corresponding structural members must be scraped. 10.1.4 When the structural member and its welding line cracks, in view of the bearing condition and situation of crake, if it can meet the original design requirement after being repaired or taken reinforcement measures, it can be only allowed for further use after the repair or the reinforcement measure is taken, otherwise it must be scraped. 10.2 The scrap of wire rope must follow up GB5972-86 “Wire rope for lifting appliances-Code of practice for examination and discard’; under the following conditions, it must be scraped, i.e.: 10.2.1 The zinc-plated©8.3-4%31Fi+PP wire rope for the suspended powered rope must be scraped if there are 3 places where the wire breaks within a length of Sem or 6 places where the wire breaks within a length of 25cm; if the wire rope is long atsufficient, it must cut the broken section, the rest can be installed for further use. 10.2.2 If the wearing capacity of the diameter of wire rope reaches 7%, it must be soraped. 10.2.3 The wire rope must be scraped immediately if wire strand unfastens, tangles, or wire bends or deforms partially. 10.2.4 The wire rope must be scraped immediately if it is under the force of the electric arc and the surface occurs the color that can be distinguished. 10.3 The cable must be scraped immediately if its rubber sheath is damaged seriously, and which impacts its strength ad insulation security. 10.4 The friction plates of the electromagnetic clutch within the hoists must be scraped if its wearing capacity reaches 2.5mm or the uneven abrasion can not be repaired. 10.5 The groupware for the braking block of centrifugal speed limiter at the motor of the hoists must be scraped immediately if the manual falling handle of the suspension platform stalls speed. 42