ZUNGERU Hydropower Plant

Spillway service gate and hydraulic hoist

System description
System description

H, 0+066.738
System description
System description
 System description
General

In ZUNGERU Hydro Power Station, the discharge system which is designed on the right bank of the
dam consists of the spillway and the bottom outlet. The spillway is equipped with 4 four-hole
operating arc gates and 1 four-hole bulkhead arc gate.
The bulkhead gate of spillway (stoplogs) is mainly used to stop water for overhauling gates. The
bulkhead gate is composed with sliding stoplogs which are placed inside the gate groove and
operated by 160kN two-way gantry crane. The stoplog gate shall be operated under the condition of
static water. Before opening the gate, the top section of stoplogs shall be lifted at 10cm for water
filling and pressure balance.
The spillway service gate employs radial gate to control the flood discharge through the spillway. The
elevation of the bottom sill of the radial gate is EL.209.722m.
The operating gate shall be operated under the condition of moving water and can be partially
opened to control water flow. Each gate is equipped with a set of overhead double-cylinder hydraulic
hoist (QHLY-2x3600kN-9.2m).
 System description
System description

General

Each set of hydraulic hoist includes one hydraulic pump unit, two servomotors (cylinders) and oil
pipelines, one set of control cabinets. The hydraulic pump units and control cabinets are arranged in
the pump house [EL.233.00m].
The servomotor of the hydraulic hoist adopts layout of tail suspension and pull back the gate. The
rotation center of the servomotor upper hinge is located at EL.230.217 m. The servomotor lifting ring
1.Stoplogs 2.Groove 3.Arc gate
is directly connected to the lower part of the gate. The center of the rotation axis of the gate arm is
located at EL.221.222m. 4.Side rail 5.Gantry crane 6.Servomotor

Spillway maintenance gate and radial

gate
 System description
General
 System description

Radial gate
Technology data of radial gate

Clear width of gate opening 15 m

Height of gate, vertical 20 m
Design pressure at sill 19.5 mWc
Design water level El. 230 m
Trunnion level El. 221.222 m
Gate sill level El. 209.722 m
Water pressure, full lowered 31008.4 kN
Radial gate raising force 2x3600 kN
 System description

Structure description of radial gate

The radial gate adopts the inclined arm main beam structure, trunnion support. It is mainly
composed of radial gate leaf, side wheel device, water seal device, radial gate arm, trunnion
assembly, side wheel device and bottom sill. In addition, the locking support device is used as the
auxiliary device of the radial gate.
The radial gate adopts double lifting points. The left and right lifting lugs are respectively set at the
lower part of the left and right beams on the downstream side of the gate leaf.
9 sets of side wheel devices are symmetrically arranged outside of left and right beams, The upper
arm of the triangular support of the radial gate is fixed on the upper beam and the lower arm is
fixed on the lower beam.
A maintenance ladder is arranged on the right side of the downstream side of the gate leaf,
extended from the bottom to the upper arm.
The water seals are set at both sides and bottom of the upstream surface of the gate leaf.
 System description
Structure
description of radial gate
 System description
Radial gate leaf The radial gate leaf is a beam lattice structure composed of
radial front panel, cross beam and longitudinal beam, made
by Q345 into sections, assembled and welded at site.
The gate leaf is 14.97m wide, arc length 22.859m, 21.88m
high. The radius of the radial panel is 22m and the thickness
of the panel is 14mm.

Two locking hooks are welded on the upstream surface of the

gate leaf, about 4m from the bottom.
 System description
Structure description of radial gate

Two locking hooks are welded on the upstream surface of the gate leaf, about 4m from the bottom.
 System description
Side wheel device
18 side wheel devices are symmetrically arranged outside the side beams on both sides of the
downstream surface of the gate leaf.

The side wheel device is composed of wheel, wheel axis, selflubricating

bearing, wheel frame, rubber plate and mounting seat. The Wheel
device is made by cast-steel, 300 mm diameter, 55mm wide. The self-
lubricating bearing is installed in the inner hole of the wheel. The wheel
axis passes through the bearing and is fixed on the wheel frame. A
rubber plate is arranged between the wheel frame and the mounting
seat.
The side wheel device is fixed on the gate leaf with bolts. When the
gate moves, the guide rollers can roll on the side guide track so as to
reduce the resistance when the gate is deflected and stuck.
 System description
Radial gate water-seal
The radial gate adopts three side water seals, composed of bottom seal and side seal.
Side seal adopts “L" type water-seal and the sealing is
realized by the precompression of the seal. The
bottom water-seal adopts stripe waterseal and the
sealing is realized by the compression deformation
due to the self weight of the gate. At the corner where
the water seals on both sides are connected with the
bottom water seal, the seals are bonded as a whole
by rubber hot pressing. The water-seal is fixed by
press plate and bolt on the gate leaf.
When the gate moves, the side water-seal moves
along the water-seal track on both sides of the
channel. The tracks are made of welded carbon steel
and embedded in the channel. The track surface is
made of stainless steel, in case the water seal is
damaged by the the rusty track.

Side water-seal and bottom water-seal

 System description
Radial gate arm and trunnion
Radial gate arms are installed on both sides. The pressure on the radial gate is passed by the arm to the
trunnion assembly.
The support arm adopts triangular frame straight arm structure and is divided into three parts: arm fork,
lower arm, connecting beam and upper arm, which are assembled on site.

The support arm section is 1240 mm x 1040mm box

beam structure, made by the steel plate welded. The
support arm fork, lower support arm and upper support
arm are connected by bolts. The upper arm and the
lower arm are welded and reinforced with a connecting
beam. The assembled support arm is connected with
the radial gate leaf and trunnion seat by bolts, The
handrail welded on the upper part of the right upper
support arm and the upper support arm form the
maintenance channel together. The maintenance
walkway on the support arm and the ladder on the
radial gate leaf are used for inspection and
maintenance on the radial gate.

Support arm, support arm fork and trunnion

 System description
Radial gate arm and trunnion

The trunnion is composed of shaft,

bearing, trunnion seat. The trunnion seat is
installed on the embedded part on the gate
piers, one on each side. The support arm
and trunnion seat are connected by the
trunnion shaft.

The spherical bearings are installed in the

trunnion seat. The seals are installed inside Trunnion
the bearing gland to prevent the sand enter into the bearing and damage the bearing.
The trunnion is the rotating center of the radial gate. When the gate moves, the gate rotates around the trunnion
shaft. The trunnion also withstands complete water pressure on the radial gate, and the raisning / lowering force
and the gate self weight, and then the load is passed to the gate piers.
 System description
Side track device and bottom sill

The radial gate side tracks are installed symmetrically on both sides of the
channel. The radial tracks are made by profile steel and steel plate welded
so that the side seal device and side wheel device can roll on them. After
field installation and adjustment, the radial tracks are fixed directly on the
embedded parts and buried on both sides of the channel in secondary
concrete casting.

The side seal device of the radial gate is close fitting on the side track to
form the side seal of the radial gate. When the radial gate is raised / lowered, Side track device and bottom sill
the side seal device of the radial gate slides on the side track device. The
track surface is made of stainless steel, in case the side seal device is damaged by the the rusty track surface.
The bottom sill is made of carbon steel welded. After field installation and adjustment, the bottom sill is fixed directly
on the embedded parts and buried on bottom of the channel in secondary concrete casting then. When the radial
gate is lowered, the bottom seal device falls on the bottom sill to form a bottom seal. The surface of the bottom sill in
contact with the bottom water seal is made of stainless steel.
 System description
Radial service gate lock device
Locking device

The radial service gate locking device are installed on the left and right
channels. They are semi-automatic hooks that can swing around the
spindle, and composed of locking seats and hooks. The spindle is fixed in
the locking seat and the locking seat is embedded in the channel. The
center elevation of the spindle is EL.232.03m.

When the gate need maintenance or raised for a long time, raise the gate
slightly above the locking pin. The locking pin of the locking device slides
into the locking hook along the outer contour line of the locking hook on the gate leaf, then lower the radial gate
slightly to make the gate completely rest on the hook to complete the automatic apply process of locking.
When release the lock device is required, raise the gate leaf slightly first, then turn the handle on the upper part of
the hook to pull the locking pin out of the locking hook on the gate leaf, then lower the gate leaf.
 System description

There are 4 spillways and 4 radial service gates in the project. Each radial service gate is
equipped with a set of QHLY-2x3600kN-9.2m hydraulic hoist, so there are 4 sets of
hydraulic hoists in total.
Each set of hydraulic hoist system consists of two (2) servomotor assembly, one hydraulic
pump unit, one set of local control cabinets and supporting hydraulic pipelines.
Each hydraulic pump unit is provided with two hydraulic pump-motor units. Two oil pump
motors, one for use and one for standby. The hydraulic pump unit and local control cabinet
are installed in the hoist room [EL.233.00m].
 Hydraulic hoist

Technical data of hydraulic hoist

Model QHLY-2x3600 kN-9.0m
Number of servomotors 2
Rated raising force 2x3600kN
Maximum lowering force Dead weight of gate
Model of motor 1LE0001-3AB03-5JA4 1470 r.p.m
Power of motor 110kW,
Model of oil pump PV270R1K1T1NMMC 35 MPa
Displacement of oil pump 270 mL/r
Gate raising pressure 17 MPa
Power of solenoid valve DC24V
Gates raising speed ~0.6 m/min
Gates lowering speed ~0.4 m/min
Power supply AC415V/240V 50Hz
Recommended hydraulic oil #46 Anti-wear oil without dust
System cleanliness NAS1638-8 级
Normal working temperature 5 ºC～55 ºC
Volume of main oil tank 4700 L
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Hydraulic schematic diagram

of spillway radial gate

13-1

111
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Working principle of the hydraulic hoist

(1) Raising the gate
Start the motor - hydraulic pump set. The pressure oil returns to the oil tank from the oil pump outlet
through cartridge valve [3.1] and return oil filter. After pressure building of the system, the
electromagnet [YV1] of solenoid valve [3.4] is powered on to make the overflow valve in the loading
state.

When the gate is raised, electromagnet [YV2] of solenoid valve [4.7] and electromagnet [YV4] of
solenoid valve [4.25.2] are not energized, the electromagnet [YV1] of solenoid valve [25.1] is
powered on. Electromagnet [YV5] of solenoid valve [4.4] and the electromagnet [BT] of the
proportional speed regulating valve are powered on.
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Working principle of the hydraulic hoist

(2) Raising gate
After the pressure oil passes through high-pressure ball valve [3.9], high-pressure oil filter [3.11] and
cartridge valve [4.22.1], it is divided into two ways: The left way oil enters the rod end chamber of the
left servomotor through speed regulating valve [4.9], high-pressure ball valve [4.18.1], hydraulic
control check valve [5.8.1] and high-pressure ball valve [5.4.1]. The right way oil enters the rod end
chamber of the right servomotor through speed regulating valves [4.10.1 and 4.10.2], high-pressure
ball valve [4.18.3], hydraulic control check valve [5.8.2] and high- pressure ball valve [5.4.3]. At the
same time, the oil in the rodless end chamber of the left servomotor is discharged through the high-
pressure ball valve [5.5.1]. Together with the oil in the rodless end chamber of the right servomotor
discharged through the high-pressure ball valve [5.5.2], all oil flows back to the oil tank through the
high-pressure ball valve [4.19], cartridge valve [4.1], cooler [1.14] and oil return filter [1.7].
Under the action of pressure oil, the servomotor piston rod retracts drive the gate to raise.
 Hydraulic hoist

Working principle of the hydraulic hoist

(3) Lowering gate
• Start the motor - hydraulic pump set, the pressure oil returns to the oil tank from the oil pump
outlet through cartridge valve [3.1] and return oil filter. After pressure building, the electromagnet
[YV1] of solenoid valve [3.4] is powered on to make the overflow valve in the loading state.
• When lowering the gate, electromagnet [YV5] of solenoid valve [4.4] and electromagnet [YV3] of
solenoid valve [4.25.1] are not energized; The electromagnet [YV4] of solenoid valve [4.25.2] is
energized, the electromagnet [YV2] of solenoid valve [4.7] is energized, the electromagnet [BT] of
the proportional speed regulating valve is powered on.
Working principle of the hydraulic hoist
(2) Lowering gate
• The pressure oil passes through high-pressure ball valve [3.9], high-pressure oil filter [3.11] and
cartridge valve [4.22.2] and is divided into two routes: one route oil passes through one-way
throttle valve [4.17] to open hydraulic control one-way valves [5.8.1 and 5.8.2]. The other route oil
 Hydraulic hoist

passes through overflow valve [4.21] and high-pressure ball valve [4.19] to enter the rodless end
chamber of the left and right servomotors respectively. Under the self weight of the gate, the oil in
the rod end chamber of the left servomotor, together with the oil in the rod end chamber of the
right servomotor through the high-pressure ball valve [5.4.3], the hydraulic control check valve
[5.8.2], the speed regulating valve [4.10.1 and 4.10.2], as well as the oil from the cartridge valve
[4.5] and the overflow valve [4.21], flow together into the rodless end chamber of the left and right
servomotors through the high-pressure ball valve [5.4.1], the hydraulic control check valve [5.8.1],
the proportional valve [4.9].
• Under the weight of the gate, the gate is lowered.
Working principle of the hydraulic hoist
(2) Lowering gate
• When the above two oil supply circuits do not meet the oil filling capacity of the
servomotor rodless end chamber when the gate is lowered, check valve [1.10] is
opened, the oil in the oil tank is sucked into the rodless end chamber of the servomotor.
 Hydraulic hoist

• Adjust the opening of speed regulating valves [4.10.1 and 4.10.2] to change the radial
gate raising / lowering speed.
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Protecting function of hydraulic system

(1) Pressure protection
• Overflow valve [3.3] is the safety valve of the whole hydraulic system to limit the maximum pressure at
the oil pump outlet.
• Overflow valves [5.7.1 and 5.7.2] limit the maximum lifting force of the left and right rod end chambers
of the servomotor respectively.
• SP1 pressure relay is the pressure protection element (mechanical) of the whole system. When the oil
outlet pressure of the system pump unit exceeds the set pressure of SP1 by 19.9 MPa, electrical control
system issues alarm signal to stop maintenance.
• SP2 pressure relay is the pressure protection element (mechanical) of the whole system. When the oil
outlet pressure of the system pump unit is under the set pressure of SP2 by 2.0 MPa, electrical control
system issues alarm signal to stop maintenance.
Protecting function of hydraulic system
(1) Pressure protection
• SP3 and SP4 are protective elements for low pressure in the rod end chamber of the left and right
 Hydraulic hoist
servomotors. The set pressure is 2.0 MPa. When SP3 and SP4 send messages, it indicates that the
working pressure of hoist rod end chamber is too low, so maintenance shall stop.
• SP5 is rodless end chamber overpressure protection element. When the gate is lowered, if the working
pressure of rodless end chamber is 2.0 MPa higher than the set pressure, electrical control system
issues alarm signal to stop operation and inspection.
• The pressure gauge is a mechanical gauge for observing and adjusting.
Protecting function of hydraulic system
(2) Oil temperature protective
• The liquid temperature controller is used to monitor the change of liquid temperature in the oil tank.
When TS1 sends a message, it indicates that the oil temperature in the tank is too low. When TS2
sends a message, it indicates that the oil temperature in the tank is too high. Electrical control system
issues alarm signal to stop inspection.
• (3) Oil level protection
• The liquid level controller is used to monitor the change of liquid level in the oil tank. When LL1 sends a
message, it indicates that the tank level is too high. When LL2 sends a message, it indicates that the
tank level is too low. The electric control system will send out alarm signals and the hydraulic pump unit
 Hydraulic hoist
stops working.
Protecting function of hydraulic system
(4) Oil filter protection
• The oil filter is equipped with a pressure transmitter. When the filter element is blocked and the pressure
difference between the inlet and outlet of the oil filter increases to the setting of the transmitter, electrical
control system issues alarm signal for replacing the filter element in time. When replacing the filter
element, just loosen the top cover of the oil filter.
(5) Air dehumidifier
• The air dehumidifier is the breather of the oil tank and has the functions of moisture absorption and air
filtration, to keep the oil in the oil tank clean and ensure that there is no pressure in the oil tank. The
color of the drying agent in the air dehumidifier will change from blue to pink with the increase of water
content, at this time, the drying agent should be replaced in time.
Protecting function of hydraulic system
(6) Opening protection
• The opening of the gate is the stroke of the piston rod of the servomotor of the hydraulic hoist
measured by the external displacement sensor. When reaching the upper limit or the lower limit, the
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gate stops.
• SQ1 and SQ2 are protective contacts of servomotor travel limit switch. When reaching the upper
limit or the lower limit, the gate stops.
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Servomotor assembly
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Servomotor assembly

Technical data of servomotor

Bore diameter of cylinder 600mm
Diameter of piston rod 300mm
Working stroke of servomotor 9m
Max. stroke 9.2 m
Maximal pressure of rod end chamber 17 MPa
Maximum pressure of rodless end chamber 0.3 MPa
Piston speed when raising (opening) gate ~0.6 m/min
Piston speed when lowering (closing) gate ~0.4 m/min
Servomotor assembly
• The servomotor is the actuator of hydraulic hoist. The radial gate is lifted by the retraction of the piston
rod driven by the pressure oil when working. The gate self weight drives the piston rod to extend to lower
the radial gate.
 Hydraulic hoist
• The servomotor head adopts spherical plain bearing to connecte the gate and the tail adopts spherical
plain bearing to connect the trunning seat shaft. The spherical bearings in both lugs of the servomotor
can make the servomotor swing around the lug axial lines to eliminate the adverse effect of the hoist and
gate manufacture and installation error on the servomotor operation.
• The servomotor rod end chamber outlet is equipped with safety locking valve block (servomotor side
group valve). The servomotor side valve group is installed on the servomotor. One end is connected to
the servomotor by steel pipe and the other end is connected to the high pressure hose through the steel
pipe. The hose can swing with the servomotor.
Servomotor assembly
• Rod end chamber and rodless end chamber of the cylinder are both equipped with exhausting and
pressure measuring joints, for the servomotor air exhaust and pressure measurement.
• Rod end chamber and rodless end chamber both have extra strokes to adapt to civil engineering error
and gate lifting lug manufacturing and installation error, at the same time, they also ensure that the gate
can be lowered tightly.
• The servomotor is mainly composed of servomotor block, piston, piston rod, guide sleeve, seal, front and
rear servomotor heads, front and rear hanging rings, servomotor side locking valve group, external travel
detection device, etc.
 Hydraulic hoist
Servomotor assembly
• Cylinder block: Item number [23]. The cylinder block is a cylandrical part, internal diameter 600mm,
outer diameter 720mm, made by seamless steel tube. Both ends of the cylinder-block are installed with
cylinder head [25], rear hoist head [1]. The front cylinder head and the cylinder block are sealed by O
ring. The front cylinder head is equipped with support belt [26], combined seal ring [27], "O" seal ring [28]
and dust ring [33]. The rear cylinder head and the cylinder block are sealed by O ring. The front and rear
cylinder heads are connected with the cylinder block by high strength hexagonal socket bolts.
• Piston: The piston is a circular ring part and is divided into left piston [18] and right piston [21]. The
support belt is sleeved on the outer circle of the right piston. After the left and right pistons are installed
with the piston rod, the assembly is installed inside the cylinder block. The seal between piston and
cylinder and piston rod depends on combined seal ring [16], "O" seal ring [19] and combined seal ring
[20]. The main purpose of the piston is to divide the space inside the hoist block into two mutually sealed
spaces (rod end chamber and rodless end chamber), moves back and forth inside the cylinder block
under the action of pressure oil from the rod end chamber or rodless end chamber, and drives the piston
rod for reciprocating linear motion.
Servomotor assembly
• Plunger rod (i.e. piston rod): Item number [22]. The plunger rod is a part of the cylinder to transfer force.
 Hydraulic hoist
One end of the plunger rod is threaded with the left piston [18] and moves under action of the piston. The
other end of the plunger rod is connected with the lifting ring through the thread to drive the object
connected to the ring to move.
• Seal rings: The dynamic seal of the servomotor adopts a combined seal ring and has good sealing
performance and lower starting pressure at the maximum and minimum operating pressure. Static seal
adopts O seal ring. The seal ring is made of NBR with good oil resistance, waterproof, smaller
permanent deformation, smaller friction resistance, not adhesive, anti aging properties.
Servomotor assembly
• Cylinder side locking valve group: The cylinder side locking valve group of left servomotor is composed
of high-pressure ball valve [5.4.1, 5.5.1, 5.4.2], overflow valve [5.7.1] and hydraulic control check valve
[5.8.1]. The cylinder side locking valve group of right servomotor is composed of high-pressure ball valve
[5.4.3, 5.5.2, 5.4.4], overflow valve [5.7.2] and hydraulic control check valve [5.8.2]. The overflow valve is
used to set the maximum working pressure of the cylinder rod end chamber. The function of the
hydraulic controlled check valve is when tube-burst accident occurs, the gate is locked at the current
position, to avoid accident expanding. The high pressure ball valve is used to close the oil ways of the
rod end chamber and rodless end chamber of the cylinder.
• Lifting ring: Item number [43]. The lifting ring is made of quality carbon steel forged and machined. The
 Hydraulic hoist
lug is installed with spherical joint bearing with good sealing performance. The joint bearing adopts self
lubricating way and can compensate tiny misalignment between the gate lifting seat and lifting lug hole.
The joint bearing is also installed with skeleton type seal ring to prevent silt enter into the joint bearing.
 Hydraulic hoist
Hydraulic pump unit
• Hydraulic pump station is composed of the air tank, oil pump motor set, control valve block, pipeline,
filter and accessories, etc.
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Hydraulic pump unit
Oil tank
• The oil tank [1.1] is used to store the hydraulic oil required by the hydraulic hoist in work and the
hydraulic oil discharged from the cylinder, on which the hydraulic valve group and monitoring instrument
are installed. The oil tank effective volume is 4700L.
• The top of the oil tank is equipped with control valve block, pressure instrument panel, return oil filter
[1.7], air filter [1.4], water level controller [1.5]. To feed the oil to the oil tank, the oil shall be filled by the
oil filter press into the oil hole on the filter.
• The oil tank is equipped with magnet string [1.8] to absorb the fine iron chips fallen from the internal
motion parts inside the hydraulic valve due to wear.
• On the four sides of the oil tank, there are oil pump inlet valves [2.6.1, 2.6.2], oil supply pipe of oil pump
and outlet high-pressure ball valve [4.18.1 ~ 4.18.3, 4.19 and 4.20], heat exchanger (oil cooler) [1.11],
liquid level thermometer [1.3.1 ~ 1.3.6] for observing the liquid temperature and liquid level of the oil tank
and manhole cover plate for maintenance.
Hydraulic pump unit
 Hydraulic hoist
Oil tank
• The oil tank is provided with local terminal box [1.12], which is installed on the oil tank side. The terminal
box adopts front open door, which is provided with lock. Bottom cable inlet is convenient for field wiring
and maintenance.
• In order to facilitate the oil maintenance, two drain and blowdown ball valves [1.9.1, 1.9.2], two drain
valves [1.2.1, 1.2.2] are equipped at the lowest position of the oil tank.
 Hydraulic hoist
Oil pump-motor set

• The hydraulic pump unit is equipped with two sets of oil pump motor units. Two motor oil pump sets are installed on
shock absorbers [2.9.1 ~ 2.9.8] of motor base. The motors [2.1.1, 2.1.2] are connected with the variable
displacement axial piston oil pump [2.3.1, 2.3.2] through the couplings. The motor shaft drives the pump shaft
through coupling and the oil pump outputs pressure oil. The oil pump oil outlet is connected directly through high
pressure hose to the valve block on the oil tank. A manual ball valve and flexible rubber joint are installed between
the oil tank and the oil inlet of the oil pump;
 Hydraulic hoist
Oil pump-motor set
• The motor adopts three-phase asynchronous motor, model 1LE0001-3AB03-5JA4, rated voltage 415V,
frequency 50Hz, rated power 110kW.
• The oil pump uses straight shaft and sloping cam plate plunger type variable delivery pump, model:
PV270R1K1T1NMMC, rated pressure 31.5MPa, displacement 270ml/r.

System valve block

• The hydraulic valve group of the hoist is divided into three parts, the oil pump outlet pressure adjustment
valve group, system control valve group, and the cylinder side valve group.
• The oil pump outlet pressure regulating valve group includes check valves [2.5.1, 2.5.2], cartridge
overflow valves [3.1 ~ 3.4], which are integrated and installed on the outlet pressure oil adjustment valve
block. The oil outlet pressure adjustment valve block is installed on the oil tank side wall at the side of
the oil pump motor.
System valve block
• The system control valve group includes cartridge directional valves [4.22.1, 4.23.1, 4.24.1, 4.25.1] and
[4.22.2, 4.23.2, 4.24.2, 4.25.2], cartridge pressure valves [4.1 ~ 4.4], cartridge directional valves [4.5,
4.6, 4.7], rectifier plates [4.8.1, 4.8.2], speed regulating valve [4.10], proportional speed regulating valve
 Hydraulic hoist
[4.9], overflow valve [4.21], speed regulating valves [4.10.1, 4.10.2, 4.17]. They are all integrated on the
control valve block. The control valve block is installed at the top of the oil tank. The layout of the
hydraulic components is flexible and this makes all valves are convenient for installation and adjustment.
 Hydraulic hoist

System valve block

• Pressure gauges are installed collectively on the top of the oil tank wall for observation and
adjustment.
• Control valve block has following functions:
• 1) Controlling the speed and direction of the servomotor;
• 2) Monitoring system oil pressure.
• The rated pressure and flow rate of all kinds of control valves should not be less than the
maximum pressure and maximum flow required by the gate raising / lowering.
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Pressure control valve

The hydraulic pressure control system of the hoist is equipped with an overflow valve and a

1) overflow valve

cartridge overflow valve.

Model of overflow valve [4.21]: R6V06- 59130B5, it is installed on the control valve group to limit
the opening pressure of the hydraulic control one-way valve.
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Pressure control valve

1) overflow valve

Model of overflow valves [5.7.1, 5.7.2]: DBDS10P1X 315. They are installed at the cylinder side
valve group to limit the maximum lifting force of the rod end chamber of the servomotor.

Pressure control valve

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2) Cartridge overflow valve

• Cartridge overflow valve [3.1 ~ 3.4] is composed of cartridge valve (model CE032C01N12V10)
and its cover plate (model C032CA14009917V10), overflow valve (model V-ZUDB1AT2Z07K)
and solenoid directional valve (model D1VW020BV JWI1N), used to set the working pressure
value of the oil pump outlet.
• Cartridge pressure valve [4.1~4.4] is composed of cartridge valve (model CE032C01N12V10),
its cover plate (model C032CA14009917V10), overflow valve (model V-ZUDB1AT2Z07B) and
solenoid directional valve (model D1VW020BVJWI2N). It is used to set the return oil pressure
value of servomotor rodless end chamber.
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Pressure control valve

2) Cartridge overflow valve

Type CE cartridge valve and type C cover plate

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Pressure control valve

3) Cartridge overflow valve

V-type Overflow valve Outline drawing of D1VW solenoid directional valve

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Proportional speed control valve

The proportional speed control valve is installed in the control valve group
and is composed of DC proportion electromagnet, valve core, valve jacket,
valve body, displacement sensor and control amplifier, etc. The proportion
electro-magnet creates corresponding motion according to the input voltage
signal to make the valve core for displacement and change the channel
opening of the valve. Through the displacement sensor, the displacement of
the proportional electromagnet armature is converted linearly into voltage
signal and sends it to the control amplifier and compare it with the input
voltage signal, and then adjust the position of the valve core by differential
value until the difference value is zero, so as to finish the pressure and flow
rate continuous output proportional to the input voltage.
2FRE proportional speed control
Proportional speed control valve must be used with amplification board. The
valve and amplifier board
amplifier board enlarges the tiny electrical signals from the displacement
sensor. After comparing with the input signal, the differential signal is
provided to proportional electromagnet to drive valve core until the difference
Model of the proportional
signal is zero.
speed control valve [4.9]:
2FRE16-4X/160LBK4M.
 Hydraulic hoist

Cartridge directional valve

Cartridge directional valve [4.5 ~ 4.7] is composed of cartridge valve
(model: CE032C08N00V10), its cover plate (model:
C032BN12V10) and solenoid directional valve (model:
D1VW020HV JWI1N). It is used to change the on- off of oil
circuit.
Cartridge directional valves [4.22.1, 4.23.1, 4.24.1, 4.25.1] and
[4.22.2, 4.23.2, 4.24.2, 4.25.2] are composed of cartridge valve
(model: CE032C04N00V10) and its cover plate (model:
C032CA00121599V10), shuttle valve (model: ZSRA1PPOZ07)
and solenoid directional valve (model: D1VW020HV JWI1N). It
is used to change the on-off of oil circuit.

Outline drawing of ZSRA shuttle valve

 Hydraulic hoist

Hydraulic controlled check valve

The model of hydraulic check valve [5.8.1, 5.8.2] is SL20PA1- 4X/.

When raising the gate, hydraulic oil is free to enter the rod end chamber of
the oil cylinder to lift the gate. After the gate raises to the position specified
and the oil pump stops, the check valve within the hydraulic controlled
check valve closes automatically. The pressure oil in the rod end chamber
of the oil cylinder can not flow out, so the gate is kept at the current
position.
When the gate is required to be lowered, the control pressure oil shall be
providet to the control port of the hydraulic controlled check valve, to open
the check valve within the hydraulic controlled check valve. The pressure
oil in the rod end chamber of the oil cylinder can flow out through the
hydraulic control check valve, and the gate can be lowered then. External view of SL hydraulic
control check valve
 Hydraulic hoist

Flow control valve

• For flow control valve used in the hydraulic hoist system, except the solenoid proportional valve
aforementioned, there are one-way throttle valve and flow control valve.

Outline drawing of F one-way Outline drawing of 2FRM

throttle valve flow regulation valve
 Hydraulic hoist

Flow control valve

The model of one-way flow control valve [4.17] is 9F600S. The model of flow regulating
valve [4.10.1, 4.10.2] is 2FRM16-3X/160L.
One-way flow control valve and flow control valve have the functions to change system flow
rate. The one-way flow control valve can only adjust the flow rate of one of two oil flow
directions, and has no flow rate control action in the opposite direction. Once the flow control
valve adjustment is completed, the valve has same impact on the oil flow rate in positive and
negative two directions, and the speed after the adjustment is less affected by external
factors (such as changes of system pressure, load, oil temperature, etc).
The F-type one-way throttle valve is directly installed on the oil pipe.
 Hydraulic hoist

Check valve
• Model of check valve [1.10] is S25A5.0/2 and model of check valves [3.2.1, 3.2.2] is
9C1600S. They are used to limit the flow direction of oil and to make the oil flow only in
accordance with the direction specified, so that reverse flow is prevented.

Check valve S25A5.0/2 Check valve 9C2400S

 Hydraulic hoist

Filters
External view of DF
high pressure oil filter

The model of the high pressure

filter [3.11] is
DF0N660TL10C1.X/L24, pipe
connection, installed in the oil
pump export steel pipe to
withstand the system working
pressure. The filtering precision
can reach 5 ~ 10 µm.
 Hydraulic hoist

Filters
• Model of return oil filter [1.7] is RF0N/HC330DG20C1.X/-L24 and it is installed at the top of the oil
tank, connected to the return oil pipe of the system as the filter on the oil return passway of the
system. When raising / lowering the gate, the hydraulic oil discharged from the system is
filtered through the oil filter and returned to the oil tank so as to keep the hydraulic system
clean.
• The oil filter is provided with the pressure difference transmitter and the by-pass valve.
When the pressure difference between the inlet and outlet of the return oil filter is bigger
than the alarm pressure of 0.2MPa, the pressure difference transmitter sends signals to
trigger the aubidle and visual alarm, at the same time, open the bypass valve automatically
to provide pathway to the hydraulic oil. When this happens, clean or replace the filter
element as soon as possible.

External view of
RF return oil filter
 Hydraulic hoist

Filters
Model of air dehumidifier [1.4] is QLS1-I-10-FB17. It is installed on the
top of the oil tank and has the function of the oil tank breathing valve.
When the air flows in and out of the oil tank, it absorbs the moisture in
the air. When color silicone is gradually changed from blue to red or
pink, the silicon gel shall be dried or replaced.

QLS air
dehumidifier
 Hydraulic hoist
Model of air filter [1.13] is EF6-80. The air filter is installed at the top of the
oil tank with the function to filter the bubbles and large particles mixed in the
filling oil. When not filling oil, it is covered by a cap.

EF air
filter
 Hydraulic hoist
The model of the pressure controller [4.13.1~4.13.3] is 69223015. It is a
mechanical pressure control signal device and sends electrical signal to
the control system when the pressure reaches setting value. It is
installed on the instrument board of the oil tank. The setting pressure is
the pressure SP3 ~SP4 of the servomotor rod end chamber setting and
the pressure SP5 of the servomotor rodless end chamber setting.

692 pressure controller

 Hydraulic hoist
Model of pressure sensor [3.7] is SCPSD-400-14-15 with numerical
display and output 4 ~ 20mA signal. It is installed on the instrument stand
of the oil tank and can send real-time output analog signal of the oil pump
outlet pressure and display the pressure.

External view of SCPSD

pressure sensor
 Hydraulic hoist

Pressure testing
External view of pressure gauge

The model of pressure gauge

used in this system is 213.53.063,
fixed on the instrument stand of on
the oil tank support by seismic
radial installation method to
display respectively oil pump
outlet pressure, the cylinder rod end chamber pressure, the cylinder rodless end chamber
pressure.
 Hydraulic hoist

Oil level monitoring

The model of the liquid level controlle [1.5] is P300- 550- 100 and it is installed on
the oil tank. When the oil level reaches the set height, it sends electrical signals.
Outline drawing of P300
liquid level controller
 Hydraulic hoist

Oil level monitoring

The model of liquid level thermometer [1.3] YWZ-254

and it is installed at the upper part of the oil tank side
wall to display directly the oil level of the oil tank and oil
temperature.

YWZ liquid level and

temperature meter
 Hydraulic hoist

Oil temerature measuring

The model of temperature sensor [1.6] is

TA1000/C- 50-100/ 242G14MS050D6 and it is
installed at the lower part of the oil tank side wall,
used to measure the oil temperature in the oil
tank and send corresponding 4 ~ 20mA analog
signals.
The working temperature range of hydraulic oil
recommended by the system is 5ºC ~
55ºC. When the oil temperature is lower than 5ºC,
the control system sends the oil temperature too
low alarm. When the oil temperature is higher
than 55ºC, the control system sends the oil
 Hydraulic hoist

temperature too high alarm.

External view of TA 1000

temperature sensor
 Hydraulic hoist

Hydraulic oil

The hydraulic oil is the medium to transfer energy in the hydraulic transmission system.
80% of the hydraulic system failure is associated with the hydraulic oil contamination, so it has great
significance to reduce hydraulic failure by maintaining the hydraulic oil clean,
The hydraulic oil brand recommended in this system is No.46 ash-free anti-wear hydraulic oil and should be
used as far as possible. When the user is going to replace other working medium, the user should consult the
manufacturer in advance.
The hydraulic oil grade to be filled in the oil tank must be same as the hydraulic oil brand used. The hydraulic oil
must be filtered before filling, and the purity of the filtered oil should reach NAS 8.

Parameters of hydraulic oil of hydraulic hoist

Oil type Model Unit Maximum oil filling volume
#46 Anti-wear oil without dust Tellus 46 L 4100
Electrical control system
Composition of control system
• Each hydraulic hoist is provided with one local control system, which consists of one control
cabinet [PI1] and one power cabinet [PI2]. 2 local control cabinets are installed in the hoist room
 Hydraulic hoist

on the dam.
• The power cabinet is used for motor power control and provides control power to the control
cabinet. The main components in the motive power cabinet include circuit breaker, contactor, dual
power switching device, soft starter, surge protector, power transformer, instrument transformers,
voltmeter and ammeter, temperature and humidity controller and heater, fan, lighting.
• The power supply system of hydraulic hoist is three phase four wire AC power supply, voltage
415V, frequency 50Hz, control power supply DC24V.
Electrical control system
Composition of control system
• After the 2-way AC supplied by the power station enters the power cabinet, the cabinet provides
power to the oil pump motor through dual power switching device and soft starter. The control
power supply of the control cabinet is taken from the output end of the dual power switching
device.
• The soft starter can provide protection against short circuit, phase loss, phase sequence, voltage
loss, overload and overcurrent for the motor.
• The temperature and humidity controller inside the control cabinet is used to for dehumidifying and
 Hydraulic hoist

heating inside the control cabinet. The temperature and humidity signal detected by the
temperature and humidity sensor are sent to the temperature and humidity controller. The
controller outputs signal when the temperature or humidity exceeds the set value to start the fan
or heater until the temperature or humidity decreases to the allowable value and then stop the fan
or heater.
 Hydraulic hoist

Electrical control system

Composition of control system

Layout of panel elements of power cabinet

• The upper elements of the power cabinet panel are voltmeters, No.1 motor ammeter, No.2 motor ammeter.
The indicators in the lower row are the normal indicators of the main power supply, power- on indicator of
main power, normal indicator of standby power, power-on indicator of standby power.
 Hydraulic hoist

Electrical control system

Composition of control system
• Control cabinet PI1 is used to collect the signal of the hydraulic hoist and output control
commands, so as to control the hydraulic hoist through PLC system or conventional relay control
circuit. The main components in the cabinet include miniature circuit breaker, PLC, expansion
module and intermediate relay, touch screen, switching power supply, temperature and humidity
controller, heater, fan, lighting lamp and maintenance socket.
• The CPU of PLC adopts Schneider BME P58 1020 processor, power module, I / O module and
network communication module. BME P58 1020 processor is equipped with two communication
ports, which can be connected to touch screen and portable computer.
Electrical control system
Composition of control system
• Two DC24V power supplies in the control cabinet, one is taken from the UPS outlet power supply
behind the dual power supply switching device, one is taken from the DC110V power supply
provided by the power station, then the cabinet provides power in parallel after switching power
supply conversion to PLC, touch screen, solenoid valve, sensor and other electrical components.
 Hydraulic hoist

• The temperature and humidity controller inside the control cabinet is used to for dehumidifying and
heating inside the control cabinet. The temperature and humidity signal detected by the
temperature and humidity sensor are sent to the temperature and humidity controller. The
controller outputs signal when the temperature or humidity exceeds the set value to start the fan
or heater until the temperature or humidity decreases to the allowable value and then stop the fan
or heater.
 Hydraulic hoist

Composition of control system

Layout of control cabinet front panel

components
 Hydraulic hoist

Composition of control system

Code number and function of local control cabinet front panel components
H3:
HL1: No. 1 H1: Oil H2: H4: Oil filter
HL3: No.2 pump 1H1: Gate full Abnormal oil
pump pressure Abnormal oil blockage
operation light raise light temperature
operation light abnormal light level light light
light
HL2: No. 1 1H3: Sliding
HL4: No. 2 pump 1H2: Gate fully 1H5: Gate H5: PLC HD: Fault
pump fault down 200mm
fault light lower light failure light trouble light warning light
light light
Touch screen
SA03: Pressure
R0:
SA01: Manual / SA02: No.1 pump building / SA04: Cooler
Proportional
automatic / / cut-off / No.2 unloading manual / SA05:
valve
remote pump selector selector switch automatic Standby
decrease /
selector switch switch of overflow selector switch
increase knob
valve
SB01:
1SB1: Gate 1SB2: Stop 1SB3: Gate SB02:Fault SC1: Light
Emergency
raising button button lowering button reset button test button
stop button
 Hydraulic hoist
Function of control system
• (1) Protection and alarm functions
• 1) PLC has self diagnosis function and can timely judge and issue alarm on PLC module,
measurement circuit disconnection and other faults. In addition, PLC software protection
program if prepared can avoid frequent starting of the motor in a short time.
• 2) The soft starter can provide protection against short circuit, phase loss, phase sequence,
voltage loss, overload and overcurrent for the motor.
• 3) Various fault alarm signals of hydraulic system (including high hydraulic system pressure,
hydraulic pump failure, oil temperature too high / too low, too high / too low oil level in the oil
tank, oil filter blockage indication, gate sliding down, etc.) are also uploaded to PLC. There is
corresponding alarm display in the alarm screen.
Function of control system
(2) Data acquisition and processing function
• 1) Data of the gate opening
• Measure the stroke of the piston rod of the servomotor of the hydraulic hoist throughthe
displacement sensor.
• 2) Analog data
 Hydraulic hoist
• Mainly including system pressure, oil temperature, data of the gate opening.
• 3) Digital data
• Mainly including the upper and lower limits of the gate, oil level, oil filter blockage signal, oil
pump operation status, etc.
Function of control system
(3) Automatic lifting function of gate sliding
• In "Local" or “Lemote” mode, the gate position is controlled by PLC wth the code signal
provided by encoder to the PLC. The PLC is connected to HMI to display real-time position
state parameter. Because of the hydraulic system leakage, when the gate slides down to
200mm from the original raised position, the oil pump motor is put automatically into operation
to raise the gate to its original position.
(4) Automatic deviation correction of gate
• When the opening deviation of the left and right sides of the gate exceeds 10mm, the system
automatically starts the deviation correction program to change the running speed of the left
servomotor through the proportional control valve and make the stroke of the left and right
servomotors of the gate tend to be synchronized. When the deviation between the left and
right opening of the gate exceeds 20mm, the system stops automatically the gate and gives an
alarm.
 Hydraulic hoist
Function of control system
(5) Data display and query
• The touch screen displays gate opening, system pressure, oil temperature, equipment status and fault
information.
(6) Data exchange with central control room
• A) The signals sent to the central control room are:
• 1) Main power failure
• 2) Standby power failure
• 3) Remote control
• 4) No.1 DC24V abnormal
• 5) No.2 DC24V abnormal
• 6) No.1 pump running
• 7) No.2 pump running
• 8) No. 1 pump fault
• 9) No.2 pump fault
• 10) The gate is fully raised.
• 11) The gate is fully lowered.
• 12) Gate is raising.
 Hydraulic hoist

Function of control system

(6) Data exchange with central control room
A) The signals sent to the central control room are:
• 13) Gate is lowering.
• 14) Gate slides down by 200mm.
• 15) Gate failure
• 16) Oil pressure abnormal
• 17) Abnormal oil level
• 18) Oil filter blockage
• 19) PLC fault
B) Signals transmitted from the central control room to the site:
• 1) Remote raising the gate
• 2) Remote lowering the gate
• 3) Remote stop
Function of control system
Control mode of control system
• The local control system of the hydraulic hoist is provided with local operation and remote operation
modes. Local manual mode and local automatic mode can be selected under local operation. Local
manual, local automatic and remote control are interlocked with each other.
 Hydraulic hoist
• In local automatic control and remote control modes, the hydraulic hoist receives local or remote
instructions to raise / lower the gate. Through PLC control output, one key can raise / lower the gate
without manual intervention.
• When the gate is raised / lowered manually at site, the control system uses relays to control the gate
step by step. Relevant buttons shall be operated on the panel of PI1 cabinet to start the motor, raise /
lower the gate.
• No matter which kinds of operation modes are selected, in the process of gate operation, the emergency
stop button can be pressed at any time to stop the gate running.
• Under normal circumstances, when "Manual / Local / Remote control mode" on the local control cabinet
panel is turned to "Remote Control" position, the gate is controlled by the central control room.
Instructions are issued from a remote operating room.
 Hydraulic hoist
Human-machine interface (HMI)
• The touch screen is installed on the control cabinet
panel, model HMIGXU5512, Mini-B USB interface.
Ethernet interface and serial interface, power supply
DC 24V.

(1) Introduction to touch screen display area and button

functions

Touch screen display area and button

functions
 Hydraulic hoist
Human-machine interface (HMI)
(2) Main screen

Gate left opening

Gate opening | rnn I rnn
Gate right opening
I U %
I nn
Preset opening | BEH rnn
Left opening minus right opening
I nn
Left cylinder change value
I nn
Right cylinder change value
I nn

Open to zero

Sliding gate value

The main screen displays the system oil pressure, oil temperature, gate opening data and opening percentage, preset
opening data and gate sliding value.
 Hydraulic hoist
Preset opening data: It is the gate opening given in automatic or remote operation mode.
Gate sliding value: After the gate is raised in place and stops, it is the sliding amount of the gate over a period of time.
 Hydraulic hoist
Human-machine interface (HMI)
(3) Input / output point monitoring screen

1 English ................................................................................................... pmepage

p ' _ DI Descr i pt ion

1 Status
No. Drawing NO
!
i Automat i c 501 ' OFF
^Remote ___5O2 . OFF
l_1# .pump sei ect rrr riFP
4 ....................................................
2# .pu.mp. se 1 ect ■ ■ 504 _ riF
. ....................................................
1# Pump- Fau l ure
_A __505 ■ _
....................................................
1# Pump- Ru n n i ng
6 • • 506 •_ OF
....................................................
2# Pump' Fau 1 ure................+
7 ' ' 507 _ OF
_L_
...................................
2# Pump Running ' ' 508 _
1 OFF
9 ® ® ® ......................................... __5O9 __
—
OFF
1. Emerg.ency. stop . . 51Q . OFF
0 . ....................................................
1# .24V Power-Err ■ ■ 511 ■
11 OF
....................................................
2# -247 Power-Err __M2 ■
12 OF
....................................................
Normal power OK
13 • • 513 _ —
UF
....................................................
Spare power OK
14 ■ ■ 514 ■ OFr
....................................................
'~Coo 1 er ope rat i on ' ' 515 ' OFr
16 Oil 1 eve 1 1ow 516 urr

Input point monitoring screen 1

 Hydraulic hoist
Human-machine interface (HMI)
(3) Input / output point monitoring screen

4 1 Fnali^h ............................. IB Ihlomepage

5

No. ........... DI Description ....................... Drawing NO: Status

17 Open ■ ■ 521 1 OFF
18 Stop _ ___ 522 1 ncr
19 Close ............................................. _ ____523___ 1 nrc
20 , Gate, f u 1 l.y .opened . . 524 . . 1 AFF
...................................................
21 ■Gate' f u 1 I'V c 1 osed.......................... ■ ■ 525 ■ ■
22 Pressure high ..................................... ■ ■ 526 ■ ■
23 Pressure ' 1 ow.................+................. ■ ■ 527
24 Barless cavity overpressure _ ___ 528
25 Low pressure Left _ ___ 529 1
26 Low pressure Right ................................ . . 530 . . 1 nFF
27 Oi l f i 1 ter .b 1 ockage......................... . . 531 . . OFF
28 ■Oi l fi 1 ter high•pressure-p1ug.................. ■ ■ 532 ■ ■ \ OFF
29 H i g h ■ 0 i 1 '1 eve'l........................... ■ ■ 533 ■ ■ \ OFF
30 Gate Remote Open ................................. ' 534 1 OFF
31 Gate Remote Stop _ ____535___
32 Gate Remote Close . 536 , , 1 1
__________________________________________________________________________________________________________________________________________________________________________________________________________________________________ I

Input point monitoring screen 2

 Hydraulic hoist
Human-machine interface (HMI)
(4) Input / output point monitoring screen

Output point monitoring screen 1

 Hydraulic hoist
Human-machine interface (HMI)
(5) Input / output point monitoring screen

Output point monitoring screen 2

The input point and output point screens display the status signals of each measurement point of the system.
 Hydraulic hoist

Human-machine interface (HMI)

(4) Input / output screen of PLC analog data

Analog input / output display screen

 Hydraulic hoist
Human-machine interface (HMI)
(4) Input / output screen of PLC analog data

Analog data description screen

Displaying the analog data and calculated value collected by the system, judging whether the equipment status
is normal.
 Hydraulic hoist
Human-machine interface (HMI)
(5) Fault display screen

Fault display screen

Record and display fault information.

 hydraulic hoist
Human-machine interface (HMI)
(6) Commissioning setting screen
• Click the "commissioning entry" button on the fault display screen, then enter the commissioning password:
1234 and enter the commissioning setting screen.

Commissioning setting screen

The commissioning setting screen can set the gate to be fully raised and the opening can be cleared.
 Operation

Notices of safety operation

• An operation regulation shall be established by the hoist management department according to

the related rules and actual circumstances. All operation regulations must include the following
content.
• (1) Special staff must be appointed for the operation, maintenance and repair of the hydraulic
hoist. The operators shall be familiar with the structure and performance of hoist, operating rules,
hydraulic components, the operating method, the performance of protecting devices and the
related electrical knowledge.
• (2) The periodic inspection of hydraulic hoist shall be performed strictly, and the scope of
inspection includes hydraulic pump plant, cylinder, limit switch and the stroke measuring system,
pipeline system and the electrical system.
• (3) It’s not allowed to store dangerous material, such as flammable/explosive in the rooms where
oil pumping plant is located.
 Operation

Notices of safety operation

• (4) During operation of gate, adjustment of the protective devices, such as pressure relays, pressure
relief valves shall be not allowed.
• (5) Once the preset values of pressure relay and relief valve have been proved to meet requirement
of the operation of the gate, no change shall be made in future.
• (6) The warning signal shall be hung near all of the normal open or normal closed valves, and all un-
authorized staffs are forbidden to operate them.
• (7) Check all fasteners before starting the machine and free of loose phenomenon. Ensure that all
safety protection facilities are complete and at the designated position, no obstacles in passway.
Ensure that all electrical cabinet doors are closed and all people know the machine is going to start.
Ensure that no one is in danger area. All fasteners shall be checked against loose before operation.
Notices of safety operation
• (8) The motor can not be started too frequently. Operate motor strictly according to the operation
process.
 Operation

• (9) If the equipment stops working beyond one month, when it is re-started, the pump must be
started and stopped for many times until the hydraulic system comes into stable work.
• (10) The system shall be stopped and repaired when the abnormal phenomenon occurs, such as
abnormal noise, lower pressure, big fluctuation of pressure, insufficient flow, big fluctuation of flow,
high oil temperature and so on. The equipment couldn’t work till the fault has been eliminated.
• (11) If electrical part fails, it shall be repaired by a professional electrician or electrical technician,
who shall abide by relevant safety operating rules. Other personnel shall not repair the machine
without authorization.
Notices of safety operation
• (12) In maintenance of electrical equipment, the shift supervisor firstly cuts off the power supply
and tag-out "No Closing" warning signboard or locked. When connecting power, the shift
supervisor should provide unified command. If live-line work is really necessary, use insulated
tools, and the specialist shall take care.
• (13) It is forbidden to use ground wire as the current-carrying zero wire.
 Operation

• (14) Check the auxiliary lines connected temporarily in fault inspection. They must be removed
immediately after troubleshooting for restoration.
• (15) Electrical equipment on fire should be immediately cut off the power supply, to put out the fire
with insulation fire extinguisher.
• (16) The abundant leaked oil must be collected, and it is not allowed that oil is discharged into the
drainage system or rivers. The little leaked oil must be cleaned out and keep the site clean. The
waste oil must be disposed appropriately.
Notices of safety operation
• (17) All doors of rooms must be closed when the hydraulic hoist is not used.
• (18) All the spare parts and parts must be properly kept and regularly checked. The instruments shall be
calibrated before use.
 Operation

Notices of safety operation

Notices during operations:
• (1) After the pump is started without load and works stably, the gate can be operated.
• (2) The oil can only be filled in oil tank after being filtered and the cleanliness of oil must reach
the prescription of this manual. (the filtration standard is less than 20μ)
• (3) Often check the oil level, oil temperature and quality of oil in the tank, if abnormal, deal with it
in time. Check the component and contamination of oil after the equipment has worked for half a
year, and discharge and re-filter all of the oil if necessary, and fill oil in the tank again after it be
tested and reach the quality required. Check and filter oil annually, and replace oil if necessary.
Notices of safety operation
 Operation

Notices during operations:

• (4) During the operation, check the motor and the pump temperature at any time, and
observe the work pressure of system at any time, and inspect the hydraulic pressure
connection at any time, in order to avoid the accident.
• (5) The hydraulic system should be running periodically so as to find faults out in time
and make the equipment work in good condition.
 Operation

Warning！！

It’s not allowed to re-adjust the rated pressure randomly after the pressure control valves have been set.
It’s forbidden to repair or maintain the component during hydraulic hoist is running. During the system
pressure testing is carried out, people are not allowed to close to the high pressure pipe. Before dismantling
hydraulic components and pipes, the incoming line of oil pump motor is cut off under the guidance of
electrical engineers, and the relevant control components are operated to discharge remnant pressure, and
the relevant stop valves are closed to avoid the outflow of hydraulic oil. The dismantled hydraulic
components must be placed in an appointed position, and the necessary packing and protection must be
used.
The system must be stopped and repaired in case the phenomenon of partial or little spout appears, and it is
not allowed to use hand or goods to block up.
During the bleeding-air operation, eyes shall not be pointed towards the direction of the air bleed hole.
 Operation
Operation of hydraulic hoist
Setpoint of hydraulic pump unit alarm signal

S.No Code Setpoint Description 1 Description 2

.
1 LL1 150 mm The oil level is too low Alarm and the pump station stop running
2 LL2 1100 mm The oil level is too high Alarm and the pump station stop running
3 TS1 5℃ Oil temperature too low Alarm and the pump station stop running
4 TS2 55℃ Oil temperature too high Alarm and the pump station stop running
5 SP1 19.9 MPa The pressure of pump outlet is too high Alarm and the pump station stop running
6 SP2 2.0 MPa The pressure of pump outlet is too low Alarm and the pump station stop running

SP3,
7 2.0 MPa The pressure in the rod cavity of the servomotor is too low Alarm and the pump station stop running
SP4

8 SP5 2.0 MPa The pressure in the rodless cavity of the servomotor is too low Alarm and the pump station stop running

9 CS 0.2 MPa Oil return filter blocked Alarm

10 HS 0.5 MPa High pressure filter blocked Alarm
 Operation
Check and preparation before the equipment operation

• (1) Check the oil level in the oil tank is higher than the minimum allowed oil level and oil color is
normal. Otherwise the hydraulic oil shall be filled into the oil tank up to the level above the
minimum oil level. The cleanliness of the oil shall reach 8 level of NAS 1638 standard and the oil
brand shall be as same as the oil brank in the oil tank.
• (2) Check the oil tank, group valve and pipe joints which shall be free of oil leakage. All meter
switches, oil pump suction port ball valve are at a normally open position.
• (3) Check the on off state of the high pressure ball valves of the hydraulic pump station and the
high-pressure ball valve on the cylinder side group valve at the correct position.
• (4) Check electric connectors in each electrical cabinet which are free of discoloration and burnt
mark. Components and wiring are without obvious loss and loose.
Check and preparation before the equipment operation

• (5) Close ATS device QF0, circuit breakers QF1 and QF2 in power cabinet PI2, and check that the
 Operation
power supply voltage indication on the panel is within 415V ± 10%.
• (6) Close the miniature circuit breakers QF01 ~ QF03 and QF11 ~ QF16 in the control cabinet,
check and confirm that the switching power supply in the control cabinet works normally, check
and confirm that the display of each circuit in the control cabinet is normal, the AC contactor and
thermal relay work normally, and the lighting power supply is normal.
• (7) PLC self-checking is passed. Touch screen display is normal. The system is free of fault
indication.
• (8) No alarm indicator light on the control cabinet panel is ON, and the emergency stop button is
released.
Radial service gate raising / lowering operation
Local raising / lowering of radial service gate
(1) Radial gate raising
• 1) Check and confirm the power supply is normal, there is no fault alarm signal in the control
system (if there is fault alarm signal, eliminate the fault first and then operate the hoist).
• 2) Switch the change-over switch SA01 "Manual / Local / Remote" on the PI1 panel of the control
 Operation
cabinet to the "local" position.
• 3) Set the gate opening on the touch screen.
• 4) Press the button (1SB1) "Gate Raising", the motor starts at no-load, No.1 pump (or No.2 pump)
operation indicator light is ON. After 10 seconds delay, the radial gate begins to rise.
Radial service gate raising / lowering operation
Local raising / lowering of radial service gate
(1) Radial gate raising
• 5) The radial gate will stop automatically after lifting to the preset opening. After a delay of 3S, the
motor is powered off and the gate raising stops.
• Notice:
• When the gate is in automatic operation mode, the operating speed of the left oil cylinder is
controlled by the proportional speed regulating valve, so as to keep the stroke of the left
and right cylinders of the gate synchronized, so manual correction is not required.
• When the gate should be fully raised for a long time, the manual locking can be applied,
then disconnect circuit breakers QF01~QF03 in PI1 cabinet.
 Operation
Radial service gate raising / lowering operation
Local raising / lowering of radial service gate
(2) Radial gate lowering
• 1) Check and confirm the power supply is normal, there is no fault alarm signal in the control
system (if there is fault alarm signal, eliminate the fault first and then operate the hoist).
• 2) Switch the change-over switch SA01 "Manual / Local / Remote" on the PI1 panel of the control
cabinet to the "Manual" position.
• 3) Switch the pump selection switch SA02 to No.1 pump or No.2 pump, After 10s delay, No.1
pump motor or No.2 pump motor starts.
• 4) Switch the overflow valve status selection switch SA03 to the "ON" position.
• 5) Press the button SB1 “Gate Raising” of the radial gate. After raising the radial gate for a short
section, press the button 1SB2 "Gate Stop".
Radial service gate raising / lowering operation
Local raising / lowering of radial service gate
(2) Radial gate lowering
 Operation
• 6) After the gate stops, switch the overflow valve status selection switch SA03 to the "OFF"
position. After 3s, switch the pump selection switch SA02 to the "OFF" position, the motor stops.
• 7) Release the radial gate lock spindle.
• 8) Switch the change-over switch SAH1 "Manual / Local / Remote" on the PI1 panel of the control
cabinet to the "Local" position;
• 9) Set the gate opening on the touch screen.
• 10) Press the button 1SB3 "Gate Lowering", the motor starts at no-load. After 10 seconds delay,
the radial gate begins to lower.
Radial service gate raising / lowering operation
Local raising / lowering of radial service gate
• (2) Radial gate lowering
• 11) The radial gate will stop automatically after it drops to the preset opening. After a delay of 3S,
the motor is powered off and the gate raising stops.
• Remarks:
• If the lock is not applied, the step 2 ~ 7 above can be skipped.
 Operation
• (3) The radial gate stops in the raising / lowering process.
• During gate raising and lowing, press the gate stop button 1SB2 at any time, the raising / lowering
operation of the gate stops.
• In case of emergency, press the emergency stop button, the raising / lowering operation of the
gate stops.
Radial service gate raising / lowering operation
Remote raise / lower of radial gate
• 1) Check and confirm the power supply is normal, the control system is free of fault alarm signal.
• 2) Switch the change-over switch SAH1 "manual / local / remote" on the PI1 panel to the "remote "
position;
• 3) The local control cabinet accepts the command from the remote control room for radial gate
raising / lowering operation.
• Remarks:
• Before lowering the radial gate, confirm that the locking is not applied.
Radial service gate raising / lowering operation
 Operation
Local - Manual mode
(1) Radial gate raising
• 1) Check and confirm the power supply is normal. There is no fault alarm signal in the control
system (if there is fault alarm signal, eliminate the fault first and then operate the hoist).
• 2) Switch the change-over switch SA01 "manual / local / remote" on the PI1 panel of the control
cabinet to the "manual" position.
• 3) Switch the pump selection switch SA02 to No.1 pump or No.2 pump. After 10s delay, No.1
pump motor or No.2 pump motor starts.
• 4) Switch the overflow valve status selection switch SA03 to the "pressure building" position.
• 5) Press the SB1 (gate raising) button of the radial gate to raise the radial gate.
Radial service gate raising / lowering operation
Local - Manual mode
(1) Radial gate raising
• 6) After the gate is lifted to a predetermined height, press the gate stop button 1SB2 "gate stop" to
stop the gate raising.
 Operation
• 6) After the gate stops, switch the overflow valve status selection switch SA03 to the "cutoff"
position. After 3S, switch the pump selection switch SA02 to the "cut-off" position, the motor stops.
(2) Radial gate lowering
• 1) Check and confirm the power supply is normal. There is no fault alarm signal in the control
system (if there is fault alarm signal, eliminate the fault first and then operate the hoist).
• 2) Switch the change-over switch SA01 "manual / local / remote" on the PI1 panel of the control
cabinet to the "manual" position.
Radial service gate raising / lowering operation
Local - Manual mode
(2) Radial gate lowering
• 3) Switch the pump selection switch SA02 to No.1 pump or No.2 pump. After 10s delay, No.1
pump motor or No.2 pump motor starts.
• 4) Switch the overflow valve status selection switch SA03 to the "pressure building" position.
• 5) Press the SB1 (gate raising) button of the radial gate. After lifting the radial gate for a short
section, press the gate stop button 1SB2 "gate stop".
 Operation
• 6) Release the radial gate lock spindle.
• 7) Press the button 1SB3 "Gate Lowering", the radial gate begins to fall.
Radial service gate raising / lowering operation
Local - Manual mode
(2) Radial gate lowering
• 8) After the gate reaches the predetermined height, press the button 1SB2 "Gate Stop" to stop the
gate raising.
• 9) After the gate stops, switch the overflow valve status selection switch SA03 to the "OFF"
position. After 3s, switch the pump selection switch SA02 to the "OFF" position, the motor stops.
• Remarks:
• If the lock is not applied, the step 2 ~ 6 above can be skipped.
Radial service gate raising / lowering operation
Local - Manual mode
(3) Precautions for local manual operation of radial gate
 Operation
1) During the raising of the gate, pressing the button “Gate Lower” is invalid. During lowering the
gate, pressing the button “Gate raising” is invalid. To change the movement direction of the gate in
operation, the gate stop button must be pressed first to stop the current movement of the gate, then
the reverse operation of the gate can be carried out.
2) Deviation correction during gate raising / lowering:
• a) When the gate opening data acquisition is normal, manual deviation correction can correct the
deviation of the gate according to the knob on the touch screen.
Radial service gate raising / lowering operation
Local - Manual mode
(3) Precautions for local manual operation of radial gate
• b) When the gate opening data acquisition is abnormal, the gate deviation must be corrected by
observing the actual situation of the gate.
• c) Description of adjusting resistance knob: The cut-off resistance is maximum and output voltage
is minimum 0V at 10. The cut-off resistance is the minimum and the output voltage is maximum
10V at 0. 0V ~ 10V is used for regulating the flow.
 Operation
Emergency shutdown
• In case of emergency, the operator can press the red "emergency stop" button on the operation
panel of PI1 cabinet door. Reset the emergency stop button after the fault is removed.
END