QUIT1-IEM-3266-RevA-Documento de pruebas.pdf

CONTRATISTA/ CONTRACTORS

FECHA /

DATE

NOME /

NAME

DIB. / DRAWN 2015.04.02 CB

CONTRL / CHKD 2015.04.02 NB

APROB. /APPD 2015.04.02 MC

QUITARACSA I

DOCUMENTO DE PRUEBAS /

TESTS DOCUMENT

Primera entrega

/First issued date

2015.04.02

ENERSUR DOCUMENTO NO.:

QUIT1-IEM-3266-RevA

Rev. No.

A

Página /

Sheet

1 of 39

A Entrega inicial CB NB MC 2015.04.02

REV DESCRIPCIÓN DIBUJO /

DRAWN

CONTROL /

CHKD

APROB. /

APPD FECHA / DATE

PROPIETARIO / EMPLOYER

PROCESS OF DEVELOPING AND PACKAGING ELECTRICAL INSTALLATIONS

FOR CRANES

COD. IP05 REV. 0 DATE 05.03.03 PG. 2 OF19

Consultation of production schedule for electrical systems

CRITICAL POINTS

DESCRIPTION OF OPERATIONS

The first stage of the process of constructing electrical installations is the consultation by the foreman (or a representative of the foreman) on the weekly schedules of production of electrical installations. Once the jobs to be carried out have been identified, the foreman assigns the jobs.

Consultation and printing of technical file (if necessary)

CRITICAL POINTS


Once the jobs to be carried out have been identified, the people in charge of the various departments (trolley department, festoon department, department for on-board electrical systems and tests) call up the technical file relating to the jobs on the computer (previously prepared by the technical office) and consult the technical file on screen or print it, as necessary. Once this has been done, the project begins, supervised by the head of department. NB The technical file consists of two sections: 1) Mechanical design 2) Electrical design


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Assembly – Cabling – Packaging – Testing of Hoist/Winch Trolley

CRITICAL POINTS


Once the project has been checked, the head of the trolley department starts the process of assembly, cabling, testing, and packaging of the trolley Assembly – Cabling – Packaging – of Hoist/Winch Trolley

The head of the trolley department consults the technical file relating to the jobs orders in progress, in order to obtain all the necessary information to be able to properly choose the components to be assembled and methods of cabling the electrical system of the trolley.

The choice of trolley as indicated in the technical file and positioning of the trolley on the appropriate supports.

Assembly of hoist on trolley as indicated in technical file. NB In the case of winch trolleys, the trolley and winch components arrive from the winch-assembly department already assembled.

Assembly of hoist hook block. NB In the case of winch trolleys, the people who assemble the crane are requested to assemble the block and rope.

Assembly of trolley geared motor as indicated in technical file.

Assembly of the electrical components on the trolley as indicated in the technical file:

1) Connector with plug or connecting box with terminals. 2) Trolley slide stop + photocell if there are several trolleys on the same

crane. 3) Lifting stop if there is a winch. If there is a hoist, the lifting stop is

placed inside the hoist. 4) Load-limiting electronic board if there is a winch. If there is a hoist, the

load limiter is placed inside the hoist. 5) Assembly of accessories supplied with the trolley (e.g. cord storage

reel, depressors for suction pads, lights, etc.)


FOR CRANES


CRITICAL POINTS


Assembly of electrical components on the trolley as indicated in thetechnical file: 1) Connection of trolley slide photocell/stop to connector with plug or the

connecting box with terminals. 2) Connection of lifting stop to connector with plug or the connecting

box with terminals. 3) Connection of load limiter to connector with plug or the connecting

box with terminals. 4) Connection of lifting motor or motors to connector with plug or the

connecting box with terminals. 5) Connection of lifting servo-brake motor to connector with plug or the

connecting box with terminals, if there is a winch. 6) Cabling of accessories supplied with the trolley (e.g. cord storage

reel, depressors for suction pads, lights, etc.) to connector with plug or connecting box with terminals.

All assembly and cabling operations of the trolley are self-monitored.

Testing of hoist/winch trolley can be carried out in two ways: 1) Using an appropriate test bench, following a guided testing procedure, as described below: A) Call up the job relating to the trolley concerned, using the appropriate testing programme. B) Insert the name of the tester in the space provided. C) Press the START button on the screen to start tests, and follow the instructions given on the test bank screen: - Check emergency lifting stop. - Check maximum lifting stop. - Check maximum lowering stop. - Check load limiter. - Check trolley sliding stop (slowing and right/left terminal). - Check direction of lifting movement and measure currents in the three stages of the single- or double-speed motor. - Check direction of trolley sliding and measure currents in the three stages of the single- or double-speed motor. - Check rotor tensions in the case of winch trolley with lifting motor with rings.

CRITICAL POINTS



FOR CRANES


D) If an error occurs during testing, a message will appear on the screen indicating the type of fault, and tests will be interrupted. Before continuing with the tests, the operator must eliminate the fault. After troubleshooting, the operator can continue testing or start new tests. E) The result of the test is positive only when all the operations requested during testing are carried out properly. F) When the test is positive, “COLLAUDO ESEGUITO CON SUCCESSO” [SUCCESSFUL TEST] will appear on the screen. At this point, the system will record the data collected during the test in the relevant FILE. G) If the test FILE for a particular job is requested, it can be called up with a special programme, to be consulted or printed. 2) In the case of special hoist/winch trolleys which cannot be tested with the test bench, the department for cabling installations on board the crane is requested to carry out the trial. See point 6 below.

During the test, acoustic and mechanical tests must also be carried out:

Noise checks of the geared motors for the trolley sliding

Noise checks of the hoist/winch

Checks for anomalous vibrations or noises in the electromechanical components

Checks for oil leaks from the hoist/winch

Checks to make sure that all warning notices have been provided.

Once the test has been completed, the hoist/winch trolley will be packaged using:

1) Wooden boxes for hoists and packaging waterproofed with nylon.

2) Wooden pallets for winches, with packaging waterproofed with nylon.

Once the packaging operation is completed, the hoist/winch trolley will be stored in the area reserved for this purpose.

NB In the case of special hoist/winch trolleys which cannot be tested with the test bench, the department responsible for cabling electrical installations on board cranes is requested to carry out the packaging operations. See point 6 below. 6. The unpacked hoist/winch trolley will be stored in the areas reserved for this purpose.

CRITICAL



FOR CRANES


POINTS

Instructions or warnings

The operator must follow the instructions supplied by the foreman or head of production carefully.

The operator must select the components to be assembled and carry out the cabling as indicated in the technical file.

The hoist/winch trolley is identified by means of job number stamped on the trolley.

All assembly and cabling operations are self-monitored, and the operator must therefore take particular care with them.

Any anomalies or discrepancies in the electrical design must be reported immediately to the foreman or the head of production, who will request help from the design office if necessary.

For assembly operations, the operator must use manual tools, rechargeable power starters and measuring tools such as: digital multimeters and digital ammeter clamps. NB The measuring instruments can be personal or supplied by the electrical workshop, and must have the calibration validation stamp with the expiry date marked.


FOR CRANES


Assembly and Cabling of Festoons

CRITICAL POINTS


Once the project has been checked, the head of the festoon department starts assembling and cabling festoons. Assembly and Cabling of Festoons

The head of the festoon department consults the technical file relating to the jobs orders in progress, in order to obtain all the necessary information to be able to properly choose the components to be assembled for the cabling of the trolley festoon and the push-button panel.

The assembly and cabling of the festoons can be carried out in two ways:

1) By means of special machinery for pulling flat cables and automatically assembling festoon trolleys. The automatic process is described below: A) On the computer installed on the festoon machine, call up the job relating to the festoon to be assembled. B) Insert the flat cables, indicated on the festoon programme of the job concerned, into the part of the machine used for pulling the festoons. C) Load the festoon trolleys, indicated on the festoon programme of the job concerned, into the machine. D) Press the START button on the screen and the START button on the machine. The machine will automatically pull the flat cables and assemble the festoon trolley. E) In case of jamming or locking during the assembly of the festoon, the operator must stop the machine immediately. Before the machine is restarted, the cause of the jam must be removed or the fault must be fixed. F) Once the festoon has been constructed, the operator moves it from the cable duct of the festoon machine to that of the mobile trolleys which carry the crane electric system. G) The festoon, using the mobile trolleys which carry the crane electric system, is taken to the area used for stripping the flat cable, attaching caps onto conductors and cabling flat cables in connectors.


FOR CRANES


CRITICAL POINTS


H) Using the machine for stripping flat cables, the external PVC covering is removed from the cable, and the internal conductors are stripped to prepare them for the next stage. I) Using semi-automatic stripping and stapling machines (the machines are subdivided according to the section of conductors), the conductors are stripped and assembled on the stripped part of the special caps which are used in the next stage of cabling. L) The flat cables are inserted into the sheaths of the connectors, and the conductors with stapled terminals are connected to the connector plugs/sockets. M) Once the plugs/sockets have been connected, they are fixed to the connector sheaths. 2) If the trolley festoon or festoon with buttons is a special type (e.g. the CP1 – IPE80 festoon trolleys – special, quantity/type of flat cables greater than standard) and cannot be assembled using the festoon machine, the department for cabling installations on board the crane is requested to assemble the festoon. See point 6 below. 6

Festoons are identified by means of paper tape marked with the job number in permanent marker. When the assembly and cabling of the festoon is completed, the mobile trolley for carrying electrical equipment will be stored in the area reserved for this purpose.


FOR CRANES


CRITICAL POINTS




The operator must choose the flat cables and festoon trolleys to be assembled following the indications in the technical file and the relevant the festoon machine programme.

Festoons must be identified by means of paper tape marked with the job number in permanent marker.



For cutting, stripping and cabling of the festoons, the operator must use manual tools, semiautomatic machines for cutting and stripping, and rechargeable electrical starters, available from the electrical workshop.


FOR CRANES


Assembly – Cabling – Testing – Packaging of crane’s on-board electrical system using test bench

CRITICAL POINTS


Once the project has been checked, the head(s) of the crane’s on-board electrical system starts the process of assembly, cabling, testing, and packaging of the electrical system on board the crane. Procedure of assembly - cabling – packaging of crane’s on-board electrical system

The head of the department for the crane’s on-board electrical systems will consult the technical file relating to the jobs in progress, in order to obtain all the information necessary to be able to select the correct components to be assembled and the methods of cabling of the crane’s on-board electrical system.

Take the mobile trolley with festoons relating to the job in progress from the festoon stockroom.

Using the mobile trolley, take the other components of the crane’s on-board electrical system indicated in the technical file.

1) Electrical panel 2) Push-button panel 3) Radio remote control (if present) 4) Connector with power line for electrical panel input or line cordsets

with connector and power socket trolley(s) (if present). 5) Connector with bridge slide plug 6) Bridge slide motors 7) Cordsets for bridge sliding motors 8) Bridge slide stop 9) Bridge slide photocells (if present), with the relevant accessories 10) Any accessories supplied with the crane’s on-board electrical

system (e.g. - lights, flashing lights to indicate crane in movement, etc.), if present.


FOR CRANES


CRITICAL POINTS


Cabling of the components of the crane’s on-board electrical system as indicated in the technical file:

1) Connection of motor cordsets, stop, and photocells, if applicable, to bridge slide connector with plug.

2) Preparation and connection of cables for any accessories supplied with the crane’s on-board electrical system (e.g. - lights, flashing lights to indicate crane in movement, etc.), if present.

3) Connection of festoon connectors with plug to electrical panel. 4) Connection of festoon connectors with socket (trolley side) to test

bench. 5) Connection of line cord connector with plug from test bench to

electrical panel. 6) All connection and cabling operations of the crane’s on-board

electrical system are self-monitored.

Calibration of inverters in the panel against the calibration table in the electrical design.

Safety check of electrical system according to IEC machine regulation EN60204-32 with ASITA MARK II instrument. List of tests to be carried out following a guided procedure on the instrument display referred to above, as described below:

A) Visual inspection of electrical system B) Continuity test of protective conductor C) Insulation resistance test NB The ASITA MARK II user’s manual is attached. NB The ASITA MARK II instrument must have the calibration validation label marked with the expiry date.

CRITICAL POINTS



FOR CRANES


Test of the crane’s on-board equipment using an appropriate test bench, following a guided testing procedure, as described below:

A) Call up the job relating to the crane’s on-board equipment, using the appropriate testing programme. B) Insert the name of the tester in the space provided. C) Press the COLLAUDO PULSANTIERA + START [TEST PUSH-BUTTON PANEL + START] button on the screen and follow the instructions given on the test bench screen: - Press the start/stop buttons, following the instructions on the screen. - Press the buttons for moving the crane (up, down, forwards, backwards, right, left), following the instructions on the screen. D) Press the COLLAUDO RADIOCOMANDO [RADIO REMOTE CONTROL TEST] button on the screen + START if there is a radio remote control in the job order, and follow the instructions on the test bench screen. - Press the start/stop buttons, following the instructions on the screen. - Press the buttons for moving the crane (up, down, forwards, backwards, right, left), following the instructions on the screen. E) Press the COLLAUDO QUADRO ELETTRICO [ELECTRIC PANEL TEST] button on the screen + START The test is carried out automatically by the test bench by means of cyclic tests on the circuits of the electrical panel. The most important tests are the following: - Check of the cabling of the circuits of the electrical panel - Check of the functioning of the components within the electrical panel, command processor, fuse holder, contactors, relays, timers, inverters, terminals, etc. - Check of sequence of power line input stages - Check of directions of movement of lifting, bridge sliding, trolley sliding. - Check of trolley festoon and relevant connectors - Check of festoon with buttons and relevant connectors NB If an error occurs during the electric panel test, a message will appear on the screen indicating the type of fault, and the test will be interrupted. To make troubleshooting easier, the test can be done separately from the rest of the festoon installation, following the relevant procedure. See point G.

CRITICAL



FOR CRANES


POINTS

F) Press the COLLAUDO PONTE E FINECORSA [BRIDGE AND STOP TEST] button on the screen + START and follow the instructions given on the test bench screen: - Check of bridge slide stop (forward/backward slowing and terminal) - Check of the bridge slide photocells (if present) - Check of the direction of movement of the left and right bridge slide motors and measuring of the currents in the three stages of the single- and double-speed motors. G) N.B. Optional procedure carried out only if necessary – see pointMove the festoon connectors with plug – electrical panel side – to the tbench. Press the COLLAUDO FESTONI [FESTOON TEST] button the screen + START. The test is carried out automatically by the tebench by means of cyclical tests on the festoon conductors. At eafestoon, the test will stop to allow the operator to change the typefestoon to be tested. If an error occurs during testing, a message will appear on the screen indicating the type of fault, and tests will be interrupted. H) If an error occurs during testing, a message will appear on the screen indicating the type of fault, and tests will be interrupted. Before continuing with the tests, the operator must eliminate the fault. Once this has been done, the operator can resume the test from the point at which it was interrupted or restart from the beginning. I) The result of the test is positive only when all the operations requested during testing are carried out properly. L) When the test has a positive result, the message “COLLAUDO ESEGUITO CON SUCCESSO” [TEST SUCCESSFUL] will appear on the screen. If successful, each test (see points C/G) will be recorded in the relevant test FILE. G) If the test FILE for a particular job is requested, it can be called up with a special programme, to be consulted or printed.

During the test, acoustic and mechanical tests must also be carried out: - Noise checks of the geared motors for the bridge sliding - Checks for anomalous vibrations or noises in the electromechanical

components


CRITICAL POINTS



FOR CRANES


Once the test is finished, before closing the cover of the electrical panel, the operator must check that the final file relating to the documentation is in the document pocket.

Once the electrical panel cover has been closed, check that the metal label “APPARECCHIATURA ELETTRICA” [ELECTRICAL EQUIPMENT] is displayed on the cover, with the CE [EC] label and the equipment’s identifying data properly stamped.

Once the test and checks are finished, the crane’s on-board electrical system will be packaged using the cardboard boxes on top of wooden pallets. The crane’s on-board equipment/system must be identified in this way: the job number must be written in permanent marker on the box containing the crane’s on-board system.

Once the packaging has been completed, the box containing the electrical system will be stored in the area reserved for this purpose.




The crane’s on-board equipment/system must be identified in this way: the job number must be written in permanent marker on the box containing the crane’s on-board system.



For the assembly and cabling operations, the operator must use manual tools, rechargeable power starters and measuring tools such as: digital multimeters and digital ammeter clamps. NB The measuring instruments can be personal or supplied by the electrical workshop, and must have the calibration validation stamp with the expiry date marked.

For the tests, the operator must use the test bench.

Assembly - cabling - test - packaging of electrical system directly on crane or

on electrical system cabling tracks (without test bench)


FOR CRANES


CRITICAL POINTS


Once the project has been checked, the head(s) of the crane’s on-board electrical system starts the process of assembling, cabling, testing, and packaging of the electrical system on board the crane. Procedure of assembly - cabling – packaging of electrical system directly on board the crane or on the electrical system cabling tracks.

The head of the department for the crane’s on-board electrical systems will print and consult the technical file relating to the jobs in progress, in order to obtain all the information necessary to be able to select the correct components to be assembled and the methods of cabling of the crane’s on-board electrical system.

Trolley festoons and festoons with buttons relevant to the job in progress assembled directly onto the channels for the festoon of the crane, or on the channels for the festoon on the electrical system cabling tracks.

Installation on the crane of other components of the electrical system indicated in the technical file:

1) Electrical panel (+ resistors, if any) 2) Push-button panel 3) Radio remote control (if present) 4) Bridge slide stop 5) Bridge slide photocells (if present), with the relevant accessories . 6) Bridge slide motors Hoist/Winch Trolley 8) Any accessories supplied with the crane’s on-board electrical system (e.g. - lights, flashing lights to indicate crane in movement, etc.), if present. 9) Power line box or connector 10) Any connecting box or connector on board the crane.

CRITICAL POINTS


Cabling of the components of the crane’s on-board electrical system as indicated in the technical file: 1) Preparation and connecting of cables of motors, stops, and bridge

stop photocell to the electrical panel


FOR CRANES


2) Preparation and connection of cables for resistors, if present, to the electrical panel.

3) Connection of trolley festoons and festoons with buttons to the electrical panel.

4) Connection of trolley festoons to the connector or to the trolley connecting box

5) Connection of pushbutton panel or radio remote control to the control connector on the pushbutton trolley or on the electric panel.

6) Preparation and connection of line cable from the line connecting box to the electric panel.

7) Preparation and connection of cables for any accessories supplied with the crane’s on-board electrical system (e.g. - lights, flashing lights to indicate crane in movement, etc.), if present.

8) All connection and cabling operations of the crane’s on-board electrical system are self-monitored.

Calibration of inverters in the panel against the calibration table in the electrical design.

Safety check of electrical system according to IEC machine regulation EN60204-32 with ASITA MARK II instrument. List of tests to be carried out following a guided procedure on the

instrument display referred to above, as described below: A) Visual inspection of electrical system B) Continuity test of protective conductor C) Insulation resistance test NB The ASITA MARK II user’s manual is attached. NB The ASITA MARK II instrument must have the calibration validation label marked with the expiry date.

CRITICAL POINTS


Manual test of crane’s on-board system, following the procedure described below:

- Check of the functioning of the push-button panel/station and radio remote control, if any. - Check of the functioning of the components within the electrical panel, command processor, fuse holder, contactors, relays, timers, inverters, terminals, etc. - Check of sequence of power line input stages - Check of directions of movement of lifting, bridge sliding, trolley


FOR CRANES


sliding. - Check of trolley festoon and relevant connectors - Check of festoon with buttons and relevant connectors - Check of lifting stop (lifting/lowering terminal, emergency lifting) - Check of bridge slide stop (forward/backward slowing and terminal) - Check of the bridge slide photocells (if present) - Check trolley sliding stop (slowing and right/left terminal). - Measure and check currents on the three stages of the single- and double-speed lifting motors, bridge sliding, trolley sliding (the acceptability is defined in the technical file). - The result of the test is positive only when all the operations requested during testing are carried out properly. - The test will be recorded by filling in all the sections of the SCHEDA COLLAUDO [TEST FORM], attached to the technical file.

During the test, acoustic and mechanical tests must also be carried out: - Noise checks of the hoist/winch

- Noise checks of the geared motors for the trolley sliding - Noise checks of the geared motors for the bridge sliding

- Checks for oil leaks from the hoist/winch - Checks for anomalous vibrations or noises in the electromechanical

components


Once the test is finished, before closing the cover of the electrical panel, the operator must check that the final file relating to the documentation is in the document pocket.

CRITICAL POINTS


Once the electrical panel cover has been closed, check that the metal label “APPARECCHIATURA ELETTRICA” [ELECTRICAL EQUIPMENT] is displayed on the cover, with the CE [EC] label and the equipment’s identifying data properly stamped.

Once the test and checks are finished, the crane’s on-board electrical system will be packaged in cardboard boxes on wooden pallets or, if the crane has a gangway or access balcony, the whole electrical system will be packaged, with waterproofing nylon, on the gangway or access balcony. The trolleys will be packaged in wooden boxes for hoists and wooden pallets for winches, with nylon waterproofing. Nylon bags will be used to cover the sliding motors on the bridge heads.

The job number must be written in permanent marker on the box


FOR CRANES


containing the on-board system, or, if it has been packaged on the gangway or access balcony, it will be identified with a stamp on the bridge beams.

Once the packaging has been completed, the box containing the crane’s on-board electrical system or the crane itself will be stored in the area reserved for this purpose.

Before approving the dispatch, the tester must check that: - All previous stages have been successfully carried out

- All the checks have been passed. Instructions or warnings



The job number must be written in permanent marker on the box containing the on-board system, or, if it has been packaged on the gangway or access balcony, it will be identified with a stamp on the bridge beams.

CRITICAL POINTS




For the assembly and cabling operations, the operator must use manual tools, rechargeable power starters and measuring tools such as: digital multimeters and digital ammeter clamps.

NB The measuring instruments can be personal or supplied by the electrical workshop, and must have the calibration validation stamp with the expiry date marked.

For tests, the operator must use the “SCHEDA COLLAUDO” [TEST FORM] attached to the technical file.


FOR CRANES


QUIT1-IEM-3266-RevA-Documento de pruebas.pdf

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