Documente Academic
Documente Profesional
Documente Cultură
Entrega inicial
REV
DESCRIPCIN
CB
DIBUJO /
DRAWN
NB
CONTROL /
CHKD
MC
APROB. /
APPD
2015.04.02
FECHA / DATE
PROPIETARIO / EMPLOYER
CONTRATISTA/ CONTRACTORS
FECHA /
DATE
DIB. / DRAWN 2015.04.02
CONTRL / CHKD 2015.04.02
APROB. /APPD 2015.04.02
NOME /
NAME
CB
NB
MC
QUITARACSA I
DOCUMENTO DE PRUEBAS /
TESTS DOCUMENT
Primera entrega
/First issued date
2015.04.02
DESCRIPTION OF OPERATIONS
DESCRIPTION OF OPERATIONS
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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DESCRIPTION OF OPERATIONS
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.)
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DESCRIPTION OF OPERATIONS
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DESCRIPTION OF OPERATIONS
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Instructions or warnings
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DESCRIPTION OF OPERATIONS
Once the project has been checked, the head of the festoon department
starts assembling and cabling festoons.
Assembly and Cabling of Festoons
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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.
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DESCRIPTION OF OPERATIONS
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.
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DESCRIPTION OF OPERATIONS
Instructions or warnings
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Assembly Cabling Testing Packaging of cranes onboard electrical system using test bench
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DESCRIPTION OF OPERATIONS
Once the project has been checked, the head(s) of the cranes 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 cranes on-board electrical
system
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The head of the department for the cranes 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 cranes
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 cranes onboard 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 cranes on-board electrical
system (e.g. - lights, flashing lights to indicate crane in movement,
etc.), if present.
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DESCRIPTION OF OPERATIONS
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Checks to make sure that all warning notices have been provided.
DESCRIPTION OF OPERATIONS
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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 equipments
identifying data properly stamped.
Once the test and checks are finished, the cranes on-board electrical
system will be packaged using the cardboard boxes on top of wooden
pallets.
The cranes on-board equipment/system must be identified in this way:
the job number must be written in permanent marker on the box
containing the cranes 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.
Instructions or warnings
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DESCRIPTION OF OPERATIONS
Once the project has been checked, the head(s) of the cranes 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.
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The head of the department for the cranes 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
cranes 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 cranes 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.
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DESCRIPTION OF OPERATIONS
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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
Checks to make sure that all warning notices have been provided.
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.
DESCRIPTION OF OPERATIONS
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 equipments
identifying data properly stamped.
Once the test and checks are finished, the cranes 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
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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 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.
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DESCRIPTION OF OPERATIONS
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 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.
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