SPX Power Team MCS Series Manuale utente
© 2014 SPX CORPORATION 1Form No. 1000773
Rev. 0 August 12, 2014
These operating instructions must be read and thoroughly understood for the
safe commissioning, operation, and maintenance of the Motion control system. The
following procedures must be performed by qualified, trained personnel who are
familiar with this equipment. While every attempt has been made to ensure clarity, the
intent of this document is to provide basic guidance and it is the responsibility of the
end user to review each application thoroughly for suitable usage. Users should utilize
sound engineering judgment prior to, and during, product operation. Failure to comply
may result in damage, injury, or death.
Tech Services: +1 800 477 8326
Fax: +1 800 765 8326
Order Entry: +1 800 541 1418
Fax: +1 800 288 7031
SPX Hydraulic Technologies
5885 11th Street
Rockford, IL 61109-3699 USA
powerteam.com
MOTION CONTROL SYSTEM
MCS Series
Operating Instructions for:
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© 2014 SPX CORPORATION 2Form No. 1000773
Rev. 0 August 12, 2014
SUBJECT PAGE
GLOSSARY 4
DESCRIPTION 6
SAFETY SYMBOLS AND DEFINITIONS 8
SAFETY PRECAUTIONS 8
• PUMP 10
• ELECTRIC DRIVEN MOTOR 10
• HOSES 10
• CYLINDER 11
• ELECTRIC CONTROL UNIT 12
GENERAL OVERVIEW 13
• CYLINDER APPROACH TO LOAD 16
TRANSPORTATION 17
UNPACKING 17
OPERATING INSTRUCTIONS 19
1. Setup 19
2. Components 19
3. Documentation 19
4. Installation 19
5. Cylinders 19
6. Linear Displacement Sensors 20
7. Hydraulic Connections 20
8. Electric Connections 20
9. Important 21
SETUP AND STARTUP 21
ALARMS AND HOW TO RESET 35
GENERAL MAINTENANCE 37
1. System Evaluation 37
2. Inspection 37
3. Periodic Cleaning 37
4. Hydraulic Fluid Level 37
5. Hose Connections 38
6. Storage 38
TROUBLESHOOTING GUIDE 39
SCHEMATICS 42
TABLE OF CONTENTS
© 2014 SPX CORPORATION 3Form No. 1000773
Rev. 0 August 12, 2014
COMPONENT SPECIFIC DATA SHEETS 43
ANNEX 44
1. SPX cylinder size and square centimeter (aera) table 44
2. Motion Control System Checklist 44
3. Declaration of Conformity 46
POWER TEAM FACILITIES 47
TABLE OF CONTENTS
© 2014 SPX CORPORATION 4Form No. 1000773
Rev. 0 August 12, 2014
In the context of this Instruction sheet, the following words have the meaning as
described:
Accuracy Difference in measurement unit (usually mm or inch) be-
tween the load movement of the leading vs the lagging lifting
point.
Actuation time Time period during which the spool of the directional valve
as well as the spool of a 2-position-2-way valve to at least
one hydraulic circuit is energized.
Displacement mode Operational mode in which the PLC unit determines the
Actuation time of each 2-position-2-way valve and thus keep
the movement of the load within the preset accuracy.
Displacement sensor Device to measure the movement of the load as a result of
the
application of forces generated by hydraulic cylinders
Forced zero Starting point of the controlled load movement achieved by
pressing the "Reset" button. For Displacement mode only
Hydraulic circuit Hydraulic Cylinder connected to a 2-way-2-position valve
and the return line of the pump unit via a hydraulic hose
Lifting point The location on the load where force generated by hydraulic
cylinders is applied
Manual mode The operator is solely responsible and in
control of the movement of each cylinder while using
manual mode!
Operational mode in which the PLC unit
does NOT have any automated control function.
Measuring system Set of analog displacement sensor, sensor cable and
analog pressure sensor, one each per hydraulic circuit
Motion Control Any type of movement or translocation of a heavy load by
means of forces generated by hydraulic cylinders operated
by and under the control of a PLC-based control system
GLOSSARY
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© 2014 SPX CORPORATION 5Form No. 1000773
Rev. 0 August 12, 2014
PLC unit Programmable Logic Controller composed of analog input chan-
nels,
digital output channels and computing capabilities to control the
advance and retract operation of hydraulic cylinders within specic
parameters of accuracy and repeatability.
Pressure mode Operational mode in which the PLC unit controls the pressure ap-
plied to each hydraulic circuit against a maximum pressure value.
There is NO control of the actual movement of the
load in this mode.
Pressure sensor Device to measure the oil-pressure within the hydraulic circuit, one
per hydraulic circuit (motion point).
Pump unit Assembly of a hydraulic pump mounted on a reservoir with valves
and pressure sensors.
Sensor cable Shielded cable between the Displacement sensor and the PLC unit
as
carrier for the analog signal generated by the Displacement sensor.
Target Total movement of the load that shall be achieved simultaneously at
all
lifting points under the control of the PLC unit.
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GLOSSARY CONTINUED
© 2014 SPX CORPORATION 6Form No. 1000773
Rev. 0 August 12, 2014
Motion control is all about precision and control of a mass in motion; precision in the measure-
ment of movements and control over the energies involved.
Whether it is a bridge, a building or any other kind of heavy load; lifting, lowering, tilting or posi-
tioning of such a load can be carried out completely automatically with a high degree of accu-
racy when using the SPX® Power Team® Motion Control System.
The PLC-controlled system includes a combination of digital actuation and digital control that
provides signicant advantages including time savings, repeatability, and extremely low inter-
nal stress in the object being moved.
In the standard conguration, a state-of-the-art A/D measurement system captures the dis-
placement of the load during the movement process, in increments of less than two hundreths
of a millimeter. Those digital signals are then processed by the PLC, utilizing powerful algo-
rithms, to generate the digital output used by the hydraulic system.
With system performance being driven by extremely short duration actuation times for speci-
cally selected valves, only small units of oil are directed to the selected hydraulic cylinders at
any given moment. With this "partitioning" of the hydraulic oil, the hydraulic system becomes a
virtual digital hydraulic system with all advantages of checkability and control over the move-
ment of the load.
Subsequently, with all movement points being synchronized and under full control, no addition-
al stresses are induced into the object being moved due to bending, torsion or shifting loads.
Measurements are taken and calculations are made utilizing a Best Developed
Available Technology (BDAT) PLC. Using the BDAT-PLC allows the operator to focus on moni-
toring the movement without having to interfere or even take long-lasting manual interventions.
This creates the basis for signicant time savings compared to traditional methods of moving
heavy loads.
Improved control in applications that involve the same movement repeatedly, such as self-
climbing formworks, strand-lift or stage-lift operations, is due to the functionality of the PLC
software and the operational features provided by the HMI (Human Machine Interface).
The same factors also allow for an automated documentation of the movement including pres-
sure (force) on the various cylinders, a time signal and all operator actions taken via the HMI
(Human
Machine Interface).
DESCRIPTION
© 2014 SPX CORPORATION 7Form No. 1000773
Rev. 0 August 12, 2014
The motion control system is a PLC-based eight lift point (expandable) motion control
system which allows for accurate and reliable control of multiple hydraulic cylinders to accom-
plish the lifting / lowering / pushing / etc. of almost any size load. The PLC software controls
valves
feeding each hydraulic cylinder in a way that will keep the load-movement synchronized within
the preset tolerance range, regardless of the actual load distribution within the hydraulic circuit.
• One hydraulic setup suits both single and double-acting cylinders under different pressure -
different load – in each circuit
NOTE: When using single - acting cylinders, an overcenter, or other appropriate valve should
be used as safety in the event of hose break.
• Controlled cylinder movement in both directions: advance and retract
• Complete Motion Control System package consists of the following modules
Controller
Measuring System
Pump Unit
Valve System
Electrics/Electronics
DESCRIPTION CONTINUED
© 2014 SPX CORPORATION 8Form No. 1000773
Rev. 0 August 12, 2014
The safety signal word designates the degree or level of hazard seriousness.
[ IMPORTANT: This guide cannot cover every hazard or situation so always do the job
with SAFETY FIRST in mind.]
Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation
which, if not avoided, may result in property damage.
IMPORTANT: Important is used when action or lack of action can cause equipment failure, either
immediate or over a long period of time.
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SAFETY SYMBOLS AND DEFINITIONS
SAFETY PRECAUTIONS
In order to take the necessary actions to avoid an accident with or any damage to the MCS
motion control system, or the load being positioned, note:
Create a lifting plan that includes:
• Who is involved and what their responsibilities are.
• What the lift objectives are and what are actions and their sequence in order to
achieve the lift.
• When the lift will take place, over what time frame .
• Where the lift takes place and where critical lift or reaction points are located.
• A comprehensive safety plan.
• Local special conditions ( legal, environmental, geographical, etc.)
Before putting the motion control system into operation, the operator shall analyze the
lift application for all foreseeable risks, their likelihood to occur, and the potential
consequences of the identied risks as per ISO 31000 and ISO/IEC 31010 in their ac-
tual
current version.
Create a lifting log documenting the lifting job as per annex XX of this manual.
© 2014 SPX CORPORATION 9Form No. 1000773
Rev. 0 August 12, 2014
SAFETY PRECAUTIONS CONTINUED
• Read and understand the Operating Manual before operating this equipment. For
the latest version of the instruction please visit the “Resources” page on our Web-
site (www.PowerTeam.com)
• IMPORTANT: For instructions specic to the various system components refer to
the related individual manufacturer’s instructions that have been included with the
MCS.
• IMPORTANT: The following procedures must be performed by qualied, trained
personnel who are familiar with this equipment. Operators must read and under-
stand all safety precautions and operating instructions included with the MCS Mo-
tion
Control System. If the operator cannot read these instructions, operating instruc-
tions and safety precautions must be read and discussed in the operator's native
language.
• The motion control system is designed for general use in normal environments.
These products are not designed for lifting and moving in special work environ-
ments such as: explosive, ammable, or corrosive. Only the user can decide the
suitability of this
system for use in these conditions or extreme environments. Power Team will
supply information necessary to help make these decisions. Consult your nearest
Power Team facility.
• Safety glasses and hearing protection must be worn at all time by the operator and
anyone within sight of the unit. Additional personal protection equipment may in-
clude: face shield, goggles, gloves, apron, hard hat, and safety shoes.
• The owner of this motion control system must ensure that safety-related decals are
installed, maintained, and replaced if they become difcult to read or understand.
• Disconnect electrical power prior to opening electrical cabinet.
To prevent operator error, perform all of the following steps to develop a
lift plan for therequirements including and especially concentrating on the controlled movement
with an assistant
operator whose sole task it is to double-check and verify any input and operational action taken
by the main operator.
IMPORTANT: All movements to be performed by the Motion Control System must be
ordered and approved by the person responsible at the job site. SPX Power Team will assist in
operating the Motion Control System, but cannot be responsible for static or strength calcula-
tions of the structure or load to be moved.
After setting up the MCS, the system needs to be tested for correct map-
ping of circuit number on the screen versus displacement sensors and correlation with the
2-way valves. Extend each displacement sensor individually for approximately 100 mm and
verify the displacement
indication on the screen to show the same change of values. Set the system into “Manual”
mode and activate each circuit one by one. Verify the function of the related 2-way valve by
checking the
movement of the spool-core.
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© 2014 SPX CORPORATION 10 Form No. 1000773
Rev. 0 August 12, 2014
PUMP
• Do not exceed the hydraulic pressure rating noted on the pump nameplate or tamper with
the pump's internal high pressure relief valve. Creating pressure beyond rated capacities
can result in personal injury.
• Retract all cylinders in the system before adding uid to prevent overlling the pump
reservoir. An over-ll can cause personal injury due to excess reservoir pressure created
when cylinders are retracted.
ELECTRIC-DRIVEN MOTOR
Electrical work must be performed and tested by a qualied electrician per local
directives and standards.
• Disconnect the pump from the power supply and relieve pressure before removing the
motor case cover, or performing maintenance or repair.
• Check the total amperage draw for the electrical circuit you will be using. For example: Do
not connect a pump that may draw 25 amps to a 20 amp fused electrical circuit.
• Never use an ungrounded power supply with this unit.
• Changing the voltage is an involved and, if incorrectly performed, hazardous procedure.
Consult the manufacturer for specic information before attempting rewiring.
• Wire pump motors for counterclockwise rotation when viewed from the shaft end of the
motor.
• Do not attempt to increase the power line capacity by replacing a fuse with another fuse of
higher value. Overheating the power line may result in re.
• Exposing electric pumps to rain or water could result in an electrical hazard.
• Avoid conditions that can cause damage to the power cord, such as abrasion, crushing,
sharp cutting edges, or corrosive environment. Damage to the power cord can cause an
electrical hazard.
HOSES
• Before operating the pump, tighten all hose connections using the correct tools. Do not
over-tighten. Connections should be only secure and leak-free. Over-tightening can cause
premature thread failure or high pressure ttings to split at pressures lower than their rated
maximum operating pressure.
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SAFETY PRECAUTIONS CONTINUED
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