NOTICE DE MONTAGE ST (anglais)
Transcript of NOTICE DE MONTAGE ST (anglais)
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01/A
A S S E M B LY I N S T R U C T I O N S
SAFETY MEASURES
Z.I. de la sablire 64270 PUYO FRANCETl. +33 5 59 65 12 19 Fax +33 5 59 65 20 05
Ml : [email protected] - site web : www.otech.fr
E A S Y I R R I G A T I O N MAJ 10/2001
mailto:[email protected]://www.otech.fr/http://www.otech.fr/mailto:[email protected] -
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INDEX
INDEX _______________________________________________________________________________2
PREVENTION PLAN ___________________________________________________________________3
SAFETY MEASURES ___________________________________________________________________4
Building site : ________________________________________________________________________4
Compulsory equipment : ______________________________________________________________4
Safety measures concerning cranes : _____________________________________________________5
Necessary equipment to assemble an ST pivot :____________________________________________6
Maintenance vehicle _________________________________________________________________6
Cranes ____________________________________________________________________________6
Straps _____________________________________________________________________________6
Spanners __________________________________________________________________________6
Toolbox ___________________________________________________________________________6
Electrician's tool kit__________________________________________________________________6Kit to lift the first beam _______________________________________________________________6
ASSEMBLING THE PIVOT______________________________________________________________7
Unloading :__________________________________________________________________________7
Beam ST lg: 32.36 m __________________________________________________________________8
Beam ST lg: 38.32 m __________________________________________________________________9
Poutre ST lg: 44.00 m ________________________________________________________________10
Beam ST lg: 50.10 m _________________________________________________________________11
Beam ST lg: 56.20 m _________________________________________________________________12
Beam ST lg: 62.15 m _________________________________________________________________13
Assembling the centre element :________________________________________________________14
Assembling the beams :_______________________________________________________________17
Assembling the first coupling fitting : ___________________________________________________22
Assembling the first span to the centre element : _____________________________________________23
Assembling an intermediate tower box :_________________________________________________25
Assembling the end boom :____________________________________________________________26Lifting procedures : stages ____________________________________________________________30
Assembling an intermediate tower : ____________________________________________________31
Assembling the last tower :____________________________________________________________34
Electric wiring diagram : _____________________________________________________________35
PIVOT ACTIVATION PROCEDURE _____________________________________________________36
Procedures without water : _____________________________________________________________36
Filling with water : __________________________________________________________________39
PIVOT REPAIR PROCEDURE __________________________________________________________40
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PREVENTION PLAN
DECREE N 92-158 of the 20th February 1992Modified by decree n 94-1159 of the 26th of December 1994
We remind you that the USER company (UC) must present its own prevention plan to the OUTSIDEcompany (OC).The user company (or customer) is responsible for prevention and safety on the building site.
Reminder: The manufacturer's assembly supervisors work under the user company's instructions (EE).However, the manufacturer's supervisors may impose certain safety measures (lifting means, individualprotective equipment (IPE)) on the user company.
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SAFETY MEASURES
Building site :
Signposts must be placed at the entrance to the building site, forbidding access to all "outside"unauthorised persons and reminding authorised personnel that safety helmets are compulsory.
Compulsory equipment :
Safety helmet Gloves
Safety shoes (or boots)An approved safety harness for all works carried
out 3.5 m above the ground
DO NOT climb on the truss rods or pipes. For all operations on beams which have alreadybeen raised, you must use a ladder fixed to the frame or to the centre pipe, in order to avoidsliding during the operation. These works are often carried out on soft or muddy grounds. WARNING: The ladder may sink as these works are often carried out on soft or muddygrounds.
You must wear gloves when handling galvanised spare parts, as there are many sharpends.
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Safety measures concerning cranes :
Cranes and maintenance vehicles must be driven by qualified personnel who possess aspecific driving licence.
Cranes must comply with the following conditions:
a) Lifting mechanisms must be equipped with a "descending" speed regulator.
b) As soon as the driver finishes, the breaks should engage automatically (the "dead man"device).
c) Command controls should return automatically to the "stop" position in the absence of thedriver's intervention. Hydraulic jacks must be equipped with an automatic valve to preventloads falling in the event of a hose breaking.
d) On equipment with a hydraulic mechanism (hydraulic crane) the pressure regulator,regulates the load. Nothing should be suspended from the hock when the crane is stopped.
e) It is forbidden to transport people on lifting equipment unless this equipment is designed forthat purpose.
f) It is forbidden to appoint drivers who are not familiar with safety measures and manoeuvresand whose ability has not been recognized by a medical examination, to drive cranes. Thisis also valid for workers directing these machines manoeuvres, by giving the driverinstructions.
g) Mechanical cranes must be placed on a resistant surface; the machine's limits must neverbe exceeded.
Cables, chains, natural and synthetic fibre cords must not be submitted to loads superior tothose laid down by the manufacturer, and approved by the Ministry of Employment. Theremustn't be any knots.
An authorized body must carry out trials and verifications regularly.
For hydraulic cranes, there is a French standard of manufacture NF E 52 088, approved byministerial order on the 22nd of April 1981 by the Secretary of State for Trade and Industry.
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Necessary equipment to assemble an ST pivot :
Maintenance vehicle
A 4 wheel drive vehicle of sufficient capacity (minimum of 2.5 tons) to lift loads of spare parts (trussrods, pipes, beams, base beams/axle trees, etc); or a tractor with a trailer which can carry 12 m pipes,to distribute the equipment on the assembly site.
Cranes
A hydraulic crane. Considering the span's weight (see table below), it is necessary to have a crane withsufficient capacity to lift loads to a height, under the hock 5.5 to 6 m (minimum distance between thevehicle and the load: 2.5 m). We recommend a 4-wheel drive vehicle equipped with a telescopic arm(photo1).
Span weight (without water)ST127 (span length: 62.15m) 1768 kgST141 (span length: 62.15m) 1910 kgST168 (span length: 62.15m) 2076 kgSR193 (span length: 50.80m) 2018 kgSR245 (span length: 39.50m) 1992 kg
Straps
These must be approved for the loads to be lifted; it is preferable to use fibre straps, 80mm diameterminimum, equipped with steel rings at the ends, for better stability and in order to avoid damagingthe pipes when these are placed.
Spanners
Electric or pneumatic, depending on whether you have a generator or a compressor, with 19-22-24-27 and 30 diameter sockets (19 and 30 equipped with an extension, if possible).
Toolbox
One wire cutter, one electrician's knife, 1 wire stripper, and two screwdrivers: one 4x100 and one Ahammer, an adjustable spanner, a claw spanner and a ratchet wheel for the socket set.
Electrician's tool kit
One wire cutter, one electrician's knife, 1 wire stripper, and two screwdrivers: one 4x100 and one
Kit to lift the first beam
Two parts to be fixed on the tower pipe and on one of the tower legs before lifting the first beam.
Table for tightening bolts quality 8.8 ISO 272 standard of the thread M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24
Tightening strength(Nm) 6.4 11.1 27 53 92 148 232 330 471 648 809
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ASSEMBLING THE PIVOTUnloading :
Check the material delivered corresponds to your order ( pipes, number of pipes, wheels,etc)
The beams must be assembled in line as much as possible to help adjustments when thepivot is activated (except for the first beam, see below).
Distribute the 12 and 6 m pipes, starting from the concrete slab - which corresponds to thecentre of the pivot; the pipes for the first span must form an angle -starting from the firsttower - to comply with diagram 1. To assemble the pivot take into account the piping plan(photo 2).
final
~ 45 cm
~250cm
Axe d'alignementFinal alignment axis
1re tour1st tower
Diagram 1
Place the coupling elements between the 12 m pipes, near the towers. The pipes should bedistributed in the area where the whole structure is to be assembled.
Distribute the truss rods at about 1.5 m either side of the pipe.
Distribute the first 1/2 coupling fitting - pivot.
Distribute the corner irons (delivered in bundles corresponding to the frames).
Distribute the elements for the centre pivot. Distribute the components for the towers along side the coupling elements: base beams,
tower legs, knee braces, nuts and bolts, etc.
Photo 1 Photo 2
Photo 3 Photo 4
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Beam ST lg: 32.36 m
0.60 m
1.50 m 3.00 m 3.00 m 1.50 m
4.78 m 1.20 m 4.78 m
11.95 m
0.77 m
0.65 m
1.05 m
1.25 m
1.81 m
1.10 m
1.87 m
1.10 m
1.49 m 3.00 m
5.98 m
0.60 m 4.78 m
e
ot
te avant porte faux
1/2 accouplement dpart pivFirst coupling fitting - pivot
1/2 accouplement dpart travFirst coupling fitting - span
1/2 accouplement tourFirst coupling fitting - tower
tEnd boom insert
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Beam ST lg: 38.32 m
0.60 m
1.50 m 3.00 m 3.00 m 1.50 m
4.78 m 1.20 m 4.78 m
11.95 m
0.77 m
0.65 m
1.05 m
1.25 m
1.81 m
1.10 m
1.87 m
1.10 m
e
ot
te avant porte faux
1/2 accouplement dpart pivFirst coupling fitting - pivot
1/2 accouplement dpart travFirst coupling fitting - span
1/2 accouplement tour coupling fitting - tower
tEnd boom insert
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Poutre ST lg: 44.00 m
0.60 m
1.50 m 3.00 m 3.00 m 1.50 m
4.78 m 1.20 m 4.78 m
11.95 m
0.77 m
0.65 m
1.05 m
1.25 m
1.81 m
1.10 m
1.87 m
1.10 m
1.49 m 3.00 m
5.98 m
0.60 m 4.78 m
e
t
te avant porte faux
1/2 accouplement dpart pivoFirst coupling fitting - pivot
1/2 accouplement dpart travFirst coupling fitting - span
1/2 accouplement tourFirst coupling fitting - tower
tEnd boom insert
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Beam ST lg: 50.10 m
0.60 m
1.50 m 3.00 m 3.00 m 1.50 m
4.78 m 1.20 m 4.78 m
11.95 m
0.77 m
0.65 m
1.05 m
1.25 m
1.81 m
1.10 m
1.87 m
1.10 m
e
t
te avant porte faux
1/2 accouplement dpart pivoFirst coupling fitting - pivot
1/2 accouplement dpart travFirst coupling fitting - span
1/2 accouplement tour coupling fitting - tower
tEnd boom insert
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Beam ST lg: 56.20 m
0.60 m
1.50 m 3.00 m 3.00 m 1.50 m
4.78 m 1.20 m 4.78 m
11.95 m
0.77 m
0.65 m
1.05 m
1.25 m
1.81 m
1.10 m
1.87 m
1.10 m
1.49 m 3.00 m
5.98 m
0.60 m 4.78 m
e
t
te avant porte faux
1/2 accouplement dpart pivoFirst coupling fitting - pivot
1/2 accouplement dpart travFirst coupling fitting - span
1/2 accouplement tour coupling fitting - tower
tEnd boom insert
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Beam ST lg: 62.15 m
0.60 m
1.50 m 3.00 m 3.00 m 1.50 m
4.78 m 1.20 m 4.78 m
11.95 m
0.77 m
0.65 m
1.05 m
1.25 m
1.81 m
1.10 m
1.87 m
1.10 m
e
ot
te avant porte faux
1/2 accouplement dpart pivFirst coupling fitting - pivot
1/2 accouplement dpart travFirst coupling fitting - span
1/2 accouplement tour coupling fitting - tower
tEnd boom insert
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Assembling the centre element :
The centre element is assembled horizontally. Assemble two tower legs with the insert - husk set(photo 5), then assemble the steps (corner irons) between these two tower legs. Repeat thisoperation for each tower leg (photo 6), always horizontally.
Lift the whole with a crane using a strap round the pivot elbow (photo 7). When the centre element issuspended, fix the feet to the ends of the tower legs.
Place the centre element on its concrete slab.
On the ground, assemble the pivot connectors to the water feed pipe (photo 8). It is VERYIMPORTANT to clean the joint opening.
Place the water feed pipe on the centre element, without forgetting to fit the drain pipe support inthe lower packing box first (photo 9); then lift the whole into the upper elbow packing box.
ST127
ST168
Fix the two connectors to the husk (photo 11).
Fix the two lower corner iron support rods of the water feed pipe between this pipe and the twocentre element tower legs (photo 12). CAREFUL: The position you choose for these corner ironsdepends on how the lower elbow is oriented, its horizontal axis must go through the V.
Assemble the packing box without forgetting the braid (photos 13 to 16).
Photo 5 Photo 6
Photo 7 Photo 8
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Photo 9 Photo 10
Photo 11 Photo 12
ST168
ST127
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Photo 13 Photo 14
Photo 15 Photo 16
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Assembly instructions Safety measures - Pivot ST MAJ 10/2001 17
Assembling the beams :
Once the pipes and span connectors are in place, loosen the plugs according to the piping plan.
Assemble the first 1/2 coupling fitting -pivot- with the first 12 m pipe, without forgetting the sealingjoint.
With a strap lift the 12 m pipe in order to assemble the two corner irons of the first frame (photo 18).CAREFUL how you assemble the corner irons (diagram below); see assembly details (photos 21
and 22).
Go back to the first coupling fitting and fix the truss rod and its extension (photo 20)
Strap another pipe in order to lift and present it facing the first pipe's flange (photos 23 to 25). Insertthe joint (photo 26) and then bolt the flanges together (photo 27), tightening them with the pneumaticspanner when the holes are in line.
Assemble the frame as explained above (photos 28 to 30).
Repeat this same procedure for all frames without forgetting the knee braces (photo 32).
Assemble the tower pipe, tighten the flange.
Fix the last truss rod to its extension, then the extension rod to the tower pipe.
CHECK ALL THE BOLTS ARE TIGHTENEDCHECK THE FLANGES ARE WELL POSITIONED
BADLY TIGHTENED BOLTS = SPAN MIGHT COLLAPSE
WRONG RIGHT
Lifting points
WARNING :Reference hole only for inside
angles (in green on the diagram)
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Photo 17
Photo 18
Photo 19 Photo 20
Photo 21 Photo 22
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Photo 23 Photo 24
Photo 25 Photo 26
Photo 27 Photo 28
Photo 29 Photo 30
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Photo 31 Photo 32
Photo 33 Photo 34
Photo 35 Photo 36
Attach the electric cables to the pipe with metallic clips, every 1.5 m (photos 37 to 40).
Allow extra cable for beyond the tower box.
Assemble the pipes according to the plan (in the case of a piping plan with drop pipes, onlyassemble the 180 elbows).
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Photo 37 Photo 38
Photo 39 Photo 40
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Assembling the first coupling fitting :
Assemble the coupling ring carefully (photo 42).
Tighten the M24 bolts and loosen 1/2 turn in order to allow the ring to turn.
Cover the end of the pipe with liquid soap.
Put the connector -equipped with joints- into the end of the tower pipe.
Place the drain joint in the first 1/2 coupling fitting -span- (photo 41) - small on the outside of thepipe.
Assemble the 1/2 coupling fitting with the ring (which is already assembled) (photo 45).
Put the connector in place and insert the M 16 locking screw (photo 44).
Photo 41Photo 42
Photo 43 Photo 44
Photo 45
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Assembling the first span to the centre element :
You must assemble the first pipe of the second span and its first frame in order to stabilize the wholeduring coupling operations (photos 46 to 49).
Photo 46 Photo 47
Photo 48 Photo 49
Before lifting the first beam, it is necessary to take the tools up the tower pipe, as in diagram 2.
Schma 2
Put the connector into the first 1/2 coupling fitting - pivot.
Strap the beam at its end (photos 50 and 51).
Start the lifting operation (photos 51 and 52).
Present the first 1/2 coupling fitting pivot - facing the holes of the upper elbow; guide the operation
from the top of the centre element (photo 53).
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Place the screws, washers, angle braces, according to diagram 3.
Tighten the M24 bolts (photo 54).
Slide the first connector into its final position.
Photo 50 Photo 51
Photo 52 Photo 53
Photo 54 Schma 3
Once the first beam is coupled to the centre element, continue assembling the following beams until the lasttower. The procedure is the same as for the first beam.
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Assembling an intermediate tower box :
Fix the alignment corner iron (photos 56 and 57).
Fix the tower box support leg (photo 58).
Assemble the tower box (photo 59).
Fix the non-wire alignment feature to the corner iron, without linking it to the box joint until the whole
is lifted (photo 60).
Photo 55 Photo 56
Photo 57 Photo 58
Photo 59 Photo 60
Once all the intermediate boxes are assembled, assemble the final box. Wire all the tower boxes (photo 61).
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Assembling the end boom :
The assembly procedure is the same for 12 to 30 m end booms.
Find and unreel the cables correctly (inscription engraved on the end) (photo 64).
Fix the back and front cables to the end boom tower legs (photos 65 and 66).
Once all the cables are in place, lift the end boom tower legs and place two screws per corner iron
(photos 69 to 71) without tightening them. Place the horizontal corner iron (photos 72 and 73).
Place the first 12 m end boom pipe and fix it by its flange (photos 74 to 76).
Keep the pipe lifted for the next operations.
Install the back cables (2 or 4 depending on the length of the end boom) (photos 79 and 80).
Screw the nut half way along the stud.
Install the front cables.
Screw the nut half way along the stud (photo 77).
Slowly lower the 12 m pipe until the cables are taut.
Tighten the bolts on the end boom tower legs.
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Photo 61 Photo 62
Photo 63 Photo 64
Photo 65 Photo 66
Photo 67
Photo 68
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Photo 69
Photo 70
Photo 71 Photo 72
Photo 73 Photo 74
Photo 75 Photo 76
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Photo 77 Photo 78
Photo 79 Photo 80
ASSEMBLING (and adjusting the gun)
20
10
170
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Lifting procedures : stages
1 Configuration of the pivot after assembly of the end boom (example of a pivot with 5 spans + end boom).
1 2 3 4 5
2 Assemble and lift the towers one by one from the first to the last except for the penultimate.
1 2 3 4 5
3 Assemble and lift the last tower using the end boom stabilizing cables to stabilize it during this operation.
1 2 3 4 5
4 Assemble and lift the penultimate tower.
1 2 3 4 5
Tower lifting point.
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Assembling an intermediate tower :
Place the 4 tower legs on the ground, along the beam and fix them with one bolt (photo 82).
Assemble the corner irons (rungs) to 2 tower legs with one bolt (photo 82).
Strap the beam round the tower pipe and start lifting slowly, the tower legs fall into placeautomatically (vertical position) (photos 83 and 84).
Place and fix the tower base without tightening the bolts (photos 85 and 86). Working upwards, place the rungs with a second bolt (photo 87).
Do not forget to lift the knee brace at the bolt.
Insert the rest of the nuts and bolts on the tower (without tightening them).
Assemble the drive train (photos 88 to 91).
Lift the whole a little more.
Place the wheels on the wheel gearbox and tighten the nuts (photos 92 and 93).
Carefully, lower the span until it touches the wheels, the tower base spins on its axis to fall intoplace.
Lift the span slightly in order to release the pressure on the tower base bolts (CAREFUL NOT TOLIFT the wheels off the ground).
Finally, go up the tower and from the top down, tighten all the nuts and bolts.
Release lifting pressure, move on to the next tower.
Photo 81 Photo 82
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Photo 83
Photo 84
Photo 85 Photo 86
Photo 87 Photo 88
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Photo 89 Photo 90
Photo 91 Photo 92
DRIVE LINE COUPLING ASSEMBLY
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Assembling the last tower :
Proceed in the same way as for the intermediate towers, paying attention to the triangle formed bythe end boom tower legs (photos 94 to 96).
During the lifting operation, two people must stabilize the end boom with stabilizing cables (photo96).
When assembling the tower base, do not forget the stabilizing cable support leg (photo 97).
Photo 93
Photo 94
Photo 95 Photo 96
WIRE ALL THE MOTORS IN THE TOWER BOXES
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Notice de montage Consignes de scurit pour pivot ST MAJ 10/2001 35
Schma de raccordement lectrique :
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PIVOT ACTIVATION PROCEDURE
Procedures without water :
Reminder : Electric wiring and start-up must be carried out by qualified personnel.
Check all the gear motors are connected in the same way (by the colour) in all the
tower boxes. Also check the cutout switches work ( I = engaged). Adjust all the intermediate tower box connection rods -set stud in such a way that the cam engages
the micro-control switch (photo 98).
Photo 97
In the main switchboard, check all the circuit breakers work (F1/F2/F3/F4) and that there arecartridge fuses. Engage the differential switch (S1) then close the double door.
F3 Q1F2 F4
S1
F1
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irritec
Frontal
Scurit
traves
Scurit
traves
Scurit
Appareil
AvantAuto
Arrire
Marcheavec eau
ArrtMarchesans eau
Doseur Cyclique
Pompe
En
Pression
MarcheAvant
MarcheArrire
Marche canon
Marche dernire tour
irritec
Frontal
11
2
3
3
Model A Model B
Engage the outside handle on the cutout fuse switch (picture 1).
Check the voltage between the phases (400v) with the fuse switch (picture 2) and the voltmeterswitch (switchboard B) or with a measuring device.
Set the WITH orWITHOUT WATER switch to WITHOUTWATER.
Set the FORWARDS/AUTO/REVERSE switch to FORWARDS.
Set the cyclic measuring device (picture 3) at 50%.
Start the pivot by putting the ON/OFF switch to ON.
The pivot should move anticlockwise. If it does not, stop the pivot immediately and reverse the 2
phases on terminals 7 and 8. The pivot should then work properly. Check all the intermediate tower box safety devices work by removing the ball joint. Also check the
last tower box by releasing the main switch of the last tower (during each operation the pivot shouldstop in SAFETY position).
Check the last tower safety device (option) works by manually operating the 2 END OF RUN switchesin both ways, in order to check both rotation directions.
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Procedure to check the automatic reverse rotation system works properly :
1. Set the FORWARD/AUTO/REVERSE switch to AUTO. The END OF RUN switch should reverse thepivot direction. Carry out a rotation in both directions, by manually operating the 2 END OFRUN switches.
2. Set FORWARD/AUTO/REVERSE switch to FORWARD. When you manually operate the END OFRUN switch, the pivot should stop but not reverse run. If you release the END OF RUN switch,the pivot restarts and moves forwards.
3. Set FORWARD/AUTO/REVERSE switch to REVERSE. When you manually operate the END OFRUN switch, the pivot should stop but should not change direction. If you release the END OFRUN switch, the pivot restarts and continues run.
The pivot must not work unattended before completing a full rotation, in order to check the rotationand safety stops have been set up according to the instructions below.
Angle de scurit
~10cm
~10cm ~
10cm
Angle de scurit ~Safety angle ~ 10 10
co
plaque
La roulette doit venir en
ntact au centre de la
The wheel should touch the
middle of the plate
Safety angle
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Filling with water :
Check the sand box situated at the end of the pivot has been removed.
Shut the mini-valve on the centre element.
Fill with water, the pivot stopped, and allow the water to drain off through the sand box "exit" forabout 10 minutes, this will prevent the sprinklers from blocking up with impurities from the different
pipes. Stop the water and let the pivot empty completely.
Close the sand box.
Set the with WATER/WITHOUT WATER switch to WITH WATER; set the FORWARD/AUTO/REVERSE switchto the direction required; and set the ON/OFF switch to ON.
The pivot does not start and the safety pilot light is on.
Re-fill with water.
Adjust the water pressure at the entrance of the pivot according to the piping plan.
Using the screw located on the upper part, set the pressure switch so the machine starts at 1 barbelow working pressure.
Adjust the working speed control switch according to the chart and according to the quantity of waterrequired.
Check all the sprinklers work properly.
Check there are no leaks, tighten the flange bolts if necessary.
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FAULT REPAIR CAUSE
Fuse failure in the QIcutout switch.
- Short-circuit on the power circuit betweenwires 7-8 and 9.- Using an ohmmeter, check the current, thereshould not be any.
- Short-circuit in the commutator.-Short-circuit in the tower box-connectingterminal.
1.Using an ohmmeter, check the transformer's1A.Am primary (380v) protection fuses.
- If fuses are faulty, replace them withidentical ones.- If fault continues, failure comes from ashort-circuit in the transformer.- This often results from over voltage.- Replace transformer.
2. Using an ohmmeter, check thetransformer's 4A Gg secondary (115v)protection fuses.
- Short-circuit in the 115V control:- in the commutator- in a valve- in the pressure switch or its cable.
- These fuses must be replaced withidentical fuses.Large diameter fuses do not increaseprotection
No control circuit.Voltage is correct butnothing works..
3.The fuses are correct but there is no circuitcontrol.
Using a voltmeter:- Check voltage on the transformer's primary(between wires 05 and 06). Voltage shouldbe 115v.- If the voltage in the primary is correct but
there is no voltage on the secondary, replacethe transformer; first check the secondaryprotection fuses are the right diameter (4AGg).
Replace HS transformer.