PTC Acs 600 Wy Quy 300t Quy100 260 User Manual

Intelligent Safe Control Solutions of Cranes
Installation Guide & User’s Manual
The ACS-600 Load Moment Limiter

（ACS Model：ACS-600-WY-QUY-300T）
(QUY100/ QUY160/ QUY200/ QUY260 Crawler Cranes)
Precise Technology (Beijing) Co., Ltd.

(Manufactured by Changsha Huizhi Technology Co., Ltd.)
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Respectful users:
We welcome you to use the ACS-600 type load moment limiter. We look forward to
providing you with a safe experience and create greater value for your work through the
usage of our quality products and services.
Precise Technology (Beijing) Co., Ltd. is a high-technology enterprise located at the hearth
of the Zhongguancun Science Park, which provides technical solutions for safe operation of
engineering machinery depending on Zhongguancun human and technological advances;
Changsha Huizhi Technology Co., Ltd. is an industry leader with over ten years of
experience in production, service and maintenance of safe control products in the area of
engineering machinery in China. The ACS series load moment limiter is a new generation of
load moment limiters under the co-development and cooperation between the two
companies, which has made breakthroughs in product precision, ease of installation and
maintenance.
This manual provides you with basic knowledge concerning daily operation, calibration,
installation, maintenance of the ACS-600 type load moment limiter. Read this manual
carefully before operation.
Precise Technology (Beijing) Co., Ltd. and Changsha Huizhi Technology Co., Ltd. will put
continuous effort into improving the product and we invite you to inquire about the latest
updates on our products through mail, telephone, fax and internet.
Mail address:
Rm. 303A, Building No.2, Fuhai, Daliushu Rd. Haidian Dist., Beijing, China
Beijing Precise Technology Co.,Ltd.
Zip code: 100081
Phone: (86)-010-62122771/62150300 13911073285
Fax: (86)-010-62120663
http://www.canadapti.com
Due to modification and technical improvements of the vehicle, Precise Technology (Beijing)
Co., Ltd. and Changsha Huizhi Technology Co., Ltd. have the right to modify the
Installation Guide & User Manual at any time. Regarding these modifactions, the user
should always refer to the actual vehicle. The interpretation right of Installation Guide &
User Manual belongs to Precise Technology (Beijing) Co., Ltd.
Copyright © 2003-2008 Precise Technology (Beijing) Co., Ltd. All Rights Reserved.
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Index
Cautions ...................................................................................5
Maintenance Instructions ....................................................... 6
Executive Standards................................................................ 6
Technical Parameters ............................................................. 6
Glossary ...................................................................................7
Instructions on Installation .....................................................7
System Composition ........................................................................................................7
Installation........................................................................................................................9
Connection Relation............................................................................................................................... 9
General Use Method................................................................11
Startup............................................................................................................................. 11
Operating Condition Interfaces .................................................................................... 11
Buttons in Operating Condition Interface ...................................................................13
Menu ..................................................................................................................................................... 13
QCHECK ............................................................................................................................................... 14
WorkStatus ............................................................................................................................................15
ShutDown ..............................................................................................................................................15
Digital Keyboards ........................................................................................................... 15
Choosing Operating Conditions....................................................................................16
Query Rated Weight ............................................................................................................................. 18
Fast Calibration...................................................................... 21
Boom Angel Calibration.................................................................................................21
Weight Calibration ........................................................................................................ 22
Radius Calibration..........................................................................................................25
Boom Radius Calibration..................................................................................................................... 25
Jib Radius Calibration..........................................................................................................................26
Tower Jib Radius Calibration.............................................................................................................. 27
Time Calibration............................................................................................................ 28
Reading Overload Data ..........................................................29
System Setup......................................................................... 30
Radius (R0) Setup ......................................................................................................... 30
Boom Angle Calibration.................................................................................................31
Boom Force Sensor Calibration ................................................................................... 32
Precision Calibration..................................................................................................... 33
Boom Free Hook Weight Calibration..................................................................................................34
Boom Poise Weight Calibration........................................................................................................... 35
Jib Free Hook Weight Calibration.......................................................................................................36
Jib Poise Weight Calibration ............................................................................................................... 37
Tower Jib Free Hook Weight Calibration ...........................................................................................38
Tower Jib Poise Weight Calibration....................................................................................................39
Modify Password ........................................................................................................... 40
Maintenance .......................................................................... 41
Breakdown Management .......................................................42
Support & Services ................................................................ 44
Appendix ................................................................................45
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Signal List of Sockets on Central Unit ..........................................................................45

Normal Voltage Value between Lines of the Central Unit External Socket.............. 46
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Cautions
Before the first time you use this crane or when you have just altered the settings of it, for the
safety of the crane, please make sure to follow the guidance in this manual for the safe
settings and operations.
Please pay attention to whether the displaying values of length, angle, etc. are consistent with
the operating status used during daily operation of load moment limiter. Abnormity, such as
incorrect display of length, angle, etc. will lead to inaccurate working radius, height, rated
lifting capacity. Then please check whether pull box can work normally and calibrate
according to the rapid calibration guide for weight display attached on the side of computer
box. If precise calibration is required, please refer to relevant chapters of this manual for
rapid adjustment.
If it is mechanical abrasion of crane or other reason which leads to deviation, please refer to
relevant chapters of this manual for calibration.
For safety of lifting operation, follow the safe operation codes for crane unconditionally
during crane operation and for any consequence due to breach of regulation or incorrect
operation, the operation unit which breaches the regulation should bear all the
responsibilities.
If there is product quality problem due to dismantlement of this product and modification of
components (central unit and sensor) without permission, it is not in the scope of guarantee
by the manufacturer.
Attention:
² Do NOT put lit cigarette or objects with sparks or unwatchable fires onto the moment
limiter.
² Do NOT put objects with grease or volatile liquids onto the moment limiter.
² Do NOT wipe the moment limiter with cleaning agent, gasoline, thinner and diluents,
etc.
² Do NOT wash the moment limiter with water directly.
² Do NOT scratch on the plate of the moment limiter with sharp-pointed objects.
Conditions not Breakdowns of the Central unit:

² When the crane is in operation, the display of the moment limiter shows nothing. The
reason may be that there is no power supply for the moment limiter.
² If the angle reading is not accurate, the reason may be that unidentified factors have
changed the original installation position of the angle sensor.
² If the length reading is not accurate, the reason may be that the cable of the reel box is
stuck or cut off.
² If the weight reading is not accurate, the reason may be that the entered length or angle
value are not consistent with the actual number; or it may be that the selected operating
condition is not consistent with the actual one (e.g. the jib’s operating condition is
selected while it is the boom that is operating.)
² If the number demonstrated changes irregularly, or leaps dramatically, the reason may
be that the cable of the relevant sensor is crushed.
² If the weight reading is not in line with the estimated weight, the reason may be that the
information out of the estimation is not exact.
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Maintenance Instructions
² Wipe out the dirt on the moment limiter with clean and moist soft cloth. Do NOT wipe it
with cleaning agent, gasoline, thinner and diluents, etc.
² Remember to shut off the power switch of the moment limiter when work is over.
² Make sure that the power switch of the moment limiter is at the OFF position before
starting the engine.
² If there is suspect of breakdowns, please read the chapter “Conditions not Breakdowns”.
Executive Standards
² GB 12602-1990 Lifting Appliances-Safety Devices against Overloading-Safety
Technology Code
² GB 7950-1990 Boom Type Cranes-Load Moment Limiters-General Technical
Requirements
² GB/T 14560-1993 Technical Requirements for Cranes with Lifting Capacity up to 150
Tons
Technical Parameters
This product is demanded to satisfy the requirements in GB12602-1990 and GB7950-1990.
² Operating Life: ＞35,000 hrs
² Operation Voltage: DC+18～+36V
² Operation Temperature: -10～+70℃
² Storage Temperature: -40～+80℃
² Anti-impact: 30G
² Relative Humidity: ≤95% (25℃)
² Rated Power: 9W
² Comprehensive Precision: ±2%F.S
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Glossary
Glossary Description
1 Length Distance from pivot point at the root of boom to the center of block at
the top end of boom
2 Angle Angle (elevation angle) between boom and level
3 Radius Distance from the gyration center of rotary table of crane to the center
of lifting hook
4 Rated Weight Maximum permissible lifting weight at certain boom length and angle
5 Actual weight Weight of actual load hoisted by the lifting hook of crane
6 Percentage Percentage between actual lifting moment and rated lifting moment
7 Multiple ratio Number of cable wire through traveling block set of lifting hook
8 Pulling force of Permissible lifting weight of single cable wire
single wire
9 R0 Distance from the pivot point at the root of main jib to the gyration
center
10 W Show value of actual weight (including weight of lifting hook)
11 W0 Weight of free hook
12 W1 Weight used to calibrate
13 Q Rated lifting capacity
Instructions on Installation
System Composition
ACS-600 type load moment limiter system, which applies to this vehicle type, is composed of
the following parts:
Name of article Quantity Description

Vehicle mounted computer 1 10.4" TFT LCD & Touch screen. The HMI
(VMC)
Central unit 1 System kernel control equipment.
Tower jib signal converter 1 Collect/convert sensors’ signals to system
(TJSC) CAN bus and transmit to central unit
Junction box 1 Junction box of the whole system
Pressure sensor 4 Two 60t pressure sensor for main boom
Two 40t pressure sensor for tower jib
Angle sensor 2 One for main boom
One for tower jib
Multi-core cable & 11
aeronautical plug-in
Central unit socket

Socket Type Description
1 8-Pin (Pin) TFT LCD
2 4-Pin (Pin) Right pressure sensor of boom
3 5-Pin (Pin) Left pressure sensor of boom
4 6-Pin (Pin) Angel sensor of boom
5 7-Pin (Pin) Power and CAN
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6 8-Pin (Pin) Output of Relay

7 7-Pin (Pin) PLC, CAN
Junction box socket

Cable Core Description
1 4 To Cable reels. Settled line
2 7 To Central unit 7-pin plug (hole)
3 3 Power, Settled line
4 N/A
Tower jib signal converter socket

Socket Type Description
1 7-Pin (Hole) Left pressure sensor of tower jib
2 4-Pin (Pin) Power and CAN
3 3-Pin (Hole) Right pressure sensor of tower jib
4 3-Pin (Pin) Angel sensor of tower jib
Multi-core cables connection guide

Cables Cable Length Port Type
No. From To Core (m) F-port T-port
1 Central unit VMC 8 2 8 (hole) 8 (hole)
2 Central unit Right pressure sensor 4 23 4 (hole) 4 (hole)
of boom
3 Central unit Left pressure sensor of 4 21 5 (hole) 4 (hole)
boom
4 Central unit Angel sensor of boom 4 12 6 (hole) 5 (hole)
5 Central unit Junction box 4 1.5 7 (hole) -
6 Central unit - 8 - 8 (hole) Line
7 Central unit - 7 - 7 (hole) Line
8 Junction box Cable reels 4 15 - 4 (hole/pin)
Zoomlion
9 Cable reels TJSC 4 100 - 4 (hole)
10 TJSC Right pressure sensor 4 15 3 (pin) 7(hole)
of tower jib
11 TJSC Left pressure sensor of 4 15 7 (pin) 7 (hole)
tower jib
12 TJSC Angel sensor of tower 4 9 5 (hole) 5 (hole)
jib
13 Junction box Battery 3 25 - Line
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Installation
Connection Relation
The connection relation of each part is shown as follows:
(Figure: Composition and structure figure of ACS-600 type load moment limiter)
² The vehicle mounted computer is installed in the operating cab of crane.

² The central unit & junction box is installed in electronic equipment control box.
² Pressure sensors of tower jib (A) are installed on the bottom of tower jib, the left of
tower jib inside.
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² Pressure sensors of main boom (B) are installed on the bottom of boom, the left of boom
inside.
² The tower jib junction box (C) is installed on the bottom of tower jib.
² Angle sensor of main boom (2) is installed on the bottom of boom.
² Angle sensor of tower jib (1) is installed on the bottom of tower jib.
The sketch map of installation position is as follows:
(Figure: Sketch map of installation position of ACS-600 load moment limiter)
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General Use Method

Startup
After the central unit is turned on by turn on the “AML” switch, the system will startup
automatically, please wait until the system finish self-checking & system load. Then the
system will display as follows:
(Figure: Startup interface)
If the system has been defined to use English interface, then the system will show English
version interface. You can click the button to convert to Chinese version interface.
The system will wait for 5 seconds and then directly enter into the operating condition
interface which is selected last time.
There are 3 operating conditions:

1. Main boom
2. Jib
3. Tower Jib
Operating Condition Interfaces

Here are the three operating condition interfaces:
1. Main boom
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(Figure: main boom operating condition interface)
2. Jib
(Figure: jib operating condition interface)
3. Tower Jib
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(Figure: tower jib operating condition interface)
Buttons in Operating Condition Interface

There are four buttons at the bottom of interface:
Menu
Click “Menu”, you can choose operation condition, setup system parameters & calibrate
system.
(Figure: menu interface)
There are 9 functions you can choose:

1. Choose operation
To choose operating conditions
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2. PLC work
To setup, search crane PLC work parameters. Password protected, only crane manufacturer
staffs can use this function.
3. Fast calibration
For crane users, you can calibrate weight, angel to make so as to vary minimally from set
industrial standard. Password protected, you can ask the owner or manager of the crane to
provide password if necessary.
4. Overload data
Check overload data list. Password protected, you can ask the owner or manager of the crane
to provide password if necessary.
5. System setup
Setup all default system parameters of the system. Password protected, only crane
manufacturer staffs can use this function. If you really need to update system configuration,
please read the whole manual and setup the system configuration step by step under the
professional maintenance workers’ control.
6. Rated weight
To query rated weight of the crane.
7. Restart
Restart the whole system.
8. Help
To read the online user manual in the system.
9. Exit
Exit the menu interface to default operating condition interface.
QCHECK
You can check rated weight of current operating condition. If you want to check all rated
weight data, you should click “Menu” button and choose “Rated Weight” function.
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(Figure: the quick rated weight check for current operating condition interface)
WorkStatus
To check default parameters of current operating condition. If you find that the default
parameters are different with real work status, please setup operating conditions again.
(Figure: the quick rated weight check for current operating condition interface)
ShutDown
If you click “Shutdown” button, the system will show message that the system is saving
settings and quit. Please wait until the system show “you can turn off the system”.
Attention: you must shutdown the system before you cut the power of crane, else the
current operation data will be lost or even caused the system crash!
Digital Keyboards
When you need to input password, setup parameters or check data, the system will pop-up
this keyboards for you to input numbers.
The left white area will show the numbers you clicked, when you click the right numbers,
click “OK” button, the numbers you clicked will be input the appointed area.
(Figure: keyboards interface)
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Choosing Operating Conditions

If the crane needs to change the operating conditions of the boom or jib, please choose the
operating conditions for the boom or jib according to the following methods.
Click the “Menu” button, then click “Choose Operation” button. The system will show the last
default operating condition.
1. Choose Boom Operation

Click “BOOM” label, then setup necessary parameters of boom conditions, including: free
hook weight, fall, boom length, intensity of single wire, work elevation limit, work bow angel
limit, boom elevation margin.
(Figure: boom operating condition setup interface)
Click “Confirm” button, then the system will calculate the data of operating condition, the
system will show words: “Please wait…”, after calculation, the system will show “download
successfully! ” and change the default condition to your new setup. Then click “Exit” button
to quit the interface.
Attention: when you click “Exit” button and quit current interface, the system will check all
data again and have 3-5 second delay!
2. Choose Jib Operation

Click “Jib” label, then setup necessary parameters of jib conditions, including: jib angel, free
hook weight, fall, boom length, jib length, intensity of single wire, work elevation limit, work
bow angel limit, boom elevation margin.
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3. Choose Tower Jib Operation

Click “Tower” label, then setup necessary parameters of tower jib conditions, including: jib
angel, free hook weight, fall, boom length, jib length, intensity of single wire, work elevation
limit, work bow angel limit, boom elevation margin.
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Query Rated Weight

You can query rated weight limit of the crane. Click “Menu” button from default operating
condition interface, then click “Rated Weight” button, the system will show the follow
interface to allow you choose one operating condition.
(Figure: choose operation condition for rated weight limit search interface)
After choose one condition, the system will show you the suitable query interface:
1. Boom
(Figure: Boom rated weight limit query condition interface)
2. Jib
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3. Tower jib
After choose search condition, click “Look” button, the system will show you the suitable
search result. Q in the interface is Rated lifting capacity.
1. Boom
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(Figure: Boom rated weight limit search result interface)
2. Jib
(Figure: Jib rated weight limit search result interface)
3. Tower jib
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(Figure: Tower jib rated weight limit search result interface)
Fast Calibration
When the crane is used for period of time, some parameters of the crane are changed because
of wear. These kinds of changes will cause inaccurate showing results. So in order to avoid
such conditions, the system provides you fast calibration function to allow you calibrate some
of the parameters in the system. This function is password protected; you should ask the
owner or manager of the crane if you need.
Click “Menu” button in the default operating condition interface, then click “Fast Calibration”
button. The system will show you the follow interface:
(Figure: Fast calibration interface)
Boom Angel Calibration

Choose “boom angel” calibration button, the system will show the follow interface:
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(Figure: Fast calibration of boom angel interface)
Draw the boom to 0 degree, double confirm again and then press “Next” button to see the
following interface:
(Figure: Setup the Range of Angel: upper limit)
Lift boom to 78 degree, double confirm again, and then press “Confirm” button. Angel
Calibration completed, the system will show “Calibration finished!”, press “Exit” button to
return to the subordinate menu.
After angle calibration completes, please recheck whether the angle shown is right. The angle
can be checked with the above angle check method or with angle meter. If deviation occurs,
then it is required to calibrate again.
Weight Calibration
If it is found during use that the display deviation exceeds ± 5% or it is considered necessary
to calibrate the show value of weight (for example: routine check by Bureau of Quality and
Technical Supervision), observe the following steps for rapid calibration:
Confirm that the crane is on solid horizontal ground, and in normal operating state; the
length, angle and radius reading values on the central unit are all identical with the actual
ones, with the deviation variance no more than ±1%; prepare 50t, 20t, 10t, 5t weight for
repetitious calibration.
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Attention: The function can only calibrate current operation condition, so if you want to
calibrate other conditions, please change operating condition first!
Click “Menu” button in the default operating condition interface, then click: “Weight” button.
The system will show you the follow interface:
1. Boom operating condition
(Figure: Input weight amount of hook & poise)
Enter the accurate weight value, which includes the weight hoisted plus the weight of the
hook, and drop/lift the boom to the position where the value of current weight equals that of
inputted weight, then pull down the poise on the ground. Lift boom again at a very low speed
from the current angle, click the “Next” button at the same time. Then the central unit shows
the following interface, indicating it is executing automatically the weight calibration.
(Figure: Weight calibration – actual calibration)
Lift boom at a very low speed to 78.5º, then reverse the action slowly. With the lifting and
dropping activities finished and the lifting boom back to the original position, the weight
calibration is completed. Press “Confirm” button to confirm.
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Special Tips:
Once the calibration procedure started, the lifting jib must maintain a slow and uniform
motion, where it can not stop or change speed suddenly.
2. Jib operating condition

Weight calibration of Jib is similar as boom, here are the interfaces:
3. Tower jib operating condition

Weight calibration of Jib is similar as boom, here are the interfaces:
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Radius Calibration
Boom Radius Calibration

You should prepare:
1. Calibration Equipment: one 30m tape measure
2. One 5 ton calibration weight
Click “Menu” button in the default operating condition interface, then click: “Radius” button.
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(Figure: Fast calibration: radius calibration)
Lift a 5-ton weight, lift the boom until the system show current weight is 5-ton. Measure the
range value from gyration center of rotary table to the center of main hook with tape, input
the measured values to make the radius equal to the current measured radius and press
“Confirm” button to confirm. Then change range upward to increase the angle by 5 degrees.
Measure the radius value from gyration center of rotary table to the center of main hook with
tape, input the current measured values and press “Confirm” button. Then measure, input
values and confirm for every 5 degrees until 79 degrees.
After calibration of complete retraction of boom completes, stretch the boom to the next
length in the rated lifting capacity table and calibrate according to the above calibration
method until the boom is fully stretched.
Jib Radius Calibration

You should prepare:
2. One 1~2 ton calibration weight
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Lift a 1~2 ton weight, lift the jib until the system show current weight is 1~2-ton. Measure the
range value from gyration center of rotary table to the center of main hook with tape, input
the measured values to make the radius equal to the current measured radius and press
“Confirm” button to confirm. Then change range upward to increase the angle by 5 degrees.
Measure the radius value from gyration center of rotary table to the center of main hook with
tape, input the current measured values and press “Confirm” button. Then measure, input
values and confirm for every 5 degrees until 79 degrees.
After calibration of complete retraction of jib completes, stretch the jib to the next length in
the rated lifting capacity table and calibrate according to the above calibration method until
the jib is fully stretched.
Tower Jib Radius Calibration

You should prepare:
2. One 1~2 ton calibration weight
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Lift a 1~2 ton weight, lift the tower jib until the system show current weight is 1~2-ton.
Measure the range value from gyration center of rotary table to the center of main hook with
tape, input the measured values to make the radius equal to the current measured radius and
press “Confirm” button to confirm. Then change range upward to increase the angle by 5
degrees. Measure the radius value from gyration center of rotary table to the center of main
hook with tape, input the current measured values and press “Confirm” button. Then
measure, input values and confirm for every 5 degrees until 79 degrees.
After calibration of complete retraction of tower jib completes, stretch the tower jib to the
next length in the rated lifting capacity table and calibrate according to the above calibration
method until the jib is fully stretched.
Time Calibration
Click “Menu” button in the default operating condition interface, then click: “Time” button.
(Figure: Fast calibration: time calibration)
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Input right date and time, then click “Confirm” button to save the setup.
Reading Overload Data

Click “Menu” button in the default operating condition interface, then click: “Overload data”
button. This function is password protected; you should ask the owner or manager of the
crane if you need. The system will show you the follow interface after you input correct
password:
(Figure: Reading overloads data)
Choose range of time, then press “Confirm” button. The system will show you the search
result of overloads data:
(Figure: Overloads data list)
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System Setup
In order to ensure the precision, during installation, the parameters of the moment limiter
must be setup before delivery. End users don’t need to setup again. If it needs to change
components for the central unit or the sensors or the lines between sensors and sensors are
broken, it will be necessary to reset the parameters under the guidance of professional
maintenance personnel.
Click “Menu” button in the default operating condition interface, then click: “System Setup”
button. This function is password protected. After you input correct password, the system
will show the interface:
(Figure: System Setup)
Attention:
The option parameters of main setup menu can’t be modified easily, or it will lead to
computation deviation of the system and subsequently incorrect computation and display of
lifting weight. It must be strictly operated by personnel familiar with this system according to
the requirement of this manual.
The password of main setup menu will not be provided with this manual. Please ask it from
the crane equipment management personnel or directly call the crane manufacturer or the
service hotline of our company to get it.
Radius (R0) Setup

button, then click “R0 Setup”:
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(Figure: Input radius interface)
R0 = the distance from the base of the boom to the rotation center. Input Radius number,
then click “Confirm” button to save.
Crane Type Radius (R0)

QUY100 1.4m
QUY160 1.4m
QUY200 1.4m
QUY260 1.4m
Boom Angle Calibration

Choose “boom angel” calibration button, the system will show the follow interface:
(Figure: Fast calibration of boom angel interface)
Draw the boom to 0 degree, double confirm again, and then press “Next” button to see the
following interface:
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(Figure: Setup the Range of Angel: upper limit)
Lift boom to 78 degree, double confirm again, and then press “Confirm” button. Angel
Calibration completed, the system will show “Calibration finished!”, press “Exit” button to
return to the subordinate menu.
After angle calibration completes, please recheck whether the angle shown is right. The angle
can be checked with the above angle check method or with angle meter. If deviation occurs,
then it is required to calibrate again.
Boom Force Sensor Calibration

There are two boom sensors: Left sensor (P1), Right sensor (P2). When you setup boom
sensor, you need to use defined length of boom for different crane type, here is the length
table for crane:
Crane Type Boom Length for

sensor calibration (m)
QUY100 61
QUY160 71
QUY200 71
QUY260 77
You must use the length for calibration. Click “Boom Sensor” calibration button in system
setup interface, the system will show the follow interface:
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(Figure: Force sensor calibration 1: setup zero of sensor)
Put down the boom on the ground, release wire to make sure all sensors are not pulled.
Click “Next” button and the screen shows the following figure:
(Figure: Force sensor calibration 2: full pull setup of boom)
Lift the boom to 0 degree. Double check the angel of boom with gradienter, click “Confirm”
button to record the sensor full pull setup data.
Precision Calibration
The precise calibration of the load moment limiter is completed by crane manufacturer
before delivery for use and user is generally not required to perform precise calibration
during use. If the required display precision can’t be achieved by rapid calibration, then
precise calibration can be performed under the guidance of professional maintenance
personnel.
Preparation:
Prepare 20t, 10t, 5t weights for calibration.
Carefully check whether the operating conditions of boom or jib shown on the display are
consistent with the actual conditions. If not so, please input the current actual operating
conditions according to the instructions of “selection of operating conditions of main jib and
auxiliary jib”.
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Make sure that the angle and length of boom/jib has been checked.
Make sure that the crane stops on solid ground and is in normal work state;
Select suitable weights according to the lifting capacity table, change radius to that equal to
the rated lifting capacity shown on the central unit, keep the main jib steady and put the
weight down on the ground.
After preparation of all above steps, Turning on the power switch of the system, and input the
precision calibration interface:
(Figure: Precision calibration interface)
Special Tips:
Once the calibration procedure started, the lifting jib must maintain a slow and uniform
motion, where it can not stop or change speed suddenly.
The weight of poise should bigger than 2 ton or the minimum weight of the current operating
condition.
Boom Free Hook Weight Calibration

Click “Boom Free Hook” button, the system display the follow interface:
(Figure: Boom Free Hook calibration interface)
Lift boom to 19 degree, make sure the hook is not on the ground, input correct hook weight,
press “Confirm” button. The system will show this interface:
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(Figure: Boom Free Hook calibration interface – in calibration process)
Don’t click “Exit” button, lift the boom from 19 degree to 78 degree with very slow speed,
then reverse the action slowly. With the lifting and dropping activities finished and the lifting
boom back to the original position, the boom free hook weight calibration is completed. Press
“Exit” button to exit and record data.
Boom Poise Weight Calibration

Choose a poise, in operating condition interface, lift the poise to a position which the value
showed by system is equal to the weight amount of poise & hook. Click “Boom Poise” button,
the system display the follow interface:
(Figure: Boom poise weight calibration interface)
hook. Click “Confirm” button, the system will show the follow interface:
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(Figure: Boom poise weight calibration interface – in calibration process)
Don’t click any buttons; lift the boom from current position to 78 degree with very slow speed,
boom back to the original position, the boom poise weight calibration is completed. Click
“Confirm” button to record calibration data, then press “Exit” button to exit the interface.
Jib Free Hook Weight Calibration

Click “Jib Free Hook” button, the system display the follow interface:
(Figure: Jib Free Hook calibration interface)
Lift boom to 30 degree, make sure the hook is not on the ground, input correct hook weight,
press “Confirm” button. The system will show this interface:
Page 37
(Figure: Jib free hook calibration interface – in calibration process)
Don’t click “Exit” button, lift the boom from 30 degree to 78 degree with very slow speed,
jib back to the original position, the jib free hook weight calibration is completed. Press “Exit”
button to exit and record data.
Jib Poise Weight Calibration

showed by system is equal to the weight amount of poise & hook. Click “Jib Poise” button, the
system display the follow interface:
(Figure: Jib poise weight calibration interface)
Page 38
(Figure: Jib poise weight calibration interface – in calibration process)
Don’t click any buttons; lift the jib from current position to 78 degree with very slow speed,
jib back to the original position, the jib poise weight calibration is completed. Click
“Confirm” button to record calibration data, then press “Exit” button to exit the interface.
Tower Jib Free Hook Weight Calibration

Click “Tower jib Free Hook” button, the system display the follow interface:
(Figure: Tower jib Free Hook calibration interface)
Lift boom to 65/75/85 degree, and drop tower jib to 0 degree, make sure the hook is not on
the ground, input correct hook weight, press “Confirm” button. The system will show this
interface:
Page 39
(Figure: Tower jib free hook calibration interface – in calibration process)
Don’t click “Exit” button, lift the tower jib from 0 degree to the status with very slow speed,:
10 degree between boom and tower jib.
Then reverse the action slowly. With the lifting and dropping activities finished and the
lifting tower jib back to the original position, the tower jib free hook weight calibration is
completed. Press “Exit” button to exit and record data.
Tower Jib Poise Weight Calibration

showed by system is equal to the weight amount of poise & hook. Click “Tower jib Poise”
button, the system display the follow interface:
(Figure: Tower jib poise weight calibration interface)
Page 40
(Figure: Tower jib poise weight calibration interface – in calibration process)
Don’t click any buttons; lift the tower jib from 0 degree to the status with very slow speed,: 10
degree between boom and tower jib. Then reverse the action slowly. With the lifting and
dropping activities finished and the lifting tower jib back to o degree, the tower jib poise
weight calibration is completed. Click “Confirm” button to record calibration data, then
press “Exit” button to exit the interface.
Modify Password
You can change all password protected functions’ password if you have the password of the
function.
button. Input correct system setup password, then click “Modify Password” button.
Attention: please make sure that you can remember the new password you updated, else you
have to ask manufacturer to provide paid onsite service.
Page 41
Maintenance
Before operating the crane, users should first conduct a visual check on the components of
the crane, central unit of the moment limiter and all the sensors, so as to timely find out
abnormalities if any. After starting the engine, users should pay attention to whether the
length and angle readings are normal or whether there are breakdowns shown on the display.
Once abnormalities or breakdown warnings are found, it’s needed to be properly managed by
professionals.
Before finding out the real reasons, NEVER blindly dismantle the central unit, components
or sensors of the moment limiter, in order not to expend the breakdowns, and induce further
ones.
In daily usage, pay attention to keeping the moment limiter clean. Keep rain, grease, organic
solvent, and other harmful liquid from dripping or splashing onto the central unit of the
moment limiter or into the sensors. Prevent heavy or sharp-pointed objects from bumping
against or scratching on the central unit, sensors and the connecting wires.
In hot summer, be aware to prevent the central unit of the moment limiter from being
exposed to the scorching sun, in order to prolong its service life. Due to the temperature
sensitive quality of the LCD, in relatively hot temperatures (＞35℃), the hue of the LCD
display of the central unit will be darker, and in low temperatures (＜10℃), the hue will be
lighter. Both situations are normal, and won’t affect its functions.
Users should constantly pay attention to the operational status of the storage battery and
generator. Breakdowns in the storage battery and generator will affect the operating
performance of the moment limiter.
Page 42
Breakdown Management
1． Checking Method
When the moment limiter shows there are abnormalities, users should first check whether all
components are operating normally, whether the cables and their joints are intact, then
double-check against the breakdown conditions table. If the breakdown still can not be fixed,
please consult directly with our company and ask for services.
2． Conditions not Breakdowns of the Central unit

When the crane is in operation, the display of the moment limiter shows nothing. The reason
may be that there is no power supply for the moment limiter.
If the angle reading is not accurate, the reason may be that unidentified factors have changed
the original installation position of the angle sensor.
If the length reading is not accurate, the reason may be that the cable of the reel box is stuck
or cut off.
If the weight reading is not accurate, the reason may be that the entered length or angle value
are not consistent with the actual number; or it may be that the selected operating condition
is not consistent with the actual one (e.g. the jib’s operating condition is selected while it is
the boom that is operating.)
If the number demonstrated changes irregularly, or leaps dramatically, the reason may be
that the cable of the relevant sensor is crushed.
If the weight reading is not in line with the estimated weight, the reason may be that the
information out of the estimation is not exact.
Page 43
3． Breakdown Status Table

The central unit of the ACS-200/600 moment limiter has self-diagnosis functions. It can
automatically demonstrate the breakdown information in text format when the connecting
wire is crushed and result in short or broken circuit, so as to warn the user.
On seeing breakdowns demonstrated, please refer to the checking methods in the following
table to fix them.
No Signal on the Display

Breakdown Description Reasons Checking and Fixing Method
Turn on the power supply Failures occur in the Double-check whether the power
and press the RST button, power supply of the supply of the upper structure is in the
without hearing the beep. upper structure. scope of 18～32V。
The power switch in Double-check whether the voltage
the electrical box of between the ① and ② pin of the
the moment limiter 7-pin plug from junction box’s power
falls off. supply is 18～32V.
Display failure. Contact us.
Angle Signal Failure

It show “Angle Over Max The shielded cable Stop the boom at about 60º. Measure
Degree”, or “Angle Failure”. between the angle if the resistance between the ① and
sensor and the central ② of the angle plug is about 5kΩ, and
unit is crushed and that between ② and ③ is about
result in short/broken 0.9kΩ.
circuit.
The angle reading is not The position of the Refer to the “Fast Angle Calibration”
consistent with the angle sensor is in the daily maintenance for
actuality. artificially changed. calibrating.
P1, P2 Signal Failure

P1, P2 over upper/lower The cable is crushed to The resistance between ① and ②, or
limits. result in short/broken ③ and ④ should be about 350～400
circuit. Ω.
Weight reading leaps The joint of shielded Check and fix the bad connection, lock
dramatically. cable or plugs/sockets well the aviation sockets.
not well connected.
Weight reading is zero or Sensor circuits Change sensors.
other symbols. shortened or damaged.
Page 44
Support & Services

The company has its own professional post-sales maintenance personnel. If breakdowns
occur, please contact the company directly, and we will respond to the customer’s
requirements immediately.
² Beijing: (86-10) 62122771

² Shanghai: (86-21) 56523529
² Changsha: (86-731) 5597296
2. The maintenance period of the central unit of ACS-200/600 moment limiter is 12 months,
within which the company provides technical services gratis and free maintenance. The
following items are not included in the maintenance (services will be paid even if within the
maintenance period).
² Breakdowns and damages resulted from the inappropriate operation of the user.
² Breakdowns and damages resulted from the repairing, changing, dismantling and
maintenance by operators or maintenance personnel not authorized by the company.
² Breakdowns and damages resulted from the dismantling, repairing, and the installation
of the central unit, circuits and sensors by the users themselves without the authorization
of the company.
² Breakdowns and damages resulted from the adding, refitting, and changing of the central
unit, circuits and sensors by the users themselves without the authorization of the
company.
² The components that has a service life and need to be changed regularly.
² Breakdowns and damages resulted from the irresistible natural disasters including fires,
flood, earth quake and thunder, etc.
² Breakdowns and damages resulted from the unallowable voltage values, etc. of the
machine.
² Breakdowns and damages resulted from the inappropriate transportation and movement
of the machine.
3. For broken products out of the maintenance period, only under repairable circumstances,
the company repairs the product and charges the maintenance fee.
4. According to the requirements of the customers, the company will regularly hold the
moment limiter central unit adjustment and maintenance personnel training class. Please
directly contact and consult with us on the training issues, then you may come to the
company to enjoy favorable training services offered by us. For specific major customers or
under special circumstances, the company may provide on-the-scene training for the
customers. The customers have to pay for this kind of training, please contact us for specific
information.
The final interpretation right of the above service terms belongs to Precise
Technology (Beijing) Co., Ltd. and Changsha Huizhi Technology Co., Ltd.
Page 45
Appendix
Signal List of Sockets on Central Unit
Pin No. Purpose

8 Pin : TFT LCD
1 N/A
2 N/A
3 N/A
4 CANH
5 CANL
6 24V
7 Ground
8 N/A
4 Pin: Right pressure sensor of boom
1 Power Supply +
2 Power Supply -
3 Signal
4 N/A
5 Pin: Left pressure sensor of boom
1 Power Supply +
2 Power Supply -
3 Signal
4 N/A
5 N/A
6 Pin: Angel sensor of boom
1 Power Supply +
2 Power Supply -
3 Signal
4 N/A
5 N/A
6 N/A
7 Pin: Power and CAN
1 24V
2 Ground
3 N/A
4 N/A
5 AML signal
6 N/A
7 N/A
8 Pin : Output of Relay
1 Overload
2 Tower jib angel upper limit alarm
3 Tower jib angel lower limit alarm
4 Boom angel lower limit alarm
5 Boom angel upper limit alarm
6 Angel lower limit between boom with tower jib alarm
7 3-color light & buzzer
8 Warning signal
Page 46
7 Pin : PLC, CAN

1 Dedicated
2 Dedicated
3 Dedicated
4 N/A
5 N/A
6 CANH (PLC)
7 CANL (PLC)
Normal Voltage Value between Lines of the Central

Unit External Socket
Pin Central Unit Socket

No. 8 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 7 Pin
1 +5V +5V +5V 18~32 V 0V (Ground)
2 0V 0V 0V 0V 0V (Ground)
3 0~4.5V 0~4.5V 0~4.5V 0V (Ground)
4 0V (Ground)
5 0V 0V (Ground)
6 18~32 V 18~32 V
7 0V 18~32 V
8
Notes:
The angle sensors and press sensors power supplies are high-precision power supplies
independent from each other, and can not be exchanged or connected with each other, still
less with the 24V wire or the ground.

PTC Acs 600 Wy Quy 300t Quy100 260 User Manual

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Intelligent Safe Control Solutions of Cranes

Installation Guide & User’s Manual

The ACS-600 Load Moment Limiter

(QUY100/ QUY160/ QUY200/ QUY260 Crawler Cranes)

Precise Technology (Beijing) Co., Ltd.

Signal List of Sockets on Central Unit ..........................................................................45

Conditions not Breakdowns of the Central unit:

Name of article Quantity Description

Central unit socket

6 8-Pin (Pin) Output of Relay

Junction box socket

Tower jib signal converter socket

Multi-core cables connection guide

² The vehicle mounted computer is installed in the operating cab of crane.

The sketch map of installation position is as follows:

(Figure: Sketch map of installation position of ACS-600 load moment limiter)

General Use Method

(Figure: Startup interface)

There are 3 operating conditions:

Operating Condition Interfaces

(Figure: main boom operating condition interface)

(Figure: jib operating condition interface)

(Figure: tower jib operating condition interface)

Buttons in Operating Condition Interface

(Figure: menu interface)

There are 9 functions you can choose:

(Figure: keyboards interface)

Choosing Operating Conditions

1. Choose Boom Operation

(Figure: boom operating condition setup interface)

2. Choose Jib Operation

(Figure: boom operating condition setup interface)

3. Choose Tower Jib Operation

(Figure: boom operating condition setup interface)

Query Rated Weight

(Figure: Boom rated weight limit query condition interface)

(Figure: Boom rated weight limit query condition interface)

(Figure: Boom rated weight limit query condition interface)

(Figure: Boom rated weight limit search result interface)

(Figure: Jib rated weight limit search result interface)

(Figure: Tower jib rated weight limit search result interface)

(Figure: Fast calibration interface)

Boom Angel Calibration

(Figure: Fast calibration of boom angel interface)

(Figure: Setup the Range of Angel: upper limit)

1. Boom operating condition

(Figure: Input weight amount of hook & poise)

(Figure: Weight calibration – actual calibration)

2. Jib operating condition

(Figure: Input weight amount of hook & poise)

(Figure: Weight calibration – actual calibration)

3. Tower jib operating condition

(Figure: Input weight amount of hook & poise)

(Figure: Weight calibration – actual calibration)

Boom Radius Calibration

(Figure: Fast calibration: radius calibration)

Jib Radius Calibration

(Figure: Fast calibration: radius calibration)

Tower Jib Radius Calibration

(Figure: Fast calibration: radius calibration)

(Figure: Fast calibration: time calibration)

Reading Overload Data

(Figure: Reading overloads data)