Acms As-100

AS-100 Anti-Collision&Zone Protection
System and Safe Load System for Tower

Cranes
Installation Manual
成都鑫飞鸟科技有限公司
CHENGDU ACMS TECHNOLOGY CO.,LTD.

Add: No.1314 Xiyuan Ave, West Hi-Tech Zone,Chengdu city,Sichuan Province, China
TEL：+86 17502820413
FAX：+86 13709023964
POST CODE：610000
E-mail：121225@163.com
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AS-100 塔机力矩保护、防互撞及区域保护系统
CONTENT
Ⅰ、AS-100 system profile................................................................................................................ 3

Ⅱ、AS-100 system basic purpose..................................................................................................... 4
2.1 Tower crane torque protection function……………………………………………….....4
2.2 Anti-collision and zone protection function………………..............................................4
2.3 Safety monitoring function................................................................................................4
Ⅲ、The characteristics of AS-100 anti-collision system.................................................................. 5
3.1 Performance feature...........................................................................................................5
3.2 Technical data.....................................................................................................................6
Ⅳ、How AS-100 system performs the anti-collision functions...... .................................................7
4.1 Torque protection………………………………………………………………………...7
4.2 Anti-collision between tower cranes……………………………………………………..7
4.3 Zone protection…………………………………………………………………………11
Ⅴ、Hardware installation of AS-100 system…………………………………………………12
5.1 Installation of radio station.....................……………………………………………….12
5.2 Installation of trolley limiter......................……………………………………………..12
5.3 Installation of swinging motion limiter………………………………………….……..13
5.4 Installation of lift hoisting limiter......................................................................………..13
5.5 Installation of load cell..........................................................................................……..14
5.6 Installation of air velocity transducer..............…………………………………………15
5.7 Installation of display in cab and control box……………………………………….…15
5.8 Cable connection…………………………………………………………………...…..15
Ⅵ、System settings and adjustment of using system………………….........................................17
6.1 Parameter setting………………………………………………………………………..17
6.2 System calibration..........................................................................……………………..20
6.3 Bypass function..........................................................................……………………......23
6.4 Data record..........................................................................…………………….............24
Ⅶ、AS-100 system maintenance………………………………………………………………26
7.1 Control Box and Monitor……………………………………………………………….26
7.2 Signal cable and Sensors…..……………………………………………………………26
Ⅷ、Fault analysis & remedies……………………………………………………………………27
Ⅸ、Technical Support & Service…………………………………………………………………28
9.1 The installation and debugging of system…….………………………………………...28
9.2 Maintenance service………………………………………………..…………………...28
CHENGDU ACMS TECHNOLOGY CO.,LTD
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Ⅰ、AS-100 system profile

AS-100 Tower Crane Multi-Functional Safety Monitoring System is a new product
issued by our company.
The system integrated load moment indicator with anti-collision&zone protection
system and remote online monitoring system.It indicates real time working states of tower
crane and tower crane group both on tower crane and on the line computer.In the meantime
it combines functions including black box,anti-collision&zone protection(to provide
remote video monitor and control system when to update).The system is applicable to
various types of level-jib and luffing tower cranes.
AS-100 system adopted the most advanced ARM embedded intelligent microprocessor
technology,high precision digital azimuth sensor,weighing sensor,angle sensor,advanced
wireless communication technology,which greatly enhanced data processing capability
with higher precision and higher stability.
Furthermore,AS-100 system adopts full-size touch screen operation and display in both
Chinese and English language,which help operators install and use the system more
easily.When the operator runs the tower crane,the system can show the comprehensive
working states of tower crane to help him run the tower crane safe and effectively.
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Ⅱ、AS-100 system basic purpose

2.1 Tower crane torque protection function:
When the tower crane in independent or multiple synchronous operation, according to the
load situation allow or prohibit the hook to lift, car forward operation. Includes 2 contacts:
lifting trolley forward, low speed.To make tower crane run more safe and stable,adding the
torque and weight adjustable three way protection,and max.default doesn’t exceed 120% of
the security range (generally safety moment value tower crane manufacturers test is 120%).
2.2 Anti-collision and zone protection function
When multiple tower cranes constructed at the same time,how to prevent the risk between
tower cranes or between tower crane and building,and the load from entering some certain
areas (such as streets, campus, public areas, railway, power etc.),which is always the catchy
security issue of constructions,and gradually brings it into the strict construction safety
management,formulated relevant regulations and standards,hope the maximally ensure
construction safety.Nevertheless,still not avoiding the collision between some tower cranes’
interference or security accident of the load strayed into protection zone.
AS-100 anti-collision&zone protection system is controlled by computer

automatically,and two challenges of treatment of the construction site: the mutual
interference between tower cranes on site and restricted zone protection. The system
is applicable to various luffing and level-jib tower cranes,can achieve real-time
monitoring for up to 30 tower cranes within the same network and save operating
records according to requirement to track and check.
AS-100 anti-collision&zone protection system can help the operator run the tower crane
safe and effectively.The system continuously calculated the position of networking tower
cranes and relative coordinates of trolleys,once detecting the possible collision between tower
crane and close to the protected areas,such as street,highway,railway,campus,public areas,it
will give an early warning,until run by this tower crane control system,automatically restrict
the operation to continue, try best to avoid the safe accident happened as negligence and error
judgment from the operator,greatly ensure the safe use of the tower crane.
2.3 Safety monitoring function
The system provides the operator with actual working states of tower crane as follows 10.2
inch sized LCD(7 inch optional):hook amplitude,rated load,actual load,torque,torque
percentage, slewing angle,hook height,wind speed, display jib angle for luffing tower
crane.When the load reaches the rated load or 90% of specified value, it wil give an early
warning,alarm if it reaches 100%,if reaches 105%,it will alarm and prevent the trolley
automatically from moving outward and the hook from lifting upward) and the position state
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between tower cranes.The tower crane alarming record can be saved for tracking and
checking(The three value can be set free,but the max.is not more than 120%).
Note: AS-100 anti-aircraft tower collisions and regional protection system is only an
auxiliary control device, it can provide useful information for tower crane operation and
necessary when forced to stop control, but can not replace the crane operator instructions.
Ⅲ、The characteristics of AS-100 anti-collision system

3.1. Performance characteristic
1) The system is with complete functions of load moment indicator,anti-collision&zone

protection.
2) The hardware system is applicable to construction site with high precision
measurement, accurate control, strong anti-interference,wide temperature environment and so
on.
3) The system software is constituted according to tower crane working characteristic and
operator’s habit, so it becomes a good assistant for tower crane’s safety system.
4) The system shows working state of tower crane through LCD(simple and dynamic
menu) which helps the operator run the tower crane safe and effectively.
5) The system can realize wireless communication among many tower cranes by adopting
wireless internet transmission technology with strong anti-interference capability and high
frequency.
6) The system occupies small space and it is easy to install,without needs to change in any
structure of the tower crane,convenient for use.
7)When one tower crane goes wrong and needed to be maintained, this one can be
removed easily in the PC system or it can be treated as fixed obstacle for zone data setup in
the system.
8) The system can save the working state records permanently.
3.2. Technical Parameter
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1) Working temperature: -20℃ ~ 60℃

2) Working humidity: ≤95%（25℃）
3) Power voltage: AC220V±25%
4) Working mode: continuous
5) Overall error: ≤±5%
6) Repeatability error of load cell: ≤±0.3%
7) Non-linear error of load cell: ≤±3%
8) Data automatically saved when power is off and recover when power is on;
9) Visual-audible pre-alarm/ alarm, multiplex control output.
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Ⅳ、How AS-100 system performs the

anti-collision functions
4.1 Torque protection

Allow or prohibit the hook lifting upward,trolley moving forward according to the
load condition.Visual-audible pre-alarm when the load reaches pre-set alarm value;
Visual-audible alarm and control when the load or radius reach pre-set dangerous
value;When the controller fails,the system will be stopped operating temporarily not
to affect the tower crane run.
4.2 Anti-collision between tower cranes
(1)Between higher crane“A”and lower crane “B”.
Figure 3
B
The risk of collision exists between the hoisting wire rope of higher crane“A”and jib or
counter-jib of lower crane “B”, therefore, at any time trolley from crane “A”must not be
permitted to travel over the jib and/or counter-jib of crane “ B ” .but there is no travel
restriction for trolley from crane“B”.
The following simple drawings will explain how numerous interference conditions under
which this system can prevent from happening:
Trolley of higher crane “A” Risk zone Jib slewing working radius
Counter-jib slewing radius
☆ The overlapping zone of the 2-jib working radius is designated as No.1 risk zone.
☆ When the jib of crane “A”+ Counter-jib of crane “B”>distance between crane
“A” and crane “B”,overlapping zone of working radius from jib of crane “A”and
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Counter-jib of crane “ B ” will exist (though rare).Designate this as No.2 Risk Zone and
marked as orange.
B
A
Figure 4
When both jib tips from crane“A”and“B”are in the risk zone, but the trolley from crane
“A” isn’t in it, slewing operations of both cranes will not be restricted.
A B
Figure 5
When crane“A” trolley and crane “B”jib approach or enter into the Risk zone, the
system will automatically start computing distance between crane“A”trolley and crane “B”
jib. When this distance reaches the pre-set safety value,the system will alarm and restrict the
slewing operation.If necessary,it will automatically trigger the slewing braking mechanism.
A B
Figure 6
When jibs from cranes“A”and “B”overlap and crane“A”trolley is approaching the

crossing point,the system will automatically restrict trolley“A”moving outward（figure5）
and inwards(figure6) and it will simultaneously restrict jib of crane “ B ” moving leftward
(figure6) and rightward(figure7).
A B
Figure 7
Figure 4-figure7 show only No.1 Risk zone.

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Figure 8 and figure 9 indicate there is a circumstances of No.2 Risk Zone,restrictions to

No.1 Risk Zone will be the same as shown in figure 4-figure 7.
A B
Figure 8
When the counter-jib tip of the crane “ B ” enters No.2 Risk Zone first,this Risk Zone
immediately becomes the no-go Zone for crane“A”trolley(either restricting its outward travel
and/or 2nd slewing angle of crane“A”).
A B
Figure 9
When crane“A”trolley enters No 2. Risk Zone first,this Risk Zone immediately becomes
the No-go zone for crane “B”counter-jib (restricting 2nd slewing angle of crane“B”)
Note: Regarding to many cranes which have different heights and interfere each other,the data
setting principles are the same,except that there will be more restrictions.
(2)Between 2 tower cranes with the same height.
A B
Figure 10
Collision risks exist either between the 2 jibs or jib and counter-jib.In other words, at any
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time during the normal operations of the 2 tower cranes,there must be a safety guarantee to
keep a sufficient distance between the two jibs or the jib and counter-jib(not<2 meters) and
this must never be overlooked.
The overlap area of slewing angles of the 2 jibs +safe distance(not <2 meters)is a Risk
Zone.
When jib length of cranes “A”/“B”+counter-jib length of crane“ B”/“A”
>distance between the two cranes,a Risk Zone will exist at the overlap areas of jib slewing
angles from cranes “A” /
“B”and counter-jib length of crane“ B” / A”+the safety distance.
“
☆ Color the symbols same as above
When the 2 jibs are both in the Risk Zone

A and are approaching the preset minimum safety
B
distance, the system will first trigger alarm on
slewing operation of one(or both,
simultaneously)of the tower cranes and then
enforce restriction.
Figure 11
Alarm Reduce Speed
Apply break
≮min safety distance
Figure 12
The preset minimum acceptable safety distance for system to alarm and decelerate (power
off) can be amended according to the actual jib length and slewing speed(the default value is
8 meters and 6 meters).Same preventive measures can be applied to the possible collision of
jib from one crane and counter-jib from another crane as they appear in the same Risk Zone.
Note: the height difference between two tower cranes is not more than 10m, the system
judges it as the same height.
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4.3 Zone protection

Protected zones prevent hook (or jib) from flying-over sensitive ( protected)zones.
Such as streets, roads, highways, school yards, public areas, railway tracks, power
lines, etc., Fixed obstacles refer to existing fixed object with certain height on site. On
completion of installing system on site, start the initial data input. These are data from
several turning points of the protected zones (they may form several close zones)that
constitute site axis values(X1,Y1),input the height data more than tower crane’s for
the fixed obstacles.
(Green) Restricted (protected) Zone
Y
Figure 13
O
X
The protected zones are the zones where trolley traveling is prohibited. When the jib tip is
in this zone, the trolley running forwards is prohibited.
See figure 13, there are two protected zones and two groups of specified site axis values.
Figure 14
Oi X
When the system judges the obstacle height is almost the same as or higher than tower
crane jib’s, it will prevent the main jib from entering into this zone.
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Ⅴ、 Hardware installation of AS-100 system

A single system includes: color LCD monitor, mainframe, trolley limit switch with
POT(DXZ-W)(angle sensor for luffing tower crane), slewing limit switch with POT(DXZ-W),
lift hoisting limiter, load cell, air velocity transducer, communication station and output
control cable.
5.1 Installation of radio station
When there are more than one tower crane, a wireless router is required for wireless
communication. The wireless should be installed on the tower crane with maximum height
and install the antenna to the top of cab which is far away from the tower crane,without any
obstruction and no electromagnetic shielding produced.
Note: when the system is on, the router should be get electricity first. And the router
keep working all time long.
5.2 Installation of trolley limiter

(1) Installation of angle sensor for luffing tower crane
Luffing tower crane use angle sensor for collecting angle information,see figure5-1 for
installation of angle sensor. Keep the angle sensor installed at right proper position of the foot
of tower crane’s main jib. Pay attention to the direction of angle sensor as marks on it.the
sensor must be pointed to main jib head,otherwise the measurement range is not covered all
work angle range,the effective range of sensor is -20~90°.
Figure5-1 Installation of Angle Sensor
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(2)Installation of trolley limit switch for level-jib tower crane

The level-jib tower crane collect amplitude signal by trolley limiter. Install the
limit switch with POT instead of original limit switch without POT. The installation
way keeps the same.
Note: The potentiometer in the limit switch needs to be adjusted after the
limit switch is changed.
5.3 Installation of slewing limiter
Install the limit switch with POT instead of original limit switch without POT. The
installation way keeps the same. The adjustment of potentiometer is the same as above.
5.4 Installation of hoisting height limiter
Replace the height stroke limiter without potentiometer in original tower crane equipped
with the height of the removed, replaced with potentiometer limiter, installation is
constant.Rotary stop above the adjustment of the potentiometer.
See figure5-2:
Figure5-2 potentiometer
Adjust the screw by a screwdriver and make the marked point not go into the
blank area(the small sector between two black lines) during all the time of tower
crane’s working. That is to say the marked point not go into the blank area when the
trolley go from foot to the tip of jib. In the slewing limit switch, the marked point not
go into the blank area when the tower crane swing 3 circles at 1080°.
Note: The marked point mustn’t go into the blank area during all the time of
tower crane’s working, or the displayed data will be wrong.
5.5 Installation of load cell

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Replace the shaft of the existing weighing wheel with a shear weighing sensor shaft in
accordance with the original assembling structure. Avoid punchy strike to the cell shaft. It’s
better to use wood hammer for striking.
To be screwed on both ends:
Bend here
Anti-rotary
clamp
（Shear）weighing sensor
shaft
Pulley
Line of two holes
crossing the center
Dynamometer
Figure5-3 Threaded fastening type
Note: when install shaft, The arrow on the sensor should keep the same direction as wire
rope's net force.
Technology parameters of weighing sensor

combined error 0.5 （linear+lag+repeatability）
sensitivity 1.5mV/V
creepage ±0.5％F²S/30min
zero-point output ±1 ％F²S
effect on zero temp. ±0.5 ％F²S/10℃
temp. effect on output ±0.5％F²S/10℃
Working temperature -20℃～+65℃
input impedence 750±30 Ω
output impedence 700±10 Ω
insulation resistance 〉5000 MΩ
safe load limit 150％ F²S
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5.6 Installation of wind speed sensor
Anemometer should be installed on top of tower crane with three M8 bolt, no any
obstructions,then connect the cable.
5.7 Installation of display in cab and control box
A. Installation of monitor:
To be installed properly on the operator’s left and mounting bracket , installation and
fixation by themselves.
B. Installation of control cabinet:
To be installed in operator’s cab, there are 5 open holes on base of control cabinet. The
users can deal with the installation and fixation by themselves.
5.8 Cable connection
(1) height signal cable (Height)

Connect the 3-core height signal cable plug to the jack which is marked Height
(2) trolley signal cable (Trolley)
Connect the 4-core trolley signal cable plug to the jack which is marked Amplitude
(3) weight signal cable (Weight)
Connect the 5-core weight signal cable plug to the jack which is marked Weight
(4) slewing signal cable (Slewing)
Connect the 6-core slewing signal cable plug to the jack which is marked Slewing
(5) wind signal cable (Wind)
Connect the 7-core wind signal cable plug to the jack which is marked Wind
(6) radio signal cable (Radio)
Connect the anti-5-core radio signal cable plug to the jack which is marked Radio.
(7) monitor cable
Connect the 4-core cable to the monitor.
(8) connection of control cables
The system supply 14 groups normal close contacts(normal open contact can be
customized),the operator can connect relevant tower crane electrical control circuit according
to cable marked.
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1#--Left slewing warning

2#--Left slewing alarming
3#--Slewing braking
4#--Right slewing warning
5#--Right slewing alarming
6#--Max.amplitude/Min.angle warning
7#--Max.amplitude/Min.angle alarming
8#--Min.amplitude/Max.angle warning
9#--Min.amplitude/Max.angle alarming
10#--Torque point 3
11#--Left slewing low speed
12#--Right slewing low speed
13#Hoist upper limit warning
14#Hoist upper limit alarming.
(9) connection of power cables
Please check installation of all hard wares, make sure the connection of cables is correct.
Requirement of power connection: don’t choose the same phase line as control circuit of
tower crane and try best to lower power interference. (It’s better to get power directly from
electrical control cabinet of tower crane. If there is AC transformer, please get electricity from
transformer to make the power stable).
Requirement of grounding: it’s a must to choose a place which is suitable for grounding
and make reliable grounding.The resistance of grounding is not more than 4Ω to ensure
system works normally.
Ⅵ、System setting and debugging of system operation

6.1 Parameter setting
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The monitoring interface is as figure6-1:
Figure6-1 monitoring interface
In this monitoring interface, the green circle indicates tower cranes which are in normal
work and the red point indicate the current position of trolley. FALL represents the number of
wirerope(ratio).Enter conformity features to change the ratio,when need parameter setup,click
the bottom right corner “Menu” of this menu button to set.
Before setup, a coordinate origin should be defined according to the site drawing and then
count the detailed coordinated axis of each tower crane at site.
① Setup on Site
The setup interface is as figure 6-2:
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Figure6-2 setup on site

For slewing calibration, the operator can choose different calibration way
according to site working condition. “single point” indicates the operator can choose
one of tower cranes on site as calibration point, “two point” indicates the operator can
choose two of tower cranes on site as calibration point A and B.“User-defined”
indicates the operator can look for two points to calibrate according to working
condition, “Trolley decelerate distance” is trolley pre-alarm distance, “Trolley brake
distance” is trolley warning distance, “Slewing brake Distance” is slewing stop
distance, “Slowing stop Distance” is slewing alarming distance, “Slewing decelerate
Distance” is slewing pre-alarming distance, “FD Time” is motor reversal time, “Brake
Time” is slewing brake time.
② Setup on Tower Crane
The setup interface is as figure 6-3:
“TC NO.” means tower crane’s serial number,“X1,Y1” means coordinate axis of tower
cranes,“X2,Y2” means the second coordinate axis of walking tower crane,“TC height” means
the height of tower crane,“Jib length” means the length of main jib,“Counter-jib length”
means the length of counter-jib.“Max Radius” means the min.work amplitude of tower
crane.“Max Angle” means the max.angle of luffing tower crane’s main jib.“Min Angle”
means the minimum angle of luffing tower crane’s main jib.“a0” means the distance from
swing point to slewing center and the unit is meter.If the swing point is closed to main jib,“a0”
is positive,if the swing point is closed to counter jib,“a0” is negative.
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Figure6-3 setup on tower crane
③Setup on Zone
When obstacle or areas needed to be protected exist, it’s needed to setup on zone for
protection. The interface of setup on zone is as figure 6-4:
“NO.” means the number of zone,the system can set up to 10 zones,H means the height of
zone.“x,y” means the X coordinate and Y coordinate of one point.The system has the function
of zone added intelligently that make main jib turned to the zone and run the trolley to some
points form zone,click the zone setup icon ,the coordinate will be calculated
automatically to fill in the table,these coordinates will be shaped zone counterclockwise.
Figure6-4 setup on zone
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④The parameter for ground monitoring software uploading

The parameter is transmitted into the control box by wireless communication after
the ground monitoring procedure on PC is set,the The ground monitoring software
parameter setup is the same as anti-collision system one.When all parameters setup is
finished,click “file uploading” button,pop-up dialog box to select tower
crane,communication is suspended,the system will upload parameter file.The ground
monitoring system will real-time indicates all tower crane monitoring data on
computer including anti-collision among tower cranes,current sensor parameter
values,torque and Bypass etc,so that the office workers know about the working state
of tower crane more intuitively,ensure tower cranes and workers’ safety more
effectively.
Figure6-5 ground monitoring working interface
6.2 System calibration

After all hardware installations are finished,power on and the system
boots,ASmonitoring system presents the detailed and dynamic display
interface,convenient for the operator choose and use.When is system is power on, it
will automatically upload and display all information of last time power off.
When the system is in normal work, the interface is as figure 6-5:
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Figure6-5 system working interface
If the setup and adjustment are needed,click “MAIN”,input password “2017” to

enter to interface selection for operation.Click icon “SET” enter into actual parameter
calibration interface,the calibration interface is as figure6-7:
Figure6-7 Parameter calibration interface
(1) Click “PARM CAL” to slewing calibration

Please enter into Site Set to slewing calibration way selection before slewing
calibration.
Single point calibration: Select single point calibration and choose reference TC on
site set.First point the main jib into reference TC,click calibration button,then turn
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tower crane counterclockwise to point the counter-jib into reference TC,and click
calibration button.
Two points calibration: Select two points calibration and choose reference TC on
site set.First point the main jib into reference TCA,click calibration button,then turn
tower crane counterclockwise to point the main-jib into reference TCB,and click
calibration button.
User defined: Select user defined calibration and input the coordinate into the table
on site set.First point the main jib into selected reference point A,click calibration
button,then turn tower crane counterclockwise to point the main-jib into reference
point B,and click calibration button.
Note: during calibration, the main jib must be turned counterclockwise.

After the system is calibrated,verify the controlling distance which has been set at
“setup on site”. If the distance is too big or too small,you can enter the site parameter
setup menu to be modified accordingly.
(2) Amplitude(angle) Calibration

Note: angle for luffing tower crane, amplitude for level-jib tower crane.
1 Calibration for luffing tower crane

a . calibration for min.angle
Run the main jib stop at the min.angle, click the “ ” button and enter current
angle figure then press confirm.
b . calibration for max.angle
Run the main jib stop at the max.angle, click the“ ” button enter current
angle figure then press confirm.
② Calibration for level-jib tower crane

a. calibration for min.amplitude
Run the trolley to the min.distance at the foot of main jib and click the“ ”
button enter current trolley position figure then press confirm.
b. calibration for max. amplitude
Run the trolley to the max.distance of main jib( limited distance) and click the
“ ” button enter current trolley position figure then press confirm.
(3) Weight calibration

Prepare the the counterweight of a known weight before weight calibration, the
weight should be 40%-50% of the tower crane's max.hoisting load capacity.
a.load weight zero
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Lift the hook down to the ground, without any load, and click “ ” to input 0
then press confirm.
b. max. load weight
Input max. load value in “weigh max”, and click “ ” to input current weight
value to confirm.
(4) Height calibration

a. min. height
Lift the hook close to the ground, and click “ ” to input the number to
confirm.
b. max. height
Lift the hook to the top height, click “ ” to input current hook height value to
confirm, the unit is meter.
(5)Walking calibration
The first point: Run the tower crane to left side of track, and click“ ” to
confirm.
The second point: Run the tower crane to another side of track and click“ ”
to confirm.
Note: The parameter calibration is finished on tower crane only, the ground
monitoring software hasn’t the function of parameter calibration.
Till now, the system calibration is finished and be in normal work.
6.3. Bypass function

When tower crane has alarmed to be stopped,if the operator still need load the
weight closed to dangerous area,the Bypass function(suspend control) is
necessary.Click Bypass and input password 705 to Bypass operation mode,this
moment work near dangerous area can be permitted.When click Bypass and input
password again far away from dangerous area,close Bypass operation mode to resume
normal working state.This system has both key switch Bypass function and upload
instruction Bypass for office ground monitoring system besides the password input
way.Any ways of them can transfer Bypass data to office,so that office workers can
observe the safe working state of tower crane more intuitively.
6.4. Data record

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AS-100 system has black box function,it can real-time record tower crane working
data,which up to 3000,000 or more,easy for operator to check in the future.
1. Working Record
2. Real-time Record
3. Anti-collision Record
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4. Operating Record
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Ⅶ、AS-100 system maintenance

7.1 Control Box and Monitor
● Often check the Mainframe and monitor. Keep it firm, stable and free of loose status.
● Check if the lead-out cable, plugs and sockets are loose. Do not insert or draw the cable
improperly. Or it may cause poor contact.
● Keep the case from rain or exposure to direct sun light.
● Keep the rear cover of the control cabinet from opening.
7.2 Signal cable and Sensors

● Regularly check arrangement of all sensor cables to avoid occurrence of crushing,
bending or damage at some locations.
● The installation of Trolley Stopper, Slewing Stopper and Hoisting Height Limiter shall be
fastened firmly. Regularly check its coordinating with drive mechanism.
● Regularly check the angle (direction of arrow) of load cell to see whether it has a
deflection or not.
● Guarantee trolley limiter fixed and stable connection.
26
Ⅷ、Fault analysis & remedies

Fault Reasons Remedies
The mainframe can’t start Disconnection of power supply Check power supply circuit
when the system is on
Part fault of main frame power supply Contact the manufacture
Start the mainframe, but the monitor

Problem between monitor and mainframe’s
reconnect, start, waiting for a few mins
power indicating light Is off connection wires or plunge. connect and press USD
board:Ctrl+Alt+F1,renew in three seconds
Start the mainframe, the monitor
Problem between monitor and As above
power light is on , mainframe’s connection
but blank screen wires or plunge.
The data change is unstable or Bad earth wire connection Check the grounding circuit
turnover
The trolley data change become soNot
large
setup the trolley data do the trolley data setup
or so small, the trolley item
is in bad state ion the picture.
Trolley data no change The signal transmit is off Check the signal cable and plug
The mainframe connection condition
Check the trolley limiter transmit shaft
azimuth data is zero or no No signal input Check the signal cable and plug
change, the picture no
Something is wrong with the slewing Contact the manufacture
change when slewing
angle sensor
The mainframe and interface Something is wrong with mainframe Use theAS-100 renew CD system(the mainframe and
showing is ok, but the system software or some procedures renew CD series number should be the same
system is in bad state 1. connect the USD driver and board to the mainframe
2. input the renew CD to start the mainframe,
it will renew the system automatically by
pressing any key(not to renew by pressing Ctrl+C),
take out the CD
3. restart the mainframe, reload all the data and setup
The mainframe is ok, but The antenna is not well done, Check the antenna installation and connection ,check the transmi
offline for longtime( without Transmit cable is broken cable
Showing) Not in line with the net frequency band Adjust the frequency band and net
Something is wrong with the radio Contact the manufacture

accessories
When working normally, there Many sets of system exit Off and restart all the working system
is offline or system halted At the same time
Disturbed by strong signal Off and restart
27
Ⅸ、Technical Support & Service

9.1 The installation and debugging of system
We will delegate personnel to provide our users with training and instructions during
installation and commissioning. To carry out installation and commissioning, the site
shall meet following requirements for the minimum:
●The crane works properly
●There should be long tape for the accurately calibrated amplitude values.
● Assistance will be needed for site installation and commissioning from:
Lifter, electrician for crane maintenance, crane operator, and fitter, etc.
9.2 Maintenance service

● We agree to repair the product on a lifetime basis.
● The warranty period for the product is one year from the date of purchase.
● We agree to repair the product free of charge within the warranty period. Beyond the
warranty period, repair will be charged for cost.
● We exclude warranty for:
Damage caused by bumping or crushing,
Damage resulted from improper dismantling,
Other damages resulted from abnormal conditions.
Our company reserves the right to change this manual without informing in advance.
28
AS-100 塔机力矩、防互撞及区域保
护系统
安装使用说明书
CHENGDU ACMS TECHNOLOGY CO.,LTD.

Add:No.1314 Xiyuan Ave, West Hi-Tech Zone,Chengdu city,Sichuan Province, China
TEL：+86 17502820413
WhatsApp：+86 13709023964
POST CODE：610000
E-mail：121225@163.com
29
目录
一、AS-100 塔机力矩保护、防互撞及区域保护系统简介.........................................................31
二、AS-100 塔机力矩保护、防互撞及区域保护系统用途..........................................................32
2.1．塔机力矩保护功能..........................................................................................................32
2.2．塔机防互撞及区域保护功能......................................................................................... 33
2.3. 安全监控功能...................................................................................................................34
三、系统特点...................................................................................................................................35
3.1．性能特点..........................................................................................................................35
3.2．技术参数..........................................................................................................................36
四、AS-100 塔机力矩保护、防互撞及区域保护系统的功能实现.............................................37
4.1.塔机力矩保护.....................................................................................................................37
4.2.塔机之间防撞.....................................................................................................................37
4.3.区域保护.............................................................................................................................42
五、系统硬件安装...........................................................................................................................44
5.1. 无线电台的安装...............................................................................................................44
5.2．幅度传感器安装..............................................................................................................44
5.3．回转行程限制器安装......................................................................................................45
5.4．起升高度限位器安装......................................................................................................45
5.5．重量传感器安装..............................................................................................................46
5.6．风速传感器安装..............................................................................................................48
5.7．司机室显示屏及主机安装............................................................................................. 48
5.8．电缆连接..........................................................................................................................48
六、系统设置及使用系统调试.......................................................................................................51
6.1. 参数设置...........................................................................................................................51
6.2. 系统标定...........................................................................................................................55
6.3 Bypass 功能 ..........................................................................……………………....59
6.4. 数据记录..................................................................................................................... ..59
七、系统维护...................................................................................................................................62
7.1．主机及显示屏..................................................................................................................62
7.2．信号电缆及传感器部份................................................................................................. 62
八、故障分析及处理.......................................................................................................................63
九、技术支持及维修服务...............................................................................................................65
9.1．系统安装调试..................................................................................................................65
9.2．维修服务..........................................................................................................................65
30
一、AS-100 塔机力矩保护、防互撞及区域
保护系统简介
AS-100 型塔机多功能安全监控管理系统是本公司推出的最新产
品。该产品将塔机报警及工作记录显示装置、塔机群防互撞及区域保
护系统、电脑监视管理系统融为一体，可实时在塔机上、在线电脑上
显示塔机或塔机群的工作状况，同时具有黑匣子功能、防互撞和区域
保护功能，可混合使用于各种类型的水平臂式、动臂式塔机。AS-100
型采用了时下最先进的 ARM 嵌入式智能微处理器技术,使系统数据
处理能力大大加强，精度更高，稳定性更强，辅之以高精度的数字方
位传感器、称重传感器、倾角传感器等，并使用先进了的无线通信技
术。另外，AS-100 型采用全触摸屏操作，中英双语显示，信息直观
易读，安装使用简便，在塔机使用过程中为操作人员和监管人员提供
了最全面的塔机工作状态信息和充分的安全保障。
31
二、AS-100 塔机力矩保护、防互撞及区域保
护系统用途
2.1．塔机力矩保护功能
当塔机在独立或是多台同步运行情况下，根据载荷情况允许或禁止吊
钩向上提升、小车向前操作。包括 2 个触点：吊钩提升、小车向前低
速。为了让塔机工作时，更加安全稳定，新增加了力矩和重量可调
3 路保护，并默认最大不超过安全范围的 120%（一般塔机厂家测试塔
机安全力矩为 120%）
32
2.2．塔机防互撞及区域保护功能
在多台塔机同时施工时，如何防止相互碰撞，以及防止塔机与建
筑物碰撞和吊物进入某些禁区（如街道、校园、公众区域、铁路、电
网等）的上空，一直是建筑施工中引人注目的安全问题，并已逐渐将
其纳入严格的施工安全管理；制订了相应的法规和标准，希望最大限
度的保证建筑施工的安全。尽管如此，还是不可避免地发生某些塔吊
间的干涉碰撞或吊物误入保护区域上空等安全事故。
AS-100 塔机群防互撞及区域保护系统的主要作用就是计算机自
动控制和处理施工现场的两大难题：工地上塔机间的相互干扰和禁行
区域的保护。本系统适用于各种平臂和动臂塔式起重机，能实现同一
工作区域多达 30 台塔机的塔机群的实时监控并能按需要存贮运行记
录，以备安全跟踪、核查。
AS-100 塔机群防互撞及区域保护系统可以使塔机操作者始终以最
高的效率安全操作其塔机工作。本系统连续不断地计算着可能会相互
干扰的联网塔机的方位及吊运车的相对坐标，一但探测到可能出现塔
机间的相互碰撞和靠近禁止吊钩或靠近敏感或保护区域，如：街道、
高速路、校园、公众区域、铁路、电网等时将先预警，直至通过此台
塔机的控制系统来动作，自动限制这种操作的继续，尽可能的避免因
操作者的疏忽或判断失误而造成安全事故，极大地保证了塔机的安全
使用。
33
2.3. 安全监控功能
本系统能够通过 10.2 吋（用户可选择 7 吋）彩色高清液晶显示
屏向塔机操作人员准确地提供当前塔机的实时工作状态(吊钩幅度、
额定重量、实际重量、力矩、力矩百分比、回转角度、吊钩高度、当
前风速，动臂塔机还能显示大臂仰角。当起重达到额定起重量 90%
时预警、100%时报警、105%时(此三项数值用户可自行设置，但是最
大不可超过 120%)报警自动切断小车幅度向外和吊钩上升的操作以
及相邻塔机的位置状态。系统能保存塔机的报警记录，以备安全跟踪、
核查。
注明：AS-100 塔机群防互撞及区域保护系统仅是一种辅助控制
装置，它能提供有用的塔机操作信息和必要时的强制停车控制，但不
能取代塔吊操作者的指令。
34
三、系统特点
3.1．性能特点
（1）集塔机力矩保护、防互撞、区域保护于一体，功能完善。
（2）本硬件系统适用于建筑施工现场，测量精度高，控制准确，抗
干扰能力强，宽温度环境等特点。
（3）本系统的软件系统是根据塔机工作的特点结合操作人员的习
惯而编制，智能程度高，是塔机安全监控的有力助手。
（4）本系统通过彩色液晶显示器，用简洁，生动地画面显示施工现
场的位置状态，通过声、光、色彩数码等方式提示操作者，当操
作无效时，计算机可以通过判断分析主动控制停车，起到安全保
护的作用。
（5）本系统采用域展无限网路传输技术，可以实现多台塔机的无线
通讯，抗干扰能力强，响应频率高。
（6）本系统结构小巧紧凑，安装简单，设计中考虑塔机的特点，安
装本系统不改动机械本身的各种结构，使用非常方便。
（7）当某台塔机因故障需停机修理时，可很容易的在 PC 机上将此
台塔机去除，也可以作为固定障碍物形式进行区域数据输入处理。
（8）系统永久性保存防撞及吊重超载工作记录。
35
3.2．技术参数
（1）工作环境温度: -20℃~ 60℃
（2）工作环境湿度: ≤95%（25℃）
（3）电源电压： AC 220V
（4）工作方式：连续
（5）系统综合误差： ≤±3%
（6）称重传感器重复性误差： ≤±0.5%
（7）称重传感器非线性误差： ≤±3%
（8）断电时自动保存当前所有数据，得电时立即恢复实时数据；
（9）声光预警/报警，24 路控制输出。
36
四、AS-100 塔机力矩保护、防互撞及区域
保护系统的功能实现
4.1.塔机力矩保护
根据塔机自身载荷情况允许或禁止吊钩向上提升、小车向外操作。
当载荷达到预先设定的报警阈值时发出声光预警；在载荷、距离等达
到预先设定的危险阈值时发出声光报警并作出相应控制；当控制器出
现故障时，系统将暂停运行，不会主动影响正常施工。
4.2.塔机之间防撞
（1）一高（A）一低（B）两塔吊间：
A机
B机
图 4-1 防撞功能示意
图
碰撞的危险将发生在较高 A 塔吊的起吊缆索与较低 B 塔吊的吊臂
或平衡臂之间。即任何时候都不允许 A 塔吊的吊运车跨越 B 塔吊的大
臂或平衡臂的上方，B 吊运车的运行不受限制。
下面以简图说明多种本系统能防止的干扰情况，
37
高塔吊之吊运车危险区域大臂回转范围平衡
臂回转范围
危险范围定义：
两大臂回转范围的重叠区域定义为第 1 危险区域。
当 A、B 臂端都进入
危险区域内，且 A 吊运
车未处于危险区域内时，
两塔机的回转将不受限制。
A B
图 4-2 防撞功能示意图
当 A 吊运车和 B 大
臂接近或进入危险
A B 区域时，系统将动态
计算 A 吊运车和 B
大臂间的距离，当达
到设定的安全值时
将预警并限制塔机
的回转操作，必要时
将强制启动回转制
动器。
图 4-3 防撞功能示意图 2
38
A B
当 A 和 B 大臂重叠
相交，A 吊运车接近
交叉点时，系统将会
限制 A 吊运车的向
外（上图）和向内（下
图）运行。同时限制
B 大臂的左转（上
图）和右转（下图）
A B
图 4-4 所示只有第 1 危险区域。
A 大臂长度＋B 平衡臂长度大于两塔吊安装距离时，将存在 A 大臂回
转范围和 B 平衡臂回转范围的重叠区域（此种情况较少）
，定义为第
2 危险区域，以色-彩标记。
图 4-5、图 4-6 第 1 危险区域与第 2 危险区域共存的情况，对第
1 危险区域的限制不变。
39
当 B 平衡臂端先进
入第 2 危险区域内
时，第 2 危险区域即
A B
成为 A 吊运车的禁
入区域。（A 吊运车
向外运行限制或对 A
的第 2 回转角度限
制）
当 A 吊运车先进
入第 2 危险区域
A B 时，第 2 危险区
域即成为 B 平衡
臂回转的禁入区
域（对 B 的第 2
回转角度限制）
注：对多台高低不一、相互有干扰的塔吊群而言也同理，只是限制的
区域增加。
（2）大臂同高度两塔吊间:
40
A机 B机
图 4-7 同高度两塔吊间防撞功能示
意
碰撞的危险将发生在两大臂之间或大臂与平衡臂之间。即两塔吊
在运行过程的任何时候，两大臂间或大臂与平衡臂之间都必须保证有
足够安全间距（不小于 2m），不得逾越。
两大臂回转角度＋安全间距（不小于 2m）的重叠区域为危险区域。
A/B 大臂长度＋B/A 平衡臂长度大于两塔吊安装距离时，将存在
A/B 大臂回转角度和 B/A 平衡臂回转角度＋安全间距的重叠区域也为
危险区域。
41
当两大臂都处于此危险区域
内，接近设定的最小安全距离
时，其中一台（或两台同时）
A 的旋转回转运行将受到限制。
B
过程见图 4-8 所示
警告减速
制动
≮最小安全距离
图 4-8
警告及减速（断电）距离(系统默认值分别为 8 m 、6m)可根据大
臂长度和回转速度进行实际参数修订，本系统可根据塔机性能设置回
转制动的时间和回转电机反转时间。
注：两塔机间高度差在 10m 以内（含 10m）时，系统认为等高度。
4.3.区域保护
区域保护指禁止吊钩或跨越的敏感（保护）区域，如：街道、高
速路、校园、公众区域、铁路、电网等，固定障碍物指施工现场存在
42
的有一定高度的固定物。在塔机群防互撞及区域保护系统现场安装完
成，初始化设置时进行参数输入。此参数为受保护区域的数个拐角点
（可形成数个封闭区域）的现场坐标值（Xi，Yi），对固定障碍物输入
高于塔机的高度数据。
表示受限（保护）区域
受保护区域为吊运车
的禁行区域。当大臂前
端处于该区域内时，吊
运车向臂端运行的幅
Y 度将受到限制。
上图中，有两处保
护区域，有两组确定的
现场坐标数据。
O
X
当系统判断到
障碍物高度接
近和大于塔机
臂高时，将会限
制大臂回转
Oi X
图 4-9 区域保护和固定障碍物防撞功能示意图
43
五、系统硬件安装
整套系统主要由：彩色液晶显示器、主机、带电位器型(DXZ-W)
小车幅度行程限位器、带电位器型(DXZ-W)回转行程限位器（使用防撞
功能时采用绝对值编码器）、带电位器型(DXZ-W)起升高度行程限位器、
重量传感器、风速传感器、通讯电台以及输出控制电缆组成。
5.1. 无线电台的安装
当本系统使用防撞功能时由多台单机系统组成的时候，需要使用
无线电台进行无线通讯，需要把无线电台安装在塔机上，并将天线安
装在驾驶室顶部远离塔帽尽量无遮挡物不会产生电磁屏蔽的位置。
注意：系统工作时，需要先将无电台通电工作。而且整个工作的过程中，电台
一直工作。
5.2．幅度传感器安装
(1)动臂塔机角度传感器安装
动臂塔机采用角度传感器采集倾角信号，系统内部程序将信号自
动换算为幅度数值；角度传感器安装：见图 4-1。把角度传感器盒安
装在靠近大臂根部右侧适当处，安装时请注意传感器的方位，传感器
盒的箭头必须指向大臂臂头，否则测量范围将无法涵盖所有工作倾角
范围，传感器的有效范围是-20°~90°。
44
图 5-1 角度传感器安装
（2）平臂塔机小车行程限制器安装
平臂塔机采用幅度限位器采集幅度信号，将原塔机配装的不带电位器
的小车行程限制器拆下，更换带电位器的限制器，安装方式不变。
注意：在更换限位器后，需要对限位器里的电位计进行调整。
5.3．回转行程限制器安装
将原塔机配装的不带电位器的回转行程限制器拆下，更换上带电位
器的限制器，安装方式不变。回转限位器电位计的调整方法同幅度限位
器。
5.4．起升高度限位器安装
将原塔机配装的不带电位器的高度行程限制器拆下，更换上带电位
器的限制器，安装方式不变。回转限位器电位计的调整同上。
电位计的结构如图 5-2 所示：
45
图 5-2 电位计
需要用一字螺丝刀调整电位计调节螺钉，让标志点在整个塔机的运行
过程中不进入盲区（两条黑线之间较小的扇形区域）范围内。(即在
小车从臂根到臂尖的整个过程中，幅度限位器的电位计的标志点不进
入盲区。在塔机回转 3 圈 1080°的过程中，回转限位器的电位计的标
志点不进入盲区。在吊钩由最低至最高运行的过程中，高度限位器的
电位计的标志点不进入盲区。)
注意：必须要保证在整个塔机运行的过程中，电位计标志点不进入盲
区，否则显示的数据会发生错误！
5.5．重量传感器安装
将原配称重轮滑轮轴拆下，按原装配关系替换为剪力传感器轴。
传感器轴装配时尽量避免强力敲击，最好使用木锤。
剪力轴两端螺纹紧固形式：
46
此处折弯
防转卡板
（剪力）传感器轴
滑轮
两孔中心连线
测力环
图 5-3 螺纹紧固式
注意：销轴安装时，传感器上的箭头方向必须和钢丝绳的合力方向一致（即钢
丝绳通过滑轮形成的夹角中心线方向）。
重量传感器技术参数
综合精度 0.5 （线性+滞后+重复性）

灵敏度 1.5mV/V
蠕变 ±0.5％F·S/30min
零点输出 ±1 ％F·S
零点温度影响 ±0.5 ％F·S/10℃
输出温度影响 ±0.5％F·S/10℃
工作温度 -20℃～+65℃
输入阻抗 750±30 Ω
输出阻抗 700±10 Ω
绝缘电阻〉5000 MΩ
安全过载 150％ F·S
47
5.6．风速传感器安装
用三个 M8 螺钉将风速传感器安装在塔机适当位置，尽量无遮挡，
并连接好电缆。
5.7．司机室显示屏及主机安装：
Ａ．显示屏安装：
安装在司机室左（或右）前方拐角处，高度以司机操作时平视稍
偏低为宜。显示屏底座带有固定孔位，具体安装固定方式用户自行处
理。
Ｂ．主机安装：
主机安装在驾驶室，主机的底座设计有 2 个安装孔，具体安装
固定方式用户自行处理。
5.8．电缆连接
（1）高度信号电缆（Height）
将 3 芯高度信号电缆插头插入控制箱上标有 Height 的插孔内。
（2）幅度信号电缆（Trolley）
将 4 芯幅度信号电缆插头插入控制箱上标有 Amplitude 的插孔内。
（3）重量信号电缆（Weight）
将 5 芯重量信号电缆插头插入控制箱上标有 Weight 的插孔内。
（4）回转信号电缆（Slewing）
将 6 芯回转信号电缆插头插入控制箱上标有 Slewing 的插孔内。

48
（5）风速信号电缆（Wind）
将 7 芯风速信号电缆插头插入控制箱上标有 Wind speed 的插孔内。
（6）电台信号电缆（Radio）
将反装 5 芯电台信号电缆插头插入控制箱上标有 Communication 的插
孔内。
（7）显示器连接线
将 4 芯信号线插头的两端分别于显示器和主机的 single 插口连接并旋
紧。
（8）控制线连接：
将本系统提供的常闭控制点接入塔机的力矩控制回路中。本系统提供
十四组继电器常闭点（可定制常开点）
。
1#--左回转预警
2#--左回转报警
3#--回转制动
4#--右回转预警
5#--右回转报警
6#--最大幅度/最小角度预警
7#--最大幅度/最小角度报警
8#--最小幅度/最大角度预警
9#--最小幅度/最大角度报警
10#--力矩点 3
11#--左反顶
49
12#--右反顶
13#--高度向上预警
14#--高度向上报警
（9）电源线连接
连接电源线之前，请检查所有硬件安装状况，确保线路正确连接，
然后将系统中三芯电源线接入塔机交流 220v 电路中。

接电要求：不要选择与塔机控制回路供电相同的相线接电，尽量减小电源干扰。
(建议最好从塔机电源控制柜直接接电，如塔机有交流变压器，请从变压器取电，
以保证电源的稳定。)
接地要求：必须选择符合接地要求的接地点进行可靠接地，接地电阻不大于
4Ω，保证系统能正常工作。
50
六、系统设置及使用系统调试
6.1.参数设置
系统的工作界面如图 6-1 所示：
图 6-1 工作界面
监控界面中，绿色的圈表示正在正常工作的塔机，小红点表示当前小
车的位置。4 代表钢丝绳数量（即倍率），进入符合特性可改变倍率。
要进行参数设置时，点击监控窗口右下角的“Menu”按钮，就可以进
行参数设置。
在进行设置之前，需要根据工地的图纸，找出一个坐标原点，并计算
出每一个塔吊在工地上的具体位置。
（1）工地设置（Setup on Site）
设置界面如图 6-2 所示：
51
图 6-2 工地设置
其中，回转标定用户可根据工地工况选择不同的标定方式。
‘single
point’表示用户可以选择工地的其中一台塔机作为标定点；
‘two
point’表示用户可以选择工地的其中 2 台塔机作为标定 AB 点；
‘User-defined’用户可根据工地工况自行寻找两个点进行标定。
‘Trolley decelerate distance’为小车预警距离，

‘Trolley brake
distance’为小车报警距离，
‘Slewing brake Distance’为回转停
止距离，
‘Slowing stop Distance’为回转报警距离，‘Slewing
decelerate Distance’为回转预警距离，
‘FD Time’为电机反转时
长，
‘Brake Time’为回转制动时长。
（2）塔机参数设置（Setup on Towercrane）
塔机设置界面如图 6-3：‘TC NO.’代表塔机编号，

‘X1,Y1’表示塔
52
机的坐标，
‘X2,Y2’表示行走塔机的第二个坐标点，
‘TC Height’表
示塔机高度，
‘Jib length’为塔机的大臂长度，
‘counter-jib length’
为平衡臂长度，
‘Min Radius’为塔机最小工作幅度。
‘Max Angle’
为动臂塔机的最大仰角，
‘Min Angle’为动臂塔机的最小仰角，
‘a0’
为动臂塔机臂根铰点到回转中心的距离，单位为米，如果铰点在靠近
大臂一方，则‘a0’为正数，如果铰点在靠近平衡臂一方，则‘a0’
为负数。
图 6-3 塔机参数设置
（3）区域设置（Setup on Zone）
当工地上存在障碍物或者有需要保护的区域的时候，通过设置区域进
行保护，区域设置界面如图 6-5：
‘No.’代表第几个区域，本系统可
设置多达十个区域，其中 H 代表区域高度，
‘x,y’分别代表一个点的
Ｘ坐标和 Y 坐标，通过设置坐标点，本系统同时拥有智能添加区域的
功能将大臂转向区域并且将小车运动至组成区域的几个点，点击区域
53
设置里面图标，坐标会自动计算并填充到表格中，这些坐标点沿
逆时针方向围成区域。
图 6-4 区域设置
（4）地面监控软件参数上传
本系统的参数也可在笔记本电脑上的地面监控程序设置后，通过无线
通讯传输到主机上，地面监控软件的参数设置与防撞系统中的参数设
置一致，当完成所有参数设置之后，点击地面监控软件界面上的“上
传文件”按键，弹出对话框，选择塔机，暂停通讯，系统将上传参数
文件！地面监控系统会将塔机监控系统所有数据都实时的显示在电脑
屏幕上，包含多塔机防撞，当前传感器参数值，力矩及 Bypass 等，
使办公室人员更能直观的了解塔机的工作状态，更能有效保障塔机及
工作人员的安全！
54
图 6-5 地面监控工作界面
6.2.系统标定
当完成所有的硬件安装之后，接通电源，系统开机。AS 监控系统具
有详细，动态的显示界面，用户可方便地进行选择、使用。系统机进
入后正常工作状态，加载并显示塔机断电时所有资料。系统正常工作
时，显示界面如图 6－6：
图 6－５系统工作界面
55
需要设置、调整时，点击‘MAIN’，输入密码‘2017’操作即可进
选择界面，点击界面 SET 图标进入实际参数标定界面，标定界面如图
6－7：
图 6-7 系统参数标定界面
（1）点击 PARM CAL 进行回转标定
进行回转标定前请进入 Site Set 选项进行回转标定方法选定
单点标定：在工地设置中选中单点标定并选择参考塔机。首先将塔机
大臂指向选择的参考塔机，点击标定按钮，然后逆时针转动塔机将平
衡臂指向参考塔机，点击标定按钮。
两点标定：在工地设置中选中两点标定并选择参考塔机。首先将塔机
大臂指向选择的参考塔机 A，点击标定按钮，然后逆时针转动塔机将
大臂指向参考塔机 B，点击标定按钮。
用户自定义：在工地设置中选中用户自定义标定并将坐标输入表格中。
首先将塔机大臂指向选择的参考 A 点，点击标定按钮，然后逆时针
56
转动塔机将大臂指向参考 B 点，点击标定按钮。
注意：在标定的过程中，大臂必须沿逆时针方向运动。
系统标定后，对工地设置是所设置的控制距离进行验证，如果距
离过大或过小，可以再次进入工地参数设定界面做出相应修正。
(2)幅度（动臂仰角度）标定
注：动臂塔机标定角度，平臂塔机标定幅度
①动臂塔机标定
a.最小角度标定:
将塔机大臂停在仰角最小角度位置处，点击界面数值栏后方的
“ ”
，输入当前角度数值，点击确定，即可完成最小角度标定。
b.最大角度标定：
将塔机大臂停在仰角最大角度位置处，点击界面数值栏后方的
“ ”
，输入当前角度数值，点击确定，即可完成最大角度标定。
②平臂塔机标定
a.最小幅度标定
将小车开到臂根最小幅度位置，点击界面数值栏后方的“ ”
，
输入当前幅度数值，点击确定，即可完成最小幅度标定。
b.最大幅度标定：
将小车开到最大幅度位置（幅度限位处），点击界面数值栏后方的
“ ”，输入当前幅度数值，点击确定，即可完成最大幅度标
定。
（3）重量标定
57
标定重量前需要准备已知重量的砝码，重量为塔机最大起重量的
40%~50%为宜。
a.吊重清零
将吊钩下行到地面附近，在不挂载重物的情况下，点击输入
清零（或吊钩重量）后确定即可完成标定
b.最大吊重：
在最大吊重栏输入最大吊重值，点击界面数值栏后方的输入
当前物体重量值，点击确定 ,即可完成标定。
(4)高度标定
a.最小高度标定
将吊钩接近地面，点击界面数值栏后方的“ ”输入数字确定，
即可完成标定。
b.最大高度标定
然后将吊钩开至最高处，点击界面数值栏后方的“ ”
，再输入
此时的吊钩高度数值，单位为米，点击确定，即可完成标定。。
(5)行走标定
第一点：将塔机开到轨道左端（坐标数值小的一端）
，点击即
可标定完成
第二点：第一端标定完成后，将塔机开到轨道另一端，点击即
可标定完成
注：系统参数标定只能在塔机上完成，地面监控软件没有参数标定功
能。
58
至此，系统参数标定完成，可以正常工作。
6.3. Bypass 功能
当塔机已经报警停车后，还需要更加的靠近危险区域才能吊装到货物
是就要用到 Bypass（暂时取消控制）功能，点击 Bypass 后输入密码
705 进入 Bypass 工况，此时可接近危险区域工作，当远离危险区域后
点击 Bypass 按钮再次输入密码，结束 Bypass 工况恢复正常工作状态。
我公司系统除了输入密码的方式还有钥匙开关 Bypass 功能以及办公
室地面监控系统上传指令 Bypass 两种方式。任何一种方式 Bypass 数
据都能传递至办公室，让办公室人员更直观的观察塔机安全运行状态。
6.4. 数据记录
系统具有黑匣子功能，可以实时记录塔机工作数据，多达 300 万条以
上，方便用户将来查询。
1.工作记录
59
2. 数据记录
3. 防撞记录
60
4. 操作记录
61
七、系统维护
7.1．主机及显示屏
● 经常检查主机箱固定支架，保证牢固、可靠、不松动。
● 主机箱引出电缆、插头、插座等无松脱；线缆不得随意插拔，
以免接触不良。
● 注意防雨，避免阳光直接照射。
● 机箱不得自行开启。
7.2．信号电缆及传感器部份
● 定期查看所有传感器电缆的布线情况，避免可能存在的局部挤
压、折弯及破损现象。
● 幅度限位器、回转限位器、高度限位器的安装一定要牢靠，定
期查看其和传动机构的配合。
● 定期查看称重传感器的角度（箭头方向）是否发生偏转。
● 定期检查风速传感器安装是否牢固。
62
八、故障分析及处理
故障现象原因处理方法
开机后屏幕不显示电源断线，显示器连线松掉检查电源，显示器连接
开机后系统不工作主机电源部份故障与厂家联系
幅度、高度、回转角度显对应的行程限制器联接松检查联接情况
示误差增大脱
对应的行程限制器的电位更换电位器
器磨损
回转角度、高度、幅度、对应的行程限制器联接松检查传动联接装配
显示数字不动脱或电位器传动不良
传感器信号传输电路断线检查接线、电缆线
及主机插头
动臂塔机大臂仰角显示不角度传感器安装位置变化检查传感器安装
准确角度标定不准确重新标定大臂角度
动臂塔机大臂仰角显示数传感器信号传输电路断线检查接线、电缆线
字不动及主机插头
角度传感器坏更换角度传感器
回转角度显示数字不准回转角度标定不准确重新标定回转角度
风速显示数字不动风速传感器坏更换风速传感器
传感器信号传输电路断线检查接线、电缆线
及主机插头
风速显示不准确传感器安装位置有遮挡重新安装传感器
传感器位置变化固定好传感器
故障现象原因处理方法
63
监控界面显示塔机为红色系统未开机打开系统
接收不到无线信号将电脑移至能接收信
号的地方
电台未打开，系统未联网打开电台
本机上不能显示相邻塔机打开主机
信息主机关闭另外找一台主机，并将
整个系统重新开机
64
九、技术支持及维修服务
9.1．系统安装调试
产品安装时，由我方专业人员对用户进行培训、指导安装和调试。
系统现场安装、调试时应具备以下条件：
● 起重机能正常工作；
●最好备有长卷尺，用以精确标定幅度值；
● 现场安装、调试时应有如下工种人员的配合：
起重工、起重机维修电工、起重机司机、钳工等。
9.2．维修服务
● 产品终身负责维修。
● 产品自购买之日起，质量保修期一年。
● 保修期内免费维修；保修期外，维修只收取成本费用。
● 有下列情况之一者，不属于保修范围：
●碰撞、挤压造成的损坏；
●野蛮拆卸造成的损坏；
●其它非正常情况造成的损坏。
本公司保留对此手册更改而不提前通知的权利。
65

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AS-100 Anti-Collision&Zone Protection

System and Safe Load System for Tower

CHENGDU ACMS TECHNOLOGY CO.,LTD.

Ⅰ、AS-100 system profile................................................................................................................ 3

Ⅰ、AS-100 system profile

Ⅱ、AS-100 system basic purpose

2.2 Anti-collision and zone protection function

AS-100 anti-collision&zone protection system is controlled by computer

2.3 Safety monitoring function

Ⅲ、The characteristics of AS-100 anti-collision system

1) The system is with complete functions of load moment indicator,anti-collision&zone

3.2. Technical Parameter

1) Working temperature: -20℃ ~ 60℃

Ⅳ、How AS-100 system performs the

4.1 Torque protection

4.2 Anti-collision between tower cranes

(1)Between higher crane“A”and lower crane “B”.

When jibs from cranes“A”and “B”overlap and crane“A”trolley is approaching the

Figure 4-figure7 show only No.1 Risk zone.

Figure 8 and figure 9 indicate there is a circumstances of No.2 Risk Zone,restrictions to

(2)Between 2 tower cranes with the same height.

☆ Color the symbols same as above

When the 2 jibs are both in the Risk Zone

≮min safety distance

4.3 Zone protection

(Green) Restricted (protected) Zone

Ⅴ、 Hardware installation of AS-100 system

5.1 Installation of radio station

5.2 Installation of trolley limiter

Figure5-1 Installation of Angle Sensor

(2)Installation of trolley limit switch for level-jib tower crane

5.3 Installation of slewing limiter

5.4 Installation of hoisting height limiter

5.5 Installation of load cell

Figure5-3 Threaded fastening type

Technology parameters of weighing sensor

5.6 Installation of wind speed sensor

5.7 Installation of display in cab and control box

5.8 Cable connection

(1) height signal cable (Height)

1#--Left slewing warning

Ⅵ、System setting and debugging of system operation

The monitoring interface is as figure6-1:

Figure6-1 monitoring interface

Figure6-2 setup on site

Figure6-3 setup on tower crane

Figure6-4 setup on zone

④The parameter for ground monitoring software uploading

Figure6-5 ground monitoring working interface

6.2 System calibration

Figure6-5 system working interface

If the setup and adjustment are needed,click “MAIN”,input password “2017” to

Figure6-7 Parameter calibration interface

(1) Click “PARM CAL” to slewing calibration

Note: during calibration, the main jib must be turned counterclockwise.

(2) Amplitude(angle) Calibration

1 Calibration for luffing tower crane

（7）当某台塔机因故障需停机修理时，可很容易的在 PC 机上将此

（1）工作环境温度: -20℃~ 60℃

（2）工作环境湿度: ≤95%（25℃）

（3）电源电压： AC 220V

（5）系统综合误差： ≤±3%

（6）称重传感器重复性误差： ≤±0.5%

（7）称重传感器非线性误差： ≤±3%

（9）声光预警/报警，24 路控制输出。

高塔吊之吊运车危险区域大臂回转范围平衡

注：两塔机间高度差在 10m 以内（含 10m）时，系统认为等高度。

主机安装在驾驶室，主机的底座设计有 2 个安装孔，具体安装

开机后屏幕不显示电源断线，显示器连线松掉检查电源，显示器连接

开机后系统不工作主机电源部份故障与厂家联系

幅度、高度、回转角度显对应的行程限制器联接松检查联接情况

回转角度、高度、幅度、对应的行程限制器联接松检查传动联接装配

动臂塔机大臂仰角显示不角度传感器安装位置变化检查传感器安装

动臂塔机大臂仰角显示数传感器信号传输电路断线检查接线、电缆线

回转角度显示数字不准回转角度标定不准确重新标定回转角度

风速显示数字不动风速传感器坏更换风速传感器

风速显示不准确传感器安装位置有遮挡重新安装传感器

监控界面显示塔机为红色系统未开机打开系统