JUNE 2013

Version
UNITED ARAB EMIRATES
EMIRATES OF ABU DHABI
.
GALVACOAT RAISING&LOWERINGSYSTEM
Page 1 of 32
www.galvacoat.ae
Any unauthorized reprint or use of this material is prohibited.
No part of this book may be reproduced or transmitted in any
form or by any means, electronic or mechanical, including
photocopying, recording, or by any information storage and
retrieval system without express written permission from the company
INDEX




- INTRODUCTION.

- COMPONENTS DESCRIPTION.

- HOW IT WORKS.

- OPERATION MANUAL.

- APPENDIX A: SYSTEM MODEL.

- APPENDIX B: MOTOR DETAILS.

- APPENDIX C: GEAR BOX DETAILS.

- APPENDIX D : SUSPENSION SYSTEM

- APPENDIX E: POWER CABLE DETAILS & JB BOXES.


















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INTRODUCTION




Highmastwithraisingandloweringfacilityisdesignedtoraiseandlowerthemobile
ringautomaticallytoanacceptablelevelinordertodothemaintenanceforthelight
fittingsusingropesandmotorizedgearedwincharrangement.

High mast with raising and lowering system is easy, fast, feasible and efficient
method to do the maintenance in some places where other method to reach the
lightfittingisnotefficientandfraughtwithrisks.

R&Lsystemsubstantially,isanelectromechanicalsystemsimpleindesigntoavoid
any mechanical/electrical fail and to achieve the accuracy required for the whole
systeminservice&maintenancepositionwithhighreliabilityandrelativelylowcost






























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COMPONENTS DESCRIPTION




Raisingandloweringsystemconsistofthefollowingmainparts(subassemblies):

1. FixedheadFramesubassemblies.
2. Mobileringwithlightfittingarmsandcentralizingsystem.
3. Stainlesssteelropessuspensionsystem.
4. Motorizeddrivesystem(motor&winch).
5. Electricalparts&Connections.

/




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1. The Head Frame



TheHeadFrameconsistsofthefollowingcomponents:

- Topfiberglasscover(canopy).
- Maintenancefreecastironsheaveswithbearing.
- SteelhousingfortheSheaves.
- NylonSheavesforguidingpowercable.
- Steelhousingforthepowercablesheaves.
- Plates(steel)supportinglatchingpins.
- Reinforcementsteelplates(Ribs)tosupportmainsupportplate.
- Steelsleeveconnectingtheassemblytopole.
-

Description:
Completeassemblyofheadfromismadefromhotdippedgalvanizedsteelattached
totheshaftwithsetsofstainlesssteelgrubscrewwhichreflectsafetyandreliability
tothesystem.
On the main support plate is having sets of pulleys made of cast iron to roll the
stainless steel ropes and Teflon for power cables which is designed to run the
system smoothly, these pulleys supported on stainless steel spindle with self
lubricatedbearingandcertainlywithguardtopreventropesslip.

Onthesupportplate,therearethreeplatssupporting3latchingpinstogovern
latchingandunlatchingoperations

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2. MOBILE RING WITH LIGHT FITTING ARMS AND
CENTRALIZING SYSTEM


TheLightfittingmountingringconsistsofthefollowing:

- ThreeLatchingArmsspacedat120onthering.
- Setof3centeringspringloadedarms(irisarms)withrolleroneacharm
- HotdipgalvanizedUchannelshapesteelring.
- Setoflightfittingsupportarmsboltedtothering.
- Removableringrestingarmabovethedoor.
- Eyebolttoconnectthestainlesssteelropestothering.

Description:

The complete system is made of hot dipped galvanized steel, main purpose of
this part is to carry/ support light fittings and lowering it for maintenance the
core element of this part is the Uchannel, the latter is used to carry the light
fittingarmsbymeanofboltingandithasthethreelatchingarmstoconductthe
latchingprocess,atthetopoftheringthereisaprovisiontotighttheeyeboltin
order to connect the suspension system ( stainless steel ropes ) , at the bottom
thereistheirisarmwhichplayveryimportantroleincontrollingtheeccentricity
oftheringwhileraisingandloweringwhichpreventtheswayingofthesystem.
These arms maintain the roller in direct contact with the shaft during
lowering/raising operation the roller is made of rubber and does not leave any
scratchesonthepoleduringoperation.




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Page 6 of 32
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3. STAINLESS STEEL ROPES SUSPENSION SYSTEM

Wireropessystem(suspensionsystem)consistsofthefollowingparts:

- Setof3stainlesssteelGr.316suspensionwireropesof4mmdiameterhaving
7x19constructionsconnectingthemobileringtotheconnectingplate.
- Set of 2 Stainless steel Gr.316 Wire Rope of 6mm Diameter having 7 x19
constructions, winding on the dual drum connecting the winch to the
combiningpulley.
- Combiningpulleytoadjust/compensatethetworopescomingfromthedual
drum.
- SteelTransitionPlatewithconnectingthesetofthree4mmropes.
- Ropesaccessoriesi.e.thimbles&clips.

Description:

Suspensionsystemconsistsofstainlesssteelwirestotransmittheloadexcreted
frommotortotheringinordertoraiseandlowerthesystem.

To achieve more reliability index of the system two drums are used giving two
ropes sharing equally the load, the rope size is 6mm made of stainless steel
Gr.316 these two ropes are tied at combing pulley thereafter the pulley is
transmittingtheloadtotheconnectingplatewhichinturntransmittingtheload
thru three stainless steel ropes fixed to the connecting plate with eye bolts, at
theendthethreeropesaretiedwiththeringbyeyeboltaswell.

Inordertostrengthentheconnectionoftheabovesaidropesastandardwayto
fixtheropesusingstainlesssteelthimblesandclipsisadopted.

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Page 7 of 32
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) R MOTO & WINCH MOTORIZED DRIVE SYSTEM ( . 4



TheMotorizedWhichDrivesystemconsistsofthefollowingcomponents:

- 1HPmotorwithbrakingdevicemadebyKEBGermanOrigin
- HeliacalwormgearmadebyKEBGermanorigin
- Dualsteeldrumhasatleast5windinglayersspareondrum.


Description:


The helical worm gear is fully submerged in oil for continuous lubrication;
comprehensivedetailsofthemotorareprovidedinAppendixA&B



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5. Electrical Components & Connections

- BottomJunctionbox(distributionbox).

Made of cast aluminum Italian origin, Located at the door opening

(compartment) connected to the top junction box by 5 cores cable easy to
access,arubbergasketisprovidedtoachievetherequiredIPratingwithmin.
IP54

ComponentsinsidethebottomJunctionBox:

Motorcircuitbreaker3phases,rating2.5to4Amps.
Contactor3phases,rating7.5kw.
Terminalblock.
Terminals.
PVCglandIP68,BrassglandIP68&shroud.

BOTTOMJUNCTIONBOX

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- Topjunctionbox(terminalbox).

Mountedonthemobileringgettingpowerfromthebottomjunctionboxand
distributes the power to the light fittings , Italian origin made of aluminum
rubbergasketisprovidedtoachieveIPratingof54asminimum.

ComponentsinsidethebottomJunctionBox:

5pinwallmountedsocket32Amps.
Ceramicfuses.
PVCglands.
Terminalsblocks.
Earthterminalblocks.

TOPJUNCTIONBOX

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- Limitswitches.

2 Nos. of Limit switches are provided inside the door compartment as an

transducer to control the movement of the mobile to monitor efficiently
latching&unlatchingoperations.

LimitswitchisIPratedtoIP67,10A/220volts,accordingtoIEC6094751

SETOFLIMITSWITCHES(2NOS.)


- Remotecontrolunit.

Comprehensive remote control unites has all the required buttons design to
suit the safety concept of the system with 2m flexible cable in order to
operatethesysteminsafearea.

REMOTECONTROLUNIT

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- Mainpowersupplycable(betweentop&bottomjunctionbox).

Low voltage rubber flexible cable NEXAN branded, 5 cores 4mm

2
with
permissiblecurrentrating38A.

5CORERUBBERCABLE



- Powercableplug.

Connectedtopowercablewhichisroutedtotopjunctionbox.

POWERCABLEPLUG


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HOW IT WORKS?


the system is used in order to do maintenance or relamping for the light
fitting used , the maintenance is done by lowering the mobile ring at the a
levelnearthegroundtoberestedontherestingarm.

Loweringthisringisdonebyusingasetofwinchandsteelropesenergizedby
electricmotor.

While lowering and raising the mobile ring, there are three iris arms to
centralizetheringandtopreventswaying.

LATCHING/UNLATCHINGMETHODOLOGY

A very vital part of the raising and lowering mechanism, is how to hang the
head frame steady in operation condition and how to release it once
maintenanceisrequired.
There are three latching plates connected in free rotating way to hinge plate
which is fixed firmly to the mobile ring, while the mobile ring is going up, it
hits the round rod between the two supporting plates and pass the said rod,
thereafter the mobile ring must be lowered down a little bit in order for the
latchingplatetosnagfirmlytothesaidroundpin.

Inordertoreleasethelatching,themobileringmustberaisedupalittlebit
so the latching plate will be released then lower down in order for the
latchingplatelatchingplatetobypasstheroundpinwithoutsnagging.

It could be considered that the latching plate is designed to work as a cam

plateinup&downdirections.

Followingpageshowingsequenceofthelatching/unlatchingprocess:

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1 Latchingplateisrestedonthepininoperationcondition

2- Raising the ring upward to release the latch



3- Continue raising upward till the pin does not block the bottom part of the latching plate,
so it can rotate under its own weigh around its centroid.
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4-lower down the ring so the back side of the latching plate (cam) will bypass the pin without
latching



In a same manner following photos shows the snagging process.



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OPERATION MANUAL


1 The resting arm as shown in drawing must be fitted, which will be used to
supportthemobileringatloweredposition.

2Openthedoorofthehighmastanddisconnectthelightfittingspowersupply
multicorecable,supplyingthepowertothetopjunctionboxonthemobilering
whichisprovidingthepowertothelightfittings.

3holdthehandy remotecontrolandstepasideapropersafedistanceabout 2
3mawayfromthepolethenoperatethewinchtolowerdownthemobileringtill
it reaches the resting arm and once it is resting on the arms do not continue
operating the winch so the wire will not be loose and will stay winded properly
onthedrum.

4conduct the required maintenance required for the lantern and use the
auxiliary cables (plug directly from the junction box on the ring to the junction
boxinthepole)whichwillberoutedexternallytotestthelanternwhiletheyare
attheloweredposition

4Toraisethemobileringagainafterdoingthemaintenance,operatethewinch
inreversedirectiontillyoudescrythecompensationplate(transitionplate).

5 Continue lifting with prudence till you make sure that the system passes
slightly the latching pin, at the same time the upper direction button on the
remotecontrolwillbedisfunctioned.

6lowerdown the mobile ring little bit by pressing the button in short bursts on
theremotecontroltilltheringisdangledonthelatchingpinthroughtheTHREE
latchingplates.
(Pleaserefertosection,HOWITWORKSforbetterunderstandingforthelatching
&unlatchingprocess)

7Connectmulticorecableagaintothepowersupply,closethedoorofthehigh
mastANDSECURE.





KEEP SAFE, IF YOU HAVE ANY DOUBT ASK!
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APPENDIX A

SYSTEM MODEL


























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ENG. AZIZ ENG. SHARAF
RAISING & LOWERING STANDARD COMPONENT
GC-RLS-200
GENERAL ARRANGEMENT
ARIFUDDIN
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APPENDIX B

MOTOR DETAILS

























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59
Helical worm gear units S





Type of construction



Foot mounted version
Hollow shaft with keyway
Example: S32A DM90L4

Foot mounted version
Output shaft with key
Example: S12AV DM80G4

Shaft mounted version
Hollow shaft with keyway
Example: S22B DM100L4



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C131 - Hubantrieb
C131 Hoist


Masse
Mass
m kg
Masse Gegengewicht
Mass of counter weight
mG kg
Hubgeschwindigkeit
Lifting speed
v m/s
Beschleunigung
Acceleration
a m/s
Wirkungsgrad bertragungselement
Efficiency of transmission element
Seilscheibe / cable sheave: 0.9
Wirkdurchmesser bertragungselement
Effektive diameter of transmission element
d mm
Getriebebersetzung
Gear ratio
i
kein Getriebe oder unbekannt: i=1
without gearbox or unknown: i=1
Massentrgheitsmoment des Antriebs
Inertia of the drive
Jm kgcm
Massentrgheitsmoment von Motor + Bremse + Getriebe, unbekannt Jm=0
Inertia of motor + brake + gearbox, unknown Jm=0
Massentrgheitsmoment der Last, bezogen
auf Motorwelle
Inertia of the load, based on the motor shaft
J kgcm
2
i 400
2
d m
J

=

Drehzahl des Antriebselementes
Speed of the drive element
n 1/min
d
60000 v
n

=

Drehzahl des Motors
Speed of motor
nm 1/min i n nm =

Winkelbeschleunigung des Motors
Angular acceleration of motor
m

1/s
d
i 2000 a
m

=
Hubkraft
Lifting force
Fh N ( ) g mG m Fh =

Beschleunigungskraft
Acceleration force
Fa N ( ) a mG m Fa + =

Motormoment aus Hubkraft
Motor torque from lifting force
Tmh Nm
i 2000
d Fh
Tmh

=
Motormoment aus Beschleunigungskraft
Motor torque from acceleration force
Tma Nm
i 2000
d Fa
Tma

=

Beschleunigungsmoment des Motors
Acceleration torque of motor
Tmb Nm
10000
m Jm
Tmb

=

Gesamtdrehmoment des Motors
Total torque of motor
Tm Nm Tmb Tma Tmh Tm + + =
Gesamtmotorleistung
Total power of motor
Pm kW
30000
nm Tm
Pm

=

C131 - Hubantrieb Hoist
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Motor options

B - Brake COMBISTOP
spring-set twin-disc safety brake
Protection standard: IP54
connection via contacts in terminal box
adjustment provision for wear of friction linings without dismantling
torque reduction possible
Standard voltages: 230VAC, 400VAC, 24VDC
Options:
Manual brake release MB
Dust- and water protection IP65

Mode of Operation
The brake is released by direct-current excitation of the brake coil (2) or
by a manual release unit MB (3) which can be attached as an option.
Braking is achieved in power off condition by means of spring force (1).
The adjusting screws (5) are used to adjust the nominal air gap (X) in
case of wear.







Technical Data
Brake

Mbr
[Nm]
Mbred
[Nm]
JB
[kgcm]
P20
[W]
t2
[ms]
t11~
[ms]
t11=
[ms]
WR0.1
[J*10^6]
WRmax
[J*10^3]
X
[mm]
Xn
[mm]
hL
[mm]
~kg
B02 5 2.5 1.5 0.3 25 40 70 10 7.5 5.3 0.2 0.4 106 1.4
B03 10 7.5 5 3 0.7 30 55 100 15 12.5 7.5 0.2 0.5 114 2.0
B04 20 15 10 6 1.4 30 90 180 25 19.1 18 0.2 0.6 128 3.6
B05 36 27 18 11 3.5 48 110 220 25 28.0 28 0.2 0.6 168 5.7
B06 70 53 35 21 5.6 62 240 260 25 28.8 38 0.3 1.0 176 9.1
B07 100 75 50 30 16 65 220 400 40 35.7 49 0.3 1.0 225 15
B08 150 113 75 45 30 75 320 700 50 44.2 56 0.4 1.2 235 24
B09 250 188 125 75 75 80 350 900 60 69.0 78 0.4 1.2 256 34
B10 500 375 250 150 210 130 400 1400 100 80.0 100 0.5 1.5 335 49


Mbr Static braking torque after completed run-in phase
Mbred possible reduced brake torques
J B Inertia
P20 Excitation rating at 20C
t2 Release time, time from connecting the current to the beginning of torque decrease
t11~ Engagement delay time for AC side switching (Fig. 1,3) Time from disconnecting the current to the raise of the torque
t11= Engagement delay time for DC side switching (Fig. 2) Time from disconnecting the current to the raise of the torque
WR0.1 friction work until 0.1mm abrasion
WRmax permissible friction work for emergency stop from 3000 1/min (B08..B10 - 1500 1/min)
X Nominal clearance
Xn Clearance, at which a readjustment is recommended


The specified switching times apply to nominal clearance and nominal torque. It relates to average values and depends on the type of
rectification and coil temperature.

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APPENDIX C

GEAR BOX DETAILS

























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PARTS LIST
Item Qty. Description
04 4 Spacer
02 2 Drums
03 2 U-Bolt with 4 Nuts & Wahsers
01 1 Electric Motor
Material
MS Pipe
H.D.G. Steel
---
ENG. AZIZ ENG. SHARAF
RAISING & LOWERING STANDARD COMPONENT
GC-RLS-203
ARIFUDDIN
MOTORIZED DRIVE SYSTEM
MAIN ASSEMBLY
Ref. Dwg. No.
GC/RLS/203-01
GC/RLS/203-02
GC/RLS/203-03
06 6 6mm Wire Rope
05 2 Angle Support
Stainless Steel
H.D.G. Steel GC/RLS/203-05
----
H.D.G. Steel
GC/RLS/203-04
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79
Dimensions

A - Foot mounted version







A AB A1 A2 A3 B B1 B2 H HA HB H1 H2 H3 H4 H5 L S1
S0 50 63 86 43 2 60 52-0.5 30 70-0.5 9 9 7.5 113 106.5 29 86 126 M6
S1 90 110 116 58 2 75 70-0.5 37.5 95-0.5 15 12 10 151.5 137.5 30 95 160 9
S2 110 135 144 72 3 90 85-0.5 45 120-0.5 18 15 18 191 175 40 120 191 11
S3 120 150 168 84 3.5 115 100-0.5 57.5 145-0.5 22 18 24 229.5 212 47 150 233 13.5
S4 150 185 202 101 4 135 125-0.5 70 180-0.5 25 22 35 280 259.5 57 180 280 17.5



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APPENDIX D

SUSPENSION SYSTEM

























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PARTS LIST
Item Qty. Description
04 6 Eye Bolt (M12x120)
05 18 Hex Nut (M12)
06 12 Flat Washer (M12)
07 3 4mm Wire Crimping Sleeve
08 1 Sub Assembly
09 1 6mm Wire Rope
02 6 Bull Dog Grip
03 6 Thimble
01 3 4mm Wire Rope
Material
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
H.D.G. Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
ENG. AZIZ ENG. SHARAF
RAISING & LOWERING STANDARD COMPONENT
GC-RLS-201
ARIFUDDIN
WIRE SUSPENSION SYSTEM
MAIN ASSEMBLY
Ref. Dwg. No.
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GC/RLS/201-01
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APPENDIX E

POWER CABLE DETAILS & JB BOXES


















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04 2 Limit Switch
05 1 Cable for Limit Switch
06 1 Bottom Junction Box
07 1 Cable for Remote Control
08 1 Remote Control
02 1 Cable for Top Junction Box
03 1 Power Socket
01 1 Top Junction Box
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
H.D.G. Steel
Stainless Steel
Stainless Steel
Stainless Steel
TOP JUNCTION BOX
LIMIT SWITCH
BOTTOM JUNCTION BOX
PARTS LIST
Item Qty. Description Material
ENG. AZIZ ENG. SHARAF
RAISING & LOWERING STANDARD COMPONENT
GC-RLS-204
ARIFUDDIN
ELECTRICAL PARTS & CONNECTION
MAIN ASSEMBLY
Ref. Dwg. No.
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END OF PAPER


















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