CMS ZDC Remote Handling Tool - CERN Indico

CMS ZDC Remote Handling Tool Instruction Manual

1

Summary Table

ZDC REMOVAL PROCEDURE

STEP 1: Set up 1.  Moving Materials 4 2.  Cables connections 5-6 3.  Laying of Cables. 7 4.  Bring sarcophagus to TAN 8 5.  Install rotation servo motor 9-11 6.  Control System Activation 12-14 7.  Crane rotation (to SARCO) 15-16 8.  Install elevator servo motor 17

STEP 2: Extraction of ZDC 1.  Rotate crane to TAN and lower elevator to ZDC 18 2.  Aligne elevator to ZDC 19 3.  Fasten vertical elevator to ZDC 20 4.  Extract the ZDC 21 5.  Rotate crane and insert ZDC in SARCO 22 6.  Unfasten ZDC 23 7.  Store ZDC in bunker 24

Continued on next page

2

Summary Table

ZDC REMOVAL PROCEDURE STEP 3 : Insertion of steel bars

1.  Raise crane to make space for copper bars 25 2.  Bring steel bars to TAN using transpallet 26 3.  Lower elevator to steel bars 27 4.  Fasten elevator to steel bars 28 5.  Extraction of bars and rotation over TAN 29 6.  Insertion of bars in TAN 30 7.  Disconnect elevator from bars 31

STEP 4: Clean up 1.  Move empty crane over sacro 32 2.  Disconnect servo motor from vertical elevator 33 3.  Move empty crane back over TAN 34 4.  Take empty sarco back to bunker 35 5.  Remove rotation servo motor 36 6.  Pull up control cables 37 7.  Disconnect Cables from control system Connections 38-39 8.  Bring materials back 40

3

STEP 1 Op. 1: Moving Materials

Bring downstairs control cabinet , remote control, motors, cables

Reference List : 1.  Control Cabinet 2.  Remote Command

Handset 3.  Baldor BSM90 Servo

motor (Rotation) 4.  Baldor BSM63 Servo

motor(vertical axis) 5.  Cables

____________________

Time : 15 min Operators : A and B

1

3 4

2 5

4

STEP 1 Op.2: Cable Connections (A)

Control System Installation (with cables connections)

____________________


5

STEP 1 Op.2: Cable Connections (B)

Control System Installation (cables connections)

Reference List :

1. B90_PWR cable 2. B90_RES cable 3. B63_PWR cable 4. B63_RES cable 5. Limit_Switch cable 6. SPARE 7. Handset cable 8. 220v 15A

____________________


8

1 2 3

7

5

4

6

6

STEP 1 Op.3: Laying of Cables

From the Control System to the ZDC Crane.

____________________


20meters

15meters

7

STEP 1 Op.4: Bring sarcophagus to TAN.

Using the transpallet bring and empty Sarcophagus to the TAN. ____________________

Time : 5 min Operators : A

8

STEP 1 Op.5: Install rotation servo motor (A)

1) Connect the Baldor BSM90 Servo motor to crane 2) Connect cables to motor

____________________


1

2

9

STEP 1 Op.5: Install rotation servo motor (A (B)

Baldor BSM90 Servo motor (Rotation) : Assembly to the crane

____________________

10

STEP 1 Op.5: Install rotation servo motor (A (C)

Baldor BSM90 Servo motor (Rotation) : Fastening

________________

11

STEP 1 Op.6: Control System Activation(A)

1.Power-ON(LV) 2.Emergency Stop&Key enabling system for HV 3. Switch control of HV motor power

____________________

Time : 2 min Operators : B

1

12

STEP 1 Op.6: Control System Activation(B)

1.Power-ON(LV) 2.Emergency Stop&Key enabling system for HV 3. Switch control of HV motor power

____________________

2

13

STEP 1 Op.6: Control System Activation(C)

1.Power-ON (LV) 2.Emergency Stop&Key enabling system for HV 3. Switch control of HV motor power

____________________

3

14

command button (rotate to TAN)

command button (rotate to SARCO)

command button (move UP)

command button (move DOWN)

Indicator light (move UP)

Indicator light (move DOWN)

Indicator light (rotate to TAN)

Indicator light (rotate to SARCO)

STEP 1 Op.7: Crane rotation to SARCO (A)

Push the command button and keep it pushed to rotate the crane to SARCO

____________________


15

STEP 1 Op.7: Crane rotation to SARCO (B)

Wait until the crane is completely extended over the SARCO

____________________

16

STEP 1 Op.8: Install elevator servo motor

1) Connect cables to Baldor BSM63 servo motor

2) Connect motor to the crane.

____________________


17

STEP 2 Op.1: Rotate crane to TAN and lower elevator to ZDC

1.  Bring back the crane in the starting position over the TAN.

2.  Then lower the Overhead Beam of the Vertical Elevator close to the ZDC Module

____________________


b

a

18

A

View « A »

STEP 2 Op.2: Aligne elevator to ZDC

Lower the Overhead Beam of the Vertical Elevator until the holes on Lifting Bridge shoe (1) are aligned with the holes on the ZDC supports (2) ____________________


1

2

19

STEP 2 Op.3: Fasten vertical elevator to ZDC

Fastening of the Lifting Bridge shoe to the ZDC supports with screws and nuts

Reference List :

1. M12 screw (4) 2. M12 Nut (4) ____________________


1

2

20

STEP 2 Op.4: Extract the ZDC

Lift the ZDC calorimeter out of the TAN ____________________


21

STEP 2 Op.5: Rotate crane and insert ZDC in SARCO

1.  Rotate the crane until completely extended over the SARCO

2.  Insert the ZDC calorimeter into the SARCO

____________________


22

STEP 2 Op.6: Unfasten ZDC

Remove the 4 screws and the 4 nuts from the ZDC supports

____________________

Time : 1 min Operators : A

23

STEP 2 Op.7: Store ZDC in bunker

Bring the sarcophagus containing the ZDC to the bunker

____________________

Time : 4 minutes Operators : A

24

STEP 3 Op.1: Raise crane to make space for copper bars.

Raise the Overhead Beam of the Vertical Elevator 10cm ____________________


a

25

26

STEP 3 Op.2: Bring steel bars to TAN using transpallet ____________________


A

View « A »

STEP 3 Op.3:Lower elevator to steel bars

Lower the Overhead Beam of the Vertical Elevator until the holes on Lifting Bridge shoe (1) are aligned with the holes on the supports of the steel bars (2) ____________________


1

2

27

STEP 3 Op.4: Fasten elevator to steel bars

Fastening of the Lifting Bridge shoe to the steel bar supports with screws and nuts

Reference List :

1. M12 screw (4) 2. M12 Nut (4) ____________________

Time : 4’ Operators : A and B

1

2

28

STEP 3 Op.5: Extraction of bars and rotation over TAN

a)  Extract the bars from the SARCO

b)  Rotate the crane until the bars are over the TAN.

____________________


29

STEP 3 Op.6: Insertion of bars in TAN

Lower the steel bars into the TAN ____________________


30

STEP 3 Op.7: Disconnect elevator from bars

Unscrew nuts that link bridge shoe to the bars and then remove screws.

Reference List :

1. M12 screw (4) 2. M12 Nut (4) ____________________


1

2

31

STEP 4 Op.1: Move empty crane over sarco

Lift the elevator bar and rotate crane over empty sarco ____________________


32

STEP 4 Op.2: Disconnect servo motor from vertical elevator

1)  Unbolt Baldor BSM63 Servo motor

2)  2 disconnect cables

____________________


33

2

1

STEP 4 Op.3: Move empty crane back over TAN

Rotate crane over empty sarco ____________________


34

STEP 4 Op.4: Take empty sarco back to bunker

____________________


35

STEP 4 Op.5: Remove rotation servo motor

1)  Uncable Baldor BSM90 servo motor

2)  Loosen and remove bolts

3)  Take off motor

________________


36

3

2

1

STEP 4 Op.6: Pull up contol cables

Gather up the cables from the Control System to the Crane.

____________________

Time : 2 Operators : A and B

20meters

37

STEP 4 Op.7: Disconnect Cables from control system Connections (A)

____________________

Time : 4 Operators : A and B

38

STEP 1 Op.7: Disconnect cable from contorl system (B)

Reference List :

1. B90_PWR cable 2. B90_RES cable 3. B63_PWR cable 4. B63_RES cable 5. Limit_Switch cable 6. SPARE 7. Handset cable 8. 220v 15A

____________________


8

1 2 3

7

5

4

6

39

STEP 4 Op. 8: Bring materials back

Bring control cabinet , remote control, motors, and cables upstairs.

Reference List : 1.  Control Cabinet 2.  Remote Command

Handset 3.  Baldor BSM90 Servo

motor (Rotation) 4.  Baldor BSM63 Servo

motor(vertical axis) 5.  Cables

____________________


1

3 4

2 5

40

CMS ZDC Remote Handling Tool - CERN Indico

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