Advertisement
Advertisement
R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 STAGEMAKER® COMPACT Concert Hoist SM5 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS JOB NO. NO. : SERIAL NO. NO. : (RECORD HOIST SERIAL NUMBER FOR FUTURE REFERENCE) 08/14/02 Bulletin: RM-SM5-MAN-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Before proceeding with the installation, operation or maintenance of the hoist it is important that installation, operating and maintenance personnel read this bulletin carefully in order to ensure the safe and efficient use of the hoist. It is strongly recommended that personnel responsible for the operation, inspection and servicing of this hoist, read and follow the Safety Standard ANSI B30.16-1993 (or current revised edition). This standard covers Overhead Hoists (under-hung) as promulgated by the American National Standards Institute and is published by the American Society of Mechanical Engineers. Copies of this publication are available from the Society at United Engineering Center, 345 East 47th St., New York, NY 10017. If any instructions are unclear, contact the manufacturer or distributor of this hoist before attempting to install or use the hoist. IMPORTANT Electrical wiring diagrams are included with this manual. Also, if an optional push or motorized trolley has been purchased, a manual is included with the trolley. If these items are missing, contact the manufacturer or distributor before attempting to install or use the hoist. R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, OH 45502 Tel. 937-328-5100 Fax 937-325-5319 Visit our website: www.rmhoist.com 08/14/02 Bulletin: RM-SM5-MAN-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 TABLE OF CONTENTS Section Page Table of Contents .....................................................................................................i Foreword ...................................................................................................................iii Warranty.........................................................................................................iii Parts & Service...............................................................................................iii Claims for Damage in Shipment ....................................................................iii 1. Installation General ...........................................................................................................1-2 Hoist Configuration ........................................................................................1-2 Mounting ........................................................................................................1-3 Lubrication .....................................................................................................1-3 Load Hook Throat Opening............................................................................1-3 Power Connections.........................................................................................1-3 2. Initial Start-Up Proper Hook Motion (Hoist Motor Rotation).................................................2-1 No Load Operational Checks .........................................................................2-2 Torque Limiter................................................................................................2-2 Load/Run Test ................................................................................................2-2 3. Safe Operation Practices General ...........................................................................................................3-1 Do’s and Don’ts (Safe Operation of Hoist) ....................................................3-2 4. Operation/Maintenance Typical Construction ......................................................................................4-1 Motors ............................................................................................................4-2 Brake/Torque Limiting Device.......................................................................4-2 Operation ............................................................................................4-2 Adjustment of the Limiter ..................................................................4-3 Adjustment of the Brake.....................................................................4-4 Frame (Hoist Body) ........................................................................................4-5 Load Chain .....................................................................................................4-5 Load Chain Inspection........................................................................4-5 Load Chain Replacement....................................................................4-6 Load Chain Removal ..........................................................................4-7 Load Chain Installation.......................................................................4-7 Fall Stop Assembly ........................................................................................4-9 Bottom Block, Load Wheel and Suspension Hook ........................................4-9 Hook Specification .............................................................................4-10 Suspension Hook ................................................................................4-11 Measurement of the Wear on the Suspension and Lifting Hook........4-11 i R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Upper & Lower Limit Switch.........................................................................4-11 Rotary Limit Switch .......................................................................................4-12 Controls ..........................................................................................................4-13 AFC Board .........................................................................................4-13 PC Board Controls .............................................................................4-14 Hoist Circuit Diagram - Standard.......................................................4-14 Control Panel..................................................................................................4-15 Circuit Diagram..............................................................................................4-19 5. Preventative Maintenance Maintenance Table .........................................................................................5-1 Lubricants .......................................................................................................5-2 Spare Parts Replacement Table ......................................................................5-2 Screw Tightening Torques..............................................................................5-2 Troubleshooting..............................................................................................5-3 6. Spare Parts Identification ii R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 FOREWORD This manual has been prepared to acquaint you with the procedures necessary for the installation, operation and maintenance of the hoist you have purchased. Proper installation is important for the performance of your equipment. Careful study of and adherence to the instructions will help ensure safe, dependable operation. It is recommended that this manual be readily accessible to operators as well as maintenance and safety personnel. Information in this manual is subject to change without notice. Warranty R&M Materials Handling, Inc. provides a two (2) year limit warranty on electric chain hoists. Please contact your Distributor for warranty details. Parts and Service R&M Materials Handling, Inc. distributes its products through a network of distributors. Please contact your Distributor for parts, service, and warranty. A list of R&M Master Distributors is listed on our website: www.rmhoist.com. Claims for Damage in Shipment All shipments are inspected and delivered to our carrier in good order. If damage is observed, refuse shipment until the carrier makes the proper notation to that effect. In the event of concealed loss or damage, notify the carrier immediately. By following these suggestions you will encounter less difficulty collecting your claim. iii R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 SECTION 1 INSTALLATION Figure 1-1 1- Hoist body/motor 2- Gears 3- Brake/limiter/housing assembly 4- Chain sprocket with output shaft 5- Chain guide assembly 6- 1-fall hook block 7- 2-fall hook block 8- Chain container 9- Electrical control panel 10-Handle IMPORTANT Hoists are designed for lifting of material only. Under no conditions or circumstances are hoists to be used for lifting or transporting of personnel. Do not transport any load over personnel without additional safety precautions. 08/14/02 1-1 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 General Each complete electric chain hoist is load tested in accordance to ANSI B30.16 at the factory at 125% of nameplate rated capacity, and is usually shipped assembled, unless otherwise stated on order inquiry. All hoists are designed for the type of mounting specified by the purchaser. The adequacy of the supporting members (monorail beams, trusses, hangers, supports, framing, etc.) is the responsibility of the user and shall be determined by qualified personnel. Prior to permanent or field installation, units shall be checked thoroughly by qualified personnel for damage during shipment or handling at the job site. Particular attention shall be taken to make sure that the load chain and other mechanical or electrical components have not been damaged through improper handling. Read the instructions contained in this manual and observe the warning tags attached before installation is started. Hoist Configuration STAGEMAKER® COMPACT concert hoists are offered in five basic configurations, each with its own control type and hoist features. Ø Configuration A: Direct motor control without control voltage. Full line voltage controller furnished separately. Ø Configuration B: Magnetic controls including a control transformer for controls and controller. Ø Configuration B1: Standard (upright) hoist mounting position only. PC Board controls and pendant controller furnished on the hoist. Ø Configuration B2: Inverted or standard hoist mounting position. PC Board controls furnished on hoist and controller ordinarily furnished separately. Ø Configuration C: Programmable controller in conjunction with PC Board controls. Controls furnished on the hoist and controller furnished separately. Ø Configuration D: Mandatory safety features are standard. PC Board controls furnished on the hoist and controller furnished separately. Ø Configuration E: Variable Frequency Drive (inverter). VFD furnished by others separate from hoist. PC Board controls utilize magnetic (low voltage) controls. PC Board controls for the SM5 concert hoists consist of controls (contactor, transformer, etc.) that are soldered to a circuit board, which provides most of the internal connections. WARNING Before installing the hoist, make certain that the main power switch supplying power to the hoist is in the open position. 08/14/02 1-2 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Mounting The hoist body should be mounted from its suspension hook allowing the body to move in the direction of the load chain pull and to hang in a straight line between the suspension hook and load block during hoisting. Non compliance to this principle may result in severe damage to the equipment. This is true if the hoist is used in the normal or inverted configuration. Lubrication The hoist gear reducer is lifetime grease lubricated needing no regular checking or maintenance. Make sure the load chain is free from contamination or dirt and adequately lubricated with SAE 80 grade oil. Bottom block must hang straight and load chain must be free of kinks or twists. Load Hook Throat Opening ANSI B30.16-1993 recommends that the throat opening of the load hook be measured and recorded prior to putting the hoist into service and that a gage be made to provide a quick visual inspection for a bent hook as required by monthly inspections. See Section 4. Power Connections Make sure that power supply voltage is the same as that shown on the hoist nameplate and that fuses or other current overload devices are provided to protect the power supply. The power source/conductors must have sufficient capacity to maintain the voltage at the hoist at ±10% of the nominal voltage under all operating conditions. Standard nominal voltages are 230 and 460V. Poor voltage maintenance can cause motor overheating or sluggishness, and chattering or inoperative motor brakes and controls. A wiring diagram is included in this manual showing the identification of the power lead connections. Refer to this wiring diagram prior to start up and/or any electrical work. If the diagram has been misplaced you may obtain one from R&M upon request. Be sure to mention the serial number of the unit. CAUTION Make sure the main disconnecting switch is off and locked in the open position before making any electrical connections. 08/14/02 1-3 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 The customer must supply power cable, power distribution set, installation fusing and main disconnect switch. PS: PB: TR: Figure 1-2 Power supply connection for hoist configuration A Combined power and controls for hoist configuration C or configuration D Controls, hoist configuration B1 or configuration B2 Trolley connection, if motorized trolley is supplied, for hoist configuration B1 only. Connection: If the hoist is not supplied with a power cable pigtail or power plug at the hoist electrical enclosure, then proceed as follows: 1. Remove the control box cover. 2. Insert the cable (PS) into the box through the PG cable gland. Cable gland accepts a cable diameter of 8-15mm. 3. Connect phases L1, L2, L3 to K10 contactor, and the ground wire to the terminal board (2). 4. Check that the terminals are correctly tightened, even unused terminals. 5. Tighten the power round cable PG gland. 6. Reinstall the control box cover. (Do not over-tighten cover screws.) 7. Check the hoist operation. Note: When making electrical connections, refer to the wire identification markers for the various power and control leads that are shown on the electrical diagrams. By doing so, this will help prevent improper electrical connections which might cause severe damage to the equipment or personnel. Note: This electric chain hoist is furnished with motor and control circuit protection as standard, which, in the Company’s interpretation, meets requirements of the National Electrical Code in effect at time of shipment from our factory. The protective devices required for the power feed are outlined in Article 610 of the NEC and are the responsibility of the user. It is recommended that the user review Article 610 as well as other applicable Articles of NEC for compliance requirements. Follow National, State and Local Codes when providing electrical service to the hoist. Only a qualified electrician shall make all electrical connections. 08/14/02 1-4 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 SECTION 2 INITIAL START-UP WARNING Before connecting the hoist to the power supply, check all “motion” buttons or selector switches on your controller or push button station to ensure that none of them bind or stick in any position. Check pendant or controller cables to ensure that they are not damaged and are wired to desired hoists. Once power has been supplied to the hoist, several important no-load checks must be made. Proper Hook Motion (Hoist Motor Rotation) Since rotation direction of any three-phase AC motor can be changed by reversing any two of the three lines feeding the motor, it is important that the direction of motion is correct with respect to the button being depressed, or the selector setting. To check/correct hook motion (motor rotation), carefully inch the up button and observe hook motion. If hook does not travel up, stop the hoist and open the main power source disconnect. WARNING Do not attempt to reverse hoist motion by changing control leads in the push button, controller or at the contactor, and do not change the nameplate on the P/B. Safety switches of the control circuit wiring as furnished from the factory are directional sensitive. Changing the push button control leads, wiring inside the controller or nameplates will prevent the safety switches from functioning properly. This might create dangerous situations. IMPORTANT Do not run the hoist with the DOWN button if direction is reversed. To correct the direction of the hook block travel, reverse any two leads supplying power to the controller, at the main power source or at the lead in connections to the hoist. Do not change the internal wiring of the hoist nor the controller. 08/14/02 2-1 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 No Load Operational Checks ü Check the hoist motor brake function. ü Run the empty hook block up or down to check that the hook drift does not exceed more than 1 inch (25mm). If so, adjust the brake as described in Section 4, Operation/Maintenance. ü Run the empty hook block down to check that the slack fall stop on the free end of the chain (inside the chain container) makes proper contact with the buffer or the limit switch, if furnished in place of the buffer. If furnished, check that the limit switch functions correctly. ü Run the empty hook block up to check that the load block makes proper contact with the rubber buffer or the limit switch, if furnished in place of the buffer. If furnished, check that the limit switch functions properly. ü Run the empty hook block up and down several times while checking for proper tracking of the load chain. Torque Limiter The electric chain hoist is equipped with a torque-limiting device to help protect against damage from attempts to lift an over-capacity load. This device is not intended as a measuring device and shall not be used as such. The device is adjusted at the factory for the rated load capacity of the hoist. Sound operating practices shall be followed to avoid attempts to lift over-capacity loads. Load/Run Test While each complete hoist is load tested at the factory, the user should perform a full load test after installation of the hoist and completion of no load operational tests. Lift a near capacity load about 1 foot (30cm) above floor level and check that the brake holds the load. Also, check the holding capability of the brake when lifting/lowering and stopping the load. 08/14/02 2-2 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 SECTION 3 SAFE OPERATING PRACTICES General There is no one single factor that is more important for minimizing the possibility of personal injury to the operator and those working in the area, or damage to property, equipment, or material, than being familiar with the equipment and using Safe Operating Practices. Hoists are designed for lifting and transporting of material only. Under no circumstances, either during initial installation or in any other use, shall the hoist be used for lifting or transporting of personnel. No operator shall be permitted to use the equipment if he is not familiar with its operation, is not physically and mentally fit, or has not been schooled in safe operating practices. The misuse of hoists can lead to certain hazards which cannot be protected against by mechanical means; hazards which can only be avoided by the exercise of intelligence, care, and common sense. Safe Operating Practices also include a program of periodic inspection and preventative maintenance (see Section 5). Part of the operator’s training shall be an awareness of potential malfunctions/hazards requiring adjustments or repairs, and bringing these to the attention of supervision for corrective action. Supervisory management has an important role to play in any safety program. They must ensure that a maintenance schedule is adhered to. Also, that the equipment provided to the operators is suitable for the job intended without violation of any of the rules covering safe operating practices and good common sense. The Safe Operating Practices shown are taken in part from the following publications: American National Standard Institute (ANSI) Safety Standards for Cranes, Derricks, Hoists ANSI B30.2 - Overhead and Gantry Cranes ANSI B30.16 - Overhead Hoists Do’s and Don’ts (Safe Operation of Hoists) The following are Do’s and Don’ts for safe operation of overhead hoist. Taking precedence over any specific rule listed here, however, is the most important rule of all: USE COMMON SENSE. A few minutes spent reading these rules can make an operator aware of dangerous practices to avoid and precautions to take for his own safety and the safety of others. Frequent examinations and periodic inspections of the equipment as well as a conscientious observance of safety rules may save lives as well as time and money. 08/14/02 3-1 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 DO’S - HOISTS 1. READ and follow manufacturer’s Instruction, Installation and Maintenance manuals. When repairing or maintaining a hoist use only manufacturer’s recommended parts and materials. 2. READ and follow all instruction and warning information on, or attached to the hoist. 3. REMOVE the hoist from service and thoroughly inspect and repair, as necessary, if unusual performance or visual defects (such as peculiar noise, jerky operation, travel in wrong direction, or obviously damaged parts) are noticed. 4. ESTABLISH a regular schedule of inspection and maintain records for all hoists with special attention given to hooks, load chains, brakes, and limit switches. See SECTION 5. 5. CHECK operation of brakes for excessive drift. 6. MAKE SURE you never lift loads over people, unless additional safety precautions are taken. 7. CHECK for damaged hooks and load chains. 8. KEEP load chain clean and well lubricated. 9. CHECK the load chain for improper seating, twisting, kinking, wear, or other defects before operating the hoists. 10. MAKE SURE a load clears neighboring stockpiles, machinery, or other obstructions when raising, lowering, or traveling the load. 11. CENTER hoist over the load before operating. 12. AVOID swinging of load or load hook when traveling the hoist. 13. BE SURE the load attachment is properly seated in the saddle of the hook. Balance load properly before handling. Avoid hook tip loading. 14. PULL in a straight line. 15. TAKE up slack slowly. 16. KEEP load chain clear from any objects. 08/14/02 3-2 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 DON’TS - HOISTS 1. NEVER lift or transport a load until all personnel are clear and do not transport the load over personnel, unless additional safety precautions are taken. 2. DO NOT allow any unqualified personnel to operate hoist. 3. NEVER pick up a load beyond the capacity rating appearing on the hoist. Overloading can be caused by jerking as well as by static overload. 4 NEVER carry personnel on the hook or the load. 5. DO NOT operate hoist if you are not physically fit. 6. DO NOT operate hoist regular to extreme limits of chain travel against the rubber buffer. 7. DO NOT operate hoist regular to extreme limits of chain travel without first checking for proper limit switch action if fitted. 8. AVOID sharp contact between two hoists or between hoist and end stops. 9. DO NOT tamper with or adjust any parts of the hoist unless specifically authorized to do so. 10. NEVER use the load chain as a sling. 11. DO NOT divert attention from load while operating hoist. 12. NEVER leave a suspended load unattended. 13. DO NOT use the buffer stop for normal operating stop(s). This effects the setting of the over load device, which is a safety device only. Adjustment shall be checked on a regular basis for proper operation (see Section 4.2). 14. DO NOT use limit switches for automatic stops. These switches are a safety device only and shall be checked on a regular basis for proper operation. 13. NEVER operate any hoist that has an inherent or suspected mechanical or electrical defect. 14. DO NOT use load chain as ground for welding. NEVER touch a live welding electrode to the load chain. Isolate load hook to prevent grounding. 15. DO NOT jog controls unnecessarily. Hoist motors are generally high torque, high slip types. Each start causes an inrush of current greater than the running current and leads to overheating and heat failure, or burnout, if continued to excess. 16. NEVER place hands on moving load chain or near moving chain pinch points. 08/14/02 3-3 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 SECTION 4 OPERATION/MAINTENANCE Typical Construction While each electric chain hoist may have some slight variations in design/arrangement, all hoists have same basic elements. 1. Motor - basic drive package. 2. Chain Sprocket - moves the load chain to lift and lower the load 3. Gear case Assembly - couples the motor to the chain sprocket 4. Brake/Torque Limiting Device - to stop and hold the load as well as to help prevent lifting of excessive loads which may damage the hoist. 5. Frame (Hoist Body) - basic structural components that support the load to be handled. 6. Bottom Block and Load Wheel - includes bottom block and chain sprocket. 7. Load Chain - load chain and end connections for picking up the load. 8. Limit Switch – a device for over-travel protection. (Optional for some hoist configurations) 9. Controls - devices for supplying power to motor and reversing direction of the motor. The following details the operation/maintenance instructions for each basic element. In Figure 4.1 the basic components inside the frame and the basic kinematics are shown. Figure 4-1 1. 2. 3. 4. 08/14/02 Motor Chain sprocket Gear Brake/limiter 4-1 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Motors The hoist motors are designed to provide dependable hoisting service. The standard motors are enclosed for protection against normal hazards of dust and moisture. The bearings are sealed and lifetime lubricated and they do not require regreasing. Brake/Torque Limiting Device The hoist brake is a D.C. disc type. The function of the hoist brake is to minimize hook drift by bringing the motor to a quick and smooth stop, and to hold loads suspended from the hook with the power off. In addition to the hoist brake, the hoist is furnished with a torque-limiting device, integral with the hoist brake. The torque-limiting device helps prevent the lifting of excessive loads, which may damage the hoist. 4 10 3 6 Air gap 7 1 5 8 X 2 9 Figure 4-2 – Hoist Brake/Torque-limiter Operation of Brake/Torque-limiter Even if the torque-limiter slips, once power is removed the brake will engage and hold. The parts of the limiter and the brake disc are mounted on the gear input shaft (1). Other brake parts are mounted to the brake housing. The spring (2) keeps the limiter (3) and the brake discs (4) plated together and defines the maximum torque that can be transferred through the limiter. The nut (5) maintains the assembly on the gear-input shaft. When the coil (6) is energized, during lifting or lowering, it moves against the anchor disc (7), which is fixed to the brake housing by an attachment screw (10) (there is an air gap for this purpose). The discs (3 and 4), that are connected together by the friction of the limiter, turn freely, transmitting the movement to the pinion (8). Braking occurs when the coil is no longer energized and the spring (9) drives back coil (6). 08/14/02 4-2 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Adjustment of the Limiter (Refer to Figure 4-3) WARNING Make sure that the main switch supplying power to the hoist is in the opened and locked position before adjusting the torque-limiter. 1. Hook a load of the percentage indicated in the table below onto the hoist. Configuration Test load: % of rated capacity A 125% B1 125% B2 125% C 125% D 250% E 125% 2. Remove the brake end cap and the seal. 3. Raise the load at slow and fast speed. 4. Turn the adjusting nut (5) in the required direction. • Turn the adjusting nut clockwise to increase the torque. • Turn the adjusting nut counterclockwise to decrease the torque. WARNING When decreasing the torque, make sure that there is no load connected to the load block. Failure to remove load from the load block before performing this procedure may result in personal injury. 5. Repeat steps 3 and 4 until the load can barely be lifted at fast speed. The limiter is now adjusted. CAUTION The limiter will generate heat whenever it is slipping. As a result of this, a massive clutch plate will absorb most of this heat. When the clutch plate becomes too hot, adjusting the limiter may be difficult due to unstable behavior of friction surfaces. If this happens let the limiter cool down for a while and then readjust the limiter. 6. Fit the brake end cap and seal. 7. Check, at fast speed, the lifting of a nominal load. WARNING Never adjust the torque limiter to allow lifting of more than the maximum capacity shown on the hoist. Failure to adhere to this restriction may result in personal injury or property damage. 08/14/02 4-3 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 11 10 6 Air gap 7 5 X 2 Figure 4-3 Adjustment of the Brake (Refer to Figure 4-3) The maximum air gap of the brake is 0.022"[0.55mm]. If this value has been reached or will be exceeded before next inspection, the brake must be adjusted. WARNING When adjusting the brake make sure that the main power switch applying current to the hoist is in open and locked position and remove the load from the hook. When testing the brake function, be sure not to touch moving and rotating parts. Before pressing the control button on the pendant station, check that the adjusting nut is clear of any misplaced items such as tools. 1. Remove the brake end cap and the seal. 2. Measure the air gap between the anchor disc (7) and the outer ring of the coil with a feeler gauge. Measure the air gap at least at 3 different points around the coil. 3. Set the air gap to 0.012” [0.3mm]. 4. Slightly open the three screws, (10) so that the adjustment nut (11) still touches to the brake housing. Turn the adjustment nut (11) counterclockwise to reduce the air gap. Turning the adjustment nut clockwise increases the air gap. 5. Check the air gap after adjusting the brake and make sure that the three screws, (10) are properly tightened to the Torque Specification in SECTION 5. 6. Check the brake function and adjustment. 7. Run the load chain up and down several times without a load to test the function of the brake. Then, lift a near-capacity load about 1 foot above the floor level and check that the brake holds the load. 8. Reinstall the seal and the brake end cap. 08/14/02 4-4 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Frame (Hoist Body) The frame (hoist body) is constructed of aluminum and, unless damaged from abuse (impact with another hoist or building structure), requires no maintenance. Any hoist with a frame that is no longer serviceable for any reason should be referred to the factory for replacement/repair. Load Chain CAUTION A hoist shall never be used if the load chain shows any evidence of mechanical damage or excessive wear. The replacement load chain shall be of exact size, grade and construction as the original load chain that was furnished with the hoist from the factory. Only use R&M load chain as specified in this manual. Clean and lubricate the load chain at regular intervals. Improper load chain storage or installation procedure can render the load chain unusable prior to the first lift. Load Chain Inspection Load chain inspection shall be conducted weekly by a designated person using good judgment in evaluating the remaining service life. Any deterioration of the load chain resulting in appreciable loss of the original strength, such as situations described below, shall be noted and evaluated. If any of the links show cracks or signs of distortion, the chain must be replaced immediately. A monthly inspection shall include a written record, dated and signed by the inspector. Test the hoist under load in lifting and lowering directions and observe the operation of the chain and sprockets. The chain should feed smoothly into and away from the sprockets. If the chain binds, jumps, or is noisy, first see that is clean and properly lubricated. If the trouble persists, inpect the chain and mating parts for wear, distortion, or other damage. Examine visually for gouges, nicks, weld splater, corrosion, and distorted links. Slacken the chain and move the adjacent links to one side to inspect for wear at the contact points. If wear is observed or if stretching is suspected, measure the chain for wear as outlined in Load Chain Replacement Section. Main items to record regularly: 1. Poor lubrication of load chain. 2. Wear of link on outside and on inside contact points. 3. Crushing, kinking, or signs of distortion. 4. Reduction of original diameter by more than 10%. During inspections evaluate those sections of chain, which are normally hidden, such as sections that pass over load wheels. 08/14/02 4-5 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Load Chain Replacement Chain Specification: Chain type: Diameter (d) x Pitch (t): Class: Grade: Maximum working stress: Hardened surface: Thickness: Standard: Marking (10 x t): Maximum working load, 1 fall: Breaking load: Maximum breaking stress: Total breaking elongation: Unit Weight: lb/ft [kg/m] Revision 1 Load chain Standard 0.189 x 0.492” (4.8 x 12.5 mm) DAT H8S or HE G80 RAS 19,652 lbs/in2 (135.5 N/mm2) 580 or 700 HV (Vickers Hardness) 0.0039” (0.1 mm) to 0.0079” (0.2 mm) DIN 5684 - 8 1 or 16 H 8 S or A 8 1100 lbs. (500 kg) 6519.50 lbfs (29 kN) 116,030 lbs/in2 (800 N/mm2) >10% min. 0.363 lbs./ft [0.54 kg/m] Figure 4-4 Measuring the load chain for wear Measuring the load chain for wear should be performed at several points. G Measure the diameter (d) and the pitch (t) of several links. G Measure the chain length over 11 links (11 t). Load Chain Wear Limits: Minimum link thickness allowed (d): Maximum pitch allowed (t): Maximum length allowed (11 t): 0.1693” (4.30 mm) 0.5157” (13.10 mm) 5.5216” (140.25 mm) If any one of these load chain wear limits is exceeded, the load chain must be replaced immediately. If a single load chain link is defective in any way, the whole chain must be replaced. In addition, the chain guide and the chain sprocket must be checked for excessive wear. If necessary, replace the chain guide and the chain sprocket. A worn chain sprocket or chain guide usually leads to premature chain wear. 08/14/02 4-6 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Load Chain Removal 1-fall chain 1. Remove the load from the hook. 2. Disassemble the hook block. 3. Drive the chain into the chain container. 4. Remove the chain container, unscrew and remove the lower chain guide. 2-fall chain 1. Raise the hook block to about 12” (30 cm) from the hoist body. 2. Remove the chain container. 3. Carefully remove the anchor of the load chain from the hoist body. 4. Disassemble the chain pin and the chain from the anchor. 5. Remove the 2-fall hook block, without disassembling it, letting the chain run through it. 6. Let the rest of the chain slide through the chain sprocket. Load Chain Installation The load chain should always be installed using the flexible plastic insertion tool (1 in Fig 4-5). Using this tool helps to ensure that the load chain is installed correctly. Support the chain during installation to prevent the insertion tool from distortion. Insertion tool is available from R&M. 1 Figure 4-5 1-fall chain: 1. Insert the last chain link onto the small plastic hook of the insertion tool. 2. Insert the other side of the tool in the sprocket as shown in Figure 4-5. 3. Place the load chain on the chain sprocket so the chain link welds are toward the pocket as shown in Figure 4-6. 4. Raise the chain at slow speed so that the tool and the chain come out the other side of the sprocket. 08/14/02 4-7 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Figure 4-6 Note: The weld (1) of the vertical chain links shall be towards the chain sprocket 2-fall chain 1. Insert the last chain link in the small plastic hook of the insertion tool. 2. Insert the other side of the tool up through the sprocket, entering the chain container side. 3. Run the hoist at slow speed so that the tool and the chain come out the other side of the sprocket. Continue until about 20” (50 cm) of chain becomes available. 4. Put the chain through the idler sprocket, making sure not to twist the chain during installation. 5. Remove the limit switch by removing the two screws. 6. Remove the chain anchor from the hoist body. 7. Disassemble the chain pin from the anchor. 8. Insert the chain end to anchor and place the chain pin into its place to fix the chain. 9. Reattach the chain anchor to the hoist body. Properly tighten bolts according to Torque Specification, SECTION 5. 10. Reinstall the limit switch to the chain guide. Properly tighten screws according to Torque Specification, SECTION 5. Run the load chain up and down a few times without load and make sure the load chain is not twisted. Lubricate the load chain. 08/14/02 4-8 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Fall Stop Assembly 1 2 6'' 3 3 Figure 4-7 REMOVAL: 1. Remove the cotter pin. 2. Slide the ring up from the stop. 3. Remove the stop. 4. Slide the ring off the load chain. REPLACEMENT: 1. Slide the ring onto the free end of the load chain. 2. Properly position the two halves of the stop around the chain (Figure 4-7), locating it approximately six inches from the free end of the load chain. 3. Insert the tube around the stop. 4. Insert the cotter pin through the stop. Note: Make sure that the stop is correctly fitted to the chain as illustrated in Figure 4-7. The locking tube shall be turned towards the hoist. Bottom Block, Load Wheel and Suspension Hook Load wheels showing evidence of scored grooves or broken/cracked flanges or sharp edges generated from wear, shall be replaced. Worn load wheels can greatly reduce the life of the load chain. Check hooks for deformation or cracks. Hooks having a throat opening more than 115% of normal, or more than 10-degree twist from the plane of the unbent hook, must be replaced. See Figure 4-8 below. Figure 4-8 08/14/02 4-9 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Due to many types and sizes of hooks that can be furnished and specified by the user, it is recommended that the user measure the actual throat opening of the hook as originally furnished and record it on the above sketch and retain for a permanent record. This record can then be used for determining when the hook must be replaced due to deformation or excessive throat opening. Note: Any hook that is twisted or has a throat opening in excess of normal indicates abuse or overloading of the unit. Other load bearing components shall be checked for damage. Safety latches shall be replaced if bent or broken to the extent that they no longer provide proper closure of the throat opening of the hook. CAUTION Repairing hooks by welding or reshaping is strictly forbidden. Hook Specification Load capacity (lbs.) 353 551 705 1102 1389 2205 Test load (lbs.) 705 1102 1411 2205 2778 4409 No Minimum Hook offalls ruin load I.D. (lbs.) 1 1764 012T 1 3472 012T 1-2 3527 012T/025 T 1-2 5512 012T/025 T 2 8752 025T 2 11023 025T ØM 0.551 0.551 0.551 0.630 0.630 0.630 Ø a1 1.181 1.181 1.181 1.417 1.417 1.417 a2 0.787 0.787 0.787 1.024 1.024 1.024 a3 1.339 1.339 1.339 1.614 1.614 1.614 b1 0.748 0.748 0.748 0.866 0.866 0.866 Dimensions (inch) b2 e1 0.591 3.268 0.591 3.268 0.591 3.268 0.748 3.780 0.748 3.780 0.748 3.780 h1 0.866 0.866 0.866 1.102 1.102 1.102 h2 0.748 0.748 0.748 0.945 0.945 0.945 t1 1.260 1.260 1.260 1.496 1.496 1.496 Figure 4-9 Mark: ISO 2766 DIN model number: 15401 DIN 15400 class: T DIN 15401 material: 35 CD 4 08/14/02 4-10 RM-SM5-MAN-2001-1-ENG t2 0.394 0.394 0.394 0.512 0.512 0.512 R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Suspension Hook Removal: 1. Remove the attaching screw and the locking plate. 2. Slide the two connection pins out of their holes and remove the hook. Replacement: 1. Check if the suspension is for a 1-fall (1/1) or for a 2-fall (2/1) hoist. The hook is asymmetrical so that by turning the hook half a turn the correct position can be selected. 2. Attach the hook into the slot in the hoist body so that the hook neck and the ball of the hook are in the same line of the correct fall marking at the hoist body (see fig 4-10). Figure 4-10 Measurement of the Wear on the Suspension and Lifting Hooks The wear of the suspension and lifting hooks (dimension a2 - see fig 4-9) shall be checked regularly. Damaged safety latches shall be replaced immediately. If the maximum dimension (a2) of the throat opening is greater than the initial dimension by more than 15%, the hook shall be replaced immediately. Hook Identification: a2, max. allowed: 012 0.905” (23 mm) 025 1.181” (30 mm) Upper & Lower Limit Switch The upper and lower limit switches are furnished as standard on the concert hoist, configuration B1 only. The weight-operated limit switch, which is only effective if the hoist is mounted in the normal position, is an automatic reset, control circuit type. The switch housing is recessed into the underside of the hoist body. The upper and lower limites switch are emergency over-travel protection devices only and are not to be used as automatic stops. The hook block activates the upper switch as it approaches the hoist body and once it is activated, only the UP circuit is opened. When the hook block is lowered to it lowest limit of travel, the fall stop, mounted on the free-end of the load chain, activates the lower limit switch, which opens the DOWN circuit only. 08/14/02 4-11 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Rotary Limit Switch The rotary limit switch is an adjustable type and provides over-travel protection for the upper and lower limits of hoist travel. The limit switch is a control circuit type. Limit switches are not available for hoist configuration A - direct (full line voltage) control. Designation of the limit switches 2 position (contacts) limit switch: Position 1: upper limit switch, Position 2: lower limit switch 1 2 3 4 4 position (contacts) limit switch: Position 1: lower limit switch, Position 2: intermediate limit switch *, Position 3: intermediate limit switch *, Position 4: upper limit switch Limit switch codes: Hoist type SM5 SM5 Chain (m) 0-13 13-30 Ratio 2 contacts 4 contacts 4+1/6 15 2249076 2249078 2249077 2249079 Adjustment: The position of the air-gap between the two discs (red – gray) determines the stopping place. This position can be found by gently turning the two discs. The length of the air gap determines the length of the reset play in the opposite direction. Gray Red Maximum height of lift Minimum height of lift Once the limit switch is tripped, the load must travel 18” [50cm] minimum in the opposite direction to reset the switch. When furnished, the rotary limit switch, regardless of type, is mounted to the outside of the SM5 hoist body. This increases some hoist body outline dimensions. *Designation of limit may vary on application. Switch number 2 and number 3 could have different functions. 08/14/02 4-12 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Controls WARNING Before removing or checking any electrical component, ensure that the power supply is shut off and the power disconnect switch is locked in open position. Standard basic control components consist of either of the following: 1. ACF Board - for direct full line voltage control (hoist configuration A) ACF board is located in the hoist electrical enclosure on the hoist and it controls the hoist brake when the hoist utilizes direct control. ACF board provides rapid brake release and engagement. ACF 1 is used for single speed hoist motors and ACF 2 is used for two speed hoist motors. The hoist motor must be connected to a power supply of either 208 volts or 230 volts. The electrical connection to the motor is the same for either 208 or 230 volts. Direct control is not being offered for higher voltages such as 460. ACF 1: Single Speed Hoists MOTOR CONNECTIONS: 208/230Vac max. POWER SUPPLY: L1 L2 L3 PE B- BRAKE: + – brake 208/230Vac: brake coil = 100Vdc ACF 2: Two Speed Hoists MOTOR CONNECTIONS: 208/230V max. B- BRAKE: + – brake POWER SUPPLY: L1 L2 L3 PE 08/14/02 208/230Vac: brake coil = 100Vdc 4-13 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 2. PC Board - control transformer and contactors are soldered to a circuit board. PC Board is furnished on the hoist for configuration B1, B2 or C. A special PC Board is furnished on the hoist for configuration D. 2 1 Note: The number, size and quantity of control devices vary considerably, depending on the number and types of motors and the many control options that are available. Refer to wiring diagram for specific details on power/control devices. No specific rules can be given as to the frequency of replacement of electrical devices. Deterioration of electrical components is directly related to the heat generated (over time) in contactor coils and transformers, and the arcing of contactors when the motor circuit is opened (starts/stops). The single speed concert chain hoist furnished with PC Board controls is available for a power supply of 208/230 volts or 460 volts. Single speed hoist furnished with a special PC Board could be voltage reconnectable for 230/460 volts if ordered that way. Ø To convert a voltage reconnectable single speed chain hoist with a special PC Board (contactor control) from 230 (208) volts to 460 volts, the connection changes include: • Checking that fuse (F100) is being used for control transformer (T100). • Reconnecting primary line connections to control transformer. • Reconnecting hoist motor leads. • Reconnecting hoist motor brake. Chain hoists with two-speed hoist motion are not voltage reconnectable. Hoist Circuit Diagram-Standard Hoist circuit (wiring) diagrams, shown on page 4-19 and after are standard for the indicated hoist configuration. When hoists of configuration B2 or C are equipped with PC Board controls with a mainline contactor, they are wired for single speed (low speed is not connected) and the mainline contactor is disabled. The function of the mainline contactor is taken over by the controller. By doing so, group control through a single standard controller is simplified. Manuals and wiring diagrams for controls and controller are furnished with the controller when they are supplied separate from the hoist. 08/14/02 4-14 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 TWO SPEED HOIST: 208V/230V or 460V (Hoist configuration B1 or B2) Figure 4-13 HOIST SUPPLY L1 L2 L3 BRAKE n BRAKE + 1U 2U 1V 2V 1W 2W hoist supply hoist supply hoist supply _ brake +brake motor supply motor supply motor supply motor supply motor supply motor supply GROUND WIRES ground terminal, 4 connections (see also figure 4-11) PE motor PE p.c. board (K10) PE trolley connection PE power supply 08/14/02 PRINTED CIRCUIT BOARD TAG STRIP X1 Terminal No: X24 plug A 11 12 13 14 15 Trolley Control Voltage SD: low speed F: high speed D2: left D1: right Pin No: 1 2 3 4 5 B 1 2 3 4 5 6 7 8 9 Push button common hoist up hoist down hoist fast emergency stop trolley fwd trolley rev trolley fast - Pin No: 1 2 3 4 5 6 7 8 X23 plug 4-15 C Protections 30-31 Thermal prot. F291 20-21 Upper limit switch S221 22-23 Lower limit switch S222 K10 Emergency stop contactor K21 Hoist UP contactor K22 Hoist DOWN contactor K25 Hoist FAST contactor T100 Control Transformer F100 Fuse 400 mA, with 230V and 460V F101 Fuse 400mA, with 208V RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com SINGLE SPEED HOIST: 208V/230V Revision 1 (Hoist configuration B1 or B2) Figure 4-14 HOIST SUPPLY L1 L2 L3 hoist supply hoist supply hoist supply Terminal X7 _ brake BRAKE + +brake T1-T9 motor supply GROUND WIRES ground terminal, 4 connections (see also figure 4-11) PE motor PE p.c. board (K10) PE trolley connection PE power supply 08/14/02 PRINTED CIRCUIT BOARD TAG STRIP X1 Terminal No: X24 plug A 11 12 13 14 15 Trolley Control Voltage SD: low speed F: high speed D2: left D1: right Pin No: 1 2 3 4 5 X23 plug B 1 2 3 4 5 6 7 8 9 Push button common hoist up hoist down hoist fast emergency stop trolley fwd trolley rev trolley fast - 4-16 C Protections 30-31 Thermal F291 20-21 Upper limit switch S221 22-23 Lower limit switch S222 K10 Emergency stop contactor K21 Hoist UP contactor K22 Hoist DOWN contactor T100 Control Transformer F100 Fuse 400 mA with 230V F101 Fuse 400mA with 208V Pin No: 1 2 3 4 5 6 7 8 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 SINGLE SPEED HOIST: 460V (Hoist configuration B1 or B2) Figure 4-15 HOIST SUPPLY L1 L2 L3 BRAKEBRAKE + T1-T9 hoist supply hoist supply hoist supply _ brake +brake motor supply GROUND WIRES Terminal X5 ground terminal, 4 connections (see also figure 4-11) PE motor PE p.c. board (K10) PE trolley connection PE power supply 08/14/02 PRINTED CIRCUIT BOARD TAG STRIP X1 Terminal No: X24 plug A 11 12 13 14 15 Trolley Control Voltage SD: low speed F: high speed D2: left D1: right Pin No: 1 2 3 4 5 X23 plug B 1 2 3 4 5 6 7 8 9 Push button common hoist up hoist down hoist fast emergency stop trolley fwd trolley rev trolley fast - 4-17 C Protections 30-31 Thermals F291 20-21 Upper limit switch S221 22-23 Lower limit switch S222 K10 Emergency stop contactor K21 Hoist UP contactor K22 Hoist DOWN contactor T100 Control Transformer F100 Fuse 400 mA Pin No: 1 2 3 4 5 6 7 8 RM-SM5-MAN-2001-13-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 SINGLE SPEED HOIST (Hoist configuration D) Configuration D hoists are equipped with a multi connector, which are wired as follows: PLUG PIN N° 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PE LEAD COLOR FUNCTION BROWN L1 POWER L2 POWER L3 POWER 48VAC E STOP SIGNAL é ACTION é “BY-PASS” SIGNAL ê ACTION ê 0 VOLT EARTH BLUE BLACK WHITE YELLOW TRANSPARENT ORANGE PINK PURPLE RED GREY GREY/WHITE BROWN/WHITE BLUE/WHITE RED/WHITE BLACK/WHITE YELLOW / GREEN HOIST TERMINAL L1 L2 L3 1 5 8 2 4 8 3 9 PE È Á Á HOIST SUPPLY L1 hoist supply L2 hoist supply L3 hoist supply BRAKE - brake BRAKE + + brake U1-V1-W1 motor supply GROUND WIRES Terminal X PE motor PE p.c. board PE power cell PE load cell 08/14/02 PRINTED CIRCUIT BOARD Controls 1 common 2 hoist up 3 hoist down 5 emergency stop PROTECTION Terminals X25 test facility F291 Thermal protection P1 Overload device S221-1 Upper rotary limit switch S222-1 Lower rotary limit switch S221-2 Intermedary rotary limit switch 4-18 S222-2 K10 K21 K22 KOL KTS KTM KSW T100 F102 F100 F101 Intermedarty rotary limit switch Emergency stop contactor Hoist UP contactor Hoist DOWN contactor Overload signal relay Main brake test relay Brake test relay U/L Limits test relay Control transformer Secondary fuse Primary fuse Primary fuse RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Hoist Circuit Diagram-Standard SINGLE SPEED HOIST: 208V / 230V 08/14/02 (Hoist configuration A) 4 -19 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Hoist Circuit Diagram-Standard TWO SPEED HOIST: 208V/230V or 460V 08/14/02 (Hoist configuration B1 or B2) 4 -20 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Hoist Circuit Diagram-Standard SINGLE SPEED HOIST: 208V/230V (Hoist SINGLE SPEED HOIST: 460V (Hoist 08/14/02 configuration B1 or B2) configuration B1 or B2) 4 -21 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Hoist Circuit Diagram (Hoist configuration D) 08/14/02 4 -22 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Hoist Circuit Diagram (Hoist configuration D) Test facility 08/14/02 4 -23 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 SECTION 5 PREVENTATIVE MAINTENANCE Maintenance table Interval Qualification of the customer’s personnel Brake operation for holding and releasing Daily Operator Visual inspection of the load chain Daily Operator Suspension of the pendant station Daily Operator Cleanliness and lubrication of the chain Monthly Operator Torque limiter operation Monthly Operator Measure for wear on the chain Every 3 months Operator Measure for wear on the hooks Every 3 months Operator Tightness of the load block screws & nuts Every 3 months Operator Check the suspension hook/coupling locking plate screws Every 3 months Operator Adjustment of the limiter and hoist brake 3 to 6 months Qualified mechanic Lubrication of open wheel gearing 3 to 6 months Qualified mechanic Tightness of wire terminal screws and terminal connections Semi-annually Qualified mechanic Lubrication of the load block idler sprocket Annually Operator Tightness of all screws to Screw Tightening Torque Specifications and check for signs of corrosion. Annually Qualified mechanic Clean motor cooling fins Annually Qualified mechanic Lubrication of the gears Lubricated for life Check CAUTION! These intervals shall be shortened if the hoist is used heavily with maximum loads or in extreme ambient conditions. Figure 5-1 08/14/02 5-1 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Lubricants Lubrication point Chain ■ Idler sprocket ▲ slide bearing + bearing Gears ● Specifications Oil or liquid grease Possible brands Chain lubricating fluid (Ceplattyn or similar) EP-90 Aral : Aralub FK 2 BP : BP Energrease LS - EP 2 Esso : Unirex N2 Mobil : Mobilgrease HP Shell : Shell Alvanio EP Grease 2 DEA : Paragon EP 2 Fuchs : Renolit Duraplex EP 2 Mobil: Mobilith SHC 007 Grease (without MoS2) KP 2 (DIN 51 502) Soap-based lithium Approx. drip point + 500°F Worked penetration 509-563°F Operating temperature - 4°F - +266°F NLGI Class 00 Synthetic hydrocarbon liquid with lithiumcomplex soap Approx. Drip point +550 °F Worked penetration 415-420°F Operating temperature –55 - +390 °F Quantity As required As required 0.11 lbs. Open Wheel Gearing: EP1 Mobilux or equivalent. Spare Parts Replacement Table Spare part Upper chain guide Output shaft PG cable gland Gear input shaft + adjusting nuts Motor end cap Gearing (1st/2nd stage) Brake cap/end cap sealing Other seals and O-rings Brake-limiter Brake end cap Lower chain guide Rubber buffer Electric box PC-board Plugs Chain Chain bucket Slack fall stop Suspension hook Hook block (1/1; 2/1) Control box To be replaced by Authorized manufacturer personnel Authorized manufacturer personnel Authorized manufacturer personnel Authorized manufacturer personnel Authorized manufacturer personnel Authorized manufacturer personnel Customer Authorized manufacturer personnel Authorized manufacturer personnel Customer Customer Customer Authorized manufacturer personnel Authorized manufacturer personnel Customer Customer Customer Customer Customer Customer Authorized manufacturer personnel Qualification of the personnel Qualified electrician & mechanic Qualified electrician & mechanic Qualified electrician Qualified mechanic Qualified mechanic Qualified electrician & mechanic Qualified mechanic Qualified mechanic Qualified electrician Qualified mechanic Qualified mechanic Qualified mechanic Qualified electrician Qualified electrician Qualified electrician Qualified mechanic Qualified mechanic Qualified mechanic Qualified mechanic Qualified mechanic Qualified electrician Once a part has been replaced, check the operation of the hoist. Screw Tightening Torque (lb. ft) Specification M5 M6 M8 M10 M12 Standard screws 4 7 18 35 61 Self-tapping screws 4 6 15 30 53 08/14/02 5-2 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Manual : 800 955-9967 web: www.rmhoist.com Revision 1 Troubleshooting Problem Possible Cause Possible Solution Hoist does not lift or lower load Emergency stop button is activated Deactivate button Blown fuse Replace the fuse Pendant plug pin pushed out Reinstall plug pin Contactor terminal screws loose Tighten screws Mainline switch shut off Turn switch on Overload condition Reduce load Worn load chain and torque limiter prevents lifting. Replace load chain Torque limiter worn or incorrectly adjusted Replace torque limiter wear items or properly adjust torque limiter Brake not releasing Check brake coil resistance Hoist does not lift load Check air gap setting. Adjust if necessary Check rectifier output voltage Brake drift more than 4 inches (100mm) Brake lining worn Adjust brake air gap setting and replace wear items as necessary Travel direction does not correspond to that indicated on push button Power supply incorrectly connected See SECTION 2 Abnormal noises while lifting or lowering Load chain and its components are not lubricated Lubricate load chain Load chain is worn Replace chain Sprocket or chain guide is worn Replace sprocket or chain guide Idler sprocket is worn Replace idler sprocket A supply phase is missing Connect the three phases Twist in load chain Remove twist 08/14/02 5-3 RM-SM5-MAN-2001-1-ENG R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Index of Exploded Illustrations and Parts Lists HOIST BODY ..................................................................................................................2 GEAR MECHANISM & VERSION 2A BRAKE ................................................................4 GEAR MECHANISM & VERSION 2B BRAKE ................................................................6 LIFTING ASSEMBLY ......................................................................................................8 CONTROLS ..................................................................................................................10 UPPER & LOWER LIMIT SWITCH ...............................................................................12 08/14/02 1 RM-SM5-SPARE-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Hoist Body 08/14/02 2 RM-SM5-SPARE-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Hoist Body Item 1 Part Number 2 3 4 6 2257016 2219961 7 8 9 10 11 12 13 15 16 17 18 19 08/14/02 8380202 2210004 2218002 2219962 2219960 2218004 Description Hoist body Stator Rotating hook set Dowel pin M8 Screw and plate Hook housing Motor endcap & hardware set Motor endcap M6 Screw Cap O-ring 2 x 120-NB70 Brake end cap Seal ring Brake endcap with counterweight Cable gromet Suspension kit for pendant Steel control enclosure Body branding label set Self adhesive load plate 3 Comments Qty 1 Incl. item 3-4 and 6 1 2 1 1 1 1 13 1 1 1 1 1 2 1 1 1 1 Specify capacity When ordering RM-SM5-SPARE-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Gear Mechanism & Brake (Brake version 2A) 08/14/02 4 RM-SM5-SPARE-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Gear Mechanism & Brake (Brake version 2A) Item 1 2 3 3 4 5 6 7 8 9 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 25 25 26 27 27b 28 29 30 31 32 33 33 33 34 35 36 08/14/02 Part Number 2211501 2215000 2215001 2214001 2219983 2210500 2210520 2210503 2210510 2210503 2219984 2211070 2211071 2211018 2211020 2211026 2211021 2211023 2211024 2211025 2211016 2211022 Description Comments Qty Self locking nut 2 Gear input shaft set 1 Rotor assembly Two speed 1 Rotor assembly Single speed 1 Bearing 1 Chain sprocket set assembled 1 Sprocket equipment 1 Bearing 1 Bushing 1 Bushing 1 Planetary gear assembly, 2nd step 16 fpm 1 Planetary gear assembly, 2nd step 32 fpm 1 Planet carrier 1 Brass washer Self lubricating bushing 3 Planet wheel 3 Retaining ring 6 Pinion 2nd step 1 Planetary gear assembly, 1st step 1 Planet carrier 1 Self lubricating bushing 3 Planet wheel 3 Pinion 1st step 1 Metal sealing ring set =21+22+23+24 1 Circlip 1 O-ring 1 Bearing 1 Metal sealing ring set 1 Complete brake & slip clutch assy 380-480V 1 Complete brake & slip clutch assy 200-240V 1 Complete brake & slip clutch assy 500-575V 1 Screw 3 Screw 3 Adjustment nut 3 Slip clutch friction disk assembly =8+28+29 1 Lipseal 1 Brake pressure disk 1 Anchor disk 1 Brake spring 1 Coil assembly 190Vdc use version 2B 200-240V 1 Coil assembly 100Vdc use version 2B 380-480V 1 Coil assembly 240Vdc use version 2B 500-600V 1 =1+34+34+34+37+35+1 Slip clutch spring set 1 Washer 3 Limiter spring 1 Friction disk 1 5 RM-SM5-SPARE-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Gear Mechanism & Brake (Brake version 2B) 08/14/02 6 RM-SM5-SPARE-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Gear Mechanism & Brake (Brake version 2B) Item 2a1 2a2 2a3 2a3 2a3 2a4 2a5 2b1 2b2 2b2 2b3 2b4 2c1 2c2 2c3 2c4 2d1 2d2 2d3 2d3 2d3 2d6 08/14/02 Part Number 2210503 2211016 2215000 2215001 2215055 8384702 2211018 300077 2210500 2210520 8262501 2211020 2210510 2211501 2214001 8182543 8381806 833706 2211081 2211080 2211082 8552528 Description Comments Pinion Limiter spring set 2 speed rotor assembly 1 speed rotor assembly-1800 rpm 1 speed rotor assembly-3600 rpm O-ring 2 x 47-NB70 Clutch disc set-number 2 Circlip 47 x 1.75 Planetary gear assy-2nd reduction Planetary gear assy-2nd reduction Retaining ring Clutch disc set-number 1 Planetary gear assy-1st reduction Gear input shaft Chain sprocket assembly Metal seal ring Lip seal Ball bearing Coil assembly 190VDC Coil assembly 100VDC Coil assembly 240VDC Sprocket tube 7 Two speed Single speed Single speed 16 fpm 32 fpm 380-480V 200-240V 500-600V Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 RM-SM5-SPARE-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Lifting Assembly 13a 10b 11a 08/14/02 8 RM-SM5-SPARE-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Lifting Assembly Item 1 2 3 4 5-8 Part Number 2214011 2214014 2214013 830931 7 9 2211050 52293185 Description Upper chain guide Lower chain guide assembly Rubber plate set Screw Standard chain bucket hoist configuration B1 only Slack fall stop Hook block complete-1 fall 10 10a 10b 11 11a 12 13 13a 14 Hook assembly-1 fall Safety latch (1 fall) Suspension plate for chain bucket Shaft 2211056 Chain bucket with hardware Screw Self locking nut External chain guide 2213308GRP Self adhesive load plate 16 17 18 19 20 20a 21 2219902 2214003 8191620 2217008 2217004 001515 2213308GRP 22 23 2213500 830910 2211045 2213523 24-27 08/14/02 Comments =2+3+4+4+13+23 Specify chain length when ordering =10+11+12+13+14+15+ 16 Size 025 001512 Hook block complete-2 fall Idler sprocket assembly Self lubricating bushing Shaft Hook assembly-2 fall Safety latch (2 fall) Self adhesive load plate Load chain 4.8 x 12.5 Screw Chain fitting tooling Chain anchor assembly 100 ft Specify capacity when ordering Size 025 Specify capacity when ordering =24+25+26+27 9 Qty 1 1 1 2 1 1 1 1 4 1 1 2 2 1 2 1 1 1 1 1 1 2 Ar 1 1 1 RM-SM5-SPARE-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Controls 08/14/02 10 RM-SM5-SPARE-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Controls Item 1 1a 2 2 3 3 3 3 4 5 6 7 8 9 10 11 12 13a 13 14 15 16 17 18 08/14/02 Part Number 2219963 2213010 7383020 2219092 2213017 2213018 2213016 2213004 7285039 8090411 2249946 2249982 2219808 833130 2219814 2213001 Description ABS Control box base & hardware Steel control box complete Ground PE terminal board Hour counter PC board 208/230/460V/60Hz/115V PC board 208/230/460V/60Hz/115V PC board 575V/60Hz/115V ACF PC board 208/230/415V Screw Stop nut Screw Female connector + wire harness Plastic screw Plug set for trolley Plug set for power supply Plug Screw Cable gland set Fuse Closing plate set Closing plate Screw Nut Counterweight Control box cover, cwt. & screw Screw 11 Comments Qty =1+6+5 Configuration B1 only 1 Includes cover 1 1 1 Two speed 1 Single speed 1 Two speed 1 Configuration A only 1 5 4 4 Configuration B1 only 1 Configuration B1 only 2 Configuration B1 only 1 Configuration B1 only 1 Configuration B1 only 1 Configuration B1 only 2 1 1 Configuration B1 only 1 Configuration B1 only 1 Configuration B1 only 4 Configuration B1 only 4 Configuration B1 only 1 Configuration B1 only 1 =16+17+18 Configuration B1 only 4 RM-SM5-SPARE-2001-1-ENG.doc R&M Materials Handling, Inc Springfield, Ohio USA STAGEMAKER® COMPACT Concert Hoist SM5 Spare Parts : 800 955-9967 web: www.rmhoist.com Revision 1 Upper & Lower Limit Switch for Upright position (Configuration B1 only) Attention: The limit switch, when furnished, is installed in place of the rubber buffer. Use screws 6x30mm. Item 1 2 3 4 5 6 08/14/02 Part Number 2213059 2219002 2219003 Description Complete limit switch Switch plate Switch set M8 x 25 screw Cable gland Spring plate Spring Comments =1+2+3+4+5+6 1 fall/2 fall 1 fall/2 fall 12 Qty 1 1 1 1 1 2/3 2/3 RM-SM5-SPARE-2001-1-ENG.doc ">
Advertisement
