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Summary of Contents for Liftket STAGEKET
- Page 1 Operating instructions STAGEKET Electric chain hoists Please do not use the electric chain hoist before all operators have carefully read and understood this manual and signed the form on the rear cover.
- Page 2 LIFTKET Hoffmann GmbH Dresdener Straße 64-68 04808 Wurzen / Germany +49-3425-89 24-0 +49-3425-89 24-99 sales@liftket.de www.liftket.de Ho 08/2017 englisch Original operating instructions © 2017...
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Page 3: Table Of Contents
Contents Safety instructions ............................5 Regulations ..............................5 Advice for the use of electric chain hoists ....................6 1.2.1 Design according to DGUV V54 (BGV D8) ....................6 1.2.2 Additional requirements when designed according to DGUV V17 (BGV C1) ..........7 Prohibitions of use ............................ - Page 4 Mechanical assembly ..........................34 4.5.1 Assembly position of the trolley on the electric chain hoist ................ 34 4.5.2 Assembly of the trolley with two connecting bolts..................35 4.5.3 Assembly of the trolley with tandem trolley ....................35 4.5.4 Assembly of the trolley with one connecting bolts ..................36 Electric trolleys with counterweight ......................
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Page 5: Safety Instructions
Safety instructions Regulations The following regulations and all recommendations of this manual serve as basis for assembly, installation, certification and maintenance of electric chain hoists, within Germany and within the area of the European community. For countries other than mentioned, local legislation and directives may apply in addition to the regulations as stated in this manual (German/European). -
Page 6: Advice For The Use Of Electric Chain Hoists
Advice for the use of electric chain hoists 1.2.1 Design according to DGUV V54 (BGV D8) Electric chain hoists are designed to lift and to lower loads vertically and to travel horizontally with those lifted loads (with trolleys). Any other use is not considered to be proper. Manufacturer does not take responsibility for any improper use and the risk is on the operator’s responsibility. -
Page 7: Additional Requirements When Designed According To Dguv V17 (Bgv C1)
1.2.2 Additional requirements when designed according to DGUV V17 (BGV C1) The electric chain hoists in the design ‚SB‘ (with 2 brakes and half load capacity) are subject to requirements of DGUV V17 (BGV C1). The operators have to be well trained in order to make them aware about the special requirements, resulting from stage and studio use of chain hoists according to DGUV V17 (BGV C1). -
Page 8: Visible Damages
Visible damages If any damages or breakdowns are detected during the operation or during hoist tests these hoists must not be operated until they have been repaired or a trained specialist has checked and approved them. In case of broken load chain, the owner/operator shall not put the chain hoist into operation until the hoist has been checked, repaired and approved by an authorized specialist. -
Page 9: Attaching Lights Or Other Equipment To The Electric Chain Hoists
1.6.5 Attaching lights or other equipment to the electric chain hoists Loads have to be attached from special scaffolds, approved working platforms or similar safe positions only. Spare parts Only original fixing components, spare parts and accessories, listed in manufacturer’s spare parts catalogue are acceptable for use. -
Page 10: Version Mb In Inverted Use According To Dguv V54 (Bgv D8)
2.1.2 Version MB in inverted use according to DGUV V54 (BGV D8) Hook tackle Lift limiter Chain guide plate Hoisting gear Chain box Drain hole Control pendant with emergency stop Excess chain 50 cm (to secure feeding of chain into the chain box) Single hole suspension eye (MB) -
Page 11: Version Sb In Upright Use According To Dguv V17 (Bgv C1)
Further completion possibilities Further completion possibilities will be provided on request. Explanation of type designation Type 500 / 2 – 4 / 1 Version STAGEKET SK 031/52 Slow lifting speed [m/min] Main lifting speed [m/min] Number of falls Safe working load (SWL) [kg] According to the Machine directive 2006/42/EC you will find all technical data in the technical documentation attached to each hoist. -
Page 12: Sectional View
Sectional view Figure no. Description Hoist body Gear cover Cap for brake Cap for gear cover Brake Clutch unit Motor pinion shaft Rotor Stator Sprocket wheel Figure 4: Sectional view... -
Page 13: Illustration Of The Load Chain Configuration
Illustration of the load chain configuration Attention! Use original chain of the manufacturer only! These original chains meet the high stress and service life standards required. Single fall version Double fall version Sprocket wheel Hold down Chain guide Chain box Lift limiter (limit stop) Hook tackle... -
Page 14: Hook Block
During maintenance work the condition of the load hook (wear and centre punch spacing), the rubber buffer, the pressure bearing, the safety latch and the pin, which secures the hook nut, have to be checked. If required, the axial bearing has to be cleaned and greased. The plastic cover of the hook tackles of chains 4×12 mm, 5×15 mm and 5.2×15 mm has to be checked additionally and changed if worn. -
Page 15: Stationary Electric Chain Hoist
3.1.3 Stationary electric chain hoist 3.1.3.1 Hoist suspension with suspension eye Caution! It is not allowed to use any other non-original parts, fixing bolts or screws to connect the electric chain hoist to the suspension. The hole for the tandem trolley on the suspension eye must be on the chain box side. Assembly: The suspension eye section must be inserted into the specially provided suspension holes on the electric chain hoist and pinned into place with the two bolts. -
Page 16: 3.1.3.2 Hoist Suspension With Single Hole Suspension Eye
3.1.3.2 Hoist suspension with single hole suspension eye Caution! It is not allowed to use any other non-original parts, fixing bolts or screws to connect the electric chain hoist to the suspension. The label of hook tackle used for the single fall version and the label of hook block used for the double fall version should be in the respective version on chain box side. -
Page 17: Hoist Suspension With Hook Suspension
3.1.3.3 Hoist suspension with hook suspension Caution! It is not allowed to use any other non-original parts, fixing bolts or screws to connect the electric chain hoist to the suspension. The label of hook tackle used for the single fall version and the label of hook block used for the double fall version should be in the respective version on chain box side. -
Page 18: Gear Ventilation
3.1.4 Gear ventilation After the completion of hoist installation, the serrated washer has to be placed under the oil filler plug (top side of casing) to avoid oil leakage due to high pressure inside the gearbox. You will find this washer fastened with a piece of self-adhesive tape next to the oil filler plug. -
Page 19: Oversize Chain Box
Caution! Ensure that the chain box is sufficient for the amount of the respective chain. The chain dimension and capacity is shown on the chain box. Insert the chain end with lift limiter and its rubber buffer loosely into the chain box. After running the entire chain length through the hoist into the chain box, check that the box is not overfilled. -
Page 20: Assembling The Load Chain In Single Fall Version
3.1.6 Assembling the load chain in single fall version 1. Push the pull-in wire (special tool) into and through the chain guide cross plate as shown in Figure 16-A until the wire hook is pushed out on the opposite side. 2. -
Page 21: Assembling The Load Chain In Double Fall Version
3.1.7 Assembling the load chain in double fall version 1. Insert the load chain into the hoist casing according to chapter 3.1.6. 2. Pull the chain through the hook block using the pull in wire (special tool) (Figure 17-A). Caution! Never allow the chain to be twisted between the chain outlet and the hook block! If the assembly according to Figure 17-B or Figure 17-C is not possible without a twisted chain one chain link has to be cut and removed to allow correct assembly. -
Page 22: Replacing The Load Chain, The Chain Guide And The Hold Down
3.1.8 Replacing the load chain, the chain guide and the hold down Caution! The chain guide and the hold down must also be changed when the load chain is being replaced. Figure 18: Replacing the load chain, the chain guide and hold down Assembly instructions: 1. -
Page 23: Operating Voltages
Fuses (slowly blowing) at 400 V (3 phase) in front of main switch: 380 - 415 V / 50 Hz 440 - 480 V / 60 Hz main fuse power cable max. P [kW] I [A] max. P [kW] I [A] A [mm²] L max.[m] 63G2... -
Page 24: Direct Control
3.2.3 Direct control The controlling of the motor is directly carried out by the control pendant. Brake contactor or current contactor Rectifier Gear cap Terminal block board Cable gland for Cap for gear cover motorized trolley Cable gland for mains supply Cable gland for control cable Figure 19: Direct control... -
Page 25: Electrical Limit Switches For Lift Limiting
3.2.5 Electrical limit switches for lift limiting The electric chain hoists with low voltage control will be equipped with electric limit switches for lift limitation of the highest and lowest load position on request. These limit switches are operated by two buttons, protruding out of the chain guide, which can be activated either by the hook (top limit) or lift limiter (bottom position). -
Page 26: Limit Switches In Upright Use
Limit switches in upright use Available equipment Four-traced gear limit switch Four-traced gear limit switch and two external limit switches Required function Operation limit switch for lifting Gear limit switch BO Gear limit switch BO Operation limit switch for lowering Gear limit switch BU Gear limit switch BU Emergency limit switch for lifting... -
Page 27: External Emergency Limit Switches
Sprocket wheel Adapter Adjusting worm screw for four traces, Contact-/trace configuration according to wiring diagram Figure 22: Gear limit switch as operation and emergency limit switches Gear limit switch for lifting as operation limit switch Gear limit switch for lowering as operation limit switch Override switch Override switch Figure 23: Override switches for operation limit switches... -
Page 28: Incremental Encoder
Incremental encoder This assembly group can be fitted to all hoists for normal (upright) or inverted use. The incremental encoder provides impulses depending on the revolutions of the sprocket wheel, which can be read by a special control circuit or a computer control. -
Page 29: Mechanical Underload Protection
Mechanical underload protection Suspension point Suspension eye Electric chain hoist Pressure spring Nut for adjustment of Limit switch underload Load centre of gravity Figure 27: Construction and function of mechanical underload protection The suspension eye is fixed at the electric chain hoist. It can move up and down at one bolt to indicate the load and swivels around the other bolt. -
Page 30: Electronic Overload And Underload Protection
Electronic overload and underload protection Integrated load sensor Figure 28: Integrated load sensor Suspension point Suspension eye with load sensor Load sensor Electric chain hoist Load centre of gravity Figure 29: Suspension eye with load sensor Adjusting screw for lifting Adjusting screw for lowering Figure 30: Comparator... - Page 31 The indirect acting overload and underload protection measures the load by means of an sensor and switches off the control path for lifting (in case of overload) or lowering (in case of underload). The threshold values can be adjusted by means of adjusting screws: Left turn: LED on Threshold values higher...
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Page 32: Control Pendant
3.10 Control pendant Emergency stop (empty) Power supply “ON” Override underload Lifting Lowering Figure 31: Control pendant A: Emergency stop The red mushroom button switches off the control and all working movements. B: Power supply „ON“ (After switching on the main switch for the whole lifting system.) After an emergency limit switch has been actuated or after the emergency stop has been pressed the power can be switched on again with this button. -
Page 33: Electric Chain Hoist With Trolley
Electric chain hoist with trolley Types of trolleys All trolleys are suitable for • flanges with small width in accordance with DIN 1025 and European regulations 24-62 • flanges with medium width in accordance with DIN 1025 • flanges with large width in accordance with DIN 1025 Caution! Elastic bumpers, with contact area at approximately the centre of the running wheels, must be mounted as limit stops at each end of the track. -
Page 34: Horizontal Movement Of Electric Chain Hoists
Horizontal movement of electric chain hoists If electric chain hoists are suspended on electric trolleys, the equipment has to be set up in a way that collisions between the crane and other parts of the crane environment are prevented. For trolleys equipped with electric limit switches, the actuating bars have to be installed in such a manner by the user, that the travelling movement is stopped securely before the trolley hits the end rail stoppers or buffers. -
Page 35: Assembly Of The Trolley With Two Connecting Bolts
4.5.2 Assembly of the trolley with two connecting bolts The two trolley connecting bolts are to be fixed to the lateral boards so as to allow a clearance of one to two millimetres between the running wheel flange and the girder flange. The width is adjusted by inserting spacing washers symmetrically. -
Page 36: Assembly Of The Trolley With One Connecting Bolts
4.5.4 Assembly of the trolley with one connecting bolts One trolley connecting bolt is to be fixed to the lateral boards so as to allow a clearance of one to two millimetres between the running wheel flange and the girder flange. The width is adjusted by inserting spacing washers symmetrically. -
Page 37: Tests
Tests The use of the electric chain hoists is possible in accordance with: • DGUV V54 (BGV D8) - Accident prevention regulations „Winches, lifting and pulling equipment“ • DGUV V17 (BGV C1) - Accident prevention regulations „Winches, lifting and pulling equipment“ •... -
Page 38: Maintenance
Maintenance • Trained specialists must carry out all maintenance work. • The Table 8 lists the parts and functions to be tested and the necessary maintenance work. Defects must be rectified immediately by a trained specialist. Defects have to be reported immediately to the owner. -
Page 39: Single Brake
Single brake 7.2.1 Description of the single brake Distance bush Air gap S Label / Type plate Flange Spring Magnetic coil Rotor with Anchor plate brake lining Fastening screws Figure 37: Construction of the brake 7.2.2 Replacement of the brake Caution! All assembly and disassembly works should be done without load. -
Page 40: Double Brake Sk 02
Casing Motor shaft with hub, clutch spring and nuts Brake 3 fastening screws Figure 38: Assembly of the brake Double brake SK 02../... and SK03../... 7.3.1 Description of the double brake Air gap S Anchor plates Label / Type plate Magnetic coil Rotor with brake lining Motor shaft with hubs... -
Page 41: Double Brake Sk 05
Type Operation Emergency Screws Tightening Coil resistance Air gap S Air gap S brake brake DIN 912 torque [Nm] R20 nominal [Ω] nominal [mm] maximal [mm] SK02../... BFK 457-06 BFK 458-06 3×M4 2101 SK03../... Table 10: Data of the brake Caution! For order of spare parts the complete type of the electric chain hoist has to be submitted. -
Page 42: Replacement Of The Brake
7.4.2 Replacement of the brake Caution! All assembly and disassembly works should be done without load. The electric chain hoist should be completely disconnected from power (Power off). Low voltage control Direct control 1. Loose screws of cap for gear cover. 1. -
Page 43: Electric Control Of The Brake
Electric control of the brake Mode of functioning The disk brake is supplied through a rectifier circuit. It operates according to the fail-safe principle. If there is a power failure, the brake acts automatically so that the load is held securely in every position. To shorten the braking time the brake is operated in a DC circuit. -
Page 44: Operation And Emergency Brake (Double Brake)
7.7.1 Operation and emergency brake (double brake) The operation and emergency brake operate independently. They are arranged in a row on the motor pinion shaft. The motor-sided brake is the operation brake Y1 and the cap-sided brake is the emergency brake Y2. Both brakes are DC-disk brakes acting according to the closed circuit current principle. -
Page 45: Safety Sliding Clutch
Safety sliding clutch The sliding clutch is located between the rotor of the lifting motor and the main pinion shaft and transmits the driving torque. At once it limits the transmissible power depending on the set coupling torque. Hence an overloading of the electric chain hoist and crane components will be prevented. A special advantage of the patented sliding clutch is that it is situated before the operating brake. -
Page 46: Adjustment Of Friction Torque At The Safety Sliding Clutch
7.8.2 Adjustment of friction torque at the safety sliding clutch Caution! The adjustment works should be executed by trained personnel only. 1. Apply the test load =1.1 times the nominal/rated load onto the load hook or the clutch testing device. 2. -
Page 47: Assembly And Disassembly Of The Brake-Clutch Assembly Group
Assembly and disassembly of the brake-clutch assembly group The brake-clutch assembly group is a separate fully closed assembly group. Caution! All assembly and disassembly works have to be done without load. The electric chain hoist has to be switched off and disconnected from the grid. Before disassembly the electric chain hoist must be suspended in normal use (upright use) or supported horizontally. -
Page 48: 7.10.2 Testing Of Wear And Replacement Of The Load Chain
7.10.2 Testing of wear and replacement of the load chain The continuous monitoring of the load chain is compulsory according to DIN 685-5:1981 and the accident prevention regulations in DGUV V54 (BGV D8), §27. The load chain must be tested before starting operation and after approx. -
Page 49: 7.12 Maintenance Work On The Trolleys
7.12 Maintenance work on the trolleys The checks and maintenance work on the electric trolleys and push trolleys have to be done in accordance with Table 8. 7.12.1 Construction of the brake of the electric trolley Type BFK The brake type BFK operates absolutely maintenance free. 3 pieces screws M3×8 DIN 912 at a circle diameter of 58 mm Motor pinion shaft... -
Page 50: Duty Rate Of An Electric Chain Hoist
1 Bm 25 % 1 Am 30 % 40 % 50 % 60 % * The operating periods t of the STAGEKET chain hoists are higher than required acc. to FEM 9.683. Table 14: Duty rate for short time duty... -
Page 51: Intermittent Duty
Intermittent duty Operation must be interrupted whenever the highest permissible operating time is reached. The following breaks are necessary depending on the duty rate c.d.f. of the electric chain hoist: Duty rate c.d.f. Break (min) 15 % 5 times running time 20 % 4 times running time 25 %... -
Page 52: Strainer Clamp For The Control Cable
Strainer clamp for the control cable Control cable Strainer clamp Control pendant Figure 50: Assembly of the strainer clamp Caution! The strainer clamp must be fixed in such a way as to prevent any tensile forces affecting the control cable. Pulling the chain hoist at the control pendant by means of the strainer clamp is not permitted. -
Page 53: Chain
The following oil sorts can be used: Supplier Oil sort Remarks © Fuchs Renolin CLP 220 © Castrol Alpha Zn 200 © ESSO EP 220 © Mobil Mobil gear 630 © Shell Omala 220 © Reductelf SP 220 © XP 220 BP Energol GR ©... -
Page 54: Hook Block And Hook Tackle
Following lubricants are recommended for lubrication of chain depending on operating conditions: Supplier Lubricant Remarks © Fuchs Stabylan 2001 © Klüber Klüberoil 4UH 1-1500 Food industry © Fuchs Ceplattyn 300 Dry-film lubricant © Castrol Optimol Viscogen KL300 © Fuchs Stabylan 5006 ©... -
Page 55: Example Of Declaration Of Conformity
Example of Declaration of Conformity... -
Page 56: Example Of Declaration Of Incorporation
Example of Declaration of Incorporation... - Page 58 The operators who have been instructed to use this hoist and have read the manual and especially the safety advice. Name, Surname Date Signature The advice contained in this manual is limited to such matters / facts which are necessary to ensure a safe operation and maintenance of the industrial hoists, to be observed by appropriate skilled and qualified operators.
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