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Starke STW Series Owner's Manual

Top running wire rope hoist
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Top Running Wire Rope Hoist
V2.0 061824
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STARKEAMERICA.COM

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  • Page 1 Top Running Wire Rope Hoist V2.0 061824 STARKEAMERICA.COM...

  • Page 2: Table Of Contents

    Table of Contents 1.0 Important Information ......................6 1.1 Safety Precautions ......................6 1.2 Warnings .......................... 6 2.0 General Description ......................6 2.1 User Manual ........................6 2.2 Operational Limits ......................7 2.3 Operational Specifications ....................7 2.4 Warranty ........................... 7 2.5 Other Notes ........................
  • Page 3 16.1.1 Lifting the Hoist ......................25 16.1.2 Double Girder ............................26 16.2 System Commissioning Guide ..................27 16.2.1 No-Load Checks ............................27 16.2.1.1 Electrical system ........................... 27 16.2.1.2 Pendant Control ............................ 27 16.2.1.3 Noise ..............................28 16.2.1.4 Upper and Lower Limit Switch Calibration ................... 29 16.2.1.5 Trolley Travel Limit Switches ........................
  • Page 4 28.10 Lower Hook and Block Part List ...................75 28.11 Fixed Pulley .........................76 28.12 Fixed Pulley Part List ....................77 28.13 Dead End Wedge Assembly Diagram ................78 28.14 Dead End Wedge Part List ..................79 29.0 Hoist Dimensions ......................80 Starke Products Warranty ......................81 V2.0 061824 STARKEAMERICA.COM...
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  • Page 6: Important Information

    DAMAGED CONDITION. Any attempt to do so will put you, others, and property at serious risk. 1.2.6 Repairs to this unit must be performed by a qualified repair facility. Contact Starke America to locate the nearest repair facility. See warranty information at the end of this manual.

  • Page 7: Operational Limits

    Starke wire rope hoists are fit for the lifting and carrying of loads subject to the maximum load capacity, FEM group and load group for which it was designed. Load capacity, FEM group and load group are indicated in the data sheet or test booklet of each hoist.

  • Page 8: Other Notes

    It is strongly recommended this hoist system be maintained and repaired by properly qualified, trained, and authorized personnel. Please contact your dealer or Starke for assistance. Items to be completed by authorized and certified crane technician before operation of this system: 2.4.1 Complete pre-use inspection before placing system into operation.

  • Page 9: Typical Applications

    3.0 Typical Applications 3.1 Applications Starke electric wire rope hoists may be installed on overhead “I” shaped steel rails (straight or curved). They are widely used in plants, mining, railway, port, warehouse, good yards, and service industries. Electric wire rope hoists improve productivity.

  • Page 10: Safe Working Time

    3.4 Safe Working Time The load spectrum is as bellow: FEM has relevant standards about hoist accidents caused by material fatigue and aging. The following form is referred to during designing of hoists. Work Duty FEM (ISO) Usage Period 1Bm(M3) 1Am(M4) 2m(M5) 3m(M6)

  • Page 11: Estimation Of Safe Working Time

    3.5 Estimation of Safe Working Time Experienced service technicians should routinely check and record the service condition of wire rope hoist, then estimate the remaining safe working time according to accepted standard. 3.6 Solution for Limited Safe Working Time 3.6.1 Suspend use of hoist system 3.6.2 If continued use is required qualified professional personnel should include the following: •...

  • Page 12: Components Of Wire Rope Hoist

    4.0 Components of Wire Rope Hoist Drawing Part Description Hoisting Transmission Lifting Motor Drum Device Trolley Frame Trolley Traveling Motor Hook & Block Assm Wire Rope Hoist Panel V2.0 061824 STARKEAMERICA.COM...

  • Page 13: Lifting Motor

    5.0 Lifting Motor The standard lifting motor is a two-speed motor with electromagnetic disc brake. A variable speed motor is optional and has electromagnetic brake. Drawing Part Description Fan Cover Brake Pack Stator Rotor Junction Box Motor Frame motor are class F rated. When the temperature is above 300 F (150 ℃), thermostats or sensors Two-speed (variable-frequency) motor has (three) thermostats or sensors.
  • Page 14 Min. rotor Thickness The IP grade of standard electromagnetic disc brake is IP54, the highest IP grade can be up to IP56. Meanwhile, electromagnetic disc brake can alternatively install manual release lever. The brake uses dust-proof design, which doesn’t need other maintenance during normal operation. IMPORTANT NOTE: It is imperative to check brake clearances on a regular basis.

  • Page 15: Hoist Transmission Gearbox

    6.0 Hoist Transmission Gearbox The wire rope drum is driven by the lifting motor via the gearbox. The output shaft has been designed with a volute spline to achieve optimal transmission reliability. For optimal performance and longevity of the gearbox please strictly follow FEM recommendations, and with the use of high quality lubricants no other maintenance during safe working time should be required under normal use conditions.

  • Page 16: Drum And Guide Information

    7.0 Drum and Guide Information Drawing Part Description Left End Plate Rope Guide Rod Drum Rope Guide Right End Plate The drum is manufactured from seamless tube, and the surface is machined into rope races according to different model requirements, such as right-handed rotation or left-and-right handed rotation.
  • Page 17 Drawing Part Description Hex Bolt Spring Washer Washer Rope Guide Ring A Clamping Roller Pin A Rope Guide Ring B Washer Rope Guide C Snap Ring Hex Bolt Clamping Roller Spring Clamping Roller Frame Clamping Roller Pin B Snap Ring Clamping Roller V2.0 061824 STARKEAMERICA.COM...
  • Page 18 Winding methods include single winding and double winding. In the illustration below note the clamps used to secure wire rope to the drum. If the drum is double wound, you will have the same clamps on the opposite end. Industry standard requires that when the lifting hook is at its lowest design position in relation to the floor that two complete wraps of wire rope encircle the drum in addition to the length under clamps.

  • Page 19: Upper And Lower Limits Warning: Set Limits Before Operation

    8.0 Upper and Lower Limits Warning: Set Limits Before Operation The Starke wire rope hoist uses a screw type cam limit switch, which is installed on side plate of drum making it convenient for precise adjustment. The switch has two separate contacts to allow the hoist to slow down upon tripping the first limit and safely stop upon tripping the second limit thus providing safe load handling.

  • Page 20: Trolley Frame

    9.0 Trolley Frame The trolley frame for a top running hoist is designed with a connecting tube and end trucks. The wire rope pulley and overload limiter are attached to the connecting tube. The size of trolley frame depends on capacity, lifting height, and other elements of system design. 10.0 Motorized Trolley Motorized trolley includes squirrel-cage motor and gearbox.

  • Page 21: Overload Limits

    11.0 Overload Limits The overload limiter will stop the hoist from lifting if the actual load is over the rated capacity. Load protection is provided by an electronic load cell. The overload limiter’s installation for single reeve is as below: IMPORTANT NOTE: The overload limiter has been calibrated in the factory with rated load.

  • Page 22: Wire Rope

    12.0 Wire Rope Wire rope is the main stressed part as well as the most vulnerable part of hoist system. To make sure safe operation is maintained, operators should strictly follow safety operation manual. Operators should also frequently check and maintain wire rope. Routine maintenance includes but not limited to: ⚫...

  • Page 23: Hoist Electrical Controls

    13.0 Hoist Electrical Controls Power supply requirements for Starke standard wire rope hoists are 460/3/60Hz and drive power is 24V/1/60Hz. The configuration for a standard wire rope hoist and trolley is two speeds, contact your dealer for optional configuration. Our Gen 2.0 hoist systems are now utilizing Danfoss variable frequency drives as standard equipment driving the trolley motor.

  • Page 24: Wire Rope Data

    Keep VFD fan and heatsink clean and remove dust build up with in control cabinet with gentle application of compressed air. Use caution if metallic dust is on the surfaces to avoid depositing it within control cabinet and its components. If the cooling fan blades are clogged with oil impregnated dust and/or heat sink fins are dirty or clogged, it may require removal of the VFD(s) for proper cleaning.

  • Page 25: Assembly And Commissioning

    16.0 Assembly and Commissioning Please read all installation and operating manuals as well as the relevant safety regulations carefully before hoist installation and commissioning. Unless stated otherwise, the standard shipping status for hoist rope, and hook, is that they have been assembled.

  • Page 26: Double Girder

    16.1.2 Double Girder The top running trolley frame wheel gage is set at the factory. The dimension of rail measurement (B) will be listed on your order. The rail should be set to (+/-) 1/8” (2mm) measurement of the trolley gage ordered. To verify that your rail size is within tolerance of the trolley wheel flanges.

  • Page 27: System Commissioning Guide

    16.2 System Commissioning Guide 16.2.1 No-Load Checks 16.2.1.1 Electrical system • Verify voltage and ampacity of the power supply circuit is in accordance with the hoist system specifications. Also verify proper phasing of power supply as hoist system is equipped with a phase monitor system that will prevent hoist from operating if phasing is incorrect.

  • Page 28: Noise

    16.2.1.3 Noise In normal use of the hoist system there will be obvious noise created by the operation of the mechanical components that comprise the system. In day to day use operators will learn what “normal” noise is as they become accustomed to the systems in operation. If excessive vibrations or loud noises become noticeable it is advisable to stop the use of the hoist system and contact appropriate maintenance personnel to determine the cause and resolution of the issue.

  • Page 29: Upper And Lower Limit Switch Calibration

    16.2.1.4 Upper and Lower Limit Switch Calibration IMPORTANT NOTE: Set Limits Before Normal Operation Check calibration of upper and lower limit switch to prevent damage to hoist system. This should be done during pre-use inspection and subsequent annual inspections. Adjustment screws are numbered next to screw. Stop the hook hoist around 8”...

  • Page 30: Trolley Travel Limit Switches

    Capacity 7.5T 29.5” 29.5” 38.5” 38.5” 37.5” 37.5” 46.5” 46.5” Floor to Hook Point = 8” 16.2.1.5 Trolley Travel Limit Switches If travel limit switches are provided for the trolley, they should be calibrated to stop trolley before contact with the runway end stops. 16.2.1.6 Hook and Sheaves Inspect the wire rope sheaves and they are freely rotating within hook body.

  • Page 31: Wire Rope

    16.2.1.7 Wire Rope Inspect wire rope and that it has not been damaged during operation. Visually inspect that wire rope is properly winding on the drum and that rope guides can freely track the coils in the grooves. Check clamp fasteners on the end(s) of drum are tightened to proper torque specification and wire rope is securely held in place.

  • Page 32: Summit Lifting Load Limiter

    17.0 Summit Lifting Load Limiter V2.0 061824 STARKEAMERICA.COM...
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  • Page 36: Bcq-Hd (W) European Weight Limiter

    18.0 BCQ-HD (W) European Weight Limiter Instruction Manual Page 36-41 Please read the instruction manual carefully before using the product. V2.0 061824 STARKEAMERICA.COM...

  • Page 37: Overview

    The hardware drawings, styles and specifications listed in the manual are for reference only. All items are subject to change. 18.1 Overview BCQ-HD (W) series hoisting weight limiter is an overload safety protection device mainly used in European single 1 beam and consists of a sensor and instrument. The main technical specification conforms to the requirements of GB/T 12602-2020 Technical specifications for Overload Protection Device of Hoisting Machinery.

  • Page 38: Installation And Adjustment

    18.4 Installation and Adjustment 18.4.1 Precautions 1. Please check if this product model is of appropriate capacity for your lifting equipment before installation. 2. Each time after starting up, press the self-test key to check whether the device is working normally. 3.
  • Page 39 BCQ-HD (W) European Weight Limiter Warning Alarm Switch Check Clear Shift Enter V2.0 061824 STARKEAMERICA.COM...

  • Page 40: Adjustments And Usage

    18.4.4 Adjustments and Usage 18.4.4.1 Keyboard Instructions: Calibration Button: Press this button to enter the calibration function. It also has the function of Escape. Switch/Shift Button: Press this button to switch the weight display unit kg or lb, Switch and the corresponding indictor light will be on with Shift function. Shift Check Check Button: Press this button to check if the system of the instrument functions...

  • Page 41: Display Instructions

    18.4.4.2 Display Instructions: • START UP DISPLAY: “U1.01” displays the software version ****** • MEASURING INTERFACE: Displays the current weight. **** • CHECK INTERFACE: Displays the overload set point weight. The red and yellow lights flashing. **.** • SAMPLING VOLTAGE INTERFACE: Displays the current sensor reference voltage –...

  • Page 42: Most Frequent Malfunctions And Solutions

    IMPORTANT NOTE: For a new initial installation, you must perform a clear operation which can only be done when no load is on the sensor. When the hoist is lifting 90%-105% of the rated weight, the instrument enters the warning state, the yellow light will flicker but will not cut off the up-control circuit.

  • Page 43: Notices

    18.4.6 Notices • It is normal for the displayed figure to change due to weight swaying. The figure will be stable as the load weight becomes stationary. The slight difference of the weight between the upper and lower positions in hoisting is due to the change of the length of the steel rope on the drum as it winds, however, the weight deviation should be within ±5%.

  • Page 44: Trolley System

    Please check that all documents included with the hoist system are in good order. Be sure to have all pre-use inspection documents properly filled out as well as owner required warranty cards and submitted to Starke. Keep inspection / maintenance logs in a safe place for reference in the service life of this hoist system.

  • Page 45: Operation

    19.0 Operation 19.1 Control Pendant The typical control device of a hoist or crane system is the pendant. Pendants can be wired or wireless and perform the same functional control over the hoist / crane system. Depending on the number of motions the system is capable of the number and function of buttons will vary by system.

  • Page 46: Inspection And Repair

    20.0 Inspection and Repair 20.1 Inspection It is recommended that a certified and accredited industrial hoist and crane service provider be utilized to inspect, maintain, and certify the hoist system. This organization should have the ability to provide the following. •...

  • Page 47: Certification After Overhaul And/Or Modification

    • If any defects are found during load testing, commissioning personnel shall have the right to re-test. IMPORTANT NOTE: According to differing jurisdictional requirements, the content of the inspections and testing may differ. If the load testing requirement is to be performed at 110% the of rated load for the dynamic test and 125% of the rated load for static test, please contact your dealer for guidance on this subject.

  • Page 48: Inspection Checklist

    IMPORTANT NOTE: Only properly trained and certified technical personnel are authorized to maintain and service Starke wire rope hoists. Starke shall not be held liable and will not take any responsibly for any failure of or injury caused using non-authorized parts or service personnel, or incorrect maintenance, or the lack thereof.

  • Page 49: Wire Rope Maintenance

    22.0 Wire Rope Maintenance 22.1 Inspection of Wire Rope Wire fractures will happen during normal use, because of continued wearing and fatigue stress. For safety reasons, it is required to check wire rope once a month. The hoist system shall be placed out of service and the wire rope must be changed if anyone of following three situations is discovered: •...

  • Page 50: Cleaning And Lubrication Of Rope Guide

    22.4 Cleaning and Lubrication of Rope Guide During normal use, the rope guide will receive lubrication through contact with the wire rope. It may also become necessary to separately lubricate the rope guide when maintaining the hoist. When lubricating, the rope guide should be removed from the drum assembly, and then apply grease to the friction surfaces.

  • Page 51: Troubleshooting

    23.0 Troubleshooting IMPORTANT NOTE: Lock out and tag out power supply before attempting any of these tests. Fault Description Possible Causes Recommended Action Remarks Check power supply and collector Check emergency stop and Hoist doesn’t operate No power contactor KI Lifting limiter is tripped Check limit switch No power...
  • Page 52 Power supply failure for Check wiring of and/or replace brake actuator brake pack Check wiring and power supply Brake doesn’t operate of brake coil Failure of rectifier Replace broken rectifier Braking not effective Clearance of brake disc Adjust clearance Insufficient lubrication of Lubricate wire rope frequently wire rope Solid attachments on...

  • Page 53: Electrical Information

    24.0 Electrical Information 24.1 Electrical Specifications Standard 460V/3 Phase Lifting Trolley Lifting Travel Gauge Model Capacity Lift Duty Motor Motor Weight Speed Speed Rating (HP) (HP) 20/4 75/20 20’ 60” STW0720-20 7.5 Ton 1,642 lbs 20/4 75/20 30’ 60” STW0720-30 7.5 Ton 1,693 lbs 20/4...

  • Page 54: Electrical Schematics

    24.2 Electrical Schematics V2.0 061824 STARKEAMERICA.COM...
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  • Page 60 Device Name Code Name Phase Sequence A-PS Contactor A-K1 Height Limitator Contactor A-K2 Trolley Limitator Contactor A-K4 Contactor A-F1 Contactor A-K3 Connector CZ11 Contactor E-KB Connector CZ12 Intermediate E-K1 Overload Limiter Relay Intermediate E-K2 Relay Intermediate E-K3 Relay Brake Resistor Inverter INVERTER V2.0 061824...

  • Page 61: Product Information

    25.0 Product Information 25.1 Wire Rope Hoist Maintenance Form Below table to be filled in by client: Manufacturer: Address: Service hot line: Type: Serial number: Manufacture date: Working group: Rated load: Lifting height: Lifting speed: Electrical outlet: V2.0 061824 STARKEAMERICA.COM...

  • Page 62: Wire Rope Hoist Yearly Inspection Record

    26.0 Wire Rope Hoist Yearly Inspection Record Inspection items Test result Inspector Date V2.0 061824 STARKEAMERICA.COM...

  • Page 63: Torque Chart

    27.0 Torque Chart Bolt Size Thread Ft/Lb Torque 1.25 1.25 1.75 1.25 V2.0 061824 STARKEAMERICA.COM...

  • Page 64: Exploded Part Drawings & Part Lists

    28.0 Exploded Part Drawings & Part Lists 28.1 Top Running Wire Rope Drawing Assembly V2.0 061824 STARKEAMERICA.COM...

  • Page 65: Top Running Wire Rope Part List

    28.2 Top Running Wire Rope Part List Drawing Part Description Lifting Motor Assembly Drum Assembly Trolley Frame Trolley End Truck Pulley Rope Dead End Hook Assembly Control Panel Height Limiter Balance Shaft Balance Shaft Plate Plate Hdwr Kit Trolley Frame Hdwr Dowel Hdwr Drum Assm.

  • Page 66: Drum Assembly Drawing

    28.3 Drum Assembly Drawing V2.0 061824 STARKEAMERICA.COM...

  • Page 67: Drum Assembly Part List

    28.4 Drum Assembly Part List Drawing Part Description Height Limiter Cotter Connect Asset Connect Sleeve Hexagon Socket Head Cap Screws Flat Washer Spring Washer Left Flange Bearing Block Bearing Spring Washer Flat Washer Screw Connect Rod Lower Cover Plate Top Cover Plate Right Flange Rope Guide Drum Device...

  • Page 68: Lifting Motor & Gearbox Part List

    28.5 Lifting Motor & Gearbox Part List V2.0 061824 STARKEAMERICA.COM...

  • Page 69: Lifting Motor

    28.6 Lifting Motor Part Numbers Drawing Part Description 3 Ton 5 Ton 10 Ton Gearbox Assy Includes Ref #1-20 600-43000 600-43001 600-43002 Hexagon Socket Head Cap Screws Dowel Pin Box Cover Plate Bearing Cylindrical Roller Bearing 310E Bearing Intermediate Disc Gear Intermediate Shaft Gear Output Disc Gear Input Disc Gear...

  • Page 70: Lifting Motor (Continued)

    28.6 Lifting Motor (Continued) Part Numbers Drawing Part Description 3 Ton 5 Ton 10 Ton Bearing Washer 600-43000 600-43001 600-43002 Skeleton Oil Seal Motor Cover Shaft Sleeve Brake Includes 40 & 41 600-43009 600-43010 600-43011 Brake Disc (Not Shown) 600-43054 600-43055 600-43056 Hexagon Socket Head Cap...
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  • Page 72: Trolley Assembly Diagram

    28.7 Trolley Assembly Diagram V2.0 061824 STARKEAMERICA.COM...

  • Page 73: Trolley Assembly Part List

    28.8 Trolley Assembly Part List Drawing Part Description End Carriage Beam Spring Washer for Shaft End Carriage Spacer Bearing End Carriage Driven Shaft End Carriage Driven Wheel Hexagon Socket Head Cap Screws Spring Washer End Carriage Flange End Carriage Drive Wheel Bumper End Carriage Flange Trolley Motor...

  • Page 74: Lower Hook And Block

    28.9 Lower Hook and Block V2.0 061824 STARKEAMERICA.COM...

  • Page 75: Lower Hook And Block Part List

    28.10 Lower Hook and Block Part List Part Numbers Drawing Part Description 3 Ton 5 Ton 10 Ton Lower Block Assy – 600-43036 600-43037 600-43038 Includes #1-21 Spring Washer Elastic Cylindrical Pin Outboard Side Cover 600-43039 600-43040 600-43041 Pulley Washer Bearing Retaining Ring for Hole Inner Lift Plate...

  • Page 76: Fixed Pulley

    28.11 Fixed Pulley V2.0 061824 STARKEAMERICA.COM...

  • Page 77: Fixed Pulley Part List

    28.12 Fixed Pulley Part List Drawing Part Description Pulley Shaft Washer Bearing Retaining Ring for Hole Pulley Lift Plate Support Shaft Hexagon Socket Head Cap Screws Self-Locking Nuts Retaining Ring for Shaft Self-Locking Nuts Hexagon Socket Head Cap Screws V2.0 061824 STARKEAMERICA.COM...

  • Page 78: Dead End Wedge Assembly Diagram

    28.13 Dead End Wedge Assembly Diagram V2.0 061824 STARKEAMERICA.COM...

  • Page 79: Dead End Wedge Part List

    28.14 Dead End Wedge Part List Drawing Part Description Brake Shoe Wedge Joint Overload Protector Hanging Board Shaft Pin External Circlips Fixed Shaft Plate Spring Washer Flat Washer Hexagon Socket Head Cap Screws Wire Rope Clamp V2.0 061824 STARKEAMERICA.COM...

  • Page 80: Hoist Dimensions

    29.0 Hoist Dimensions 21 13/16” 26 1/2” 60” MIN 77 3/16” MIN 28 3/4” 2 1/4” 54 3/16” STW0720 21 13/16” 26 1/2” 60” MIN 77 3/16” MIN 28 3/4” 2 1/4” 54 3/16” STW1020 26 5/8” 33 3/8” 60” MIN 77 11/16”...

  • Page 81: Starke Products Warranty

    ALL OTHER REPRESENTATIONS, EXPRESS OR IMPLIED, WARRANTY, OR LIABILITY RELATING TO THE CONDITION OR USE OF THE PRODUCT ARE SPECIFICALLY DISAVOWED, AND IN NO EVENT SHALL STARKE BE LIABLE TO BUYER, OR ANY THIRD PARTY, FOR ANY DIRECT OR INDIRECT CONSEQUENTIAL OR INCIDENTAL DAMAGES STARKE Starkeamerica.com/contact-us/...
  • Page 82 Notes V2.0 061824 STARKEAMERICA.COM...
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